Merge pull request 'feat: systemd auto-start for ROS2 + dashboard on Orin boot (bd-1hyn)' (#732) from sl-perception/bd-1hyn-orin-autostart into main

Extends the bd-66hx serial protocol with two new Orin→ESP32 commands:
  CMD_OTA_CHECK  (0x10): triggers gitea_ota_check_now(), responds with
    TELEM_VERSION_INFO (0x84) for Balance and IO (current + available ver).
  CMD_OTA_UPDATE (0x11): uint8 target (0=balance, 1=io, 2=both) — triggers
    uart_ota_trigger() for IO or ota_self_trigger() for Balance.
    NACK with ERR_OTA_BUSY or ERR_OTA_NO_UPDATE on failure.
New telemetry: TELEM_OTA_STATUS (0x83, target+state+progress+err),
  TELEM_VERSION_INFO (0x84, target+current[16]+available[16]).
Wires OTA stack into app_main: ota_self_health_check on boot,
  gitea_ota_init + ota_display_init after peripherals ready.
CMakeLists updated with all OTA component dependencies.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

.gitea/workflows/ota-release.yml

@@ -0,0 +1,162 @@
+# .gitea/workflows/ota-release.yml
+# Gitea Actions — ESP32 OTA firmware build & release (bd-9kod)
+#
+# Triggers on signed release tags:
+#   esp32-balance/vX.Y.Z  →  builds esp32s3/balance/   (ESP32-S3 Balance board)
+#   esp32-io/vX.Y.Z       →  builds esp32s3-io/         (ESP32-S3 IO board)
+#
+# Uses the official espressif/idf Docker image for reproducible builds.
+# Attaches <app>_<version>.bin + <app>_<version>.sha256 to the Gitea release.
+# The ESP32 Balance OTA system fetches the .bin from the release asset URL.
+
+name: OTA release — build & attach firmware
+
+on:
+  push:
+    tags:
+      - "esp32-balance/v*"
+      - "esp32-io/v*"
+
+permissions:
+  contents: write
+
+jobs:
+  build-and-release:
+    name: Build ${{ github.ref_name }}
+    runs-on: ubuntu-latest
+    container:
+      image: espressif/idf:v5.2.2
+      options: --user root
+
+    steps:
+      # ── 1. Checkout ───────────────────────────────────────────────────────────
+      - name: Checkout
+        uses: actions/checkout@v4
+
+      # ── 2. Resolve build target from tag ─────────────────────────────────────
+      # Tag format:  esp32-balance/v1.2.3  or  esp32-io/v1.2.3
+      - name: Resolve project from tag
+        id: proj
+        shell: bash
+        run: |
+          TAG="${GITHUB_REF_NAME}"
+          case "$TAG" in
+            esp32-balance/*)
+              DIR="esp32s3/balance"
+              APP="esp32s3_balance"
+              ;;
+            esp32-io/*)
+              DIR="esp32s3-io"
+              APP="esp32s3_io"
+              ;;
+            *)
+              echo "::error::Unrecognised tag prefix: ${TAG}"
+              exit 1
+              ;;
+          esac
+          VERSION="${TAG#*/}"
+          echo "dir=${DIR}"         >> "$GITHUB_OUTPUT"
+          echo "app=${APP}"         >> "$GITHUB_OUTPUT"
+          echo "version=${VERSION}" >> "$GITHUB_OUTPUT"
+          echo "tag=${TAG}"         >> "$GITHUB_OUTPUT"
+          echo "Build: ${APP} ${VERSION} from ${DIR}"
+
+      # ── 3. Build with ESP-IDF ─────────────────────────────────────────────────
+      - name: Build firmware (idf.py build)
+        shell: bash
+        run: |
+          . "${IDF_PATH}/export.sh"
+          cd "${{ steps.proj.outputs.dir }}"
+          idf.py build
+
+      # ── 4. Collect binary & generate checksum ────────────────────────────────
+      - name: Collect artifacts
+        id: art
+        shell: bash
+        run: |
