docs: add FRI realtime scheduling guide

cobot-setting.yaml

@@ -1,11 +1,9 @@
 robot:
   name: "iiwa7"
-  ip: "192.170.10.2"
+  ip: "192.168.21.147"
   port: 30200
   fri_cycle_ms: 10          # период FRI-цикла: 5 мс (200 Гц) или 10 мс (100 Гц)
-  joint_position_tau: 0.04   # EMA фильтр позиций [с]: сглаживает команды перед отправкой в FRI
+  joint_position_tau: 0.04  # EMA позиций FRI [с]; 0 отключает сглаживание
-  joint_velocity_tau: 0.01   # EMA фильтр скорости [с]: убирает выбросы конечных разностей
-  active_controller: "jtc"  # "jtc" = MoveIt/JointTrajectoryController, "forward" = ForwardCommandController
   description: pkg://iiwa_description/urdf/iiwa7.urdf.xacro
 
 

cobot/commands/robot_setup.py

@@ -143,13 +143,6 @@ _BLOCKS: List[_Block] = [
             _Field("fri_cycle_ms", "Цикл FRI (мс):", "10",
                    note="5 мс = 200 Гц, 10 мс = 100 Гц",
                    options=["10", "5"]),
-            _Field("active_controller", "Активный ROS-контроллер:", "jtc",
-                   note="jtc = JointTrajectoryController (MoveIt), forward = ForwardCommandController",
-                   options=["jtc", "forward"]),
-            _Field("joint_position_tau", "EMA tau фильтра положения (с):", "0.04",
-                   note="Сглаживает команды положения перед отправкой в FRI"),
-            _Field("joint_velocity_tau", "EMA tau фильтра скорости (с):", "0.01",
-                   note="Убирает выбросы из оценки скорости конечной разностью"),
         ],
     ),
 ]

cobot/commands/update.py

@@ -4,13 +4,23 @@ import argparse
 import subprocess
 from pathlib import Path
 
-from cobot import process, ui
+from cobot import process
 from cobot.ui import done
 from cobot.process import StepProgress
 
 _PROJECT_DIR = Path(__file__).parent.parent.parent
 
 
+def _plain(message: str) -> None:
+    """Print after replacing this command's own uv environment.
+
+    Rich modules loaded before ``uv tool install`` can no longer be complete after
+    uv replaces the editable tool environment. Do not render with Rich after that
+    command returns.
+    """
+    print(message, flush=True)
+
+
 def _git(*args: str) -> str:
     """Run a git command in the project dir and return its stripped stdout.
     Запускает git-команду в директории проекта и возвращает обрезанный stdout.
@@ -18,13 +28,12 @@ def _git(*args: str) -> str:
     return subprocess.check_output(["git", *args], cwd=_PROJECT_DIR, text=True).strip()
 
 
-def _update() -> None:
+def _update() -> int:
     """Fetch the current branch, show incoming commits, pull, and reinstall the cobot CLI.
     Progress: fetch (0-30 %), pull (30-80 %), reinstall (80-100 %).
     Получает текущую ветку, показывает входящие коммиты, делает pull и переустанавливает CLI.
     Прогресс: fetch (0-30 %), pull (30-80 %), переустановка (80-100 %).
     """
-    ok, fail_msg = True, ""
     with StepProgress("Обновление проекта") as p:
         try:
             branch = _git("rev-parse", "--abbrev-ref", "HEAD")
@@ -32,42 +41,49 @@ def _update() -> None:
 
             p.set(0, "Получение с удалённого репозитория...")
             rc = process.stream(["git", "fetch", "origin"], cwd=str(_PROJECT_DIR), on_line=p.log)
-            if rc not in (0, -9, -15):
+            if rc != 0:
-                done(False, "git fetch завершился с ошибкой")
+                done(False, f"git fetch завершился с кодом {rc}")
-                return
+                return 1
             p.set(30)
 
             behind = _git("rev-list", f"HEAD..origin/{branch}", "--count")
             if behind == "0":
-                p.set(100, "Уже актуально")
+                p.log("Исходники уже актуальны; проверка установки CLI...")
-                done(True, "Уже актуальная версия")
-                return
-
-            p.raw(f"\n[bold]{behind} новых коммит(ов):[/bold]")
-            for line in _git("log", f"HEAD..origin/{branch}", "--oneline").splitlines():
-                p.log(line)
-
-            p.set(30, "Применение изменений...")
-            rc = process.stream(["git", "pull", "origin", branch],
-                               cwd=str(_PROJECT_DIR), on_line=p.log)
-            if rc not in (0, -9, -15):
-                done(False, "git pull завершился с ошибкой")
-                return
-            p.set(80)
-
-            p.set(80, "Переустановка cobot CLI...")
-            p.raw("\n[cyan]▸[/cyan] Переустановка cobot CLI...")
-            rc = process.stream(["uv", "tool", "install", "--editable", str(_PROJECT_DIR)],
-                               on_line=p.log)
-            if rc in (0, -9, -15):
-                p.raw("[green]✓[/green] cobot переустановлен")
             else:
-                p.raw("[yellow]Предупреждение:[/yellow] переустановка не удалась")
+                p.raw(f"\n[bold]{behind} новых коммит(ов):[/bold]")
-            p.set(100, "Готово")
+                for line in _git("log", f"HEAD..origin/{branch}", "--oneline").splitlines():
-        except subprocess.CalledProcessError as exc:
+                    p.log(line)
-            ok, fail_msg = False, str(exc)
 
-    done(ok, "Проект обновлён" if ok else fail_msg)
+                p.set(30, "Применение изменений...")
+                rc = process.stream(["git", "pull", "origin", branch],
+                                   cwd=str(_PROJECT_DIR), on_line=p.log)
+                if rc != 0:
+                    done(False, f"git pull завершился с кодом {rc}")
+                    return 1
+            p.set(80)
+        except (subprocess.CalledProcessError, OSError) as exc:
+            done(False, str(exc))
+            return 1
+
+    # uv can replace the Rich package of this running CLI. Keep this stage outside
+    # StepProgress and only use built-in print afterwards.
+    _plain("\n▸ Переустановка cobot CLI...")
+    try:
+        rc = process.stream(
+            ["uv", "tool", "install", "--editable", str(_PROJECT_DIR)],
+            on_line=lambda line: _plain(f"  {line}"),
+        )
+    except OSError as exc:
+        _plain(f"✗ Не удалось запустить установщик: {exc}")
+        return 1
+    if rc != 0:
+        _plain(
+            f"✗ Установка CLI завершилась с кодом {rc}. Исходники обновлены, "
+            "но установка не завершена. Сохраните вывод выше и повторите cobot update."
+        )
+        return 1
+    _plain("✓ Проект обновлён и cobot переустановлен")
+    return 0
 
 
 def register(subparsers: argparse._SubParsersAction) -> None:
@@ -76,4 +92,4 @@ def register(subparsers: argparse._SubParsersAction) -> None:
 
 
 def run(args: argparse.Namespace) -> None:
-    _update()
+    raise SystemExit(_update())

cobot/test/test_update.py

@@ -0,0 +1,71 @@
+"""Update recovery checks; external git and installer operations are isolated."""
+
+import io
+import unittest
+from unittest.mock import patch
+
+from rich.console import Console
+
+from cobot.commands import update
+
+
+class UpdateTests(unittest.TestCase):
+    def run_update(self, codes, behind="1"):
+        output = io.StringIO()
+        commands = []
+
+        def stream(command, **kwargs):
+            commands.append(command)
+            result = next(codes, 0)
+            if isinstance(result, Exception):
+                raise result
+            return result
+
+        def git(*args):
+            return {"rev-parse": "controller", "rev-list": behind,
+                    "log": "abc123 Update CLI"}[args[0]]
+
+        console = Console(file=output, color_system=None)
+        with patch.object(update, "_git", side_effect=git), \
+                patch.object(update.process, "stream", side_effect=stream), \
+                patch.object(update, "_plain"), \
+                patch("cobot.process.console", console), \
+                patch("cobot.ui.console", console):
+            code = update._update()
+        return code, output.getvalue(), commands
+
+    def test_install_failure_reports_failure(self):
+        for install_code in (1, -9, -15):
+            with self.subTest(install_code=install_code):
+                code, output, _ = self.run_update(iter([0, 0, install_code]))
+                self.assertEqual(code, 1)
+                self.assertNotIn("Проект обновлён", output)
+
+    def test_current_checkout_still_retries_installation(self):
+        code, _, commands = self.run_update(iter([0, 0]), behind="0")
+        self.assertEqual([command[:2] for command in commands],
+                         [["git", "fetch"], ["uv", "tool"]])
+        self.assertEqual(code, 0)
+
+    def test_killed_git_stops_before_next_step(self):
+        for codes, expected_count in [([-9], 1), ([0, -15], 2)]:
+            with self.subTest(codes=codes):
+                code, output, commands = self.run_update(iter(codes))
+                self.assertNotEqual(code, 0)
+                self.assertEqual(len(commands), expected_count)
+                self.assertNotIn("Проект обновлён", output)
+
+    def test_missing_installer_reports_failure_without_traceback(self):
+        code, _, _ = self.run_update(
+            iter([0, 0, FileNotFoundError("uv not found")]))
+        self.assertNotEqual(code, 0)
+
+    def test_command_exits_nonzero_after_failed_installation(self):
+        with patch.object(update, "_update", return_value=1):
+            with self.assertRaises(SystemExit) as result:
+                update.run(None)
+        self.assertEqual(result.exception.code, 1)
+
+
+if __name__ == "__main__":
+    unittest.main()

doc/lwc-doc/docs/getting-started/configuration.en.md

@@ -26,9 +26,6 @@ robot:
   ip: "192.170.10.2"
   port: 30200
   fri_cycle_ms: 10
-  joint_position_tau: 0.04
-  joint_velocity_tau: 0.01
-  active_controller: "jtc"
   description: pkg://iiwa_description/urdf/iiwa7.urdf.xacro
 ```
 
@@ -38,11 +35,11 @@ robot:
 | `ip` | KUKA controller IP address | **Change** to the actual controller address |
 | `port` | FRI UDP port | Default: `30200`; change only if the port conflicts |
 | `fri_cycle_ms` | FRI cycle: `5` ms = 200 Hz, `10` ms = 100 Hz | Use `10` for stable operation or `5` for high-precision tasks |
-| `joint_position_tau` | Position EMA filter [s], smoothing commands before transmission | Decrease for a faster response; increase if vibration occurs |
+| `joint_position_tau` | FRI command EMA time constant, s | `0.04`; `0` disables smoothing |
-| `joint_velocity_tau` | Velocity EMA filter [s], removing finite-difference spikes | Tune in the same way as `joint_position_tau` |
-| `active_controller` | Control mode: `jtc` (MoveIt / JointTrajectory) or `forward` (direct control) | Use `jtc` for most tasks |
 | `description` | Path to the robot URDF | Do not change |
 
+Motion always uses JointTrajectoryController. The position command is smoothed before FRI transmission with `robot.joint_position_tau`; no velocity filter is applied.
+
 ---
 
 ## `digital_twin` section — simulator
@@ -70,6 +67,7 @@ digital_twin:
 | `webots.cameras` | List of YAML configurations for connected cameras |
 | `rviz.config` | Path to the RViz configuration |
 
+
 ---
 
 ## `tool` section — active tool
@@ -169,7 +167,6 @@ The remaining parameters (`tls`, `topic_whitelist`, `min_qos_depth`, and others)
 | ✅ | `robot.fri_cycle_ms` | Select `10` (standard) or `5` (high frequency) |
 | ✅ | `tool.active` | Set the active tool |
 | ✅ | `web.enabled` | Set to `false` if the web interface is not needed |
-| ⚠️ | `robot.active_controller` | Change only when intentionally switching the control mode |
 | ⚠️ | `planning.*` | Change only when another planner or other parameters are required |
 | ❌ | `robot.description` | Do not change; this is the URDF path |
 | ❌ | `controller.moveit.*` | Do not change; these are package-internal MoveIt configuration paths |

doc/lwc-doc/docs/getting-started/configuration.md

@@ -28,9 +28,6 @@ robot:
   ip: "192.170.10.2"
   port: 30200
   fri_cycle_ms: 10
-  joint_position_tau: 0.04
-  joint_velocity_tau: 0.01
-  active_controller: "jtc"
   description: pkg://iiwa_description/urdf/iiwa7.urdf.xacro
 ```
 
@@ -40,11 +37,11 @@ robot:
 | `ip` | IP-адрес контроллера KUKA | **Изменить** на реальный IP вашего контроллера |
 | `port` | UDP-порт FRI | По умолчанию `30200` — менять только при конфликте портов |
 | `fri_cycle_ms` | Период цикла FRI: `5` мс = 200 Гц, `10` мс = 100 Гц | `10` для стабильной работы, `5` для высокоточных задач |
-| `joint_position_tau` | EMA-фильтр позиций [с] — сглаживает команды перед отправкой | Уменьшать для более быстрой реакции, увеличивать при вибрациях |
+| `joint_position_tau` | Постоянная времени EMA команд FRI, с | `0.04`; `0` отключает сглаживание |
-| `joint_velocity_tau` | EMA-фильтр скорости [с] — убирает выбросы конечных разностей | Аналогично `joint_position_tau` |
-| `active_controller` | Режим управления: `jtc` (MoveIt / JointTrajectory) или `forward` (прямое управление) | `jtc` для большинства задач |
 | `description` | Путь к URDF-описанию робота | Не менять |
 
+Управление движением всегда выполняет JointTrajectoryController. Перед отправкой в FRI позиционная команда сглаживается EMA с постоянной времени `robot.joint_position_tau`; фильтр скорости не применяется.
+
 ---
 
 ## Блок `digital_twin` — симулятор
@@ -72,6 +69,7 @@ digital_twin:
 | `webots.cameras` | Список YAML-конфигов подключённых камер |
 | `rviz.config` | Путь к конфигурации RViz |
 
+
 ---
 
 ## Блок `tool` — активный инструмент
@@ -171,7 +169,6 @@ foxglove:
 | ✅ | `robot.fri_cycle_ms` | Выбрать `10` (стандарт) или `5` (высокая частота) |
 | ✅ | `tool.active` | Указать активный инструмент |
 | ✅ | `web.enabled` | Выключить (`false`), если веб-интерфейс не нужен |
-| ⚠️ | `robot.active_controller` | Менять только при намеренном переключении режима управления |
 | ⚠️ | `planning.*` | Менять при необходимости другого планировщика или параметров |
 | ❌ | `robot.description` | Не трогать — путь к URDF |
 | ❌ | `controller.moveit.*` | Не трогать — пути к конфигам MoveIt внутри пакетов |

doc/lwc-doc/docs/realtime-fri.en.md

@@ -0,0 +1,84 @@
+# FIFO priority for FRI
+
+## Why it is needed
+
+FRI exchanges a position command on every cycle. With a 10 ms period, a new packet should be handled about every 10 ms. The regular Linux scheduler can delay the control thread behind other processes. The log then contains messages such as:
+
+```text
+Could not enable FIFO RT scheduling: Operation not permitted
+Overrun might occur ... Read time: 11500 us
+```
+
+`SCHED_FIFO` is Linux scheduling for threads with fixed priority. This project requests priority 50 for `controller_manager` and priority 80 for the FRI worker. The FRI worker receives the higher priority so it can receive a KUKA packet and send the reply on time.
+
+Configure this on the **ROS 2 computer** that runs `cobot run`. It does not require changes to the Sunrise Cabinet or `cobot-setting.yaml`.
+
+## Ubuntu 24.04 setup
+
+On the ROS 2 computer, run these commands as the user who starts `cobot`:
+
+```bash
+sudo groupadd -f realtime
+sudo usermod -aG realtime "$USER"
+sudo tee /etc/security/limits.d/99-ros2-realtime.conf >/dev/null <<'EOF'
+@realtime soft rtprio 99
+@realtime soft priority 99
+@realtime soft memlock unlimited
+@realtime hard rtprio 99
+@realtime hard priority 99
+@realtime hard memlock unlimited
+EOF
+```
+
+Log out of the desktop session completely and log in again, or reboot. An already open terminal does not receive the new group and limits.
+
+## Verification
+
+In a new terminal, verify the group and limits:
+
+```bash
+id -nG | tr ' ' '\n' | grep -x realtime
+ulimit -r
+ulimit -l
+```
+
+The expected output is `realtime`, then `99`, then `unlimited`.
+
+Start FRI without commanding robot motion and check the log for:
+
+```text
+FRI worker uses FIFO priority 80
+```
+
+You can also inspect the policies of all threads in the process:
+
+```bash
+PID=$(pgrep -n ros2_control_node)
+ps -L -p "$PID" -o pid,tid,cls,rtprio,pri,comm
+```
+
+Realtime threads have `FF` in the `CLS` column. The FRI worker has `RTPRIO` 80 and the `controller_manager` main loop has 50.
+
+!!! warning "Before the first motion"
+    First confirm that FRI connects and that the log contains `FRI worker uses FIFO priority 80`. Then make a short move at speed 0.1 with an operator supervising. FIFO reduces jitter on the computer; it does not replace network checks, robot limits, or a clear work area.
+
+## If setup does not work
+
+- If `realtime` is missing from `id`, log out and log in again.
+- If `ulimit -r` is less than 80, check `/etc/security/limits.d/99-ros2-realtime.conf` and that PAM loads `pam_limits.so`.
+- If the log still says `Operation not permitted`, make sure `cobot run` is started by the same user passed to `usermod`.
+- A Python virtualenv needs no extra setup: permissions are assigned to the user and inherited by Python.
+- Docker requires `--cap-add=sys_nice --ulimit rtprio=99 --ulimit memlock=-1`.
+
+## Rollback
+
+To remove the setup, run:
+
+```bash
+sudo rm /etc/security/limits.d/99-ros2-realtime.conf
+sudo gpasswd -d "$USER" realtime
+```
+
+After logging in again, processes use the regular Linux scheduler.
+
+See the official [ros2_control documentation](https://control.ros.org/jazzy/doc/ros2_control/controller_manager/doc/userdoc.html#determinism) for controller-manager priorities and limits.

