scanengine-3/docs/hardware/HELIOS_DRIVER_README.md

Helios Laser System Driver

Overview

This directory contains a complete implementation of the Helios laser system driver. The driver implements the full RS-232 ASCII communications protocol as specified in the helios_comms_protocol.pdf document.

The Helios laser system is a pulsed solid-state laser with:

• Diode-pumped Nd:YAG/Nd:YLF laser head
• Q-switched operation
• Frequency control (16.7 kHz - 125 kHz)
• Current control (0-7000 mA)
• Power monitoring
• Temperature monitoring (4 sensors)
• External trigger capability

Architecture

The Helios driver is split into three layers:

1. Protocol Layer (helios_protocol.py)

Low-level protocol implementation that handles:

• ASCII command construction
• Response parsing and validation
• Unit conversions (Hz ↔ ns, °C ↔ m°C)
• Parameter range validation
• Status register decoding

Key Classes:

• HeliosCommand: Command constants and builders
• HeliosProtocol: High-level protocol interface with validation

2. Driver Layer (helios_driver.py)

Complete driver implementation providing:

• RS-232 serial communication (9600 baud, 8N1)
• Thread-safe command/query operations
• Comprehensive status monitoring
• Temperature monitoring (pump, resonator, q-switch, power stage)
• Power monitoring
• Laser enable/disable control
• Pulse mode control (single, gating, continuous)
• Frequency and current control

Key Classes:

• PulseMode: Enumeration of pulse modes
• HeliosStatus: Status data structure
• HeliosDriver: Main driver class for laser communication

3. Integration Layer (hardware/microscope.py)

Application-specific integration that:

• Combines Helios with Genesis microscope systems
• Provides unified status monitoring
• Integrates with nueScan application
• Implements safety interlocks
• Provides emergency stop functionality

Features

Communication

• ASCII-based RS-232 protocol
• Baud rate: 9600, 8 data bits, no parity, 1 stop bit
• Commands terminated with carriage return (CR)
• Thread-safe operation with mutex locking
• Configurable timeout (default: 1 second)

Laser Control

• Laser enable/disable
• Three pulse modes:
  • Single pulse (one pulse per trigger)
  • Continuous gating (pulse train while triggered)
  • Continuous pulsing (free-running)
• Frequency control (16.7 kHz to 125 kHz)
• Diode current control (0-7000 mA)

Monitoring

• Real-time power measurement (mW)
• Four temperature sensors:
  • Pump diode temperature
  • Resonator temperature
  • Q-switch temperature
  • Power stage temperature
• Operation hours counter
• Comprehensive status register
• Error detection

Safety

• Temperature monitoring with warnings
• Error status detection
• Laser enable/disable control
• Emergency stop capability
• Integration with system interlocks

Usage

Connection Methods

The driver supports connection to a specific COM port:

from hardware.helios_driver import HeliosDriver

# Create driver instance
driver = HeliosDriver(timeout=1.0)

# List available COM ports
ports = HeliosDriver.list_available_ports()
for port in ports:
    print(f"Available port: {port}")

# Connect to specific port
driver.connect('COM5')  # or '/dev/ttyUSB0' on Linux

# Get device information
print(f"Controller S/N: {driver.get_controller_serial()}")
print(f"Head S/N: {driver.get_head_serial()}")

Basic Laser Control

# Set frequency (in Hz)
driver.set_frequency_hz(10000)  # 10 kHz

# Set diode current (in mA)
driver.set_current_ma(500)  # 500 mA

# Set pulse mode
from hardware.helios_driver import PulseMode
driver.set_pulse_mode(PulseMode.CONTINUOUS_PULSING)

# Enable laser
driver.set_laser_enable(True)

# Check if laser is enabled
if driver.is_laser_enabled():
    print("Laser is ON")

# Disable laser
driver.set_laser_enable(False)

# Disconnect
driver.disconnect()

Monitoring

# Get current power
power_mw = driver.get_power_mw()
print(f"Output power: {power_mw} mW")

# Get temperatures (in Celsius)
temps = driver.get_all_temperatures()
print(f"Pump: {temps['pump_temp_c']:.1f}°C")
print(f"Resonator: {temps['resonator_temp_c']:.1f}°C")
print(f"Q-switch: {temps['qswitch_temp_c']:.1f}°C")
print(f"Power stage: {temps['power_stage_temp_c']:.1f}°C")