+          APP="${{ steps.proj.outputs.app }}"
+          VER="${{ steps.proj.outputs.version }}"
+          BIN_SRC="${{ steps.proj.outputs.dir }}/build/${APP}.bin"
+          BIN_OUT="${APP}_${VER}.bin"
+          SHA_OUT="${APP}_${VER}.sha256"
+
+          cp "$BIN_SRC" "$BIN_OUT"
+          sha256sum "$BIN_OUT" > "$SHA_OUT"
+
+          echo "bin=${BIN_OUT}" >> "$GITHUB_OUTPUT"
+          echo "sha=${SHA_OUT}" >> "$GITHUB_OUTPUT"
+
+          echo "Binary:   ${BIN_OUT} ($(wc -c < "$BIN_OUT") bytes)"
+          echo "Checksum: $(cat "$SHA_OUT")"
+
+      # ── 5. Archive artifacts in CI workspace ─────────────────────────────────
+      - name: Upload build artifacts
+        uses: actions/upload-artifact@v4
+        with:
+          name: firmware-${{ steps.proj.outputs.app }}-${{ steps.proj.outputs.version }}
+          path: |
+            ${{ steps.art.outputs.bin }}
+            ${{ steps.art.outputs.sha }}
+
+      # ── 6. Create Gitea release (if needed) & upload assets ──────────────────
+      # Uses GITHUB_TOKEN (auto-provided, contents:write from permissions block).
+      # URL-encodes the tag to handle the slash in esp32-balance/vX.Y.Z.
+      - name: Publish assets to Gitea release
+        shell: bash
+        env:
+          GITEA_URL: https://gitea.vayrette.com
+          TOKEN: ${{ secrets.GITHUB_TOKEN }}
+          REPO: ${{ github.repository }}
+          TAG: ${{ steps.proj.outputs.tag }}
+          BIN: ${{ steps.art.outputs.bin }}
+          SHA: ${{ steps.art.outputs.sha }}
+        run: |
+          API="${GITEA_URL}/api/v1/repos/${REPO}"
+
+          # URL-encode the tag (slash in esp32-balance/vX.Y.Z must be escaped)
+          TAG_ENC=$(python3 -c "
+          import urllib.parse, sys
+          print(urllib.parse.quote(sys.argv[1], safe=''))
+          " "$TAG")
+
+          # Try to fetch an existing release for this tag
+          RELEASE=$(curl -sf \
+            -H "Authorization: token ${TOKEN}" \
+            "${API}/releases/tags/${TAG_ENC}") || true
+
+          # If no release yet, create it
+          if [ -z "$RELEASE" ]; then
+            echo "Creating release for tag: ${TAG}"
+            RELEASE=$(curl -sf \
+              -X POST \
+              -H "Authorization: token ${TOKEN}" \
+              -H "Content-Type: application/json" \
+              -d "$(python3 -c "
+          import json, sys
+          print(json.dumps({
+              'tag_name': sys.argv[1],
+              'name':     sys.argv[1],
+              'draft':    False,
+              'prerelease': False,
+          }))
+          " "$TAG")" \
+              "${API}/releases")
+          fi
+
+          RELEASE_ID=$(echo "$RELEASE" | python3 -c "
+          import sys, json; print(json.load(sys.stdin)['id'])
+          ")
+          echo "Release ID: ${RELEASE_ID}"
+
+          # Upload binary and checksum
+          for FILE in "$BIN" "$SHA"; do
+            FNAME=$(basename "$FILE")
+            echo "Uploading: ${FNAME}"
+            curl -sf \
+              -X POST \
+              -H "Authorization: token ${TOKEN}" \
+              -F "attachment=@${FILE}" \
+              "${API}/releases/${RELEASE_ID}/assets?name=${FNAME}"
+          done
+
+          echo "Published: ${BIN} + ${SHA} → release ${TAG}"

AUTONOMOUS_ARMING.md

@@ -7,7 +7,11 @@ The robot can now be armed and operated autonomously from the Jetson without req
 
 ### Jetson Autonomous Arming
 - Command: `A\n` (single byte 'A' followed by newline)