doc/lwc-doc/docs/realtime-fri.md

@@ -0,0 +1,84 @@
+# FIFO-приоритет для FRI
+
+## Зачем это нужно
+
+FRI передаёт позиционную команду каждый цикл. При выбранном периоде 10 мс новый пакет должен обрабатываться примерно каждые 10 мс. Обычный планировщик Linux может задержать поток другим процессом. В журнале это видно по сообщениям:
+
+```text
+Could not enable FIFO RT scheduling: Operation not permitted
+Overrun might occur ... Read time: 11500 us
+```
+
+`SCHED_FIFO` — политика планировщика Linux для потоков с фиксированным приоритетом. В проекте `controller_manager` запрашивает приоритет 50, а FRI-поток — 80. Поток FRI получает более высокий приоритет, чтобы вовремя принять пакет KUKA и отправить ответ.
+
+Настройку выполняют **на компьютере с ROS 2**, с которого запускается `cobot run`. Sunrise Cabinet и `cobot-setting.yaml` менять для этого не нужно.
+
+## Настройка Ubuntu 24.04
+
+Выполните на компьютере с ROS 2 под пользователем, который запускает `cobot`:
+
+```bash
+sudo groupadd -f realtime
+sudo usermod -aG realtime "$USER"
+sudo tee /etc/security/limits.d/99-ros2-realtime.conf >/dev/null <<'EOF'
+@realtime soft rtprio 99
+@realtime soft priority 99
+@realtime soft memlock unlimited
+@realtime hard rtprio 99
+@realtime hard priority 99
+@realtime hard memlock unlimited
+EOF
+```
+
+Затем полностью выйдите из графического сеанса и войдите снова либо перезагрузите компьютер. Открытый терминал не получает новую группу и лимиты.
+
+## Проверка
+
+В новом терминале проверьте группу и лимиты:
+
+```bash
+id -nG | tr ' ' '\n' | grep -x realtime
+ulimit -r
+ulimit -l
+```
+
+Ожидаемый результат: первая команда выводит `realtime`, вторая — `99`, третья — `unlimited`.
+
+Запустите FRI без движения робота и убедитесь, что в журнале есть:
+
+```text
+FRI worker uses FIFO priority 80
+```
+
+После запуска можно дополнительно посмотреть политики всех потоков процесса:
+
+```bash
+PID=$(pgrep -n ros2_control_node)
+ps -L -p "$PID" -o pid,tid,cls,rtprio,pri,comm
+```
+
+Для потоков реального времени в столбце `CLS` будет `FF`; у FRI-потока `RTPRIO` равен 80, у основного цикла `controller_manager` — 50.
+
+!!! warning "Перед первым движением"
+    Сначала проверьте успешное подключение FRI и строку `FRI worker uses FIFO priority 80`. Затем выполните короткое перемещение на скорости 0.1 при наблюдении оператора. FIFO уменьшает jitter компьютера, но не отменяет контроль сети, ограничений робота и рабочей зоны.
+
+## Если настройка не сработала
+
+- Если `realtime` отсутствует в выводе `id`, выйдите из системы и войдите снова.
+- Если `ulimit -r` меньше 80, проверьте файл `/etc/security/limits.d/99-ros2-realtime.conf` и наличие `pam_limits.so` в конфигурации PAM.
+- Если лог всё ещё сообщает `Operation not permitted`, убедитесь, что `cobot run` запущен тем же пользователем, для которого выполнен `usermod`.
+- В Python virtualenv дополнительных действий не требуется: права задаются пользователю и наследуются процессом Python.
+- Для Docker нужны права контейнера: `--cap-add=sys_nice --ulimit rtprio=99 --ulimit memlock=-1`.
+
+## Откат
+
+Чтобы удалить настройку, выполните:
+
+```bash
+sudo rm /etc/security/limits.d/99-ros2-realtime.conf
+sudo gpasswd -d "$USER" realtime
+```
+
+После повторного входа процессы снова будут работать с обычным планировщиком Linux.
+
+Подробнее о лимитах и приоритете `controller_manager` — в [документации ros2_control](https://control.ros.org/jazzy/doc/ros2_control/controller_manager/doc/userdoc.html#determinism).

doc/lwc-doc/mkdocs.yml

@@ -141,5 +141,6 @@ nav:
         - Меню IO Group:       sunrise/kuka/features/io-group.md
 
   - Решение проблем:
+    - Реальное время FRI: realtime-fri.md
     - Ошибка конфигурации: troubleshooting/config-error.md
     - Ошибка SSL (rosdep/setup): troubleshooting/ssl-error.md

src/iiwa_bringup/launch/iiwa.launch.py

@@ -4,7 +4,7 @@ import sys
 sys.path.insert(0, os.path.dirname(os.path.abspath(__file__)))
 
 from launch import LaunchDescription
-from launch.actions import DeclareLaunchArgument, IncludeLaunchDescription, OpaqueFunction
+from launch.actions import DeclareLaunchArgument, IncludeLaunchDescription, LogInfo, OpaqueFunction
 from launch.launch_description_sources import PythonLaunchDescriptionSource
 from launch.substitutions import LaunchConfiguration, PathJoinSubstitution
 from launch_ros.actions import Node
@@ -50,8 +50,9 @@ def _runtime_setup(context, *args, **kwargs):
             "initial_positions_file": settings.controller.moveit.initial_positions,
             "robot_ip": settings.robot.ip,
             "fri_port": str(settings.robot.port),
-            "simulate": "false",
+            "fri_cycle_ms": str(settings.robot.fri_cycle_ms),
             "joint_position_tau": str(settings.robot.joint_position_tau),
+            "simulate": "false",
         }
 
     robot_description = converter.load_robot_description(
@@ -118,9 +119,18 @@ def _runtime_setup(context, *args, **kwargs):
             "controller_timer": str(settings.digital_twin.webots.controller_timer),
             "fri_cycle_ms": str(settings.robot.fri_cycle_ms),
             "joint_position_tau": str(settings.robot.joint_position_tau),
-            "controller": settings.robot.active_controller,
+            "robot_ip": settings.robot.ip,
+            "fri_port": str(settings.robot.port),
         }
 
+    if not simulate:
+        setup.append(LogInfo(msg=(
+            "FRI configured from cobot-setting.yaml: "
+            f"period={settings.robot.fri_cycle_ms} ms, "
+            f"position_tau={settings.robot.joint_position_tau:.3f} s, "
+            f"endpoint={settings.robot.ip}:{settings.robot.port}"
+        )))
+
     setup.append(IncludeLaunchDescription(
         PythonLaunchDescriptionSource(
             PathJoinSubstitution([

src/iiwa_bringup/launch/supported/controllers.launch.py

@@ -1,10 +1,15 @@
+import math
+
 from launch import LaunchDescription
-from launch.actions import DeclareLaunchArgument, OpaqueFunction
+from launch.actions import DeclareLaunchArgument, LogInfo, OpaqueFunction
 from launch.substitutions import LaunchConfiguration
 from launch.event_handlers import OnProcessExit
 from launch.actions import RegisterEventHandler
 from launch_ros.actions import Node
 from webots_ros2_driver.urdf_spawner import URDFSpawner
+from ament_index_python.packages import get_package_share_directory
+from pathlib import Path
+from xml.etree import ElementTree
 
 
 from iiwa_utils import converter
@@ -19,9 +24,12 @@ def _setup_controllers(context, *args, **kwargs):
     controller_timer = LaunchConfiguration("controller_timer").perform(context)
     controller_path = LaunchConfiguration("controller_path").perform(context)
     simulate = LaunchConfiguration("simulate").perform(context).lower() in ("true", "1", "yes")
-    controller = LaunchConfiguration("controller").perform(context)  # "jtc" | "forward"
     fri_cycle_ms = int(LaunchConfiguration("fri_cycle_ms").perform(context))
-    joint_position_tau = LaunchConfiguration("joint_position_tau").perform(context)
+    if not 1 <= fri_cycle_ms <= 100:
+        raise ValueError("fri_cycle_ms must be within the FRI 1.16 range 1..100 ms")
+    joint_position_tau = float(LaunchConfiguration("joint_position_tau").perform(context))
+    if not math.isfinite(joint_position_tau) or joint_position_tau < 0.0:
+        raise ValueError("joint_position_tau must be finite and non-negative")
     update_rate = 1000 // fri_cycle_ms
 
     xacro_args = {"initial_positions_file": initial_positions_file}
@@ -29,7 +37,10 @@ def _setup_controllers(context, *args, **kwargs):
     if simulate:
         xacro_args["simulate"] = "true"
     else:
-        xacro_args["joint_position_tau"] = joint_position_tau
+        xacro_args["robot_ip"] = LaunchConfiguration("robot_ip").perform(context)
+        xacro_args["fri_port"] = LaunchConfiguration("fri_port").perform(context)
+        xacro_args["fri_cycle_ms"] = str(fri_cycle_ms)
+        xacro_args["joint_position_tau"] = str(joint_position_tau)
 
     robot_description = converter.load_robot_description(
         model_path=description,
@@ -75,6 +86,13 @@ def _setup_controllers(context, *args, **kwargs):
 
     # FRI
     else:
+        manifest = Path(get_package_share_directory("controller_manager")) / "package.xml"
+        version = ElementTree.parse(manifest).findtext("version", "0.0.0")
+        if tuple(int(part) for part in version.split(".")[:3]) < (4, 48, 0):
+            raise RuntimeError(
+                "FRI synchronization requires controller_manager >= 4.48.0 (ROS 2 Jazzy); "
+                f"installed: {version}"
+            )
         ros2_control_node = Node(
             package="controller_manager",
             executable="ros2_control_node",
@@ -83,6 +101,7 @@ def _setup_controllers(context, *args, **kwargs):
                 {"robot_description": robot_description},
                 controller_path,
                 {"update_rate": update_rate},
+                {"hardware_synchronization.expect_blocking_read_write": True},
             ],
         )
 
@@ -98,37 +117,23 @@ def _setup_controllers(context, *args, **kwargs):
 
         cm = ["--controller-manager", "/controller_manager"]
 
-        jtc_args = ["iiwa_arm_controller"] + cm
-        if controller == "forward":
-            jtc_args += ["--inactive"]
-
-        # ForwardCommandController: активен если controller=forward, иначе --inactive
-        forward_args = ["forward_position_controller"] + cm
-        if controller != "forward":
-            forward_args += ["--inactive"]
-
         jtc = Node(
             package="controller_manager",
             executable="spawner",
             output="screen",
-            arguments=jtc_args,
+            arguments=["iiwa_arm_controller"] + cm,
-        )
-
-        forward_controller = Node(
-            package="controller_manager",
-            executable="spawner",
-            output="screen",
-            arguments=forward_args,
         )
 
         jtc_after_jsb = RegisterEventHandler(
             OnProcessExit(
                 target_action=jsb,
-                on_exit=[jtc, forward_controller],
+                on_exit=[jtc],
             )
         )
 
         return [
+            LogInfo(msg=(f"FRI controller period={fri_cycle_ms} ms; Controller Manager rate={update_rate} Hz; "
+                         f"position smoothing tau={joint_position_tau:.3f} s")),
             ros2_control_node,
             jsb,
             jtc_after_jsb,
@@ -139,6 +144,7 @@ def generate_launch_description():
     return LaunchDescription([
         DeclareLaunchArgument("fri_cycle_ms", default_value="5"),
         DeclareLaunchArgument("joint_position_tau", default_value="0.04"),
-        DeclareLaunchArgument("controller", default_value="jtc"),
+        DeclareLaunchArgument("robot_ip", default_value="192.170.10.2"),
+        DeclareLaunchArgument("fri_port", default_value="30200"),
         OpaqueFunction(function=_setup_controllers),
     ])

src/iiwa_bringup/launch/supported/webots_spawn.launch.py

@@ -39,6 +39,13 @@ def _spawn_setup(context, *args, **kwargs):
     with open(controller, "r") as f:
         controller_cfg = yaml.safe_load(f) or {}
 
+    # FRI sets the hardware cycle dynamically in controllers.launch.py. Webots
+    # has no FRI period, so preserve its established 200 Hz controller cycle.
+    manager_params = controller_cfg.setdefault("controller_manager", {}).setdefault(
+        "ros__parameters", {}
+    )
+    manager_params["update_rate"] = 200
+
     combined = {
         "/**": {"ros__parameters": {
             "robot_description": robot_description,

src/iiwa_bringup/package.xml

@@ -26,7 +26,7 @@
   <exec_depend>rviz2</exec_depend>
 
   <!-- ros2_control -->
-  <exec_depend>controller_manager</exec_depend>
+  <exec_depend version_gte="4.48.0">controller_manager</exec_depend>
   <exec_depend>joint_state_broadcaster</exec_depend>
   <exec_depend>joint_trajectory_controller</exec_depend>
   <exec_depend>forward_command_controller</exec_depend>

src/iiwa_config/config/moveit/iiwa_controller.yaml

@@ -1,6 +1,8 @@
 controller_manager:
   ros__parameters:
-    update_rate: 200  # резервное значение; при запуске через launch: 1000 // fri_cycle_ms
+    # `update_rate` задаётся FRI launch-файлом как 1000 / robot.fri_cycle_ms.
+    # Не фиксировать его здесь: KLI Position всегда выдаёт 10 мс (100 Гц),
+    # а KONI может работать с 5 мс (200 Гц).
 
     joint_state_broadcaster:
       type: "joint_state_broadcaster/JointStateBroadcaster"
@@ -8,8 +10,6 @@ controller_manager:
     iiwa_arm_controller:
       type: "joint_trajectory_controller/JointTrajectoryController"
 
-    forward_position_controller:
-      type: "forward_command_controller/ForwardCommandController"
 
 joint_state_broadcaster:
   ros__parameters:
@@ -58,15 +58,3 @@ iiwa_arm_controller:
     #   joint5: { trajectory: 0.1, goal: 0.01 }
     #   joint6: { trajectory: 0.1, goal: 0.01 }
     #   joint7: { trajectory: 0.1, goal: 0.01 }
-
-forward_position_controller:
-  ros__parameters:
-    joints:
-      - joint1
-      - joint2
-      - joint3
-      - joint4
-      - joint5
-      - joint6
-      - joint7
-    interface_name: position

src/iiwa_config/config/setting.yaml

@@ -1,11 +1,9 @@
 robot:
   name: "iiwa7"
-  ip: "192.170.10.2"
+  ip: "192.168.21.147"
   port: 30200
   fri_cycle_ms: 10          # период FRI-цикла: 5 мс (200 Гц) или 10 мс (100 Гц)
-  joint_position_tau: 0.04   # EMA фильтр позиций [с]: сглаживает команды перед отправкой в FRI
+  joint_position_tau: 0.04  # EMA позиций FRI [с]; 0 отключает сглаживание
-  joint_velocity_tau: 0.01   # EMA фильтр скорости [с]: убирает выбросы конечных разностей
-  active_controller: "jtc"  # "jtc" = MoveIt/JointTrajectoryController, "forward" = ForwardCommandController
   description: pkg://iiwa_description/urdf/iiwa7.urdf.xacro
 