# Get operation hours
hours = driver.get_operation_hours()
print(f"Operation time: {hours} hours")

# Get comprehensive status
status = driver.get_status()
print(f"Connected: {status['connected']}")
print(f"Laser enabled: {status['laser_enabled']}")
print(f"Frequency: {status['frequency_hz']} Hz")
print(f"Current: {status['current_ma']} mA")
print(f"Power: {status['power_mw']} mW")
print(f"Has errors: {status['has_errors']}")

Status Updates

# Manually update status from hardware
driver.update_status()

# Status is automatically updated on each get_status() call
status = driver.get_status()

# Access cached values without querying hardware
freq = driver.get_frequency_hz()  # Returns last read value
current = driver.get_current_ma()  # Returns last read value

Using Through Microscope Controller

The Helios driver is integrated into the application through the MicroscopeController:

from hardware.microscope import MicroscopeController

# Create controller
microscope = MicroscopeController()

# Connect Helios
microscope.connect_helios('COM5')

# Apply settings from dialog
settings = {
    'com_port': 'COM5',
    'frequency_hz': 10000,
    'current_ma': 500
}
microscope.apply_helios_settings(settings)

# Enable laser
microscope.helios_enable_laser(True)

# Get status
status = microscope.get_helios_status()
print(f"Helios ready: {status['ready']}")
print(f"Power: {status['power_mw']} mW")

# Disable laser
microscope.helios_enable_laser(False)

# Disconnect
microscope.disconnect_helios()

Configuration

Frequency Control

The Helios laser operates by setting the pulse period in nanoseconds. The driver automatically converts between frequency (Hz) and period (ns):

# Set frequency in Hz (driver converts to period in ns)
driver.set_frequency_hz(10000)  # 10 kHz → 100,000 ns period

# Valid frequency range: 16.7 kHz to 125 kHz
# Valid period range: 8000 ns to 60000 ns

Conversion formulas:

Period (ns) = 1,000,000,000 / Frequency (Hz)
Frequency (Hz) = 1,000,000,000 / Period (ns)

Current Control

The diode current controls the laser output power:

# Set current in milliamps
driver.set_current_ma(500)  # 500 mA

# Valid range: 0 to 7000 mA

Important: Higher currents produce more power but also more heat. Monitor temperatures when operating at high current.

Pulse Modes

Three pulse modes are available:

from hardware.helios_driver import PulseMode

# Single pulse mode (one pulse per trigger)
driver.set_pulse_mode(PulseMode.SINGLE_PULSE)

# Continuous gating mode (pulse train while triggered)
driver.set_pulse_mode(PulseMode.CONTINUOUS_GATING)

# Continuous pulsing mode (free-running)
driver.set_pulse_mode(PulseMode.CONTINUOUS_PULSING)

Mode Descriptions:

• Single Pulse (LDG=0): One pulse generated per external trigger
• Continuous Gating (LDG=1): Pulse train while external trigger is high
• Continuous Pulsing (LDG=2): Free-running at set frequency (default)

Temperature Monitoring

The driver monitors four temperature sensors:

# Individual temperatures
pump_temp = driver.query_pump_temp_c()
resonator_temp = driver.query_resonator_temp_c()
qswitch_temp = driver.query_qswitch_temp_c()
power_stage_temp = driver.query_power_stage_temp_c()

# All temperatures at once
temps = driver.get_all_temperatures()

Temperature Ranges:

• Normal operation: < 50°C
• Warning threshold: > 60°C
• Critical threshold: > 70°C

Integration with nueScan

The Helios driver is integrated into nueScan through the settings dialog and microscope controller.