-- Sent via USB CDC to the STM32 firmware
+<<<<<<< HEAD
+- Sent via USB CDC to the ESP32 BALANCE firmware
+=======
+- Sent via USB Serial (CH343) to the ESP32-S3 firmware
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 - Robot arms after ARMING_HOLD_MS (~500ms) safety hold period
 - Works even when RC is not connected or not armed
 
@@ -42,7 +46,11 @@ The robot can now be armed and operated autonomously from the Jetson without req
 
 ## Command Protocol
 
-### From Jetson to STM32 (USB CDC)
+<<<<<<< HEAD
+### From Jetson to ESP32 BALANCE (USB CDC)
+=======
+### From Jetson to ESP32-S3 (USB Serial (CH343))
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 ```
 A           — Request arm (triggers safety hold, then motors enable)
 D           — Request disarm (immediate motor stop)
@@ -52,7 +60,11 @@ H           — Heartbeat (refresh timeout timer, every 500ms)
 C<spd>,<str> — Drive command: speed, steer (also refreshes heartbeat)
 ```
 
-### From STM32 to Jetson (USB CDC)
+<<<<<<< HEAD
+### From ESP32 BALANCE to Jetson (USB CDC)
+=======
+### From ESP32-S3 to Jetson (USB Serial (CH343))
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 Motor commands are gated by `bal.state == BALANCE_ARMED`:
 - When ARMED: Motor commands sent every 20ms (50 Hz)
 - When DISARMED: Zero sent every 20ms (prevents ESC timeout)

CLAUDE.md

@@ -1,17 +1,36 @@
 # SaltyLab Firmware — Agent Playbook
 
 ## Project
-Self-balancing two-wheeled robot: STM32F722 flight controller, hoverboard hub motors, Jetson Nano for AI/SLAM.
+<<<<<<< HEAD
+**SAUL-TEE** — 4-wheel wagon (870×510×550 mm, 23 kg).
+Two ESP32-S3 boards + Jetson Orin via CAN. Full spec: `docs/SAUL-TEE-SYSTEM-REFERENCE.md`
+
+| Board | Role |
+|-------|------|
+| **ESP32-S3 BALANCE** | QMI8658 IMU, PID balance, CAN→VESC (L:68 / R:56), GC9A01 LCD (Waveshare Touch LCD 1.28) |
+| **ESP32-S3 IO** | TBS Crossfire RC, ELRS failover, BTS7960 motors, NFC/baro/ToF, WS2812 |
+| **Jetson Orin** | AI/SLAM, CANable2 USB→CAN, cmds 0x300–0x303, telemetry 0x400–0x401 |
+
+> **Legacy:** `src/` and `include/` = archived STM32 HAL — do not extend. New firmware in `esp32/`.
+=======
+Self-balancing two-wheeled robot: ESP32-S3 ESP32-S3 BALANCE, hoverboard hub motors, Jetson Orin Nano Super for AI/SLAM.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Team
 | Agent | Role | Focus |
 |-------|------|-------|
-| **sl-firmware** | Embedded Firmware Lead | STM32 HAL, USB CDC debugging, SPI/UART, PlatformIO, DFU bootloader |
+<<<<<<< HEAD
+| **sl-firmware** | Embedded Firmware Lead | ESP32-S3, ESP-IDF, QMI8658, CAN/UART protocol, BTS7960 |
+| **sl-controls** | Control Systems Engineer | PID tuning, IMU fusion, balance loop, safety |
+| **sl-perception** | Perception / SLAM Engineer | Jetson Orin, RealSense D435i, RPLIDAR, ROS2, Nav2 |
+=======
+| **sl-firmware** | Embedded Firmware Lead | ESP-IDF, USB Serial (CH343) debugging, SPI/UART, PlatformIO, DFU bootloader |
 | **sl-controls** | Control Systems Engineer | PID tuning, IMU sensor fusion, real-time control loops, safety systems |
-| **sl-perception** | Perception / SLAM Engineer | Jetson Nano, RealSense D435i, RPLIDAR, ROS2, Nav2 |
+| **sl-perception** | Perception / SLAM Engineer | Jetson Orin Nano Super, RealSense D435i, RPLIDAR, ROS2, Nav2 |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Status
-USB CDC TX bug resolved (PR #10 — DCache MPU non-cacheable region + IWDG ordering fix).