 
@@ -79,4 +77,4 @@ foxglove:
     - assets
   include_hidden: false # Показывать клиенту скрытые топики и сервисы (начинаются с _)
   asset_uri_allowlist: ['^package://(?:[-\w%]+/)*[-\w%.]+\.(?:dae|fbx|glb|gltf|jpeg|jpg|mtl|obj|png|stl|tif|tiff|urdf|webp|xacro)$'] # Regex-список URI вида package://..., из которых bridge разрешает отдавать файлы-ассеты (URDF, mesh и т.п.)
-  ignore_unresponsive_param_nodes: true # Не падать, если нода не отвечает на запросы параметров (защита от зависания при старте)
+  ignore_unresponsive_param_nodes: true # Не падать, если нода не отвечает на запросы параметров (защита от зависания при старте)

src/iiwa_controller/CMakeLists.txt

@@ -33,7 +33,7 @@ file(GLOB_RECURSE FRI_SOURCES
 
 add_library(fri_client_sdk STATIC ${FRI_SOURCES})
 
-target_include_directories(fri_client_sdk PUBLIC
+target_include_directories(fri_client_sdk SYSTEM PUBLIC
   ${FRI_SDK_DIR}/include
   ${FRI_SDK_DIR}/src/nanopb-0.2.8
   ${FRI_SDK_DIR}/src/protobuf
@@ -93,4 +93,17 @@ ament_export_targets(export_${PROJECT_NAME})
 ament_export_dependencies(
   controller_interface hardware_interface pluginlib rclcpp rclcpp_lifecycle realtime_tools std_msgs)
 
-ament_package()
+if(BUILD_TESTING)
+  # Manual bounded loopback integration harness; no physical hardware access.
+  add_executable(fake_fri_server test/fake_fri_server.cpp)
+  target_link_libraries(fake_fri_server fri_client_sdk)
+  add_library(fri_loopback_bind SHARED test/loopback_bind.cpp)
+  target_link_libraries(fri_loopback_bind dl)
+  find_package(ament_cmake_gtest REQUIRED)
+  ament_add_gtest(test_fri_client test/test_fri_client.cpp)
+  target_link_libraries(test_fri_client ${PROJECT_NAME} fri_client_sdk)
+  ament_add_gtest(test_hardware test/test_hardware.cpp)
+  target_link_libraries(test_hardware ${PROJECT_NAME} fri_client_sdk hardware_interface::hardware_interface)
+endif()
+
+ament_package()

src/iiwa_controller/include/iiwa_controller/FRIClient.h

@@ -2,6 +2,7 @@
 
 #include <array>
 #include <atomic>
+#include <chrono>
 #include <mutex>
 
 #include "friClientApplication.h"
@@ -10,62 +11,70 @@
 
 namespace iiwa_controller
 {
-
-
-// Снимок состояния робота захватывается атомарно за один lock в FRI-потоке
-// и так же за один lock читается из read() в потоке управления.
 struct IIWAStateSnapshot
 {
-  std::array<double, 7> measured_pos{}; // в Commanding = filtered_pos_ (open-loop)
+  std::array<double, 7> measured_pos{};  // encoder position [rad], never a command
-  std::array<double, 7> measured_tau{}; // измеренные моменты [Нм]
+  std::array<double, 7> measured_tau{};  // measured torque [Nm]
-  std::array<double, 7> external_tau{}; // внешние моменты без компенсации модели [Нм]
+  std::array<double, 7> external_tau{};  // estimated external torque [Nm]
-  std::array<double, 7> ipo_pos{};      // позиция интерполятора [рад], только в Commanding
+  std::array<double, 7> ipo_pos{};       // interpolator position [rad]
-  double sample_time{0.005};            // период цикла FRI [с]
+  std::array<double, 7> command_pos{};   // position sent in the current FRI reply [rad]
+  double sample_time{0.0};
+  KUKA::FRI::ESessionState session{KUKA::FRI::IDLE};
   KUKA::FRI::EConnectionQuality quality{KUKA::FRI::POOR};
-  bool ipo_valid{false};                // в Monitor-режиме IPO недоступна
+  KUKA::FRI::ESafetyState safety{KUKA::FRI::NORMAL_OPERATION};
-  unsigned int time_stamp_sec{0};       // Unix-время пакета [с]
+  KUKA::FRI::EDriveState drives{KUKA::FRI::OFF};
-  unsigned int time_stamp_nano_sec{0};  // наносекундная часть [нс]
+  KUKA::FRI::EOperationMode operation{KUKA::FRI::TEST_MODE_1};
+  KUKA::FRI::EControlMode control{KUKA::FRI::NO_CONTROL};
+  KUKA::FRI::EClientCommandMode command_mode{KUKA::FRI::NO_COMMAND_MODE};
+  KUKA::FRI::EOverlayType overlay{KUKA::FRI::NO_OVERLAY};
+  double tracking_performance{0.0};
+  bool valid{false};
+  bool ipo_valid{false};
+  unsigned int time_stamp_sec{0};
+  unsigned int time_stamp_nano_sec{0};
+  std::chrono::steady_clock::time_point received_at{};
 };
 
 class FRIClient : public KUKA::FRI::LBRClient
 {
 public:
-  static constexpr size_t N_JOINTS = 7;
+  static constexpr size_t N_JOINTS = KUKA::FRI::LBRState::NUMBER_OF_JOINTS;
-
+  using Joints = std::array<double, N_JOINTS>;
-  // joint_position_tau — постоянная времени экспоненциального фильтра позиций [с].
+  explicit FRIClient(double position_smoothing_tau = 0.04);
-  // Аналог joint_position_tau из lbr_fri_ros2_stack (по умолчанию 0.04 с = 40 мс).
-  // Сглаживает скачки команд перед отправкой роботу → убирает писк и стук суставов.
-  explicit FRIClient(double joint_position_tau = 0.04);
-  ~FRIClient() override = default;
-
-  // Коллбэки FRI SDK, вызываются из friThreadFunc через ClientApplication::step()
   void monitor() override;
   void waitForCommand() override;
   void command() override;
-  void onStateChange(
+  void onStateChange(KUKA::FRI::ESessionState oldState,
-    KUKA::FRI::ESessionState oldState, KUKA::FRI::ESessionState newState) override;
+    KUKA::FRI::ESessionState newState) override;
 
-  // Потокобезопасное API для ros2_control, вызывается из read() и write()
+  // Configure before starting the FRI thread; limits come from the robot URDF.
-  void setTargetJointPositions(const std::array<double, N_JOINTS> & q);
+  void setLimits(const Joints & lower, const Joints & upper, const Joints & velocity);
-  IIWAStateSnapshot getStateSnapshot() const;
+  void setExpectedSampleTime(double seconds) {expected_sample_time_ = seconds;}
+  void setTargetJointPositions(const Joints & q);
+  IIWAStateSnapshot getStateSnapshot() const;  // lifecycle/non-RT use
+  bool tryGetStateSnapshot(IIWAStateSnapshot & snapshot) const;
   bool isCommandingActive() const;
   KUKA::FRI::ESessionState getSessionState() const;
 
 private:
-  double joint_position_tau_;
   std::atomic<KUKA::FRI::ESessionState> session_state_{KUKA::FRI::IDLE};
-
+  mutable std::mutex state_mutex_;
-  mutable std::mutex data_mutex_;
+  std::mutex command_mutex_;
-  std::array<double, N_JOINTS> target_pos_{};
+  Joints target_pos_{};
-  // Сглаженная позиция, которую реально отправляем роботу.
+  Joints filtered_pos_{};
-  // Инициализируется IPO-позицией в waitForCommand(), чтобы не было скачка при старте.
+  Joints requested_pos_{};
-  std::array<double, N_JOINTS> filtered_pos_{};
+  Joints sent_pos_{};
-  IIWAStateSnapshot snapshot_{};
+  Joints lower_, upper_, max_velocity_;
-
+  bool initialized_{false};
-  // Обновить snapshot_ без поля ipo_pos (в Monitor-режиме getIpoJointPosition() недоступна)
+  bool requested_{false};
-  void captureMonitoringData();
+  double position_smoothing_tau_{0.04};
-  // Обновить snapshot_ вместе с ipo_pos (в Commanding-режиме)
+  double expected_sample_time_{0.0};
-  void captureCommandingData();
+  std::chrono::steady_clock::time_point requested_at_{};
+  std::chrono::steady_clock::time_point last_command_at_{};
+  IIWAStateSnapshot snapshot_{};  // published under state_mutex_
+  IIWAStateSnapshot current_{};   // owned exclusively by FRI thread
+  void captureData(bool commanding);
+  void publishState();
+  void validateCommanding() const;
 };
-
 }  // namespace iiwa_controller

src/iiwa_controller/include/iiwa_controller/FRICycleGate.hpp

@@ -0,0 +1,67 @@
+#pragma once
+
+#include <chrono>
+#include <condition_variable>
+#include <mutex>
+
+namespace iiwa_controller
+{
+// One SDK step -> one read/update/write -> next SDK step. No queued commands,
+// no independent ROS timer and no overwrite of an unconsumed setpoint.
+class FRICycleGate
+{
+public:
+  void reset()
+  {
+    std::lock_guard<std::mutex> lock(mutex_);
+    stopped_ = available_ = acquired_ = completed_ = false;
+  }
+  void stop()
+  {
+    std::lock_guard<std::mutex> lock(mutex_);
+    stopped_ = true;
+    cv_.notify_all();
+  }
+  bool publishAndWait()
+  {
+    std::unique_lock<std::mutex> lock(mutex_);
+    if (stopped_) {return false;}
+    available_ = true;
+    completed_ = false;
+    cv_.notify_all();
+    if (!cv_.wait_for(lock, timeout_, [&] {return stopped_ || completed_;})) {
+      stopped_ = true;
+      cv_.notify_all();
+    }
+    return !stopped_;
+  }
+  bool waitReady(std::chrono::milliseconds timeout)
+  {
+    std::unique_lock<std::mutex> lock(mutex_);
+    return cv_.wait_for(lock, timeout, [&] {return stopped_ || available_;}) && !stopped_;
+  }
+  bool acquire()
+  {
+    std::unique_lock<std::mutex> lock(mutex_);
+    if (acquired_ || !cv_.wait_for(lock, timeout_, [&] {return stopped_ || available_;}) ||
+      stopped_) {return false;}
+    available_ = false;
+    acquired_ = true;
+    return true;
+  }
+  bool complete()
+  {
+    std::lock_guard<std::mutex> lock(mutex_);
+    if (stopped_ || !acquired_) {return false;}
+    acquired_ = false;
+    completed_ = true;
+    cv_.notify_all();
+    return true;
+  }
+private:
+  static constexpr std::chrono::milliseconds timeout_{100};
+  std::mutex mutex_;
+  std::condition_variable cv_;
+  bool stopped_{true}, available_{false}, acquired_{false}, completed_{false};
+};
+}  // namespace iiwa_controller

src/iiwa_controller/include/iiwa_controller/IIWAHardwareInterface.hpp

@@ -8,10 +8,7 @@
 #include <thread>
 #include <vector>
 
-// В Jazzy 4.44.0+ нельзя переопределять export_state_interfaces() и export_command_interfaces().
+// Jazzy 4.48: framework-managed interfaces and handle API.
-// Устаревший конструктор не регистрирует introspection-callback pal_statistics,
-// из-за чего падает с segfault. Базовый класс сам создаёт интерфейсы из URDF.
-// Данные читаем и пишем через handle-API: set_state() и get_command().
 #include "hardware_interface/hardware_info.hpp"
 #include "hardware_interface/system_interface.hpp"
 #include "hardware_interface/types/hardware_component_interface_params.hpp"
@@ -23,6 +20,7 @@
 #include "rclcpp_lifecycle/state.hpp"
 
 #include "iiwa_controller/FRIClient.h"
+#include "iiwa_controller/FRICycleGate.hpp"
 
 namespace iiwa_controller
 {
@@ -31,6 +29,7 @@ class IIWAHardwareInterface : public hardware_interface::SystemInterface
 {
 public:
   RCLCPP_SHARED_PTR_DEFINITIONS(IIWAHardwareInterface)
+  ~IIWAHardwareInterface() override;
 
   CallbackReturn on_init(
     const hardware_interface::HardwareComponentInterfaceParams & params) override;
@@ -39,13 +38,16 @@ public:
   std::vector<hardware_interface::InterfaceDescription>
   export_unlisted_state_interface_descriptions() override;
 
-  // Полный lifecycle: configure открывает сокет, activate запускает поток,
+  // Полный lifecycle: configure создаёт SDK, activate открывает сокет и запускает поток,
   // deactivate останавливает поток, cleanup освобождает FRI-объекты.
   CallbackReturn on_configure(const rclcpp_lifecycle::State & previous_state) override;
   CallbackReturn on_activate(const rclcpp_lifecycle::State & previous_state) override;
   CallbackReturn on_deactivate(const rclcpp_lifecycle::State & previous_state) override;
   CallbackReturn on_cleanup(const rclcpp_lifecycle::State & previous_state) override;
 
+  CallbackReturn on_shutdown(const rclcpp_lifecycle::State & previous_state) override;
+  CallbackReturn on_error(const rclcpp_lifecycle::State & previous_state) override;
+
   hardware_interface::return_type read(
     const rclcpp::Time & time, const rclcpp::Duration & period) override;
 
@@ -58,44 +60,48 @@ private:
   // Параметры из секции <hardware><param> в URDF
   std::string robot_ip_;
   int fri_port_{30200};
-  bool simulate_{false};
+  int fri_cycle_ms_{5};
   double joint_position_tau_{0.04};
-  // EMA-фильтр скорости: сглаживает одиночные выбросы конечных разностей.
+  int rt_prio_{80};
-  // joint_velocity_tau = 0 отключает фильтр (raw finite difference).
+  bool simulate_{false};
-  double joint_velocity_tau_{0.01};
-
   // Объекты FRI SDK
   std::unique_ptr<FRIClient> fri_client_;
   std::unique_ptr<KUKA::FRI::UdpConnection> connection_;
   std::unique_ptr<KUKA::FRI::ClientApplication> app_;
 
   // FRI работает в отдельном потоке: step() блокируется в recvfrom().
-  // read() лишь читает готовый снимок — без блокировки RT-потока.
+  // read/write rendezvous once per SDK step; network I/O stays in this worker.
+  // Requires controller_manager hardware_synchronization mode (Jazzy 4.48+).
   std::thread fri_thread_;
+  FRICycleGate cycle_gate_;
   std::atomic<bool> fri_running_{false};
   void friThreadFunc();
+  void stopFRI();
+  void releaseFRI();
+  std::atomic<bool> fri_fault_{false};
+  bool active_{false};
+  IIWAStateSnapshot last_snapshot_{};
+  std::array<double, N_JOINTS> lower_, upper_, max_velocity_;
 
   // Хэндлы интерфейсов состояния, заполняются в on_activate
   std::array<hardware_interface::StateInterface::SharedPtr, N_JOINTS> h_pos_;
   std::array<hardware_interface::StateInterface::SharedPtr, N_JOINTS> h_vel_;
   std::array<hardware_interface::StateInterface::SharedPtr, N_JOINTS> h_eff_;
   std::array<hardware_interface::StateInterface::SharedPtr, N_JOINTS> h_ext_;
+  std::array<hardware_interface::StateInterface::SharedPtr, N_JOINTS> h_ipo_;
+  std::array<hardware_interface::StateInterface::SharedPtr, N_JOINTS> h_fri_cmd_;
 
   std::array<hardware_interface::CommandInterface::SharedPtr, N_JOINTS> h_cmd_pos_;
 
-  // Вычисление скорости: конечные разности + EMA-фильтр
+  // Вычисление скорости по измеренной позиции и меткам времени FRI.
   std::array<double, N_JOINTS> prev_pos_{};
-  std::array<double, N_JOINTS> velocity_{};        // отфильтрованная скорость, публикуется в JTC
+  std::array<double, N_JOINTS> velocity_{};        // измеренная скорость [рад/с]
-  std::array<double, N_JOINTS> velocity_raw_{};    // сырая скорость до фильтра
   unsigned int last_ts_sec_{0};
   unsigned int last_ts_nsec_{0};
   bool velocity_initialized_{false};
   void compute_velocity_(const IIWAStateSnapshot & snap);
 
-  // Отслеживание сессии FRI для обнаружения потери управления
-  KUKA::FRI::ESessionState previous_session_state_{KUKA::FRI::IDLE};
 
