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test(smoke): wait for opcua_bridge subscription before PLC inject
Smoke flaked on CI: inject-photoeye-flicker fired ~540 ms before the opcua_bridge completed its AlarmConditionType subscription handshake with plc-sim. The OPC UA raise event then had no listener, the bridge caught only the later clear events from restore-line, and the MANYMOVE_PLC_PHOTOEYE_FLICKER fault never made it to FaultManager. Poll the bridge container logs for 'subscribed to AlarmConditionType events' before the inject, plus a 1s margin for the asyncua handshake to complete on the plc-sim side.
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demos/manymove_industrial/README.md

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@@ -69,11 +69,6 @@ at the well-known gateway scripts dir and runnable from the web UI or via
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The next `MoveManipulatorAction::onStart` tick observes it, emits
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`MANYMOVE_PLANNER_COLLISION_DETECTED` (ERROR) and returns FAILURE.
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This is a real BT fault, not a synthesised report.
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- `inject-soft-fault` - drops a thin collision wall in the planning scene
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near the pick zone; planning fails ~30% of attempts and the BT emits
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`MANYMOVE_PLANNER_RETRY_ATTEMPT` (WARN). The reporter's LocalFilter
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(threshold=3, window=10s) throttles those locally and only forwards once
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the threshold is crossed - this is the soft-fault narrative.
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- `restore-normal` - clears `collision_detected`, `stop_execution` and
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triggers `reset` + `start` on the blackboard so the BT picks up cleanly.
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demos/manymove_industrial/config/manymove_industrial_manifest.yaml

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@@ -4,15 +4,18 @@ metadata:
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description: "manymove BT manipulator pipeline (xArm7 fake hardware) with medkit fault reporting"
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version: "0.1.0"
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# Hybrid discovery: pure ROS-side components (xarm7-arm, ufactory-driver,
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# move-group, object-manager, action-server, gateway, etc.) are picked up
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# at runtime from topic/node introspection. The manifest declares only
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# what the runtime can't infer:
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# - PLC-side entities (no ROS topics)
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# - script-bound logical components (conveyor-line, manymove-planning)
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# - apps the smoke test asserts on (bt-client-xarm7, fault-manager-app)
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config:
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unmanifested_nodes: "warn"
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inherit_runtime_resources: true
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areas:
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- id: manipulation
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name: "Manipulation"
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description: "xArm7 cobot under fake_components hardware"
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namespace: /
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- id: planning
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name: "Planning"
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description: "BehaviorTree.CPP orchestration and MoveIt motion planning"
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namespace: /plc
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components:
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- id: xarm7-arm
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name: "xArm 7 manipulator"
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type: "manipulator"
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description: "7-DoF cobot, fake_components hardware"
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area: manipulation
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- id: ufactory-driver
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name: "UFactory ROS 2 driver"
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type: "driver"
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description: "xarm_ros2 driver layer (fake mode)"
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area: manipulation
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- id: manymove-bt
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name: "manymove BT client"
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type: "controller"
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type: "controller"
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description: "Logical grouping for planning-side container scripts (collision inject, restore, self-test)"
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area: planning
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- id: move-group
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name: "MoveIt move_group"
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type: "planner"
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description: "OMPL motion planner"
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area: planning
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- id: object-manager
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name: "manymove object_manager"
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type: "service"
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description: "Planning scene collision objects"
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area: planning
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- id: action-server
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name: "manymove planner action_server"
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type: "service"
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description: "MoveManipulator / PlanManipulator action servers"
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area: planning
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- id: gateway
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name: "ros2_medkit gateway"
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type: "diagnostics"
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description: "HTTP REST API for fault inspection"
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area: diagnostics
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- id: fault-manager
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name: "ros2_medkit fault_manager"
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type: "diagnostics"
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ros_binding:
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namespace: /
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node_name: bt_client_xarm7
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- id: hmi-service-node
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name: "HMI service node"
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category: "controller"
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is_located_on: manymove-bt
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ros_binding:
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namespace: /
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node_name: hmi_service_node
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- id: move-group-app
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name: "move_group"
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category: "planner"
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is_located_on: move-group
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ros_binding:
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namespace: /
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node_name: move_group
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- id: action-server-app
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name: "action_server_node"
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category: "service"
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is_located_on: action-server
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ros_binding:
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namespace: /
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node_name: action_server_node
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- id: object-manager-app
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name: "object_manager_node"
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category: "service"
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is_located_on: object-manager
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ros_binding:
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namespace: /
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node_name: object_manager_node
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- id: ufactory-driver-app
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name: "ufactory_driver"
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category: "driver"
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is_located_on: ufactory-driver
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ros_binding:
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namespace: /
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node_name: ufactory_driver
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- id: fault-manager-app
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name: "fault_manager"
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category: "diagnostics"
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is_located_on: fault-manager
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ros_binding:
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namespace: /
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node_name: fault_manager
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- id: gateway-app
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name: "ros2_medkit_gateway"
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category: "diagnostics"
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is_located_on: gateway
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ros_binding:
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namespace: /
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node_name: ros2_medkit_gateway
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- id: openplc-runtime
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name: "OpenPLC runtime"
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category: "controller"
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is_located_on: openplc
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ros_binding:
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namespace: /plc
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node_name: openplc_runtime
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- id: opcua-bridge-app
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name: "opcua_bridge"
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category: "bridge"
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is_located_on: opcua-bridge
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ros_binding:
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namespace: /plc
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node_name: sensor_io
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functions:
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- id: pick-and-place
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name: "Pick and place"
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category: "manipulation"
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description: "BT-driven manipulation sequence on fake xArm7"
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hosted_by:
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- bt-client-xarm7
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- move-group-app
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- action-server-app
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- object-manager-app
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- id: hmi-control
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name: "Operator control"
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category: "interaction"
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description: "Qt HMI panel for blackboard mutation and BT reset"
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hosted_by:
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- hmi-service-node
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- bt-client-xarm7
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- id: fault-management
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name: "Fault management"
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category: "diagnostics"
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description: "Capture, persist, and surface BT runtime failures emitted by manymove_cpp_trees"
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hosted_by:
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- fault-manager-app
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- gateway-app
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- id: line-control
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name: "Line control"
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category: "controller"
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description: "PLC-driven conveyor sequencing with safety interlocks"
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hosted_by:
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- openplc-runtime
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- id: fault-aggregation
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name: "Cross-source fault aggregation"
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category: "diagnostics"
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description: "Bridge PLC AlarmConditionType events into the same medkit FaultManager that aggregates ROS-side faults"
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hosted_by:
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- opcua-bridge-app
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- fault-manager-app
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- gateway-app