+USB Serial (CH343) TX bug resolved (PR #10 — DCache MPU non-cacheable region + IWDG ordering fix).
 
 ## Repo Structure
 - `projects/saltybot/SALTYLAB.md` — Design doc
@@ -29,11 +48,11 @@ USB CDC TX bug resolved (PR #10 — DCache MPU non-cacheable region + IWDG order
 | `saltyrover-dev` | Integration — rover variant |
 | `saltytank` | Stable — tracked tank variant |
 | `saltytank-dev` | Integration — tank variant |
-| `main` | Shared code only (IMU drivers, USB CDC, balance core, safety) |
+| `main` | Shared code only (IMU drivers, USB Serial (CH343), balance core, safety) |
 
 ### Rules
 - Agents branch FROM `<variant>-dev` and PR back TO `<variant>-dev`
-- Shared/infrastructure code (IMU drivers, USB CDC, balance core, safety) goes in `main`
+- Shared/infrastructure code (IMU drivers, USB Serial (CH343), balance core, safety) goes in `main`
 - Variant-specific code (motor topology, kinematics, config) goes in variant branches
 - Stable branches get promoted from `-dev` after review and hardware testing
 - **Current SaltyLab team** works against `saltylab-dev`

TEAM.md

@@ -1,12 +1,22 @@
 # SaltyLab — Ideal Team
 
 ## Project
-Self-balancing two-wheeled robot using a drone flight controller (STM32F722), hoverboard hub motors, and eventually a Jetson Nano for AI/SLAM.
+<<<<<<< HEAD
+**SAUL-TEE** — 4-wheel wagon (870×510×550 mm, 23 kg).
+Two ESP32-S3 boards (BALANCE + IO) + Jetson Orin. See `docs/SAUL-TEE-SYSTEM-REFERENCE.md`.
+
+## Current Status
+- **Hardware:** ESP32-S3 BALANCE (Waveshare Touch LCD 1.28, CH343 USB) + ESP32-S3 IO (bare devkit, JTAG USB)
+- **Firmware:** ESP-IDF/PlatformIO target; legacy `src/` STM32 HAL archived
+- **Comms:** UART 460800 baud inter-board; CANable2 USB→CAN for Orin; CAN 500 kbps to VESCs (L:68 / R:56)
+=======
+Self-balancing two-wheeled robot using a drone ESP32-S3 BALANCE (ESP32-S3), hoverboard hub motors, and eventually a Jetson Orin Nano Super for AI/SLAM.
 
 ## Current Status
 - **Hardware:** Assembled — FC, motors, ESC, IMU, battery, RC all on hand
-- **Firmware:** Balance PID + hoverboard ESC protocol written, but blocked by USB CDC bug
+- **Firmware:** Balance PID + hoverboard ESC protocol written, but blocked by USB Serial (CH343) bug
-- **Blocker:** USB CDC TX stops working when peripheral inits (SPI/UART/GPIO) are added alongside USB OTG FS — see `USB_CDC_BUG.md`
+- **Blocker:** USB Serial (CH343) TX stops working when peripheral inits (SPI/UART/GPIO) are added alongside USB on ESP32-S3 — see `legacy/stm32/USB_CDC_BUG.md` for historical context
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ---
 
@@ -14,18 +24,30 @@ Self-balancing two-wheeled robot using a drone flight controller (STM32F722), ho
 
 ### 1. Embedded Firmware Engineer (Lead)
 **Must-have:**
-- Deep STM32 HAL experience (F7 series specifically)
+<<<<<<< HEAD
+- Deep ESP32 (Arduino/ESP-IDF) or STM32 HAL experience
 - USB OTG FS / CDC ACM debugging (TxState, endpoint management, DMA conflicts)
-- SPI + UART + USB coexistence on STM32
+- SPI + UART + USB coexistence on ESP32
-- PlatformIO or bare-metal STM32 toolchain
+- PlatformIO or bare-metal ESP32 toolchain
 - DFU bootloader implementation
+=======
+- Deep ESP-IDF experience (ESP32-S3 specifically)
+- USB Serial (CH343) / UART debugging on ESP32-S3
+- SPI + UART + USB coexistence on ESP32-S3
+- ESP-IDF / Arduino-ESP32 toolchain
+- OTA firmware update implementation
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 **Nice-to-have:**
-- Betaflight/iNav/ArduPilot codebase familiarity
+- ESP32-S3 peripheral coexistence (SPI + UART + USB)
 - PID control loop tuning for balance robots
 - FOC motor control (hoverboard ESC protocol)
 
-**Why:** The immediate blocker is a USB peripheral conflict. Need someone who's debugged STM32 USB issues before — this is not a software logic bug, it's a hardware peripheral interaction issue.