Configuration in UI

1. Open Helios Settings

   • Click "Helios Device Settings" button in main window

2. Configure Parameters

   • COM Port: Select from dropdown (automatically populated)
   • Frequency: Enter in Hz (16,666 - 125,000 Hz)
   • Current: Enter in mA (0 - 7000 mA)

3. Apply Settings

   • Click OK to apply and connect
   • Settings are validated before sending to hardware

Settings Dialog Integration

The HeliosDialog class provides:

• Automatic COM port enumeration
• Input validation with range checking
• User-friendly error messages
• Settings persistence

# Dialog usage (called from main window)
from dialogs.helios_dialog import HeliosDialog

dialog = HeliosDialog(parent=self)
if dialog.exec() == QDialog.DialogCode.Accepted:
    settings = dialog.get_settings()  # Returns None if validation fails
    if settings:
        self.microscope.apply_helios_settings(settings)

Validation Rules

The dialog validates all inputs before accepting:

Frequency Validation:

• Range: 16,666 Hz to 125,000 Hz
• Reason: Hardware period limit of 8000-60000 ns
• Error message shows entered value and valid range

Current Validation:

• Range: 0 to 7000 mA
• Reason: Maximum diode current rating
• Error message shows entered value and valid range

COM Port Validation:

• Must select valid port from list
• Cannot accept "No ports found" placeholder
• Error message prompts to check connections

Protocol Details

Command Format

All commands follow the format:

COMMAND [value]<CR>

Where:

• COMMAND is a 3-letter mnemonic (e.g., LDO, LDF, LDS)
• [value] is optional numeric parameter
• <CR> is carriage return (0x0D)

Command Set

Command	Parameter	Description
LDO	0/1	Laser enable (0=off, 1=on)
LDG	0/1/2	Pulse mode (0=single, 1=gating, 2=continuous)
LDF	8000-60000	Pulse period in nanoseconds
LDS	0-7000	Diode current in milliamps
LDP	-	Query output power (mW)
LDPT	-	Query pump temperature (m°C)
LDRT	-	Query resonator temperature (m°C)
LDQT	-	Query q-switch temperature (m°C)
LDPST	-	Query power stage temperature (m°C)
LDSR	-	Query status register
LDOH	-	Query operation hours
LDCSN	-	Query controller serial number
LDHSN	-	Query head serial number

Response Format

Responses are numeric values terminated with <CR>:

12345<CR>

Exception: Serial numbers are returned as strings:

SN12345678<CR>

Status Register

The status register (LDSR) returns a 16-bit value with error flags:

Bit	Mask	Meaning
0	0x0001	Pump temperature error
1	0x0002	Resonator temperature error
2	0x0004	Q-switch temperature error
3	0x0008	Power stage temperature error
4	0x0010	Diode current error
5	0x0020	Interlock open
6	0x0040	Over-power condition
7	0x0080	Under-voltage condition

A status of 0 indicates no errors.

Set and Verify Pattern

For critical parameters, the driver uses a set-and-verify pattern:

def _set_and_verify(self, set_cmd: bytes, query_cmd: bytes, expected: str) -> bool:
    # Send set command
    self._serial.write(set_cmd)
    time.sleep(0.05)  # Allow hardware to process

    # Query back the value
    self._serial.write(query_cmd)
    response = self._read_response()

    # Verify it matches
    return response.strip() == expected.strip()

This ensures commands are executed correctly and hardware state matches software state.

