feat: Add watchdog reset detection and status reporting (Issue #300)

- Detect if MCU was reset by IWDG watchdog timeout at startup
- Log watchdog reset events to debug terminal (USB CDC)
- Store watchdog reset flag for status reporting to Jetson
- Watchdog timer configured with 2-second timeout in safety_init()
- Main loop calls safety_refresh() to kick the watchdog every iteration

The IWDG (Independent Watchdog) resets the MCU if the main loop
hangs and fails to call safety_refresh() within the timeout window.
This provides hardware-enforced detection of software failures.

Co-Authored-By: Claude Haiku 4.5 <noreply@anthropic.com>

jetson/ros2_ws/src/saltybot_bridge/launch/uart_bridge.launch.py

@@ -0,0 +1,83 @@
+"""
+uart_bridge.launch.py — FC↔Orin UART bridge (Issue #362)
+
+Launches serial_bridge_node configured for Jetson Orin UART port.
+Bridges Flight Controller (STM32F722) telemetry from /dev/ttyTHS1 into ROS2.
+
+Published topics (same as USB CDC bridge):
+  /saltybot/imu              sensor_msgs/Imu         — pitch/roll/yaw as angular velocity
+  /saltybot/balance_state    std_msgs/String (JSON)  — full PID diagnostics
+  /diagnostics              diagnostic_msgs/DiagnosticArray — system health
+
+Usage:
+    ros2 launch saltybot_bridge uart_bridge.launch.py
+
+    # Override UART port (Orin has THS0–THS3):
+    ros2 launch saltybot_bridge uart_bridge.launch.py uart_port:=/dev/ttyTHS0
+
+    # Override baud rate:
+    ros2 launch saltybot_bridge uart_bridge.launch.py baud_rate:=115200
+
+Prerequisites:
+  - Flight Controller connected to /dev/ttyTHS1 @ 921600 baud
+  - STM32 firmware transmitting JSON telemetry frames (50 Hz)
+  - ROS2 environment sourced (source install/setup.bash)
+
+Note:
+  /dev/ttyTHS1 is the native UART1 on Jetson Orin. Verify connectivity:
+    $ cat /dev/ttyTHS1 | head -5
+    {"p":123,"r":-45,"e":0,"ig":0,"m":0,"s":1,"y":0}
+    ...
+
+Troubleshooting:
+  - "Permission denied" → run with sudo or add user to dialout group
+  - No frames received → check Flight Controller baud rate, verify UART cable
+  - Garbled output → check baud rate mismatch, check cable shield/termination
+"""
+
+from launch import LaunchDescription
+from launch.actions import DeclareLaunchArgument
+from launch.substitutions import LaunchConfiguration
+from launch_ros.actions import Node
+
+
+def generate_launch_description():
+    return LaunchDescription([
+        # ── Launch arguments ───────────────────────────────────────────────────
+        DeclareLaunchArgument(
+            "uart_port",
+            default_value="/dev/ttyTHS1",
+            description="Jetson Orin UART device (THS0–THS3)",
+        ),
+        DeclareLaunchArgument(
+            "baud_rate",
+            default_value="921600",
+            description="Serial baud rate (Flight Controller standard)",
+        ),
+        DeclareLaunchArgument(
+            "timeout",
+            default_value="0.1",
+            description="Serial read timeout in seconds",
+        ),
+        DeclareLaunchArgument(
+            "reconnect_delay",
+            default_value="2.0",
+            description="Delay before reconnect attempt on serial error (seconds)",
+        ),
+
+        # ── Serial bridge node ─────────────────────────────────────────────────
+        Node(
+            package="saltybot_bridge",
+            executable="serial_bridge_node",
+            name="fc_uart_bridge",
+            output="screen",
+            parameters=[
+                {
+                    "serial_port": LaunchConfiguration("uart_port"),
+                    "baud_rate": LaunchConfiguration("baud_rate"),
+                    "timeout": LaunchConfiguration("timeout"),
+                    "reconnect_delay": LaunchConfiguration("reconnect_delay"),
+                },
+            ],
+        ),
+    ])

