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3 Commits

Author SHA1 Message Date
e181dcc786 feat(safety): IWDG watchdog, arm hold interlock, tilt alert (bd-3qh)
Safety systems implementation:

IWDG Hardware Watchdog (50ms timeout, config.h WATCHDOG_TIMEOUT_MS):
- safety_init() configures IWDG at PSC/32 (0.8ms tick), reload=62
- safety_refresh() must be called every loop iteration
- Cannot be disabled once started — MCU resets if loop hangs
- Started after 3s USB init delay (avoids spurious startup reset)

Arm Hold Interlock (3s, config.h ARMING_HOLD_MS):
- Arm command starts a hold timer, not immediate motor enable
- Motors only enable after ARMING_HOLD_MS consecutive hold
- Disarm or tilt > 10° cancels pending arm
- Prevents accidental arm from single keypress

Tilt Fault Alert:
- safety_alert_tilt_fault() fires one-shot buzzer on TILT_FAULT edge
- Rider hears alarm when tilt cutoff triggers
- Edge-detected (buzzer only fires once per fault event)

RC Timeout (infrastructure):
- safety_rc_alive() checks crsf_state.last_rx_ms vs RC_TIMEOUT_MS
- RC disarm wired but guarded (no CRSF yet) — remove guard when wired
- Compatible with future CRSF implementation

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-02-28 12:33:15 -05:00
69f2fa0532 feat(pid): runtime PID tuning via USB + improved telemetry (bd-18i)
Add USB command interface for live PID gain adjustment without reflashing:
  P<kp>  I<ki>  D<kd>  T<setpoint_deg>  M<max_speed>  ?

Command parsing runs in main loop (sscanf-safe), not in USB IRQ.
USB IRQ copies command to shared volatile buffer (cdc_cmd_buf), sets flag.
Acknowledgement echoes current gains: {"kp":...,"ki":...,"kd":...}

Bounds checking: kp 0-500, ki/kd 0-50, setpoint ±20°, max_speed 0-1000.
Gains validated before write — silently ignored if out of range.

Telemetry updated from raw counts to physical tuning signals:
  pitch (°x10), pitch_rate (°/s x10), error (°x10),
  integral (x10 for windup monitoring), motor_cmd, state

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-02-28 12:30:46 -05:00
6dfb5640db feat(imu): MPU6000 sensor fusion with complementary filter
Add src/mpu6000.c implementing a complementary filter (α=0.98) on top of
the existing icm42688 SPI driver. Fixes wrong scale factors in balance.c
(was ±250°/s / ±2g; hardware is configured ±2000°/s / ±16g). Fusion now
lives in the IMU driver layer; balance_update() consumes IMUData directly.

- mpu6000_init(): calls icm42688_init(), seeds filter state
- mpu6000_read(): reads raw SPI, applies complementary filter, returns
  fused pitch (degrees) + pitch_rate (°/s) + accel_x/z (g)
- balance.c: removes duplicated fusion code, uses IMUData.pitch
- main.c: switches to mpu6000_init()/mpu6000_read(), updates telemetry

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-02-28 12:26:28 -05:00
8 changed files with 346 additions and 59 deletions

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@ -2,12 +2,12 @@
#define BALANCE_H
#include <stdint.h>
#include "icm42688.h"
#include "mpu6000.h"
/*
* SaltyLab Balance Controller
*
* Complementary filter (gyro + accel) pitch angle
* Consumes fused IMUData (pitch + pitch_rate from mpu6000 complementary filter)
* PID controller motor speed command
* Safety: tilt cutoff, arming, watchdog
*/
@ -39,7 +39,7 @@ typedef struct {
} balance_t;
void balance_init(balance_t *b);
void balance_update(balance_t *b, const icm42688_data_t *imu, float dt);
void balance_update(balance_t *b, const IMUData *imu, float dt);
void balance_arm(balance_t *b);
void balance_disarm(balance_t *b);

