Process I/O and sensing: current status
On this page
RosieOS moves the robot. It does not yet run the welding process. This page states exactly what exists, so you do not plan around features that are not there.
| Capability | Status |
|---|---|
| Cell digital inputs and non-torch outputs | Implemented in rt-core. Not qualified on hardware. |
| Torch output (arc on/off) | Refused everywhere |
| Weld parameters (wire, gas, arc, travel speed) | Stored as program and preset data. Nothing sends them to a power source. |
| Seam tracking and sensing (laser, vision, touch, through-arc) | Not implemented |
Cell I/O in rt-core#
A machine config can declare one digital I/O terminal in its io block, selected by io.profile from rt-core/config/drives/. It has up to eight inputs and eight outputs.
| Field | Values | Meaning |
|---|---|---|
io.torch_qualified | false only | Torch outputs are unqualified. The compiler accepts no other value. |
io.inputs[].class | fast or supervisory | A fast input must be satisfied for outputs to stay on. |
io.inputs[].polarity | active_high or active_low | |
io.outputs[].class | process or torch | torch outputs are always refused. |
io.outputs[].safe_state | false only | Every output's safe state is OFF. |
io.outputs[].expiry_ns | 1 to 1,000,000,000 ns | An ON intent lapses after this long unless renewed. |
io.outputs[].readback_bit, readback_polarity | input bit 0–7 | Independent physical feedback for the output. |
A process output turns on only when all of these hold:
- The session holds a current grant and has armed I/O with
io_arm.io_armrequires a fresh I/O exchange, satisfied fast inputs and OFF readback on every output after the last fence. - A trajectory point sets the output's bit in
io_maskandio_values, both 8-bit fields in configured output order. - The core's final output permit holds for that cycle.
An output goes OFF on its own when its expiry passes. The core drops every output to OFF and disarms I/O when any of these happens:
- Stop or a new generation fences the session
- the permit lapses
- a fast input drops
- the I/O exchange is lost
- readback still disagrees with the commanded value three exchanges after a change
Intent and readback are reported separately in status. A commanded value is never taken as proof that the output switched. Reason codes include io_not_configured, io_not_armed, io_fast_input_unsatisfied, io_readback_disagreement, io_marker_late and io_exchange_lost. See Error codes.
Warning
Cell I/O is a process interlock, not a safety function. A fast input is not a safety input. Wire guards and the E-stop into the hardware safety chain. See the safety model.
The channel counts, expiry ceiling and readback window above are marked unverified on hardware in the code (io_channels_unverified, io_readback_cycles_unverified).
Torch outputs are refused#
Switching the arc is refused at every layer until it is qualified on hardware:
- rt-core refuses any intent on a
torch-class output withio_torch_unqualified, and every machine config must declaretorch_qualified: false. - The dense trajectory daemon refuses a
.rdtthat contains torch samples withnative_torch_unsupportedand the consumer actionremove_torch_samples. - OLP refuses to load a program that still requires process outputs. Choose the run mode Dry run · process outputs off, which strips them before Load. The motion is unchanged.
The OLP STOP button's tooltip mentions dropping the torch. That describes the Stop path, which drives every output OFF. It does not mean the torch output works.
No seam tracking or sensing#
RosieOS has no laser, vision, touch or through-arc sensing, and no runtime path correction. The robot follows the planned trajectory exactly.
The word "tracking" in the weld planner means something else. It is the tracking certificate: a geometric bound on how far the planned tool centre point (TCP) may deviate from the seam model. The default tolerance is 0.5 mm, unless the weld's own tolerance.position_mm sets another. The verifier checks it before a program is admitted. It says nothing about where the real seam is. See Weld planning and verification.
Weld parameters are data#
Weld presets in weld_planner/v1/data/presets/weld/ describe a process: method, ISO 4063 number, travel speed, arc, wire, gas, weave, and start and end behaviour. Torch presets are in data/presets/torch/. The planner uses travel speed and torch geometry to plan motion. The arc, wire and gas fields are carried with the program, but nothing drives a welding power source from them.