+<<<<<<< HEAD
+**Why:** The immediate blocker is a USB peripheral conflict. Need someone who's debugged STM32 USB issues before — ESP32 firmware for the balance loop and I/O needs to be written from scratch.
+=======
+**Why:** The immediate blocker is a USB peripheral conflict on ESP32-S3. Need someone who's debugged ESP32-S3 USB Serial (CH343) issues before — this is not a software logic bug, it's a hardware peripheral interaction issue.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ### 2. Control Systems / Robotics Engineer
 **Must-have:**
@@ -43,7 +65,7 @@ Self-balancing two-wheeled robot using a drone flight controller (STM32F722), ho
 
 ### 3. Perception / SLAM Engineer (Phase 2)
 **Must-have:**
-- Jetson Nano / NVIDIA Jetson platform
+- Jetson Orin Nano Super / NVIDIA Jetson platform
 - Intel RealSense D435i depth camera
 - RPLIDAR integration
 - SLAM (ORB-SLAM3, RTAB-Map, or similar)
@@ -54,19 +76,23 @@ Self-balancing two-wheeled robot using a drone flight controller (STM32F722), ho
 - Obstacle avoidance
 - Nav2 stack
 
-**Why:** Phase 2 goal is autonomous navigation. Jetson Nano with RealSense + RPLIDAR for indoor mapping and person following.
+**Why:** Phase 2 goal is autonomous navigation. Jetson Orin Nano Super with RealSense + RPLIDAR for indoor mapping and person following.
 
 ---
 
 ## Hardware Reference
 | Component | Details |
 |-----------|---------|
-| FC | MAMBA F722S (STM32F722RET6, MPU6000) |
+<<<<<<< HEAD
+| FC | ESP32 BALANCE (ESP32RET6, MPU6000) |
+=======
+| FC | ESP32-S3 BALANCE (ESP32-S3RET6, QMI8658) |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | Motors | 2x 8" pneumatic hoverboard hub motors |
 | ESC | Hoverboard ESC (EFeru FOC firmware) |
 | Battery | 36V pack |
 | RC | BetaFPV ELRS 2.4GHz TX + RX |
-| AI Brain | Jetson Nano + Noctua fan |
+| AI Brain | Jetson Orin Nano Super + Noctua fan |
 | Depth | Intel RealSense D435i |
 | LIDAR | RPLIDAR A1M8 |
 | Spare IMUs | BNO055, MPU6050 |
@@ -74,4 +100,4 @@ Self-balancing two-wheeled robot using a drone flight controller (STM32F722), ho
 ## Repo
 - Gitea: https://gitea.vayrette.com/seb/saltylab-firmware
 - Design doc: `projects/saltybot/SALTYLAB.md`
-- Bug doc: `USB_CDC_BUG.md`
+- Bug doc: `legacy/stm32/USB_CDC_BUG.md` (archived — STM32 era)

USB_CDC_BUG.md

@@ -1,44 +0,0 @@
-# USB CDC TX Bug — 2026-02-28
-
-## Problem
-Balance firmware produces no USB CDC output. Minimal "hello" test firmware works fine.