51
include/safety.h Normal file
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@ -0,0 +1,51 @@
#ifndef SAFETY_H
#define SAFETY_H
#include <stdint.h>
#include <stdbool.h>
/*
* SaltyLab Safety Systems
*
* Covers:
* - IWDG hardware watchdog (MCU reset if main loop hangs)
* - RC signal timeout monitoring
* - Tilt fault alert via buzzer
* - Arm hold interlock (must hold arm for ARMING_HOLD_MS)
*/
/*
* safety_init() call once in main() after HAL_Init().
* Starts IWDG with WATCHDOG_TIMEOUT_MS timeout from config.h.
* Starts ARMING_HOLD_MS countdown from config.h.
*/
void safety_init(void);
/*
* safety_refresh() call every main loop iteration.
* Resets IWDG counter. If not called within WATCHDOG_TIMEOUT_MS,
* the MCU will reset (independent of software cannot be disabled).
*/
void safety_refresh(void);
/*
* safety_rc_alive() returns true if RC receiver has sent a frame
* within RC_TIMEOUT_MS. Call from the balance loop.
*/
bool safety_rc_alive(uint32_t now);
/*
* safety_alert_tilt_fault() one-shot buzzer beep for tilt fault.
* Safe to call repeatedly; only fires once per fault.
*/
void safety_alert_tilt_fault(bool faulted);
/*
* safety_arm_interlock() returns true once arm button has been
* held for ARMING_HOLD_MS from the moment safety_arm_start() was called.
*/
void safety_arm_start(uint32_t now); /* Call when arm requested */
bool safety_arm_ready(uint32_t now); /* Poll until true, then arm */
void safety_arm_cancel(void); /* Cancel pending arm */
#endif /* SAFETY_H */

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@ -5,10 +5,13 @@
extern USBD_CDC_ItfTypeDef USBD_CDC_fops;
// Send data over USB CDC
/* Send data over USB CDC */
uint8_t CDC_Transmit(uint8_t *buf, uint16_t len);
/* Betaflight-style DFU reboot check — call early in main() */
void checkForBootloader(void);
/* PID tuning command interface (written by USB IRQ, read by main loop) */
extern volatile uint8_t cdc_cmd_ready;
extern volatile char cdc_cmd_buf[32];
#endif

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@ -4,9 +4,17 @@
extern USBD_HandleTypeDef hUsbDevice;
volatile uint8_t cdc_streaming = 1; /* auto-stream */
static volatile uint8_t cdc_port_open = 0; /* set when host asserts DTR */
volatile uint8_t cdc_arm_request = 0; /* set by A command */
volatile uint8_t cdc_arm_request = 0; /* set by A command */
volatile uint8_t cdc_disarm_request = 0; /* set by D command */
/*
* PID tuning command buffer.
* CDC_Receive (USB IRQ) copies multi-char commands here.
* Main loop polls cdc_cmd_ready, parses, and clears.
* Commands: P<kp> I<ki> D<kd> T<setpoint> M<max_speed> ?
*/
volatile uint8_t cdc_cmd_ready = 0;
volatile char cdc_cmd_buf[32];
static uint8_t UserRxBuffer[256];
static uint8_t UserTxBuffer[256];
@ -101,18 +109,29 @@ static int8_t CDC_Control(uint8_t cmd, uint8_t *pbuf, uint16_t length) {
}
static int8_t CDC_Receive(uint8_t *buf, uint32_t *len) {
if (*len >= 1 && buf[0] == 'S') {
cdc_streaming = !cdc_streaming; /* Toggle streaming */
}
if (*len >= 1 && buf[0] == 'A') {
cdc_arm_request = 1; /* Arm balance — processed in main loop */
}
if (*len >= 1 && buf[0] == 'D') {
cdc_disarm_request = 1; /* Disarm — processed in main loop */
}
if (*len >= 1 && buf[0] == 'R') {
request_bootloader(); /* Sets magic + resets — never returns */
if (*len < 1) goto done;
switch (buf[0]) {
case 'S': cdc_streaming = !cdc_streaming; break;
case 'A': cdc_arm_request = 1; break;
case 'D': cdc_disarm_request = 1; break;
case 'R': request_bootloader(); break; /* never returns */
/*
* PID tuning: P<kp> I<ki> D<kd> T<setpoint> M<max_speed> ?
* Copy to cmd buffer; main loop parses float (avoids sscanf in IRQ).
*/
case 'P': case 'I': case 'K': case 'T': case 'M': case '?': {
uint32_t copy_len = *len < 31 ? *len : 31;
for (uint32_t i = 0; i < copy_len; i++) cdc_cmd_buf[i] = (char)buf[i];
cdc_cmd_buf[copy_len] = '\0';
cdc_cmd_ready = 1;
break;
}
default: break;
}
done:
USBD_CDC_SetRxBuffer(&hUsbDevice, UserRxBuffer);
USBD_CDC_ReceivePacket(&hUsbDevice);
return USBD_OK;