-  rclcpp::Clock throttle_clock_{RCL_STEADY_TIME};
 
 };
 

src/iiwa_controller/package.xml

@@ -17,6 +17,7 @@
   <depend>realtime_tools</depend>
   <depend>std_msgs</depend>
 
+  <test_depend>ament_cmake_gtest</test_depend>
   <test_depend>ament_lint_auto</test_depend>
   <test_depend>ament_lint_common</test_depend>
 

src/iiwa_controller/src/FRIClient.cpp

@@ -1,155 +1,220 @@
 #include "iiwa_controller/FRIClient.h"
 
+#include <algorithm>
 #include <cmath>
-#include <cstring>
+#include <limits>
-
+#include <stdexcept>
-#include <rclcpp/rclcpp.hpp>
 
 namespace iiwa_controller
 {
+using namespace KUKA::FRI;
 
-static const char * friStateName(KUKA::FRI::ESessionState s)
+FRIClient::FRIClient(double position_smoothing_tau)
+: position_smoothing_tau_(position_smoothing_tau)
 {
-  switch (s) {
+  if (!std::isfinite(position_smoothing_tau_) || position_smoothing_tau_ < 0.0) {
-    case KUKA::FRI::IDLE: return "IDLE";
+    throw std::invalid_argument("Position smoothing tau must be finite and non-negative");
-    case KUKA::FRI::MONITORING_WAIT: return "MONITORING_WAIT";
-    case KUKA::FRI::MONITORING_READY: return "MONITORING_READY";
-    case KUKA::FRI::COMMANDING_WAIT: return "COMMANDING_WAIT";
-    case KUKA::FRI::COMMANDING_ACTIVE: return "COMMANDING_ACTIVE";
-    default: return "UNKNOWN";
   }
+  lower_.fill(-std::numeric_limits<double>::infinity());
+  upper_.fill(std::numeric_limits<double>::infinity());
+  max_velocity_.fill(std::numeric_limits<double>::infinity());
 }
 
-FRIClient::FRIClient(double joint_position_tau)
+void FRIClient::setLimits(const Joints & lower, const Joints & upper, const Joints & velocity)
-: joint_position_tau_(joint_position_tau)
 {
-  target_pos_.fill(0.0);
+  lower_ = lower;
-  filtered_pos_.fill(0.0);
+  upper_ = upper;
+  max_velocity_ = velocity;
 }
 
-// Вызывается только в Monitor-состояниях.
+void FRIClient::captureData(bool commanding)
-// В Monitor-режиме getIpoJointPosition() бросает FRIException, поэтому здесь не зовём.
-void FRIClient::captureMonitoringData()
 {
-  std::memcpy(
+  const auto & state = robotState();
-    snapshot_.measured_pos.data(),
+  std::copy_n(state.getMeasuredJointPosition(), N_JOINTS, current_.measured_pos.begin());
-    robotState().getMeasuredJointPosition(), N_JOINTS * sizeof(double));
+  std::copy_n(state.getMeasuredTorque(), N_JOINTS, current_.measured_tau.begin());
-  std::memcpy(
+  std::copy_n(state.getExternalTorque(), N_JOINTS, current_.external_tau.begin());
-    snapshot_.measured_tau.data(),
+  if (!commanding) {
-    robotState().getMeasuredTorque(), N_JOINTS * sizeof(double));
+    // No application command exists outside a commanding FRI state.
-  std::memcpy(
+    current_.command_pos = current_.measured_pos;
-    snapshot_.external_tau.data(),
-    robotState().getExternalTorque(), N_JOINTS * sizeof(double));
-  snapshot_.sample_time = robotState().getSampleTime();
-  snapshot_.quality = robotState().getConnectionQuality();
-  snapshot_.ipo_valid = false;
-  snapshot_.time_stamp_sec = robotState().getTimestampSec();
-  snapshot_.time_stamp_nano_sec = robotState().getTimestampNanoSec();
-}
-
-// Вызывается из Commanding-состояний (COMMANDING_WAIT и COMMANDING_ACTIVE).
-// В отличие от Monitor, здесь getIpoJointPosition() доступна.
-void FRIClient::captureCommandingData()
-{
-  captureMonitoringData();
-  std::memcpy(
-    snapshot_.ipo_pos.data(),
-    robotState().getIpoJointPosition(), N_JOINTS * sizeof(double));
-  snapshot_.ipo_valid = true;
-  // Open-loop: JTC видит filtered_pos_ как «измеренную» позицию — как в lbr_fri_ros2_stack.
-  // Благодаря этому JTC не видит расхождения и не генерирует коррекций.
-  snapshot_.measured_pos = filtered_pos_;
-}
-
-// Вызывается в MONITORING_WAIT и MONITORING_READY
-void FRIClient::monitor()
-{
-  std::lock_guard<std::mutex> lock(data_mutex_);
-  captureMonitoringData();
-}
-
-// Вызывается в COMMANDING_WAIT.
-// По документации FRI (п. 6.2.2) клиент должен отправлять команды в каждом цикле.
-// Переход в COMMANDING_ACTIVE происходит только когда разница между commanded_position
-// и IPO_position меньше 0.001 рад для всех суставов.
-// Важно эхировать именно IPO-позицию, не measured. Если взять measured,
-// статическое отклонение не даст выполниться этому условию.
-void FRIClient::waitForCommand()
-{
-  std::lock_guard<std::mutex> lock(data_mutex_);
-  captureCommandingData();
-
-  // Инициализируем цель и фильтр IPO-позицией.
-  // Фильтр стартует с IPO — это гарантирует нулевой скачок при переходе в COMMANDING_ACTIVE.
-  std::memcpy(target_pos_.data(), snapshot_.ipo_pos.data(), N_JOINTS * sizeof(double));
-  std::memcpy(filtered_pos_.data(), snapshot_.ipo_pos.data(), N_JOINTS * sizeof(double));
-
-  robotCommand().setJointPosition(filtered_pos_.data());
-}
-
-// Вызывается в COMMANDING_ACTIVE, основной цикл управления
-void FRIClient::command()
-{
-  std::lock_guard<std::mutex> lock(data_mutex_);
-
-  // EMA-фильтр применяется ДО захвата снимка — тогда snapshot_.measured_pos = filtered_pos_
-  // будет содержать то, что реально отправлено роботу в этом цикле (не прошлом).
-  // Это соответствует lbr_fri_ros2_stack: снимок захватывается post-EMA.
-  const double dt = robotState().getSampleTime();
-  const double alpha = (joint_position_tau_ > 0.0) ? dt / (joint_position_tau_ + dt) : 1.0;
-  for (size_t i = 0; i < N_JOINTS; ++i) {
-    filtered_pos_[i] = alpha * target_pos_[i] + (1.0 - alpha) * filtered_pos_[i];
   }
-
+  current_.sample_time = state.getSampleTime();
-  robotCommand().setJointPosition(filtered_pos_.data());
+  current_.session = state.getSessionState();
-
+  current_.quality = state.getConnectionQuality();
-  // Захватываем снимок ПОСЛЕ EMA: measured_pos = filtered_pos_ = что робот только что получил.
+  current_.safety = state.getSafetyState();
-  captureCommandingData();
+  current_.drives = state.getDriveState();
-}
+  current_.operation = state.getOperationMode();
-
+  current_.control = state.getControlMode();
-void FRIClient::onStateChange(
+  current_.command_mode = commanding ? state.getClientCommandMode() : NO_COMMAND_MODE;
-  KUKA::FRI::ESessionState oldState, KUKA::FRI::ESessionState newState)
+  current_.overlay = commanding ? state.getOverlayType() : NO_OVERLAY;
-{
+  current_.tracking_performance = commanding ? state.getTrackingPerformance() : 0.0;
-  session_state_.store(newState, std::memory_order_relaxed);
+  current_.ipo_valid = commanding;
-
+  if (commanding) {
-  RCLCPP_INFO(
+    std::copy_n(state.getIpoJointPosition(), N_JOINTS, current_.ipo_pos.begin());
-    rclcpp::get_logger("FRIClient"),
+  }
-    "FRI смена состояния: %s, теперь %s", friStateName(oldState), friStateName(newState));
+  const auto sec = state.getTimestampSec();
-
+  const auto nsec = state.getTimestampNanoSec();
-  if (newState == KUKA::FRI::IDLE ||
+  if (current_.valid && (sec < current_.time_stamp_sec ||
-    newState == KUKA::FRI::MONITORING_WAIT ||
+    (sec == current_.time_stamp_sec && nsec <= current_.time_stamp_nano_sec)))
-    newState == KUKA::FRI::MONITORING_READY)
   {
+    throw std::runtime_error("FRI timestamp did not advance");
   }
-}
+  if (nsec >= 1000000000 || !std::isfinite(current_.sample_time) || current_.sample_time <= 0.0) {
-
+    throw std::runtime_error("Invalid FRI timestamp/sample period");
-void FRIClient::setTargetJointPositions(const std::array<double, N_JOINTS> & q)
+  }
-{
+  if (expected_sample_time_ > 0.0 &&
-  // До первой команды контроллера интерфейс содержит NaN.
+    std::abs(current_.sample_time - expected_sample_time_) > 1e-9)
-  // Если отправить NaN роботу в COMMANDING_ACTIVE, получим CK_COMPOUND_RETURN_ERROR.
+  {
-  for (const auto & v : q) {
+    throw std::runtime_error(
-    if (!std::isfinite(v)) {
+            "Sunrise FRI period is " + std::to_string(current_.sample_time * 1000.0) +
-      return;
+            " ms, but robot.fri_cycle_ms is " +
+            std::to_string(expected_sample_time_ * 1000.0) + " ms");
+  }
+  if (current_.valid && current_.session == COMMANDING_ACTIVE) {
+    const double elapsed = static_cast<double>(sec - current_.time_stamp_sec) +
+      (static_cast<double>(nsec) - current_.time_stamp_nano_sec) * 1e-9;
+    if (std::abs(elapsed - current_.sample_time) > 1e-6) {
+      throw std::runtime_error("FRI commanding packet gap; refusing to catch up trajectory");
     }
   }
-  std::lock_guard<std::mutex> lock(data_mutex_);
+  for (size_t i = 0; i < N_JOINTS; ++i) {
-  target_pos_ = q;
+    if (!std::isfinite(current_.measured_pos[i]) || !std::isfinite(current_.measured_tau[i]) ||
+      !std::isfinite(current_.external_tau[i]) ||
+      (commanding && !std::isfinite(current_.ipo_pos[i])))
+    {
+      throw std::runtime_error("Non-finite FRI telemetry");
+    }
+  }
+  current_.time_stamp_sec = sec;
+  current_.time_stamp_nano_sec = nsec;
+  current_.received_at = std::chrono::steady_clock::now();
+  current_.valid = true;
+}
+
+void FRIClient::publishState()
+{
+  std::unique_lock<std::mutex> lock(state_mutex_, std::try_to_lock);
+  if (lock.owns_lock()) {snapshot_ = current_;}
+}
+
+void FRIClient::validateCommanding() const
+{
+  if (current_.command_mode != POSITION || current_.overlay != JOINT ||
+    (current_.control != POSITION_CONTROL_MODE && current_.control != JOINT_IMP_CONTROL_MODE &&
+    current_.control != CART_IMP_CONTROL_MODE))
+  {
+    throw std::runtime_error("Expected FRI POSITION command mode with JOINT overlay");
+  }
+  if (current_.quality < GOOD || current_.safety != NORMAL_OPERATION ||
+    current_.drives != ACTIVE)
+  {
+    throw std::runtime_error("FRI commanding unavailable: quality, safety or drives");
+  }
+}
+
+void FRIClient::monitor()
+{
+  captureData(false);
+  LBRClient::monitor();
+  initialized_ = false;
+  publishState();
+}
+
+void FRIClient::waitForCommand()
+{
+  captureData(true);
+  validateCommanding();
+  LBRClient::waitForCommand();  // SDK 1.16 mirrors IPO, not measured position.
+  sent_pos_ = target_pos_ = filtered_pos_ = current_.ipo_pos;
+  current_.command_pos = sent_pos_;
+  initialized_ = true;
+  last_command_at_ = current_.received_at;
+  publishState();
+}
+
+void FRIClient::command()
+{
+  captureData(true);
+  validateCommanding();
+  if (!initialized_) {
+    sent_pos_ = target_pos_ = filtered_pos_ = current_.ipo_pos;
+    last_command_at_ = current_.received_at;
+    initialized_ = true;
+  }
+  {
+    std::lock_guard<std::mutex> lock(command_mutex_);
+    if (requested_ && requested_at_ > last_command_at_) {
+      target_pos_ = requested_pos_;
+      last_command_at_ = requested_at_;
+    }
+    requested_ = false;
+  }
+  // Local watchdog: a stalled ros2_control loop must not leave a moving target active.
+  if (current_.received_at - last_command_at_ > std::chrono::milliseconds(100)) {
+    throw std::runtime_error("FRI command watchdog expired");
+  }
+  const double dt = current_.sample_time;
+  const double alpha = position_smoothing_tau_ == 0.0 ? 1.0 :
+    dt / (position_smoothing_tau_ + dt);
+  for (size_t i = 0; i < N_JOINTS; ++i) {
+    if (!std::isfinite(target_pos_[i]) || target_pos_[i] < lower_[i] ||
+      target_pos_[i] > upper_[i])
+    {
+      throw std::runtime_error("FRI position command outside configured limits");
+    }
+    filtered_pos_[i] = alpha * target_pos_[i] + (1.0 - alpha) * filtered_pos_[i];
+    const double step = filtered_pos_[i] - sent_pos_[i];
+    sent_pos_[i] += std::clamp(step, -max_velocity_[i] * dt, max_velocity_[i] * dt);
+  }
+  robotCommand().setJointPosition(sent_pos_.data());
+  current_.command_pos = sent_pos_;
+  publishState();
+}
+
+void FRIClient::onStateChange(ESessionState oldState, ESessionState newState)
+{
+  session_state_.store(newState);
+  if (oldState == COMMANDING_ACTIVE && newState != COMMANDING_ACTIVE) {
+    throw std::runtime_error("FRI left COMMANDING_ACTIVE; explicit recovery required");
+  }
+}
+
+void FRIClient::setTargetJointPositions(const Joints & q)
+{
+  for (size_t i = 0; i < N_JOINTS; ++i) {
+    if (!std::isfinite(q[i]) || q[i] < lower_[i] || q[i] > upper_[i]) {
+      throw std::invalid_argument("Invalid FRI position command");
+    }
+  }
+  std::lock_guard<std::mutex> lock(command_mutex_);
+  if (requested_) {
+    throw std::logic_error("Previous FRI command has not been consumed");
+  }
+  requested_pos_ = q;
+  requested_at_ = std::chrono::steady_clock::now();
+  requested_ = true;
 }
 
 IIWAStateSnapshot FRIClient::getStateSnapshot() const
 {
-  std::lock_guard<std::mutex> lock(data_mutex_);
+  std::lock_guard<std::mutex> lock(state_mutex_);
   return snapshot_;
 }
 
+bool FRIClient::tryGetStateSnapshot(IIWAStateSnapshot & snapshot) const
+{
+  std::unique_lock<std::mutex> lock(state_mutex_, std::try_to_lock);
+  if (!lock.owns_lock()) {return false;}
+  snapshot = snapshot_;
+  return true;
+}
+
 bool FRIClient::isCommandingActive() const
 {
-  return session_state_.load(std::memory_order_relaxed) == KUKA::FRI::COMMANDING_ACTIVE;
+  return getSessionState() == COMMANDING_ACTIVE;
 }
 
-KUKA::FRI::ESessionState FRIClient::getSessionState() const
+ESessionState FRIClient::getSessionState() const
 {
-  return session_state_.load(std::memory_order_relaxed);
+  return session_state_.load();
 }
-
 }  // namespace iiwa_controller

src/iiwa_controller/src/IIWAHardwareInterface.cpp

@@ -1,5 +1,10 @@
 #include "iiwa_controller/IIWAHardwareInterface.hpp"
 
+#include <algorithm>
+#include <arpa/inet.h>
+#include <limits>
+#include <stdexcept>
+#include "friException.h"
 #include <chrono>
 #include <cmath>
 #include <cstdint>
@@ -10,6 +15,7 @@
 #include "hardware_interface/types/hardware_interface_type_values.hpp"
 #include "pluginlib/class_list_macros.hpp"
 #include "rclcpp/rclcpp.hpp"
+#include "realtime_tools/realtime_helpers.hpp"
 