-
-## What Works
-- **Test firmware** (just sends `{"hello":N}` at 10Hz after 3s delay): **DATA FLOWS**
-- USB enumeration works in both cases (port appears as `/dev/cu.usbmodemSALTY0011`)
-- DFU reboot via RTC backup register works (Betaflight-proven pattern)
-
-## What Doesn't Work
-- **Balance firmware**: port opens, no data ever arrives
-- Tried: removing init transmit, 3s boot delay, TxState recovery, DTR detection, streaming flags
-- None of it helps
-
-## Key Difference Between Working & Broken
-- **Working test**: main.c only includes USB CDC headers, HAL, string, stdio
-- **Balance firmware**: includes icm42688.h, bmp280.h, balance.h, hoverboard.h, config.h, status.h
-- Balance firmware inits SPI1 (IMU), USART2 (hoverboard), GPIO (LEDs, buzzer)
-- Likely culprit: **peripheral init (SPI/UART/GPIO) is interfering with USB OTG FS**
-
-## Suspected Root Cause
-One of the additional peripheral inits (SPI1 for IMU, USART2 for hoverboard ESC, or GPIO for status LEDs) is likely conflicting with the USB OTG FS peripheral — either a clock conflict, GPIO pin conflict, or interrupt priority issue.
-
-## Hardware
-- MAMBA F722S FC (STM32F722RET6)
-- Betaflight target: DIAT-MAMBAF722_2022B
-- IMU: MPU6000 on SPI1 (PA4/PA5/PA6/PA7)
-- USB: OTG FS (PA11/PA12)
-- Hoverboard ESC: USART2 (PA2/PA3)
-- LEDs: PC14, PC15
-- Buzzer: PB2
-
-## Files
-- PlatformIO project: `~/Projects/saltylab-firmware/` on mbpm4 (192.168.87.40)
-- Working test: was in src/main.c (replaced with balance code)
-- Balance main.c backup: src/main.c.bak
-- CDC implementation: lib/USB_CDC/src/usbd_cdc_if.c
-
-## To Debug
-1. Add peripherals one at a time to the test firmware to find which one breaks CDC TX
-2. Check for GPIO pin conflicts with USB OTG FS (PA11/PA12)
-3. Check interrupt priorities — USB OTG FS IRQ might be getting starved
-4. Check if DCache (disabled via SCB_DisableDCache) is needed for USB DMA

android/build.gradle

@@ -0,0 +1,46 @@
+plugins {
+    id 'com.android.application'
+    id 'kotlin-android'
+}
+
+android {
+    compileSdk 34
+    namespace 'com.saltylab.uwbtag'
+
+    defaultConfig {
+        applicationId "com.saltylab.uwbtag"
+        minSdk 26
+        targetSdk 34
+        versionCode 1
+        versionName "1.0"
+    }
+
+    buildTypes {
+        release {
+            minifyEnabled false
+        }
+    }
+
+    buildFeatures {
+        viewBinding true
+    }
+
+    compileOptions {
+        sourceCompatibility JavaVersion.VERSION_17
+        targetCompatibility JavaVersion.VERSION_17
+    }
+
+    kotlinOptions {
+        jvmTarget = '17'
+    }
+}
+
+dependencies {
+    implementation 'androidx.core:core-ktx:1.12.0'
+    implementation 'androidx.appcompat:appcompat:1.6.1'
+    implementation 'com.google.android.material:material:1.11.0'
+    implementation 'androidx.recyclerview:recyclerview:1.3.2'
+    implementation 'androidx.lifecycle:lifecycle-runtime-ktx:2.7.0'
+    implementation 'org.jetbrains.kotlinx:kotlinx-coroutines-android:1.7.3'
+    implementation 'com.google.code.gson:gson:2.10.1'
+}

android/src/main/AndroidManifest.xml

@@ -0,0 +1,37 @@
+<?xml version="1.0" encoding="utf-8"?>
+<manifest xmlns:android="http://schemas.android.com/apk/res/android">
+
+    <!-- BLE permissions (API 31+) -->
+    <uses-permission android:name="android.permission.BLUETOOTH_SCAN"
+        android:usesPermissionFlags="neverForLocation" />
+    <uses-permission android:name="android.permission.BLUETOOTH_CONNECT" />