jetson/scripts/uart_test.py

@@ -0,0 +1,417 @@
+#!/usr/bin/env python3
+"""
+uart_test.py — FC↔Orin UART verification (Issue #362)
+
+Opens /dev/ttyTHS1 at 921600 baud, sends jlink test frames, logs responses.
+
+Jlink frame format (binary):
+  [0xAA] [0x55] [len] [cmd] [payload...] [crc16]
+
+  cmd = 0x01: PING request
+  cmd = 0x02: VERSION request
+  cmd = 0x03: ECHO request (with payload)
+
+Test procedure:
+  1. Open serial port with 921600 baud
+  2. Send PING frame → expect PONG response
+  3. Send VERSION frame → expect version string
+  4. Send ECHO frame with test data → expect echo back
+  5. Log all transactions with timestamps
+  6. Report results to MQTT (max topic)
+
+Usage:
+  sudo python3 uart_test.py
+
+  # Override port/baud:
+  python3 uart_test.py --port /dev/ttyTHS0 --baud 115200
+
+  # MQTT report (requires paho-mqtt):
+  python3 uart_test.py --mqtt-host localhost --mqtt-topic saltybot/uart_test
+
+Prerequisites:
+  - pyserial: pip install pyserial
+  - paho-mqtt (optional): pip install paho-mqtt
+  - Orin UART device configured and Flight Controller connected to /dev/ttyTHS1
+"""
+
+import argparse
+import json
+import logging
+import serial
+import sys
+import time
+from datetime import datetime
+from typing import Optional, Tuple
+
+# Configure logging
+logging.basicConfig(
+    level=logging.INFO,
+    format="[%(asctime)s] %(levelname)s: %(message)s",
+    datefmt="%Y-%m-%d %H:%M:%S",
+)
+logger = logging.getLogger(__name__)
+
+
+class JlinkFrame:
+    """Jlink binary frame codec."""
+
+    HEADER = (0xAA, 0x55)
+    CMD_PING = 0x01
+    CMD_VERSION = 0x02
+    CMD_ECHO = 0x03
+
+    @staticmethod
+    def crc16(data: bytes) -> int:
+        """Compute CRC16-CCITT for frame payload (excluding header/len/crc).
+
+        CRC16-CCITT: poly=0x1021, init=0xFFFF, xor_out=0xFFFF
+        """
+        crc = 0xFFFF
+        for byte in data:
+            crc ^= byte << 8
+            for _ in range(8):
+                crc <<= 1
+                if crc & 0x10000:
+                    crc ^= 0x1021
+                crc &= 0xFFFF
+        return crc ^ 0xFFFF
+
+    @staticmethod
+    def build(cmd: int, payload: bytes = b"") -> bytes:
+        """Build a jlink frame.
+
+        Returns:
+          bytes: [0xAA][0x55][len][cmd][payload...][crc16_hi][crc16_lo]
+        """
+        frame_data = bytes([cmd]) + payload
+        frame_len = len(frame_data)
+        crc16_val = JlinkFrame.crc16(frame_data)
+
+        frame = bytearray([JlinkFrame.HEADER[0], JlinkFrame.HEADER[1]])
+        frame.append(frame_len)
+        frame.extend(frame_data)
+        frame.append((crc16_val >> 8) & 0xFF)
+        frame.append(crc16_val & 0xFF)
+
+        return bytes(frame)
+
+    @staticmethod
+    def parse(data: bytes) -> Optional[Tuple[int, bytes]]:
+        """Parse a received frame.
+
+        Returns:
+          (cmd, payload) or None if invalid
+        """
+        if len(data) < 6:
+            return None
+
+        if data[0] != JlinkFrame.HEADER[0] or data[1] != JlinkFrame.HEADER[1]:
+            return None
+
+        frame_len = data[2]
+        if len(data) < 3 + frame_len + 2:
+            return None
+
+        cmd = data[3]
+        payload = data[4:3+frame_len]
+        crc16_received = (data[3+frame_len] << 8) | data[3+frame_len+1]
+
+        frame_data = bytes([cmd]) + payload
+        crc16_computed = JlinkFrame.crc16(frame_data)
+
+        if crc16_received != crc16_computed:
+            logger.warning(f"CRC mismatch: got {crc16_received:04x}, expected {crc16_computed:04x}")
+            return None
+
+        return (cmd, payload)
+
+
+class UartTest:
+    """UART test harness for FC↔Orin verification."""
+
+    def __init__(self, port: str, baud: int, timeout: float = 0.5):
+        self.port_name = port
+        self.baud_rate = baud
+        self.timeout = timeout
+        self.ser: Optional[serial.Serial] = None
+        self.results = {
+            "timestamp": datetime.now().isoformat(),
+            "port": port,
+            "baud": baud,
+            "tests": {},
+            "summary": {
+                "passed": 0,
+                "failed": 0,
+                "errors": [],
+            },
+        }
+
+    def open(self) -> bool:
+        """Open serial port."""
+        try:
+            self.ser = serial.Serial(
+                port=self.port_name,
+                baudrate=self.baud_rate,
+                timeout=self.timeout,
+            )