 PLUGINLIB_EXPORT_CLASS(
   iiwa_controller::IIWAHardwareInterface,
@@ -21,6 +27,32 @@ namespace iiwa_controller
 using CallbackReturn =
   rclcpp_lifecycle::node_interfaces::LifecycleNodeInterface::CallbackReturn;
 
+// The SDK keeps a 100 ms receive bound after the first packet. During startup
+// only, allow 15 s for the operator to start Sunrise without retrying failed SDK steps.
+class StartupConnection : public KUKA::FRI::UdpConnection
+{
+public:
+  explicit StartupConnection(const std::atomic<bool> & running)
+  : KUKA::FRI::UdpConnection(100), running_(running) {}
+
+  int receive(char * buffer, int size) override
+  {
+    const auto deadline = std::chrono::steady_clock::now() + std::chrono::seconds(15);
+    do {
+      const int received = KUKA::FRI::UdpConnection::receive(buffer, size);
+      if (received >= 0) {
+        started_ = true;
+        return received;
+      }
+      if (started_) {return received;}
+    } while (running_.load() && std::chrono::steady_clock::now() < deadline);
+    return -1;
+  }
+private:
+  const std::atomic<bool> & running_;
+  bool started_{false};
+};
+
 static const char * LOG = "IIWAHardwareInterface";
 
 static std::string getParam(
@@ -43,18 +75,44 @@ CallbackReturn IIWAHardwareInterface::on_init(
 
   const auto & info = params.hardware_info;
 
-  robot_ip_            = getParam(info, "robot_ip", "192.170.10.2");
+  try {
-  fri_port_            = std::stoi(getParam(info, "fri_port", "30200"));
+    robot_ip_ = getParam(info, "robot_ip", "192.170.10.2");
-  simulate_            = (getParam(info, "simulate", "false") == "true");
+    size_t used = 0;
-  joint_position_tau_  = std::stod(getParam(info, "joint_position_tau", "0.04"));
+    const auto port = getParam(info, "fri_port", "30200");
-  joint_velocity_tau_  = std::stod(getParam(info, "joint_velocity_tau", "0.01"));
+    fri_port_ = std::stoi(port, &used);
-
+    if (used != port.size() || fri_port_ < 1 || fri_port_ > 65535) {
-  RCLCPP_INFO(rclcpp::get_logger(LOG),
+      throw std::invalid_argument("Invalid fri_port");
-    "on_init: ip=%s port=%d simulate=%s pos_tau=%.3f vel_tau=%.3f",
+    }
-    robot_ip_.c_str(), fri_port_,
+    const auto cycle = getParam(info, "fri_cycle_ms", "5");
-    simulate_ ? "true" : "false",
+    fri_cycle_ms_ = std::stoi(cycle, &used);
-    joint_position_tau_,
+    if (used != cycle.size() || fri_cycle_ms_ < 1 || fri_cycle_ms_ > 100) {
-    joint_velocity_tau_);
+      throw std::invalid_argument("Invalid fri_cycle_ms (expected 1..100)");
+    }
+    const auto position_tau = getParam(info, "joint_position_tau", "0.04");
+    joint_position_tau_ = std::stod(position_tau, &used);
+    if (used != position_tau.size() || !std::isfinite(joint_position_tau_) ||
+      joint_position_tau_ < 0.0)
+    {
+      throw std::invalid_argument("Invalid joint_position_tau (expected >= 0)");
+    }
+    const auto rt_prio = getParam(info, "rt_prio", "80");
+    rt_prio_ = std::stoi(rt_prio, &used);
+    if (used != rt_prio.size() || rt_prio_ < 1 || rt_prio_ > 99) {
+      throw std::invalid_argument("Invalid rt_prio (expected 1..99)");
+    }
+    const auto simulation = getParam(info, "simulate", "false");
+    if (simulation != "true" && simulation != "false") {
+      throw std::invalid_argument("simulate must be true or false");
+    }
+    simulate_ = simulation == "true";
+    in_addr address{};
+    if (!simulate_ && inet_pton(AF_INET, robot_ip_.c_str(), &address) != 1) {
+      throw std::invalid_argument("robot_ip must be an IPv4 address");
+    }
+  } catch (const std::exception & e) {
+    RCLCPP_ERROR(rclcpp::get_logger(LOG), "Invalid hardware parameters: %s", e.what());
+    return CallbackReturn::ERROR;
+  }
 
   if (info.joints.size() != N_JOINTS) {
     RCLCPP_FATAL(rclcpp::get_logger(LOG),
@@ -62,9 +120,41 @@ CallbackReturn IIWAHardwareInterface::on_init(
     return CallbackReturn::ERROR;
   }
 
+  for (size_t i = 0; i < N_JOINTS; ++i) {
+    const auto & joint = info.joints[i];
+    // SDK arrays are ordered A1..A7. Never silently permute axes.
+    if (joint.name != "joint" + std::to_string(i + 1) ||
+      joint.command_interfaces.size() != 1 || joint.command_interfaces[0].name != "position")
+    {
+      RCLCPP_ERROR(rclcpp::get_logger(LOG), "Expected joint1..joint7 with position commands");
+      return CallbackReturn::ERROR;
+    }
+    for (const auto * name : {"position", "velocity", "effort"}) {
+      if (std::none_of(joint.state_interfaces.begin(), joint.state_interfaces.end(),
+        [&](const auto & interface) {return interface.name == name;}))
+      {
+        return CallbackReturn::ERROR;
+      }
+    }
+    const auto limits = info.limits.find(joint.name);
+    if (limits == info.limits.end() || !limits->second.has_position_limits ||
+      !limits->second.has_velocity_limits)
+    {
+      RCLCPP_ERROR(rclcpp::get_logger(LOG), "Missing position/velocity limits for %s", joint.name.c_str());
+      return CallbackReturn::ERROR;
+    }
+    lower_[i] = limits->second.min_position;
+    upper_[i] = limits->second.max_position;
+    max_velocity_[i] = limits->second.max_velocity;
+    if (!std::isfinite(lower_[i]) || !std::isfinite(upper_[i]) || lower_[i] >= upper_[i] ||
+      !std::isfinite(max_velocity_[i]) || max_velocity_[i] <= 0.0)
+    {
+      return CallbackReturn::ERROR;
+    }
+  }
+
   prev_pos_.fill(0.0);
   velocity_.fill(0.0);
-  velocity_raw_.fill(0.0);
   return CallbackReturn::SUCCESS;
 }
 
@@ -74,21 +164,23 @@ std::vector<hardware_interface::InterfaceDescription>
 IIWAHardwareInterface::export_unlisted_state_interface_descriptions()
 {
   std::vector<hardware_interface::InterfaceDescription> descs;
-  descs.reserve(N_JOINTS);
+  descs.reserve(3 * N_JOINTS);
 
   for (size_t i = 0; i < N_JOINTS; ++i) {
-    hardware_interface::InterfaceInfo if_info;
+    for (const auto * name : {"external_torque", "ipo_position", "fri_command_position"}) {
-    if_info.name          = "external_torque";
+      hardware_interface::InterfaceInfo if_info;
-    if_info.data_type     = "double";
+      if_info.name = name;
-    if_info.initial_value = "0.0";
+      if_info.data_type = "double";
-    descs.emplace_back(info_.joints[i].name, if_info);
+      if_info.initial_value = "0.0";
+      descs.emplace_back(info_.joints[i].name, if_info);
+    }
   }
 
   return descs;
 }
 
 // ── on_configure ───────────────────────────────────────────────────────────────
-// Открывает UDP-сокет и создаёт FRI-объекты. Не запускает поток.
+// Создаёт FRI-объекты. Сокет и поток запускаются при активации.
 
 CallbackReturn IIWAHardwareInterface::on_configure(const rclcpp_lifecycle::State &)
 {
@@ -97,143 +189,171 @@ CallbackReturn IIWAHardwareInterface::on_configure(const rclcpp_lifecycle::State
     return CallbackReturn::SUCCESS;
   }
 
+  releaseFRI();
   fri_client_ = std::make_unique<FRIClient>(joint_position_tau_);
-  // 100 мс таймаут recvfrom — поток корректно завершится после disconnect().
+  fri_client_->setLimits(lower_, upper_, max_velocity_);
-  connection_ = std::make_unique<KUKA::FRI::UdpConnection>(100);
+  fri_client_->setExpectedSampleTime(fri_cycle_ms_ * 0.001);
-  app_        = std::make_unique<KUKA::FRI::ClientApplication>(*connection_, *fri_client_);
+  connection_ = std::make_unique<StartupConnection>(fri_running_);
+  app_ = std::make_unique<KUKA::FRI::ClientApplication>(*connection_, *fri_client_);
+  return CallbackReturn::SUCCESS;
+}
 
-  if (!app_->connect(fri_port_, robot_ip_.c_str())) {
+CallbackReturn IIWAHardwareInterface::on_activate(const rclcpp_lifecycle::State & state)
-    RCLCPP_FATAL(rclcpp::get_logger(LOG),
+{
-      "Не удалось открыть UDP-сокет на порту %d (робот: %s)", fri_port_, robot_ip_.c_str());
+  stopFRI();
+  velocity_initialized_ = false;
+  last_snapshot_ = {};
+  try {
+    for (size_t i = 0; i < N_JOINTS; ++i) {
+      const auto & name = info_.joints[i].name;
+      h_pos_[i] = get_state_interface_handle(name + "/position");
+      h_vel_[i] = get_state_interface_handle(name + "/velocity");
+      h_eff_[i] = get_state_interface_handle(name + "/effort");
+      h_ext_[i] = get_state_interface_handle(name + "/external_torque");
+      h_ipo_[i] = get_state_interface_handle(name + "/ipo_position");
+      h_fri_cmd_[i] = get_state_interface_handle(name + "/fri_command_position");
+      h_cmd_pos_[i] = get_command_interface_handle(name + "/position");
+    }
+    if (!simulate_) {
+      // Recreate SDK sequence counters and buffers for every new session.
+      if (on_configure(state) != CallbackReturn::SUCCESS ||
+        !app_->connect(fri_port_, robot_ip_.c_str()))
+      {
+        releaseFRI();
+        return CallbackReturn::ERROR;
+      }
+      fri_fault_.store(false);
+      fri_running_.store(true);
+      cycle_gate_.reset();
+      fri_thread_ = std::thread(&IIWAHardwareInterface::friThreadFunc, this);
+      const bool ready = cycle_gate_.waitReady(std::chrono::seconds(15));
+      last_snapshot_ = fri_client_->getStateSnapshot();
+      if (!ready || fri_fault_.load() || !last_snapshot_.valid ||
+        last_snapshot_.quality < KUKA::FRI::GOOD ||
+        last_snapshot_.session < KUKA::FRI::MONITORING_READY ||
+        std::chrono::steady_clock::now() - last_snapshot_.received_at > std::chrono::milliseconds(100))
+      {
+        stopFRI();
+        RCLCPP_ERROR(rclcpp::get_logger(LOG), "FRI activation failed: no fresh ready session");
+        return CallbackReturn::ERROR;
+      }
+    }
+    for (size_t i = 0; i < N_JOINTS; ++i) {
+      double position = 0.0;
+      if (simulate_) {
+        get_state(h_pos_[i], position, true);
+        if (!std::isfinite(position)) {position = 0.0;}
+      } else {
+        position = last_snapshot_.measured_pos[i];
+      }
+      set_state(h_pos_[i], position, true);
+      set_state(h_vel_[i], 0.0, true);
+      set_state(h_eff_[i], simulate_ ? 0.0 : last_snapshot_.measured_tau[i], true);
+      set_state(h_ext_[i], simulate_ ? 0.0 : last_snapshot_.external_tau[i], true);
+      set_state(h_ipo_[i], position, true);
+      set_state(h_fri_cmd_[i], position, true);
+      set_command(h_cmd_pos_[i], position, true);
+    }
+  } catch (const std::exception & e) {
+    stopFRI();
+    RCLCPP_ERROR(rclcpp::get_logger(LOG), "Activation failed: %s", e.what());
     return CallbackReturn::ERROR;
   }
-
+  active_ = true;
-  RCLCPP_INFO(rclcpp::get_logger(LOG),
-    "UDP-порт %d открыт. Запустите ServerFriRos2 на роботе (%s)...",
-    fri_port_, robot_ip_.c_str());
-
   return CallbackReturn::SUCCESS;
 }
 
-// ── on_activate ────────────────────────────────────────────────────────────────
+void IIWAHardwareInterface::stopFRI()
-// Получает хэндлы интерфейсов, запускает FRI-поток и ждёт установки сессии.
-
-CallbackReturn IIWAHardwareInterface::on_activate(const rclcpp_lifecycle::State &)
 {
-  RCLCPP_INFO(rclcpp::get_logger(LOG), "Активация...");
+  active_ = false;
-
+  fri_running_.store(false);
-  for (size_t i = 0; i < N_JOINTS; ++i) {
+  cycle_gate_.stop();
-    const std::string & jn = info_.joints[i].name;
+  // Receive has a finite timeout. Never close a socket while step() uses it.
-
+  if (fri_thread_.joinable()) {fri_thread_.join();}
-    h_pos_[i]     = get_state_interface_handle(jn + "/" + hardware_interface::HW_IF_POSITION);
+  if (app_) {app_->disconnect();}
-    h_vel_[i]     = get_state_interface_handle(jn + "/" + hardware_interface::HW_IF_VELOCITY);
-    h_eff_[i]     = get_state_interface_handle(jn + "/" + hardware_interface::HW_IF_EFFORT);
-    h_ext_[i]     = get_state_interface_handle(jn + "/external_torque");
-    h_cmd_pos_[i] = get_command_interface_handle(jn + "/" + hardware_interface::HW_IF_POSITION);
-
-    if (!h_pos_[i] || !h_vel_[i] || !h_eff_[i] || !h_ext_[i] || !h_cmd_pos_[i])
-    {
-      RCLCPP_FATAL(rclcpp::get_logger(LOG),
-        "Не удалось получить хэндл интерфейса для сустава '%s'. "
-        "Проверьте объявление <state_interface>/<command_interface> в URDF.",
-        jn.c_str());
-      return CallbackReturn::ERROR;
-    }
-  }
-
-  if (simulate_) {
-    return CallbackReturn::SUCCESS;
-  }
-
-  fri_running_.store(true, std::memory_order_relaxed);
-  fri_thread_ = std::thread(&IIWAHardwareInterface::friThreadFunc, this);
-
-  constexpr int kTimeoutMs = 15000;
-  constexpr int kPollMs    = 200;
-  for (int elapsed = 0;
-       fri_client_->getSessionState() == KUKA::FRI::IDLE && elapsed < kTimeoutMs;
-       elapsed += kPollMs)
-  {
-    RCLCPP_INFO_THROTTLE(rclcpp::get_logger(LOG), throttle_clock_, 2000,
-      "Ожидание FRI-сессии... (%d мс)", elapsed);
-    std::this_thread::sleep_for(std::chrono::milliseconds(kPollMs));
-  }
-
-  if (fri_client_->getSessionState() == KUKA::FRI::IDLE) {
-    RCLCPP_ERROR(rclcpp::get_logger(LOG),
-      "FRI не подключился за %d с. Проверьте ServerFriRos2 на %s",
-      kTimeoutMs / 1000, robot_ip_.c_str());
-  } else {
-    RCLCPP_INFO(rclcpp::get_logger(LOG), "FRI сессия установлена!");
-    const auto snap = fri_client_->getStateSnapshot();
-    prev_pos_     = snap.measured_pos;
-    last_ts_sec_  = snap.time_stamp_sec;
-    last_ts_nsec_ = snap.time_stamp_nano_sec;
-    velocity_.fill(0.0);
-    velocity_initialized_ = true;
-  }
-
-  previous_session_state_ = fri_client_->getSessionState();
-  return CallbackReturn::SUCCESS;
 }
 
-// ── on_deactivate ──────────────────────────────────────────────────────────────
+void IIWAHardwareInterface::releaseFRI()
-// Останавливает FRI-поток. FRI-объекты остаются — их очищает on_cleanup().
+{
+  stopFRI();
+  // ClientApplication::~ClientApplication calls the connection by reference.
+  app_.reset();
+  connection_.reset();
+  fri_client_.reset();
+}
+
+IIWAHardwareInterface::~IIWAHardwareInterface() {releaseFRI();}
 