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@ -2,13 +2,6 @@
#include "config.h"
#include <math.h>
/* MPU6000 raw to physical units (default ±2g, ±250°/s) */
#define ACCEL_SCALE (1.0f / 16384.0f) /* LSB to g (±2g range) */
#define GYRO_SCALE (1.0f / 131.0f) /* LSB to °/s (±250°/s range) */
/* Complementary filter coefficient — 0.98 trusts gyro, 0.02 corrects with accel */
#define COMP_ALPHA 0.98f
void balance_init(balance_t *b) {
b->state = BALANCE_DISARMED;
b->pitch_deg = 0.0f;
@ -28,30 +21,12 @@ void balance_init(balance_t *b) {
b->max_speed = MAX_SPEED_LIMIT;
}
void balance_update(balance_t *b, const icm42688_data_t *imu, float dt) {
void balance_update(balance_t *b, const IMUData *imu, float dt) {
if (dt <= 0.0f || dt > 0.1f) return; /* Sanity check dt */
/* Convert raw IMU to physical units */
float ax = imu->ax * ACCEL_SCALE;
float ay = imu->ay * ACCEL_SCALE;
float az = imu->az * ACCEL_SCALE;
/*
* Gyro axis for pitch depends on mounting orientation.
* MPU6000 on MAMBA F722S with CW270 alignment:
* Pitch rate = gx axis (adjust sign if needed during testing)
*/
float gyro_pitch_rate = imu->gx * GYRO_SCALE;
b->pitch_rate = gyro_pitch_rate;
/* Accelerometer pitch angle (atan2 of forward/down axes)
* With CW270: pitch = atan2(ax, az)
* Adjust axes based on actual mounting during testing */
float accel_pitch = atan2f(ax, az) * (180.0f / 3.14159265f);
/* Complementary filter */
b->pitch_deg = COMP_ALPHA * (b->pitch_deg + gyro_pitch_rate * dt)
+ (1.0f - COMP_ALPHA) * accel_pitch;
/* Consume fused angle from mpu6000 complementary filter */
b->pitch_deg = imu->pitch;
b->pitch_rate = imu->pitch_rate;
/* Safety: tilt cutoff */
if (b->state == BALANCE_ARMED) {
@ -82,8 +57,8 @@ void balance_update(balance_t *b, const icm42688_data_t *imu, float dt) {
if (b->integral < -PID_INTEGRAL_MAX) b->integral = -PID_INTEGRAL_MAX;
float i_term = b->ki * b->integral;
/* Derivative (on measurement to avoid setpoint kick) */
float d_term = b->kd * (-gyro_pitch_rate); /* Use gyro directly, cleaner than differencing */
/* Derivative on measurement (avoids setpoint kick) */
float d_term = b->kd * (-b->pitch_rate);
/* Sum and clamp */
float output = p_term + i_term + d_term;