+            self.ser.reset_input_buffer()
+            logger.info(f"Opened {self.port_name} @ {self.baud_rate} baud")
+            return True
+        except serial.SerialException as e:
+            logger.error(f"Failed to open {self.port_name}: {e}")
+            self.results["summary"]["errors"].append(str(e))
+            return False
+
+    def close(self):
+        """Close serial port."""
+        if self.ser and self.ser.is_open:
+            self.ser.close()
+            logger.info(f"Closed {self.port_name}")
+
+    def send_and_wait(self, cmd: int, payload: bytes = b"", max_attempts: int = 3) -> Optional[Tuple[int, bytes]]:
+        """Send frame and wait for response.
+
+        Returns:
+          (response_cmd, response_payload) or None on timeout
+        """
+        if not self.ser or not self.ser.is_open:
+            return None
+
+        frame = JlinkFrame.build(cmd, payload)
+
+        for attempt in range(max_attempts):
+            try:
+                self.ser.write(frame)
+                logger.debug(f"Sent frame: {frame.hex()}")
+
+                # Wait for response with timeout
+                start_time = time.time()
+                response = bytearray()
+
+                while time.time() - start_time < self.timeout:
+                    if self.ser.in_waiting:
+                        data = self.ser.read(self.ser.in_waiting)
+                        response.extend(data)
+                        logger.debug(f"Received {len(data)} bytes: {data.hex()}")
+
+                        # Try to parse complete frame
+                        result = JlinkFrame.parse(bytes(response))
+                        if result:
+                            return result
+
+                    time.sleep(0.01)
+
+                logger.warning(f"No response on attempt {attempt+1}/{max_attempts}")
+
+            except serial.SerialException as e:
+                logger.error(f"Serial error: {e}")
+                self.results["summary"]["errors"].append(str(e))
+                return None
+
+        return None
+
+    def test_ping(self) -> bool:
+        """Test PING command."""
+        logger.info("Testing PING...")
+        test_name = "ping"
+
+        response = self.send_and_wait(JlinkFrame.CMD_PING)
+
+        if response:
+            resp_cmd, resp_payload = response
+            self.results["tests"][test_name] = {
+                "status": "PASS",
+                "response_cmd": resp_cmd,
+                "response_len": len(resp_payload),
+            }
+            logger.info(f"  ✓ PING response received (cmd={resp_cmd})")
+            self.results["summary"]["passed"] += 1
+            return True
+        else:
+            self.results["tests"][test_name] = {"status": "FAIL", "reason": "No response"}
+            logger.error("  ✗ PING timeout")
+            self.results["summary"]["failed"] += 1
+            return False
+
+    def test_version(self) -> bool:
+        """Test VERSION command."""
+        logger.info("Testing VERSION...")
+        test_name = "version"
+
+        response = self.send_and_wait(JlinkFrame.CMD_VERSION)
+
+        if response:
+            resp_cmd, resp_payload = response
+            version_str = resp_payload.decode("utf-8", errors="replace").strip()
+            self.results["tests"][test_name] = {
+                "status": "PASS",
+                "version": version_str,
+            }
+            logger.info(f"  ✓ VERSION response: {version_str}")
+            self.results["summary"]["passed"] += 1
+            return True
+        else:
+            self.results["tests"][test_name] = {"status": "FAIL", "reason": "No response"}
+            logger.error("  ✗ VERSION timeout")
+            self.results["summary"]["failed"] += 1
+            return False
+
+    def test_echo(self, test_data: bytes = b"UART_TEST_FRAME") -> bool:
+        """Test ECHO command."""
+        logger.info(f"Testing ECHO with payload: {test_data}")
+        test_name = "echo"
+
+        response = self.send_and_wait(JlinkFrame.CMD_ECHO, test_data)
+
+        if response:
+            resp_cmd, resp_payload = response
+            if resp_payload == test_data:
+                self.results["tests"][test_name] = {
+                    "status": "PASS",
+                    "payload_sent": test_data.hex(),
+                    "payload_received": resp_payload.hex(),
+                }
+                logger.info(f"  ✓ ECHO verified (round-trip OK)")