 CallbackReturn IIWAHardwareInterface::on_deactivate(const rclcpp_lifecycle::State &)
 {
-  RCLCPP_INFO(rclcpp::get_logger(LOG), "Деактивация...");
+  stopFRI();
-
-  if (!simulate_ && fri_running_.load()) {
-    fri_running_.store(false, std::memory_order_relaxed);
-    // Сначала закрываем сокет — это разблокирует recvfrom() в FRI-потоке.
-    // Только потом join(), иначе он зависнет навсегда.
-    if (app_) { app_->disconnect(); }
-    if (fri_thread_.joinable()) { fri_thread_.join(); }
-    RCLCPP_INFO(rclcpp::get_logger(LOG), "FRI поток остановлен");
-  }
-
-  for (size_t i = 0; i < N_JOINTS; ++i) {
-    h_pos_[i] = h_vel_[i] = h_eff_[i] = h_ext_[i] = nullptr;
-    h_cmd_pos_[i] = nullptr;
-  }
-
   velocity_initialized_ = false;
   return CallbackReturn::SUCCESS;
 }
 
-// ── on_cleanup ─────────────────────────────────────────────────────────────────
-// Освобождает FRI-объекты. Вызывается после on_deactivate().
-
 CallbackReturn IIWAHardwareInterface::on_cleanup(const rclcpp_lifecycle::State &)
 {
-  fri_client_.reset();
+  releaseFRI();
-  connection_.reset();
-  app_.reset();
   return CallbackReturn::SUCCESS;
 }
 
-// ── friThreadFunc ──────────────────────────────────────────────────────────────
+CallbackReturn IIWAHardwareInterface::on_shutdown(const rclcpp_lifecycle::State & state)
+{
+  return on_cleanup(state);
+}
+
+CallbackReturn IIWAHardwareInterface::on_error(const rclcpp_lifecycle::State & state)
+{
+  return on_cleanup(state);
+}
 
 void IIWAHardwareInterface::friThreadFunc()
 {
-  RCLCPP_INFO(rclcpp::get_logger(LOG), "FRI поток запущен");
+  try {
-
+    if (!realtime_tools::configure_sched_fifo(rt_prio_)) {
-  while (fri_running_.load(std::memory_order_relaxed)) {
+      RCLCPP_WARN(rclcpp::get_logger(LOG),
-    if (!app_->step()) {
+        "FRI worker could not enable FIFO priority %d; configure realtime permissions for this user",
-      RCLCPP_WARN_THROTTLE(rclcpp::get_logger(LOG), throttle_clock_, 2000,
+        rt_prio_);
-        "FRI: step() вернул false, возможно потеряли соединение");
+    } else {
+      RCLCPP_INFO(rclcpp::get_logger(LOG), "FRI worker uses FIFO priority %d", rt_prio_);
     }
+    bool synchronized = false;
+    const auto startup_deadline = std::chrono::steady_clock::now() + std::chrono::seconds(15);
+    while (fri_running_.load()) {
+      if (!app_->step()) {
+        throw std::runtime_error("FRI step failed");
+      }
+      if (fri_client_->getSessionState() == KUKA::FRI::IDLE) {
+        throw std::runtime_error("FRI session ended");
+      }
+      const auto snapshot = fri_client_->getStateSnapshot();
+      synchronized = synchronized || (snapshot.quality >= KUKA::FRI::GOOD &&
+        snapshot.session >= KUKA::FRI::MONITORING_READY);
+      if (synchronized) {
+        if (!cycle_gate_.publishAndWait()) {
+          if (!fri_running_.load()) {break;}
+          throw std::runtime_error("FRI cycle was not completed by ros2_control within 100 ms");
+        }
+      } else if (std::chrono::steady_clock::now() >= startup_deadline) {
+        throw std::runtime_error("FRI did not reach MONITORING_READY within 15 s");
+      }
+    }
+  } catch (const KUKA::FRI::FRIException & e) {
+    fri_fault_.store(true);
+    RCLCPP_ERROR(rclcpp::get_logger(LOG), "FRI SDK: %s", e.getErrorMessage());
+  } catch (const std::exception & e) {
+    fri_fault_.store(true);
+    RCLCPP_ERROR(rclcpp::get_logger(LOG), "FRI: %s", e.what());
+  } catch (...) {
+    fri_fault_.store(true);
+    RCLCPP_ERROR(rclcpp::get_logger(LOG), "Unknown FRI failure");
   }
-
+  fri_running_.store(false);
-  RCLCPP_INFO(rclcpp::get_logger(LOG), "FRI поток завершён");
+  cycle_gate_.stop();
 }
 
 // ── compute_velocity_ ──────────────────────────────────────────────────────────
-// Конечные разности + EMA-фильтр.
+// Velocity is the finite difference of measured positions at robot timestamps.
-// int64-вычитание timestamp'ов предотвращает потерю точности при больших Unix-значениях.
-// EMA-фильтр (joint_velocity_tau) убирает одиночные выбросы, которые видит JTC как
-// скачки состояния и компенсирует агрессивными командами → хруст двигателей.
 
 void IIWAHardwareInterface::compute_velocity_(const IIWAStateSnapshot & snap)
 {
@@ -242,7 +362,6 @@ void IIWAHardwareInterface::compute_velocity_(const IIWAStateSnapshot & snap)
     last_ts_sec_  = snap.time_stamp_sec;
     last_ts_nsec_ = snap.time_stamp_nano_sec;
     velocity_.fill(0.0);
-    velocity_raw_.fill(0.0);
     velocity_initialized_ = true;
     return;
   }
@@ -258,23 +377,10 @@ void IIWAHardwareInterface::compute_velocity_(const IIWAStateSnapshot & snap)
     (static_cast<double>(snap.time_stamp_nano_sec) -
      static_cast<double>(last_ts_nsec_)) * 1e-9;
 
-  static constexpr std::array<double, N_JOINTS> kMaxVel =
-    {1.71, 1.71, 1.75, 2.27, 2.44, 3.14, 3.14};
-  static constexpr double kVelDeadband = 1e-4;
 
   if (dt > 0.0) {
-    // EMA alpha для фильтра скорости: tau=0 → alpha=1 (без фильтра)
-    const double vel_alpha = (joint_velocity_tau_ > 0.0)
-      ? dt / (joint_velocity_tau_ + dt)
-      : 1.0;
-
     for (size_t i = 0; i < N_JOINTS; ++i) {
-      const double raw     = (snap.measured_pos[i] - prev_pos_[i]) / dt;
+      velocity_[i] = (snap.measured_pos[i] - prev_pos_[i]) / dt;
-      const double clamped = std::clamp(raw, -kMaxVel[i], kMaxVel[i]);
-      velocity_raw_[i] = (std::abs(clamped) < kVelDeadband) ? 0.0 : clamped;
-
-      // EMA: velocity_[i] = alpha * raw + (1 - alpha) * prev_filtered
-      velocity_[i] = vel_alpha * velocity_raw_[i] + (1.0 - vel_alpha) * velocity_[i];
     }
   }
 
@@ -288,31 +394,40 @@ void IIWAHardwareInterface::compute_velocity_(const IIWAStateSnapshot & snap)
 hardware_interface::return_type IIWAHardwareInterface::read(
   const rclcpp::Time &, const rclcpp::Duration &)
 {
+  if (!active_) {return hardware_interface::return_type::OK;}
   if (simulate_) {
     for (size_t i = 0; i < N_JOINTS; ++i) {
       double pos = 0.0;
-      get_command(h_cmd_pos_[i], pos, false);
+      if (!get_command(h_cmd_pos_[i], pos, false) || !std::isfinite(pos)) {
+        return hardware_interface::return_type::ERROR;
+      }
       set_state(h_pos_[i], pos, false);
       set_state(h_vel_[i], 0.0, false);
       set_state(h_eff_[i], 0.0, false);
       set_state(h_ext_[i], 0.0, false);
+      set_state(h_ipo_[i], pos, false);
+      set_state(h_fri_cmd_[i], pos, false);
     }
     return hardware_interface::return_type::OK;
   }
 
-  const auto snap = fri_client_->getStateSnapshot();
+  if (!fri_client_ || fri_fault_.load() || !fri_running_.load()) {
-
+    return hardware_interface::return_type::ERROR;
-  // Обнаружение потери управления: неожиданный выход из COMMANDING_ACTIVE.
+  }
-  const auto current_state = fri_client_->getSessionState();
+  if (!cycle_gate_.acquire()) {
-  if (previous_session_state_ == KUKA::FRI::COMMANDING_ACTIVE &&
+    fri_fault_.store(true);
-      current_state != KUKA::FRI::COMMANDING_ACTIVE)
+    fri_running_.store(false);
+    cycle_gate_.stop();
+    return hardware_interface::return_type::ERROR;
+  }
+  last_snapshot_ = fri_client_->getStateSnapshot();
+  const auto & snap = last_snapshot_;
+  if (!snap.valid || std::chrono::steady_clock::now() - snap.received_at >
+    std::chrono::milliseconds(100))
   {
-    RCLCPP_ERROR(rclcpp::get_logger(LOG),
+    fri_running_.store(false);
-      "Робот вышел из COMMANDING_ACTIVE! Деактивируйте и повторно активируйте контроллер.");
     return hardware_interface::return_type::ERROR;
   }
-  previous_session_state_ = current_state;
-
   compute_velocity_(snap);
 
   for (size_t i = 0; i < N_JOINTS; ++i) {
@@ -320,6 +435,8 @@ hardware_interface::return_type IIWAHardwareInterface::read(
     set_state(h_vel_[i], velocity_[i],         false);
     set_state(h_eff_[i], snap.measured_tau[i], false);
     set_state(h_ext_[i], snap.external_tau[i], false);
+    set_state(h_ipo_[i], snap.ipo_valid ? snap.ipo_pos[i] : snap.measured_pos[i], false);
+    set_state(h_fri_cmd_[i], snap.command_pos[i], false);
   }
 
   return hardware_interface::return_type::OK;
@@ -330,22 +447,34 @@ hardware_interface::return_type IIWAHardwareInterface::read(
 hardware_interface::return_type IIWAHardwareInterface::write(
   const rclcpp::Time &, const rclcpp::Duration &)
 {
-  if (simulate_) {
+  if (!active_ || simulate_) {return hardware_interface::return_type::OK;}
-    return hardware_interface::return_type::OK;
+  if (!fri_client_ || fri_fault_.load() || !fri_running_.load()) {
+    return hardware_interface::return_type::ERROR;
   }
-
+  if (!fri_client_->isCommandingActive()) {
-  if (fri_client_->getSessionState() != KUKA::FRI::COMMANDING_ACTIVE) {
+    return cycle_gate_.complete() ? hardware_interface::return_type::OK :
-    return hardware_interface::return_type::OK;
+           hardware_interface::return_type::ERROR;
   }
-
   std::array<double, N_JOINTS> pos_cmd{};
   for (size_t i = 0; i < N_JOINTS; ++i) {
-    get_command(h_cmd_pos_[i], pos_cmd[i], false);
+    if (!get_command(h_cmd_pos_[i], pos_cmd[i], false)) {
+      cycle_gate_.stop();
+      return hardware_interface::return_type::ERROR;
+    }
+    if (!std::isfinite(pos_cmd[i]) || pos_cmd[i] < lower_[i] || pos_cmd[i] > upper_[i]) {
+      fri_fault_.store(true);
+      fri_running_.store(false);
+      return hardware_interface::return_type::ERROR;
+    }
   }
-
+  try {
-  fri_client_->setTargetJointPositions(pos_cmd);
+    fri_client_->setTargetJointPositions(pos_cmd);
-
+  } catch (const std::exception &) {
-  return hardware_interface::return_type::OK;
+    cycle_gate_.stop();
+    return hardware_interface::return_type::ERROR;
+  }
+  return cycle_gate_.complete() ? hardware_interface::return_type::OK :
+         hardware_interface::return_type::ERROR;
 }
 
 }  // namespace iiwa_controller

src/iiwa_controller/test/fake_fri_server.cpp

@@ -0,0 +1,112 @@
+// Offline protocol peer, not a dynamics or Sunrise safety simulator.
+// Both endpoints are hardcoded loopback addresses. Never accepts a robot IP.
+#include <arpa/inet.h>
+#include <sys/socket.h>
+#include <unistd.h>
+#include <array>
+#include <chrono>
+#include <cmath>
+#include <fstream>
+#include <iostream>
+#include <thread>
+#include "FRIMessages.pb.h"
+#include "pb_encode.h"
+#include "pb_decode.h"
+#include "pb_frimessages_callbacks.h"
+
+int main(int argc, char ** argv)
+{
+  if (argc != 2) {return 2;}
+  std::ofstream csv(argv[1]);
+  csv << "sequence,session,receive_seconds,position,delta\n";
+  csv.flush();
+  int fd = socket(AF_INET, SOCK_DGRAM, 0);
+  sockaddr_in local{}, remote{};
+  local.sin_family = remote.sin_family = AF_INET;
+  local.sin_port = remote.sin_port = htons(30283);
+  inet_pton(AF_INET, "127.0.0.2", &local.sin_addr);
+  inet_pton(AF_INET, "127.0.0.1", &remote.sin_addr);
+  if (fd < 0 || bind(fd, reinterpret_cast<sockaddr *>(&local), sizeof(local))) {
+    perror("fake FRI loopback bind"); return 2;
+  }
+  timeval timeout{0, 20000};
+  setsockopt(fd, SOL_SOCKET, SO_RCVTIMEO, &timeout, sizeof(timeout));
+  std::array<double, 7> q{}, zero{}, received{};
+  std::array<int64_t, 7> drives{};
+  drives.fill(DriveState_ACTIVE);
+  tRepeatedDoubleArguments positions{7, 7, q.data()}, zeros{7, 7, zero.data()};
+  tRepeatedIntArguments drive_values{7, 7, drives.data()};
+  FRIMonitoringMessage m{};
+  m.header.messageIdentifier = 0x245142;  // Bundled SDK LBRMONITORMESSAGEID.
+  m.has_robotInfo = m.has_monitorData = m.has_connectionInfo = true;
+  m.robotInfo.has_numberOfJoints = m.robotInfo.has_safetyState = true;
+  m.robotInfo.has_operationMode = m.robotInfo.has_controlMode = true;
+  m.robotInfo.numberOfJoints = 7;
+  m.robotInfo.safetyState = SafetyState_NORMAL_OPERATION;
+  m.robotInfo.operationMode = OperationMode_AUTOMATIC_MODE;
+  m.robotInfo.controlMode = ControlMode_POSITION_CONTROLMODE;
+  m.robotInfo.driveState.funcs.encode = encode_repeatedInt;
+  m.robotInfo.driveState.arg = &drive_values;
+  m.connectionInfo.quality = FRIConnectionQuality_GOOD;
+  m.connectionInfo.has_sendPeriod = m.connectionInfo.has_receiveMultiplier = true;
+  m.connectionInfo.sendPeriod = 10;
+  m.connectionInfo.receiveMultiplier = 1;
+  auto & md = m.monitorData;
+  md.has_timestamp = md.has_measuredJointPosition = md.has_commandedJointPosition = true;
+  md.has_measuredTorque = md.has_commandedTorque = md.has_externalTorque = true;
+  for (auto * values : {&md.measuredJointPosition, &md.commandedJointPosition, &m.ipoData.jointPosition}) {
+    values->value.funcs.encode = encode_repeatedDouble;
+    values->value.arg = &positions;
+  }
+  for (auto * values : {&md.measuredTorque, &md.commandedTorque, &md.externalTorque}) {
+    values->value.funcs.encode = encode_repeatedDouble;
+    values->value.arg = &zeros;
+  }
+  m.ipoData.has_jointPosition = m.ipoData.has_clientCommandMode = true;
+  m.ipoData.has_overlayType = m.ipoData.has_trackingPerformance = true;
+  m.ipoData.clientCommandMode = ClientCommandMode_POSITION;
+  m.ipoData.overlayType = OverlayType_JOINT;
+  m.ipoData.trackingPerformance = 1.0;
+  using Clock = std::chrono::steady_clock;
+  const auto start = Clock::now();
+  auto next = start;
+  unsigned replies = 0;
+  for (unsigned seq = 0; Clock::now() - start < std::chrono::seconds(45); ++seq) {
+    m.header.sequenceCounter = seq;
+    m.connectionInfo.sessionState = replies < 20 ? FRISessionState_MONITORING_READY :
+      replies < 40 ? FRISessionState_COMMANDING_WAIT : FRISessionState_COMMANDING_ACTIVE;
+    m.has_ipoData = replies >= 20;
+    md.timestamp.sec = 1 + seq / 100;
+    md.timestamp.nanosec = (seq % 100) * 10000000;
+    uint8_t buffer[2048];
+    auto output = pb_ostream_from_buffer(buffer, sizeof(buffer));
+    if (!pb_encode(&output, FRIMonitoringMessage_fields, &m)) {return 3;}
+    sendto(fd, buffer, output.bytes_written, 0, reinterpret_cast<sockaddr *>(&remote), sizeof(remote));
+    auto count = recv(fd, buffer, sizeof(buffer), 0);
+    if (count > 0) {
+      FRICommandMessage command{};
+      tRepeatedDoubleArguments target{0, 7, received.data()};
+      command.commandData.jointPosition.value.funcs.decode = decode_repeatedDouble;
+      command.commandData.jointPosition.value.arg = &target;
+      auto input = pb_istream_from_buffer(buffer, count);
+      if (!pb_decode(&input, FRICommandMessage_fields, &command) ||
+        !command.has_commandData || !command.commandData.has_jointPosition) {return 4;}
+      for (double value : received) {if (!std::isfinite(value)) {return 5;}}
+      const double delta = received[0] - q[0];
+      csv << seq << ',' << m.connectionInfo.sessionState << ',' <<
+        std::chrono::duration<double>(Clock::now() - start).count() << ',' << received[0] << ',' << delta << '\n';
+      csv.flush();
+      q = received;
+      m.header.reflectedSequenceCounter = command.header.sequenceCounter;
+      ++replies;
+    } else if (replies) {
+      std::cerr << "Reply timeout after " << replies << " frames\n";
+      close(fd); return 6;
+    }
+    // Before connection, avoid catch-up bursts after receive timeouts.
+    next = replies ? next + std::chrono::milliseconds(10) : Clock::now();
+    std::this_thread::sleep_until(next);
+  }
+  close(fd);
+  return 0;
+}