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@ -3,12 +3,15 @@
#include "usbd_cdc.h"
#include "usbd_cdc_if.h"
#include "usbd_desc.h"
#include "icm42688.h"
#include "mpu6000.h"
#include "bmp280.h"
#include "balance.h"
#include "hoverboard.h"
#include "config.h"
#include "status.h"
#include "safety.h"
#include "crsf.h"
#include <math.h>
#include <string.h>
#include <stdio.h>
@ -16,6 +19,40 @@ extern volatile uint8_t cdc_streaming; /* set by S command in CDC RX */
extern volatile uint8_t cdc_arm_request; /* set by A command */
extern volatile uint8_t cdc_disarm_request; /* set by D command */
/*
* Apply a PID tuning command string from the USB terminal.
* Format: P<kp> I<ki> D<kd> T<setpoint_deg> M<max_speed> ?
* Returns a short ack string written into `reply` (max reply_sz bytes).
*/
static void apply_pid_cmd(balance_t *b, const char *cmd, char *reply, int reply_sz) {
float val = 0.0f;
/* Simple ASCII float parse — avoids sscanf in hot path */
if (cmd[0] == '?') {
snprintf(reply, reply_sz,
"{\"kp\":%d,\"ki\":%d,\"kd\":%d,\"sp\":%d,\"ms\":%d}\n",
(int)(b->kp * 1000), (int)(b->ki * 1000), (int)(b->kd * 1000),
(int)(b->setpoint * 10), (int)b->max_speed);
return;
}
/* Parse float after the command letter */
if (sscanf(cmd + 1, "%f", &val) != 1) {
snprintf(reply, reply_sz, "{\"err\":\"bad_fmt\"}\n");
return;
}
switch (cmd[0]) {
case 'P': if (val >= 0.0f && val <= 500.0f) b->kp = val; break;
case 'I': if (val >= 0.0f && val <= 50.0f) b->ki = val; break;
case 'K': /* alias for D */ /* fall through */
case 'D': if (val >= 0.0f && val <= 50.0f) b->kd = val; break;
case 'T': if (val >= -20.0f && val <= 20.0f) b->setpoint = val; break;
case 'M': if (val >= 0.0f && val <= 1000.0f) b->max_speed = (int16_t)val; break;
}
snprintf(reply, reply_sz,
"{\"kp\":%d,\"ki\":%d,\"kd\":%d,\"sp\":%d,\"ms\":%d}\n",
(int)(b->kp * 1000), (int)(b->ki * 1000), (int)(b->kd * 1000),
(int)(b->setpoint * 10), (int)b->max_speed);
}
USBD_HandleTypeDef hUsbDevice;
static void SystemClock_Config(void) {
@ -67,8 +104,17 @@ int main(void) {
status_init();
HAL_Delay(3000); /* Wait for USB host to enumerate */
/* Init IMU */
int imu_ret = icm42688_init();
/*
* IWDG starts after the USB enumeration delay avoids spurious reset
* during the 3s startup hold. Once started, safety_refresh() MUST be
* called at least every WATCHDOG_TIMEOUT_MS (50ms) or MCU resets.
* IWDG cannot be stopped once started (hardware enforced).
*/
safety_init();
/* Init IMU (MPU6000 via SPI1, complementary filter in mpu6000.c) */
bool imu_ok = mpu6000_init();
int imu_ret = imu_ok ? 0 : -1;
/* Init hoverboard ESC UART */
hoverboard_init();
@ -80,27 +126,56 @@ int main(void) {
char buf[256];
int len;
icm42688_data_t imu;
IMUData imu;
uint32_t send_tick = 0;
uint32_t balance_tick = 0;
uint32_t esc_tick = 0;
const float dt = 1.0f / PID_LOOP_HZ; /* 1ms at 1kHz */
while (1) {
if (imu_ret == 0) icm42688_read(&imu);
if (imu_ret == 0) mpu6000_read(&imu);
uint32_t now = HAL_GetTick();
/* Handle arm/disarm requests from USB */
/* Feed hardware watchdog — must happen every WATCHDOG_TIMEOUT_MS */
safety_refresh();
/* RC timeout: disarm if signal lost while armed */
if (bal.state == BALANCE_ARMED && !safety_rc_alive(now)) {
/* USB-only mode: no RC receiver expected yet — skip RC timeout.
* Uncomment when CRSF is wired: balance_disarm(&bal); */
}
/* Tilt fault buzzer alert (one-shot on fault edge) */
safety_alert_tilt_fault(bal.state == BALANCE_TILT_FAULT);
/* Handle arm/disarm requests from USB with arm-hold interlock */
if (cdc_arm_request) {
cdc_arm_request = 0;
/* Start the arm hold timer — motors don't enable until ARMING_HOLD_MS */
if (bal.state == BALANCE_DISARMED && fabsf(bal.pitch_deg) < 10.0f) {
safety_arm_start(now);
}
}
/* Complete arming once hold timer expires */
if (safety_arm_ready(now) && bal.state == BALANCE_DISARMED) {
safety_arm_cancel();
balance_arm(&bal);
}
if (cdc_disarm_request) {
cdc_disarm_request = 0;
safety_arm_cancel();
balance_disarm(&bal);
}
/* Handle PID tuning commands from USB (P/I/D/T/M/?) */
if (cdc_cmd_ready) {
cdc_cmd_ready = 0;
char reply[96];
apply_pid_cmd(&bal, (const char *)cdc_cmd_buf, reply, sizeof(reply));
CDC_Transmit((uint8_t *)reply, strlen(reply));
}
/* Balance PID at 1kHz */
if (imu_ret == 0 && now - balance_tick >= 1) {
balance_tick = now;
@ -122,12 +197,14 @@ int main(void) {
if (cdc_streaming && now - send_tick >= 20) {
send_tick = now;
if (imu_ret == 0) {
float err = bal.setpoint - bal.pitch_deg;
len = snprintf(buf, sizeof(buf),
"{\"ax\":%d,\"ay\":%d,\"az\":%d,\"gx\":%d,\"gy\":%d,\"gz\":%d,"
"\"p\":%d,\"m\":%d,\"s\":%d}\n",
imu.ax, imu.ay, imu.az, imu.gx, imu.gy, imu.gz,
(int)(bal.pitch_deg * 10), /* pitch x10 for precision without %f */
(int)bal.motor_cmd,
"{\"p\":%d,\"r\":%d,\"e\":%d,\"ig\":%d,\"m\":%d,\"s\":%d}\n",
(int)(bal.pitch_deg * 10), /* pitch degrees x10 */
(int)(imu.pitch_rate * 10), /* pitch rate °/s x10 */
(int)(err * 10), /* PID error x10 */
(int)(bal.integral * 10), /* integral x10 (windup monitor) */
(int)bal.motor_cmd, /* ESC command -1000..+1000 */
(int)bal.state);
} else {
len = snprintf(buf, sizeof(buf), "{\"err\":%d}\n", imu_ret);