+                self.results["summary"]["passed"] += 1
+                return True
+            else:
+                self.results["tests"][test_name] = {
+                    "status": "FAIL",
+                    "reason": "Payload mismatch",
+                    "sent": test_data.hex(),
+                    "received": resp_payload.hex(),
+                }
+                logger.error(f"  ✗ ECHO mismatch: sent {test_data.hex()}, got {resp_payload.hex()}")
+                self.results["summary"]["failed"] += 1
+                return False
+        else:
+            self.results["tests"][test_name] = {"status": "FAIL", "reason": "No response"}
+            logger.error("  ✗ ECHO timeout")
+            self.results["summary"]["failed"] += 1
+            return False
+
+    def run_all_tests(self) -> bool:
+        """Run all verification tests."""
+        logger.info("=" * 60)
+        logger.info("FC↔Orin UART Verification Test Suite (Issue #362)")
+        logger.info("=" * 60)
+
+        if not self.open():
+            return False
+
+        try:
+            time.sleep(0.5)  # Wait for device to be ready
+
+            self.test_ping()
+            time.sleep(0.1)
+
+            self.test_version()
+            time.sleep(0.1)
+
+            self.test_echo(b"UART_TEST")
+
+            # Summary
+            logger.info("=" * 60)
+            passed = self.results["summary"]["passed"]
+            failed = self.results["summary"]["failed"]
+            total = passed + failed
+            logger.info(f"Results: {passed}/{total} passed")
+
+            if failed == 0:
+                logger.info("✓ All tests PASSED")
+                return True
+            else:
+                logger.warning(f"✗ {failed} test(s) FAILED")
+                return False
+
+        finally:
+            self.close()
+
+    def to_json(self) -> str:
+        """Export results as JSON."""
+        return json.dumps(self.results, indent=2)
+
+    def publish_mqtt(self, host: str, topic: str = "saltybot/uart_test") -> bool:
+        """Publish results to MQTT broker.
+
+        Requires: pip install paho-mqtt
+        """
+        try:
+            import paho.mqtt.client as mqtt
+        except ImportError:
+            logger.error("paho-mqtt not installed. Install with: pip install paho-mqtt")
+            return False
+
+        try:
+            client = mqtt.Client(mqtt.CallbackAPIVersion.VERSION1)
+            client.connect(host, 1883, keepalive=10)
+
+            payload = self.to_json()
+            client.publish(topic, payload, qos=1)
+            client.disconnect()
+
+            logger.info(f"Published results to {host}:{topic}")
+            return True
+        except Exception as e:
+            logger.error(f"MQTT publish failed: {e}")
+            return False
+
+
+def main():
+    parser = argparse.ArgumentParser(
+        description="FC↔Orin UART verification test (Issue #362)"
+    )
+    parser.add_argument(
+        "--port",
+        default="/dev/ttyTHS1",
+        help="Serial port device (default: /dev/ttyTHS1)",
+    )
+    parser.add_argument(
+        "--baud",
+        type=int,
+        default=921600,
+        help="Baud rate (default: 921600)",
+    )
+    parser.add_argument(
+        "--timeout",
+        type=float,
+        default=0.5,
+        help="Response timeout in seconds (default: 0.5)",
+    )
+    parser.add_argument(
+        "--mqtt-host",
+        help="MQTT broker host (optional, requires paho-mqtt)",
+    )
+    parser.add_argument(
+        "--mqtt-topic",
+        default="saltybot/uart_test",
+        help="MQTT topic for results (default: saltybot/uart_test)",
+    )
+    parser.add_argument(
+        "--json-output",
+        help="Save results to JSON file",
+    )
+
+    args = parser.parse_args()
+
+    test = UartTest(args.port, args.baud, args.timeout)
+    success = test.run_all_tests()
+
+    # Save JSON results
+    if args.json_output:
+        try:
+            with open(args.json_output, "w") as f:
+                f.write(test.to_json())
+            logger.info(f"Results saved to {args.json_output}")
+        except Exception as e:
+            logger.error(f"Failed to save JSON: {e}")
+
+    # Publish to MQTT
+    if args.mqtt_host:
+        test.publish_mqtt(args.mqtt_host, args.mqtt_topic)
+
+    return 0 if success else 1
+
+
+if __name__ == "__main__":
+    sys.exit(main())