src/iiwa_controller/test/loopback_bind.cpp

@@ -0,0 +1,20 @@
+// Test-only interposer: allow the unmodified SDK and fake robot to share one host.
+// The SDK otherwise binds all local addresses at the robot's source port.
+#include <arpa/inet.h>
+#include <dlfcn.h>
+#include <sys/socket.h>
+
+extern "C" int bind(int fd, const sockaddr * address, socklen_t length)
+{
+  using Bind = int (*)(int, const sockaddr *, socklen_t);
+  static auto real_bind = reinterpret_cast<Bind>(dlsym(RTLD_NEXT, "bind"));
+  if (address->sa_family == AF_INET && length == sizeof(sockaddr_in)) {
+    auto local = *reinterpret_cast<const sockaddr_in *>(address);
+    // Dedicated smoke-test port only; never alter DDS or other application binds.
+    if (local.sin_port == htons(30283) && local.sin_addr.s_addr == htonl(INADDR_ANY)) {
+      inet_pton(AF_INET, "127.0.0.1", &local.sin_addr);
+      return real_bind(fd, reinterpret_cast<const sockaddr *>(&local), sizeof(local));
+    }
+  }
+  return real_bind(fd, address, length);
+}

src/iiwa_controller/test/smoke_fri.py

@@ -0,0 +1,83 @@
+"""Manual bounded real-SDK/JTC integration check over loopback only.
+
+Run after building/sourcing iiwa_controller; never connects physical hardware.
+"""
+import csv
+import sys
+import time
+import os
+import signal
+import subprocess
+import tempfile
+from pathlib import Path
+import xacro
+import yaml
+
+root = Path(__file__).resolve().parents[3]
+work = Path(tempfile.mkdtemp(prefix='iiwa-fri-smoke-'))
+env = dict(os.environ, ROS_DOMAIN_ID='83', ROS_LOCALHOST_ONLY='1', ROS_LOG_DIR=str(work / 'logs'), ROS_HOME=str(work / 'ros'))
+env['CYCLONEDDS_URI'] = '<CycloneDDS><Domain><General><Interfaces><NetworkInterface name="lo"/></Interfaces><AllowMulticast>false</AllowMulticast></General><Discovery><Peers><Peer Address="127.0.0.1"/></Peers></Discovery></Domain></CycloneDDS>'
+xml = xacro.process_file(str(root / 'src/iiwa_description/urdf/iiwa7.urdf.xacro'), mappings={'robot_ip': '127.0.0.2', 'fri_port': '30283', 'fri_cycle_ms': '10'}).toxml()
+assert '<param name="simulate">false</param>' in xml
+assert '<param name="robot_ip">127.0.0.2</param>' in xml
+assert '<param name="fri_port">30283</param>' in xml
+build = Path(sys.argv[1]) if len(sys.argv) > 1 else root / 'build/iiwa_controller'
+server = build / 'fake_fri_server'
+shim = build / 'libfri_loopback_bind.so'
+assert server.is_file() and shim.is_file(), 'Build the test harness first'
+trace = work / 'commands.csv'
+params = work / 'robot.yaml'
+params.write_text(yaml.safe_dump({'/**': {'ros__parameters': {'robot_description': xml}}}))
+processes = []
+handles = []
+try:
+    server_log = (work / 'fake_fri_server.log').open('w')
+    handles.append(server_log)
+    processes.append(subprocess.Popen([str(server), str(trace)], stdout=server_log, stderr=subprocess.STDOUT, start_new_session=True))
+    time.sleep(0.1)
+    assert processes[0].poll() is None, 'Fake peer failed to bind'
+    for package, executable, extra in [
+        ('robot_state_publisher', 'robot_state_publisher', []),
+        ('controller_manager', 'ros2_control_node', ['--params-file', str(root / 'src/iiwa_config/config/moveit/iiwa_controller.yaml'), '-p', 'update_rate:=100', '-p', 'hardware_synchronization.expect_blocking_read_write:=true']),
+    ]:
+        log = (work / (executable + '.log')).open('w')
+        handles.append(log)
+        processes.append(subprocess.Popen(['ros2', 'run', package, executable, '--ros-args', '--params-file', str(params)] + extra,
+                                          env=dict(env, **({'LD_PRELOAD': str(shim)} if executable == 'ros2_control_node' else {})), stdout=log, stderr=subprocess.STDOUT, start_new_session=True))
+    for name in ['joint_state_broadcaster', 'iiwa_arm_controller']:
+        result = subprocess.run(['ros2', 'run', 'controller_manager', 'spawner', name, '--controller-manager-timeout', '15'],
+                                env=env, text=True, capture_output=True, timeout=25)
+        print(result.stdout, result.stderr, flush=True)
+        assert result.returncode == 0, name
+    result = subprocess.run(['ros2', 'control', 'list_controllers'], env=env, text=True, capture_output=True, timeout=10)
+    print(result.stdout, result.stderr, flush=True)
+    assert result.returncode == 0 and 'iiwa_arm_controller' in result.stdout and 'active' in result.stdout
+    initial = yaml.safe_load((root / 'src/iiwa_config/config/moveit/initial_positions.yaml').read_text())['initial_positions']
+    positions = [float(initial[f'joint{i}']) for i in range(1, 8)]
+    positions[0] += 0.02
+    goal = {'trajectory': {'joint_names': [f'joint{i}' for i in range(1, 8)],
+            'points': [{'positions': positions, 'time_from_start': {'sec': 2, 'nanosec': 0}}]}}
+    result = subprocess.run(['ros2', 'action', 'send_goal', '/iiwa_arm_controller/follow_joint_trajectory',
+                             'control_msgs/action/FollowJointTrajectory', yaml.safe_dump(goal)],
+                            env=env, text=True, capture_output=True, timeout=15)
+    print(result.stdout, result.stderr, flush=True)
+    assert result.returncode == 0 and 'SUCCEEDED' in result.stdout
+    rows = list(csv.DictReader(trace.open()))
+    assert len(rows) > 100 and processes[0].poll() is None, 'FRI stream stopped'
+    active = [r for r in rows if int(r['session']) == 4]
+    assert active and abs(float(active[-1]['position']) - 0.02) < 0.001
+    deltas = [abs(float(r['delta'])) for r in active]
+    intervals = [float(b['receive_seconds']) - float(a['receive_seconds']) for a, b in zip(active, active[1:])]
+    assert max(deltas) <= 1.71 * 0.01 + 1e-6, 'Command exceeds per-frame velocity limit'
+    print(f'SMOKE PASS: real SDK loopback + actual CM/JTC action succeeded; {len(active)} active frames, max delta={max(deltas):.8f} rad; receive interval min/max={min(intervals):.6f}/{max(intervals):.6f} s.', flush=True)
+finally:
+    for process in processes:
+        if process.poll() is None:
+            os.killpg(process.pid, signal.SIGINT)
+    for process in processes:
+        try: process.wait(timeout=5)
+        except subprocess.TimeoutExpired: os.killpg(process.pid, signal.SIGKILL)
+    for handle in handles: handle.close()
+    for log in work.glob('*.log'):
+        print('\n' + log.name + '\n' + log.read_text()[-4500:])
+    print('Logs:', work)

src/iiwa_controller/test/smoke_jtc.py

@@ -0,0 +1,59 @@
+"""Manual local JTC integration check; never opens a FRI connection."""
+import os
+import signal
+import subprocess
+import tempfile
+from pathlib import Path
+import xacro
+import yaml
+
+root = Path(__file__).resolve().parents[3]
+work = Path(tempfile.mkdtemp(prefix='iiwa-controller-smoke-'))
+env = dict(os.environ, ROS_DOMAIN_ID='83', ROS_LOCALHOST_ONLY='1', ROS_LOG_DIR=str(work / 'logs'), ROS_HOME=str(work / 'ros'))
+env['CYCLONEDDS_URI'] = '<CycloneDDS><Domain><General><Interfaces><NetworkInterface name="lo"/></Interfaces><AllowMulticast>false</AllowMulticast></General><Discovery><Peers><Peer Address="127.0.0.1"/></Peers></Discovery></Domain></CycloneDDS>'
+xml = xacro.process_file(str(root / 'src/iiwa_description/urdf/iiwa7.urdf.xacro')).toxml()
+assert '<param name="simulate">false</param>' in xml
+# Exercise our plugin's explicit local simulation path, with no FRI socket.
+xml = xml.replace('<param name="simulate">false</param>', '<param name="simulate">true</param>')
+params = work / 'robot.yaml'
+params.write_text(yaml.safe_dump({'/**': {'ros__parameters': {'robot_description': xml}}}))
+processes = []
+handles = []
+try:
+    for package, executable, extra in [
+        ('robot_state_publisher', 'robot_state_publisher', []),
+        ('controller_manager', 'ros2_control_node', ['--params-file', str(root / 'src/iiwa_config/config/moveit/iiwa_controller.yaml')]),
+    ]:
+        log = (work / (executable + '.log')).open('w')
+        handles.append(log)
+        processes.append(subprocess.Popen(['ros2', 'run', package, executable, '--ros-args', '--params-file', str(params)] + extra,
+                                          env=env, stdout=log, stderr=subprocess.STDOUT, start_new_session=True))
+    for name in ['joint_state_broadcaster', 'iiwa_arm_controller']:
+        result = subprocess.run(['ros2', 'run', 'controller_manager', 'spawner', name, '--controller-manager-timeout', '15'],
+                                env=env, text=True, capture_output=True, timeout=25)
+        print(result.stdout, result.stderr, flush=True)
+        assert result.returncode == 0, name
+    result = subprocess.run(['ros2', 'control', 'list_controllers'], env=env, text=True, capture_output=True, timeout=10)
+    print(result.stdout, result.stderr, flush=True)
+    assert result.returncode == 0 and 'iiwa_arm_controller' in result.stdout and 'active' in result.stdout
+    initial = yaml.safe_load((root / 'src/iiwa_config/config/moveit/initial_positions.yaml').read_text())['initial_positions']
+    positions = [float(initial[f'joint{i}']) for i in range(1, 8)]
+    positions[0] += 0.02
+    goal = {'trajectory': {'joint_names': [f'joint{i}' for i in range(1, 8)],
+            'points': [{'positions': positions, 'time_from_start': {'sec': 2, 'nanosec': 0}}]}}
+    result = subprocess.run(['ros2', 'action', 'send_goal', '/iiwa_arm_controller/follow_joint_trajectory',
+                             'control_msgs/action/FollowJointTrajectory', yaml.safe_dump(goal)],
+                            env=env, text=True, capture_output=True, timeout=15)
+    print(result.stdout, result.stderr, flush=True)
+    assert result.returncode == 0 and 'SUCCEEDED' in result.stdout
+    print('SMOKE PASS: actual URDF, iiwa hardware plugin, broadcaster and JTC active; no FRI connection.', flush=True)
+finally:
+    for process in processes:
+        os.killpg(process.pid, signal.SIGINT)
+    for process in processes:
+        try: process.wait(timeout=5)
+        except subprocess.TimeoutExpired: os.killpg(process.pid, signal.SIGKILL)
+    for handle in handles: handle.close()
+    for log in work.glob('*.log'):
+        print('\n' + log.name + '\n' + log.read_text()[-4500:])
+    print('Logs:', work)