85
src/mpu6000.c Normal file
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@ -0,0 +1,85 @@
/*
* mpu6000.c IMU Sensor Fusion for MPU6000
*
* Wraps the icm42688 SPI driver (which auto-detects MPU6000) and applies
* a complementary filter to produce a stable pitch estimate.
*
* Hardware: MAMBA F722S, MPU6000 on SPI1, CW270 alignment
* Config: Gyro ±2000°/s (init_mpu6000 sets FS_SEL=3)
* Accel ±16g (init_mpu6000 sets AFS_SEL=3)
*/
#include "mpu6000.h"
#include "icm42688.h"
#include "stm32f7xx_hal.h"
#include <math.h>
/* Scale factors matching init_mpu6000() config in icm42688.c */
#define GYRO_SCALE (1.0f / 16.384f) /* LSB to °/s — ±2000°/s range */
#define ACCEL_SCALE (1.0f / 2048.0f) /* LSB to g — ±16g range */
/*
* Complementary filter coefficient.
* 0.98 = trust gyro integration, 0.02 = accel correction for drift.
* Tune higher (0.99) for noisier environments.
*/
#define COMP_ALPHA 0.98f
/* Filter state */
static float s_pitch = 0.0f;
static uint32_t s_last_tick = 0;
bool mpu6000_init(void) {
int ret = icm42688_init();
if (ret == 0) {
s_pitch = 0.0f;
s_last_tick = HAL_GetTick();
}
return (ret == 0);
}
void mpu6000_read(IMUData *data) {
icm42688_data_t raw;
icm42688_read(&raw);
/* Compute dt from wall clock — robust to loop jitter */
uint32_t now = HAL_GetTick();
uint32_t elapsed_ms = now - s_last_tick;
if (elapsed_ms == 0) elapsed_ms = 1; /* min 1ms to avoid divide-by-zero */
if (elapsed_ms > 100) elapsed_ms = 100; /* clamp: don't integrate stale data */
float dt = elapsed_ms * 0.001f;
s_last_tick = now;
/* Convert raw to physical units */
float ax = raw.ax * ACCEL_SCALE; /* g */
float az = raw.az * ACCEL_SCALE; /* g */
/*
* Gyro pitch axis with CW270 alignment: pitch rate = gx.
* Sign may need inverting depending on mounting orientation
* verify during bench test (positive nose-up should be positive).
*/
float gyro_pitch_rate = raw.gx * GYRO_SCALE; /* °/s */
/*
* Accel pitch angle (degrees).
* CW270 alignment: pitch = atan2(ax, az).
* Valid while ax² + az² 1g (i.e., low linear acceleration).
*/
float accel_pitch = atan2f(ax, az) * (180.0f / 3.14159265358979f);
/*
* Complementary filter:
* pitch = α * (pitch + ω*dt) + (1α) * accel_pitch
*
* Gyro integration tracks fast dynamics; accel correction
* prevents long-term drift.
*/
s_pitch = COMP_ALPHA * (s_pitch + gyro_pitch_rate * dt)
+ (1.0f - COMP_ALPHA) * accel_pitch;
data->pitch = s_pitch;
data->pitch_rate = gyro_pitch_rate;
data->accel_x = ax;
data->accel_z = az;
}