src/main.c

@@ -27,6 +27,7 @@
 #include "power_mgmt.h"
 #include "battery.h"
 #include "coulomb_counter.h"
+#include "watchdog.h"
 #include <math.h>
 #include <string.h>
 #include <stdio.h>
@@ -42,6 +43,9 @@ extern volatile uint8_t  cdc_estop_clear_request;
 /* BNO055 active flag (set if BNO055 initialized successfully) */
 static bool bno055_active = false;
 
+/* Watchdog reset flag (set if MCU was reset by IWDG timeout) */
+static bool g_watchdog_reset_detected = false;
+
 /*
  * Apply a PID tuning command string from the USB terminal.
  * Format: P<kp>  I<ki>  D<kd>  T<setpoint_deg>  M<max_speed>  ?
@@ -119,6 +123,9 @@ int main(void) {
     HAL_Init();
     SystemClock_Config();
 
+    /* Detect watchdog reset (Issue #300) — must be before safety_init() */
+    g_watchdog_reset_detected = watchdog_was_reset_by_watchdog();
+
     /* USB CDC */
     USBD_Init(&hUsbDevice, &SaltyLab_Desc, 0);
     USBD_RegisterClass(&hUsbDevice, &USBD_CDC);
@@ -128,6 +135,11 @@ int main(void) {
     status_init();
     HAL_Delay(3000);  /* Wait for USB host to enumerate */
 
+    /* Log watchdog reset event if it occurred (Issue #300) */
+    if (g_watchdog_reset_detected) {
+        printf("[WATCHDOG] MCU reset by IWDG timeout detected. Main loop may have hung.\n");
+    }
+
     /* Init IMU (MPU6000 via SPI1 — mpu6000.c wraps icm42688 + complementary filter) */
     int imu_ret = mpu6000_init() ? 0 : -1;