src/iiwa_controller/test/test_fri_client.cpp

@@ -0,0 +1,279 @@
+#include <gtest/gtest.h>
+#include <algorithm>
+#include <limits>
+#include <memory>
+#include <stdexcept>
+#include <thread>
+#include "iiwa_controller/FRIClient.h"
+#include "iiwa_controller/FRICycleGate.hpp"
+#include <atomic>
+#include <vector>
+#include "friClientData.h"
+#include "pb_frimessages_callbacks.h"
+
+using namespace KUKA::FRI;
+
+class TestApplication : public ClientApplication
+{
+public:
+  using ClientApplication::ClientApplication;
+  ClientData * data() {return _data;}
+};
+
+class ClientFixture : public iiwa_controller::FRIClient
+{
+public:
+  explicit ClientFixture(double position_smoothing_tau = 0.04)
+  : FRIClient(position_smoothing_tau), app(connection, *this), data(app.data())
+  {
+    auto & m = data->monitoringMsg;
+    m.connectionInfo.sendPeriod = 10;
+    m.connectionInfo.quality = FRIConnectionQuality_GOOD;
+    m.robotInfo.safetyState = SafetyState_NORMAL_OPERATION;
+    m.robotInfo.operationMode = OperationMode_AUTOMATIC_MODE;
+    m.robotInfo.controlMode = ControlMode_POSITION_CONTROLMODE;
+    auto * drives = static_cast<tRepeatedIntArguments *>(m.robotInfo.driveState.arg);
+    std::fill_n(drives->value, 7, DriveState_ACTIVE);
+    m.ipoData.clientCommandMode = ClientCommandMode_POSITION;
+    m.ipoData.overlayType = OverlayType_JOINT;
+    m.ipoData.has_trackingPerformance = false;
+    m.monitorData.timestamp.sec = 1;
+    m.monitorData.timestamp.nanosec = 0;
+    fill(m.monitorData.measuredJointPosition, 0.2);
+    fill(m.monitorData.commandedJointPosition, 0.3);
+    fill(m.monitorData.measuredTorque, 1.0);
+    fill(m.monitorData.externalTorque, 0.1);
+    fill(m.ipoData.jointPosition, 0.4);
+  }
+  static void fill(JointValues & values, double value)
+  {
+    auto * args = static_cast<tRepeatedDoubleArguments *>(values.value.arg);
+    std::fill_n(args->value, 7, value);
+    args->size = 7;
+  }
+  void cycle(ESessionState state)
+  {
+    data->resetCommandMessage();
+    data->monitoringMsg.ipoData.has_jointPosition = state >= COMMANDING_WAIT;
+    data->monitoringMsg.connectionInfo.sessionState = static_cast<FRISessionState>(state);
+    onStateChange(data->lastState, state);
+    data->lastState = state;
+    data->monitoringMsg.monitorData.timestamp.nanosec += 10000000;
+    if (state == COMMANDING_WAIT) waitForCommand();
+    else if (state == COMMANDING_ACTIVE) command();
+    else monitor();
+  }
+  double sentPosition()
+  {
+    return static_cast<tRepeatedDoubleArguments *>(
+      data->commandMsg.commandData.jointPosition.value.arg)->value[0];
+  }
+  UdpConnection connection;
+  TestApplication app;
+  ClientData * data;
+};
+
+TEST(FRIClient, ReportsMeasuredPositionInCommanding)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  EXPECT_DOUBLE_EQ(client.sentPosition(), 0.4);
+  EXPECT_DOUBLE_EQ(client.getStateSnapshot().measured_pos[0], 0.2);
+  client.cycle(COMMANDING_ACTIVE);
+  EXPECT_DOUBLE_EQ(client.getStateSnapshot().measured_pos[0], 0.2);
+}
+
+TEST(FRIClient, PreservesSdkMonitoringReplyWithoutIpo)
+{
+  ClientFixture client;
+  client.cycle(MONITORING_READY);
+  EXPECT_TRUE(client.data->commandMsg.commandData.has_jointPosition);
+  EXPECT_DOUBLE_EQ(client.sentPosition(), 0.3);
+  EXPECT_FALSE(client.getStateSnapshot().ipo_valid);
+}
+
+TEST(FRIClient, RejectsUnsupportedCommandModeBeforeSending)
+{
+  ClientFixture client;
+  client.data->monitoringMsg.ipoData.clientCommandMode = ClientCommandMode_TORQUE;
+  EXPECT_THROW(client.cycle(COMMANDING_WAIT), std::runtime_error);
+  EXPECT_FALSE(client.data->commandMsg.commandData.has_jointPosition);
+}
+
+TEST(FRIClient, PositionCommandsAreSmoothedBeforeSending)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  client.cycle(COMMANDING_ACTIVE);
+  iiwa_controller::FRIClient::Joints q;
+  q.fill(0.41);
+  client.setTargetJointPositions(q);
+  client.cycle(COMMANDING_ACTIVE);
+  // tau=40 ms, dt=10 ms: alpha=dt/(tau+dt)=0.2.
+  EXPECT_DOUBLE_EQ(client.sentPosition(), 0.402);
+  EXPECT_DOUBLE_EQ(client.getStateSnapshot().measured_pos[0], 0.2);
+}
+
+TEST(FRIClient, ZeroPositionSmoothingTauForwardsStepImmediately)
+{
+  ClientFixture client(0.0);
+  client.cycle(COMMANDING_WAIT);
+  client.cycle(COMMANDING_ACTIVE);
+  iiwa_controller::FRIClient::Joints q;
+  q.fill(0.41);
+  client.setTargetJointPositions(q);
+  client.cycle(COMMANDING_ACTIVE);
+  EXPECT_DOUBLE_EQ(client.sentPosition(), 0.41);
+}
+
+TEST(FRIClient, RejectsInvalidCommandsAndBoundsCommandRate)
+{
+  ClientFixture client;
+  iiwa_controller::FRIClient::Joints lower, upper, velocity, q;
+  lower.fill(-1.0); upper.fill(1.0); velocity.fill(1.0);
+  client.setLimits(lower, upper, velocity);
+  client.cycle(COMMANDING_WAIT);
+  client.cycle(COMMANDING_ACTIVE);
+  q.fill(0.8);
+  client.setTargetJointPositions(q);
+  client.cycle(COMMANDING_ACTIVE);
+  EXPECT_NEAR(client.sentPosition(), 0.41, 1e-12);  // 1 rad/s * 10 ms
+  q[0] = 1.1;
+  EXPECT_THROW(client.setTargetJointPositions(q), std::invalid_argument);
+  q[0] = std::numeric_limits<double>::quiet_NaN();
+  EXPECT_THROW(client.setTargetJointPositions(q), std::invalid_argument);
+}
+
+TEST(FRIClient, SafetyStopCannotSendApplicationCommand)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  client.data->monitoringMsg.robotInfo.safetyState = SafetyState_SAFETY_STOP_LEVEL_1;
+  EXPECT_THROW(client.cycle(COMMANDING_ACTIVE), std::runtime_error);
+  EXPECT_FALSE(client.data->commandMsg.commandData.has_jointPosition);
+}
+
+TEST(FRIClient, DuplicateTimestampIsNotFreshTelemetry)
+{
+  ClientFixture client;
+  client.cycle(MONITORING_READY);
+  EXPECT_THROW(client.monitor(), std::runtime_error);
+}
+
+TEST(FRIClient, RejectsMismatchedPeriodAndMissingCommandingPackets)
+{
+  ClientFixture mismatch;
+  mismatch.setExpectedSampleTime(0.005);
+  EXPECT_THROW(mismatch.cycle(MONITORING_READY), std::runtime_error);
+  ClientFixture gap;
+  gap.cycle(COMMANDING_WAIT);
+  gap.data->monitoringMsg.monitorData.timestamp.nanosec += 10000000;
+  EXPECT_THROW(gap.cycle(COMMANDING_ACTIVE), std::runtime_error);
+  EXPECT_FALSE(gap.data->commandMsg.commandData.has_jointPosition);
+}
+
+TEST(FRIClient, LeavingCommandingRequiresExplicitRecovery)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  client.cycle(COMMANDING_ACTIVE);
+  EXPECT_THROW(client.cycle(MONITORING_READY), std::runtime_error);
+}
+
+TEST(FRIClient, PositionOverlaySupportsSunriseImpedanceModes)
+{
+  for (auto mode : {ControlMode_JOINT_IMPEDANCE_CONTROLMODE,
+    ControlMode_CARTESIAN_IMPEDANCE_CONTROLMODE})
+  {
+    ClientFixture client;
+    client.data->monitoringMsg.robotInfo.controlMode = mode;
+    EXPECT_NO_THROW(client.cycle(COMMANDING_WAIT));
+    EXPECT_DOUBLE_EQ(client.sentPosition(), 0.4);
+  }
+}
+
+TEST(FRIClient, StalledRosCommandStreamStopsBeforeSending)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  client.cycle(COMMANDING_ACTIVE);
+  std::this_thread::sleep_for(std::chrono::milliseconds(110));
+  EXPECT_THROW(client.cycle(COMMANDING_ACTIVE), std::runtime_error);
+  EXPECT_FALSE(client.data->commandMsg.commandData.has_jointPosition);
+}
+
+TEST(FRIClient, RejectsOverwritingAnUnconsumedPoint)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  client.cycle(COMMANDING_ACTIVE);
+  iiwa_controller::FRIClient::Joints q;
+  q.fill(0.401);
+  client.setTargetJointPositions(q);
+  q.fill(0.402);
+  EXPECT_THROW(client.setTargetJointPositions(q), std::logic_error);
+  client.cycle(COMMANDING_ACTIVE);
+  EXPECT_DOUBLE_EQ(client.sentPosition(), 0.4002);
+}
+
+TEST(FRIClient, SynchronizedCyclesPreserveEveryPointDespiteSchedulingJitter)
+{
+  ClientFixture client;
+  client.cycle(COMMANDING_WAIT);
+  iiwa_controller::FRICycleGate gate;
+  gate.reset();
+  std::atomic<bool> worker_ok{true};
+  std::vector<double> sent;
+  std::thread worker([&] {
+    for (int frame = 0; frame <= 8; ++frame) {
+      client.cycle(COMMANDING_ACTIVE);
+      sent.push_back(client.sentPosition());
+      if (frame < 8 && !gate.publishAndWait()) {worker_ok = false; break;}
+    }
+  });
+  for (int frame = 1; frame <= 8; ++frame) {
+    if (!gate.acquire()) {worker_ok = false; break;}
+    // Variable controller execution time cannot cause a point to be overwritten.
+    std::this_thread::sleep_for(std::chrono::milliseconds(frame % 3));
+    iiwa_controller::FRIClient::Joints q;
+    q.fill(0.4 + frame * 0.001);
+    client.setTargetJointPositions(q);
+    if (!gate.complete()) {worker_ok = false; break;}
+  }
+  worker.join();
+  ASSERT_TRUE(worker_ok);
+  ASSERT_EQ(sent.size(), 9u);
+  double expected = 0.4;
+  for (size_t frame = 1; frame < sent.size(); ++frame) {
+    const double target = 0.4 + static_cast<double>(frame) * 0.001;
+    expected = 0.2 * target + 0.8 * expected;
+    EXPECT_NEAR(sent[frame], expected, 1e-12);
+  }
+}
+
+TEST(FRICycleGate, DuplicateReadOrWriteCannotAdvanceWorker)
+{
+  iiwa_controller::FRICycleGate gate;
+  gate.reset();
+  EXPECT_FALSE(gate.complete());
+  std::thread worker([&] {EXPECT_TRUE(gate.publishAndWait());});
+  EXPECT_TRUE(gate.acquire());
+  EXPECT_FALSE(gate.acquire());
+  EXPECT_TRUE(gate.complete());
+  EXPECT_FALSE(gate.complete());
+  worker.join();
+}
+
+TEST(FRICycleGate, StopWakesWorkerAndMissingWriteTimesOut)
+{
+  iiwa_controller::FRICycleGate gate;
+  gate.reset();
+  std::thread worker([&] {EXPECT_FALSE(gate.publishAndWait());});
+  EXPECT_TRUE(gate.acquire());
+  gate.stop();
+  worker.join();
+  gate.reset();
+  EXPECT_FALSE(gate.publishAndWait());
+  EXPECT_FALSE(gate.acquire());
+  EXPECT_FALSE(gate.complete());
+}

src/iiwa_controller/test/test_hardware.cpp

@@ -0,0 +1,109 @@
+#include <gtest/gtest.h>
+#include "iiwa_controller/IIWAHardwareInterface.hpp"
+
+using Hardware = iiwa_controller::IIWAHardwareInterface;
+using Return = hardware_interface::CallbackReturn;
+
+hardware_interface::HardwareComponentInterfaceParams parameters()
+{
+  hardware_interface::HardwareComponentInterfaceParams params;
+  auto & info = params.hardware_info;
+  info.name = "iiwa_test";
+  info.type = "system";
+  info.hardware_parameters["simulate"] = "true";
+  for (int i = 1; i <= 7; ++i) {
+    hardware_interface::ComponentInfo joint;
+    joint.name = "joint" + std::to_string(i);
+    for (const auto * name : {"position", "velocity", "effort"}) {
+      hardware_interface::InterfaceInfo interface;
+      interface.name = name;
+      interface.data_type = "double";
+      interface.initial_value = "0.2";
+      joint.state_interfaces.push_back(interface);
+    }
+    hardware_interface::InterfaceInfo command;
+    command.name = "position";
+    command.data_type = "double";
+    joint.command_interfaces.push_back(command);
+    joint_limits::JointLimits limits;
+    limits.has_position_limits = true;
+    limits.min_position = -2.0;
+    limits.max_position = 2.0;
+    limits.has_velocity_limits = true;
+    limits.max_velocity = 1.0;
+    info.limits[joint.name] = limits;
+    info.joints.push_back(joint);
+  }
+  return params;
+}
+
+TEST(Hardware, RejectsMalformedPortWithoutThrowing)
+{
+  Hardware hardware;
+  auto params = parameters();
+  params.hardware_info.hardware_parameters["fri_port"] = "30200oops";
+  EXPECT_EQ(hardware.on_init(params), Return::ERROR);
+}
+
+TEST(Hardware, RejectsInvalidRealtimePriority)
+{
+  Hardware hardware;
+  auto params = parameters();
+  params.hardware_info.hardware_parameters["rt_prio"] = "0";
+  EXPECT_EQ(hardware.on_init(params), Return::ERROR);
+}
+
+TEST(Hardware, RejectsInvalidPositionSmoothingTau)
+{
+  Hardware hardware;
+  auto params = parameters();
+  params.hardware_info.hardware_parameters["joint_position_tau"] = "-0.01";
+  EXPECT_EQ(hardware.on_init(params), Return::ERROR);
+}
+
+TEST(Hardware, RejectsWrongJointOrderAndMissingInterfaces)
+{
+  auto params = parameters();
+  std::swap(params.hardware_info.joints[0], params.hardware_info.joints[1]);
+  Hardware wrong_order;
+  EXPECT_EQ(wrong_order.on_init(params), Return::ERROR);
+  params = parameters();
+  params.hardware_info.joints[0].state_interfaces.pop_back();
+  Hardware missing_interface;
+  EXPECT_EQ(missing_interface.on_init(params), Return::ERROR);
+}
+
+TEST(Hardware, SimulationSeedsCommandsAndSupportsRepeatedLifecycle)
+{
+  Hardware hardware;
+  ASSERT_EQ(hardware.on_init(parameters()), Return::SUCCESS);
+  auto states = hardware.on_export_state_interfaces();
+  auto commands = hardware.on_export_command_interfaces();
+  const rclcpp_lifecycle::State state;
+  ASSERT_EQ(hardware.on_configure(state), Return::SUCCESS);
+  for (int cycle = 0; cycle < 2; ++cycle) {
+    ASSERT_EQ(hardware.on_activate(state), Return::SUCCESS);
+    const double command = hardware.get_command<double>("joint1/position");
+    EXPECT_DOUBLE_EQ(command, 0.2);
+    EXPECT_EQ(hardware.read(rclcpp::Time(0), rclcpp::Duration::from_seconds(0.01)),
+      hardware_interface::return_type::OK);
+    EXPECT_EQ(hardware.on_deactivate(state), Return::SUCCESS);
+    EXPECT_EQ(hardware.read(rclcpp::Time(0), rclcpp::Duration::from_seconds(0.01)),
+      hardware_interface::return_type::OK);
+  }
+  EXPECT_EQ(hardware.on_cleanup(state), Return::SUCCESS);
+  EXPECT_EQ(hardware.on_shutdown(state), Return::SUCCESS);
+}
+
+TEST(Hardware, ConfiguredRealHardwareCleansUpInDependencyOrder)
+{
+  Hardware hardware;
+  auto params = parameters();
+  params.hardware_info.hardware_parameters["simulate"] = "false";
+  params.hardware_info.hardware_parameters["robot_ip"] = "127.0.0.1";
+  ASSERT_EQ(hardware.on_init(params), Return::SUCCESS);
+  const rclcpp_lifecycle::State state;
+  ASSERT_EQ(hardware.on_configure(state), Return::SUCCESS);
+  EXPECT_EQ(hardware.on_cleanup(state), Return::SUCCESS);
+  EXPECT_EQ(hardware.on_error(state), Return::SUCCESS);
+}

src/iiwa_description/urdf/iiwa7.urdf.xacro

@@ -6,8 +6,8 @@
     <xacro:arg name="simulate" default="false"/>
     <xacro:arg name="robot_ip" default="192.170.10.2"/>
     <xacro:arg name="fri_port" default="30200"/>
+    <xacro:arg name="fri_cycle_ms" default="5"/>
     <xacro:arg name="joint_position_tau" default="0.04"/>
-    <xacro:arg name="joint_velocity_tau" default="0.01"/>
 
     <xacro:property name="initial_positions"
                     value="${xacro.load_yaml('$(arg initial_positions_file)')['initial_positions']}"/>
@@ -145,9 +145,10 @@
                 <plugin>iiwa_controller/IIWAHardwareInterface</plugin>
                 <param name="robot_ip">$(arg robot_ip)</param>
                 <param name="fri_port">$(arg fri_port)</param>
-                <param name="simulate">false</param>
+                <param name="fri_cycle_ms">$(arg fri_cycle_ms)</param>
                 <param name="joint_position_tau">$(arg joint_position_tau)</param>
-                <param name="joint_velocity_tau">$(arg joint_velocity_tau)</param>
+                <param name="rt_prio">80</param>
+                <param name="simulate">false</param>
             </hardware>
 
             <joint name="joint1">
@@ -245,4 +246,4 @@
 
     </xacro:unless>
 
-</robot>
+</robot>

src/iiwa_utils/iiwa_utils/setting_loader.py

@@ -1,3 +1,4 @@
+import math
 import os
 from dataclasses import dataclass, fields, is_dataclass
 from typing import Any, Dict, List, Optional, Type, TypeVar
@@ -16,7 +17,6 @@ class RobotCfg:
     description: str
     fri_cycle_ms: int
     joint_position_tau: float
-    active_controller: str  # "jtc" | "forward"
 
 
 @dataclass(frozen=True)
@@ -284,14 +284,16 @@ def build_settings(settings_path: str, check_files: bool = True) -> Settings:
 
     # robot
     robot_raw = require(raw, "robot")
+    joint_position_tau = float(robot_raw.get("joint_position_tau", 0.04))
+    if not math.isfinite(joint_position_tau) or joint_position_tau < 0.0:
+        raise ValueError("robot.joint_position_tau must be a finite value >= 0")
     robot = RobotCfg(
         name=str(require(robot_raw, "name")),
         ip=str(require(robot_raw, "ip")),
         port=int(require(robot_raw, "port")),
         description=resolve_path(str(require(robot_raw, "description")), settings_dir),
         fri_cycle_ms=int(robot_raw.get("fri_cycle_ms", 5)),
-        joint_position_tau=float(robot_raw.get("joint_position_tau", 0.04)),
+        joint_position_tau=joint_position_tau,
-        active_controller=str(robot_raw.get("active_controller", "jtc")),
     )
 
     # digital_twin