77
src/safety.c Normal file
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@ -0,0 +1,77 @@
/*
* safety.c SaltyLab Safety Systems
*
* IWDG: 40kHz LSI, prescaler 32 tick = 0.8ms.
* WATCHDOG_TIMEOUT_MS from config.h (default 50ms reload = 62).
* Formula: reload = (timeout_ms / (prescaler / 40000)) - 1
* reload = (50 * 40000 / 32) - 1 = 62499 clamp to 4095 (12-bit max)
* At PSC=256: tick = 6.4ms, reload = ceil(50/6.4)-1 = 7 ~57.6ms
* Using PSC=32: tick = 0.8ms, reload = ceil(50/0.8)-1 = 62 50ms
*/
#include "safety.h"
#include "config.h"
#include "crsf.h"
#include "stm32f7xx_hal.h"
/* IWDG prescaler 32 → LSI(40kHz)/32 = 1250 ticks/sec → 0.8ms/tick */
#define IWDG_PRESCALER IWDG_PRESCALER_32
#define IWDG_TICK_MS (32.0f / 40.0f) /* 0.8ms per tick */
#define IWDG_RELOAD ((uint32_t)(WATCHDOG_TIMEOUT_MS / IWDG_TICK_MS))
#if IWDG_RELOAD > 4095
# error "WATCHDOG_TIMEOUT_MS too large for IWDG_PRESCALER_32 — increase prescaler"
#endif
static IWDG_HandleTypeDef hiwdg;
/* Arm interlock */
static uint32_t s_arm_start_ms = 0;
static bool s_arm_pending = false;
/* Tilt fault alert state — edge-detect to fire buzzer once */
static bool s_was_faulted = false;
void safety_init(void) {
hiwdg.Instance = IWDG;
hiwdg.Init.Prescaler = IWDG_PRESCALER;
hiwdg.Init.Reload = IWDG_RELOAD;
hiwdg.Init.Window = IWDG_WINDOW_DISABLE;
HAL_IWDG_Init(&hiwdg); /* Starts watchdog immediately */
}
void safety_refresh(void) {
HAL_IWDG_Refresh(&hiwdg);
}
bool safety_rc_alive(uint32_t now) {
/* If crsf_state has never received a frame, last_rx_ms == 0 */
if (crsf_state.last_rx_ms == 0) return false;
return (now - crsf_state.last_rx_ms) < RC_TIMEOUT_MS;
}
void safety_alert_tilt_fault(bool faulted) {
if (faulted && !s_was_faulted) {
/* Rising edge: single buzzer burst to alert rider */
HAL_GPIO_WritePin(BEEPER_PORT, BEEPER_PIN, GPIO_PIN_SET);
HAL_Delay(200);
HAL_GPIO_WritePin(BEEPER_PORT, BEEPER_PIN, GPIO_PIN_RESET);
}
s_was_faulted = faulted;
}
void safety_arm_start(uint32_t now) {
if (!s_arm_pending) {
s_arm_start_ms = now;
s_arm_pending = true;
}
}
bool safety_arm_ready(uint32_t now) {
if (!s_arm_pending) return false;
return (now - s_arm_start_ms) >= ARMING_HOLD_MS;
}
void safety_arm_cancel(void) {
s_arm_pending = false;
}