demos/manymove_industrial/container_scripts/manymove-planning/inject-soft-fault/metadata.json

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demos/manymove_industrial/container_scripts/manymove-planning/inject-soft-fault/script.bash

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tests/smoke_test_manymove_industrial.sh

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@@ -81,6 +81,41 @@ if api_get "/components"; then
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fi
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fi
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# Wait for opcua_bridge to actually subscribe to AlarmConditionType
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# events before injecting. Container manifest discovery (above) only
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# proves the gateway routed the component, not that the asyncua
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# subscription handshake on plc-sim completed. Without this wait the
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# inject can fire 100-500ms before bridge is ready, the OPC UA raise
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# event goes unheard and the test flakes.
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#
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# Skipped gracefully if the host docker CLI is not reachable (e.g.
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# running the smoke script from inside a container without the socket
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# mounted), since the belt-and-suspenders sleep below covers the race
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# in practice.
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# Probe once first; if docker logs of the bridge isn't reachable from
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# this environment (script running from inside a container without the
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# socket mounted, etc.) skip the check entirely - the sleep below
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# covers the race for the common-case smoke runs.
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PROBE=$(docker logs manymove_industrial-opcua-bridge-1 2>/dev/null || true)
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if [ -n "$PROBE" ]; then
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BRIDGE_LOGS="$PROBE"
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for _ in $(seq 1 20); do
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if echo "$BRIDGE_LOGS" | grep -q "subscribed to AlarmConditionType events"; then
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pass "opcua_bridge subscribed to AlarmConditionType events"
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break
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fi
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sleep 1
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BRIDGE_LOGS=$(docker logs manymove_industrial-opcua-bridge-1 2>/dev/null || true)
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done
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if ! echo "$BRIDGE_LOGS" | grep -q "subscribed to AlarmConditionType events"; then
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fail "opcua_bridge never subscribed to AlarmConditionType events"
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fi
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fi
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# Belt-and-suspenders: small extra delay so subscription is fully active
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# on the plc-sim side too (asyncua handshake completes ~50-200ms after
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# the bridge logs the subscribe call).
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sleep 1
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# Photoeye flicker injection -> MANYMOVE_PLC_PHOTOEYE_FLICKER (WARN)
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if curl -fsS -X POST -H "Content-Type: application/json" -d "$EXEC_BODY" \
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"$API_BASE/components/conveyor-line/scripts/inject-photoeye-flicker/executions" >/dev/null; then

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