Troubleshooting

Connection Issues

Problem: Cannot connect to laser

Solutions:

• Verify COM port name is correct (HeliosDriver.list_available_ports())
• Check RS-232 cable connection
• Verify laser controller is powered on
• Try different COM port
• Check device permissions on Linux (sudo usermod -a -G dialout $USER)

Communication Errors

Problem: Commands fail or no response

Solutions:

• Verify baud rate is 9600 (default)
• Check cable for proper null-modem configuration if needed
• Increase timeout: driver = HeliosDriver(timeout=2.0)
• Check for CR line termination (0x0D)
• Verify no other software has port open

Frequency/Current Not Updating

Problem: Settings don't change on hardware

Solutions:

• Check return value of set_frequency_hz() and set_current_ma()
• Verify parameters are in valid range
• Check status register for errors: driver.query_status_register()
• Ensure laser is not in error state
• Try power cycling the controller

Temperature Warnings

Problem: High temperature readings

Solutions:

• Check ventilation around laser head and controller
• Reduce diode current if at maximum
• Allow longer cool-down between operations
• Clean air filters if present
• Check for blocked cooling fans

Laser Won't Enable

Problem: set_laser_enable(True) fails or laser stays off

Solutions:

• Check interlock connections (bit 5 of status register)
• Verify all interlocks are closed
• Check for error flags in status register
• Ensure parameters (frequency, current) are set
• Check external enable switch if present
• Review safety interlock documentation

Status Register Errors

Problem: Status register shows error bits set

Solutions:

• Decode status register: HeliosProtocol.decode_status_register(value)
• Address specific error conditions:
  • Temperature errors: Improve cooling
  • Current error: Reduce current setting
  • Interlock open: Check safety connections
  • Over-power: Reduce current
  • Under-voltage: Check power supply

Debug Output

The driver provides extensive debug output:

INFO: Informational messages about operations
DEBUG: Detailed command/response information
WARNING: Potential issues (high temp, errors)
ERROR: Operation failures

Enable Python logging to capture all output:

import logging
logging.basicConfig(level=logging.DEBUG)

Example debug output:

INFO: Connecting to Helios laser on COM5
DEBUG: Sending command: b'LDCSN\r'
DEBUG: Received response: SN12345678
INFO: Successfully connected to Helios on COM5
DEBUG: Sending command: b'LDF 100000\r'
DEBUG: Verifying frequency setting...
INFO: Frequency set to 10000.0 Hz (period: 100000 ns)

Performance Notes

• Command response time: 50-100ms typical
• Temperature queries: ~100ms per sensor
• Status register query: ~50ms
• All queries are synchronous (blocking)
• Thread-safe for concurrent access (mutex protected)
• Set-and-verify adds ~50ms overhead for reliability

Safety Considerations

Laser Safety

• Class 4 Laser: Hazardous to eyes and skin
• Always verify laser is disabled before opening beam paths
• Use appropriate laser safety eyewear
• Follow all facility laser safety procedures
• Ensure proper interlock connections

Thermal Management

• Monitor temperatures during operation
• Allow adequate cool-down between high-power operations
• Ensure proper ventilation
• Do not block cooling vents

Electrical Safety

• Verify proper grounding
• Use shielded cables for trigger/status connections
• Follow proper ESD procedures when servicing

Hardware Connections

Utility Connector (9-pin D-Sub)

The utility connector provides external control:

Pin	Signal	Description
1	GND	Ground
2	Laser Disable	Input: Pull low to disable laser
3	External Trigger	Input: Rising edge triggers pulse
4	Status Out	Output: High when ready
5	GND	Ground
6-9	NC	Not connected

Trigger specifications:

• Input: TTL/CMOS compatible
• Minimum pulse width: 100ns
• Maximum frequency: Limited by pulse mode setting

References

• Protocol Documentation: helios_comms_protocol.pdf
• RS-232 Standard: EIA/TIA-232
• Integration Guide: SETUP.md
• Connection Guide: See main window Helios settings dialog

License

Copyright (C) 2025 Thomas Ales Licensed under GNU General Public License v2.0