+    <uses-permission android:name="android.permission.BLUETOOTH_ADVERTISE" />
+
+    <!-- Legacy BLE (API < 31) -->
+    <uses-permission android:name="android.permission.BLUETOOTH"
+        android:maxSdkVersion="30" />
+    <uses-permission android:name="android.permission.BLUETOOTH_ADMIN"
+        android:maxSdkVersion="30" />
+    <uses-permission android:name="android.permission.ACCESS_FINE_LOCATION"
+        android:maxSdkVersion="30" />
+
+    <uses-feature android:name="android.hardware.bluetooth_le" android:required="true" />
+
+    <application
+        android:allowBackup="true"
+        android:label="UWB Tag Config"
+        android:theme="@style/Theme.MaterialComponents.DayNight.DarkActionBar">
+
+        <activity
+            android:name=".UwbTagBleActivity"
+            android:exported="true"
+            android:launchMode="singleTop">
+            <intent-filter>
+                <action android:name="android.intent.action.MAIN" />
+                <category android:name="android.intent.category.LAUNCHER" />
+            </intent-filter>
+        </activity>
+
+    </application>
+
+</manifest>

android/src/main/kotlin/com/saltylab/uwbtag/UwbTagBleActivity.kt

@@ -0,0 +1,444 @@
+package com.saltylab.uwbtag
+
+import android.Manifest
+import android.annotation.SuppressLint
+import android.bluetooth.*
+import android.bluetooth.le.*
+import android.content.Context
+import android.content.pm.PackageManager
+import android.os.Build
+import android.os.Bundle
+import android.os.Handler
+import android.os.Looper
+import android.view.LayoutInflater
+import android.view.View
+import android.view.ViewGroup
+import android.widget.Button
+import android.widget.TextView
+import android.widget.Toast
+import androidx.appcompat.app.AppCompatActivity
+import androidx.core.app.ActivityCompat
+import androidx.core.content.ContextCompat
+import androidx.recyclerview.widget.LinearLayoutManager
+import androidx.recyclerview.widget.RecyclerView
+import com.google.android.material.card.MaterialCardView
+import com.google.android.material.switchmaterial.SwitchMaterial
+import com.google.android.material.textfield.TextInputEditText
+import com.google.gson.Gson
+import com.saltylab.uwbtag.databinding.ActivityUwbTagBleBinding
+import java.util.UUID
+
+// ---------------------------------------------------------------------------
+// GATT service / characteristic UUIDs
+// ---------------------------------------------------------------------------
+private val SERVICE_UUID     = UUID.fromString("12345678-1234-5678-1234-56789abcdef0")
+private val CHAR_CONFIG_UUID = UUID.fromString("12345678-1234-5678-1234-56789abcdef1") // read/write JSON config
+private val CHAR_STATUS_UUID = UUID.fromString("12345678-1234-5678-1234-56789abcdef2") // notify: tag status string
+private val CHAR_BATT_UUID   = UUID.fromString("12345678-1234-5678-1234-56789abcdef3") // notify: battery %
+private val CCCD_UUID        = UUID.fromString("00002902-0000-1000-8000-00805f9b34fb")
+
+// BLE scan timeout
+private const val SCAN_TIMEOUT_MS = 15_000L
+
+// Permissions request code
+private const val REQ_PERMISSIONS = 1001
+
+// ---------------------------------------------------------------------------
+// Data model
+// ---------------------------------------------------------------------------
+data class TagConfig(
+    val tag_name: String = "UWB_TAG_0001",
+    val sleep_timeout_s: Int = 300,
+    val display_brightness: Int = 50,
+    val uwb_channel: Int = 9,
+    val ranging_interval_ms: Int = 100,
+    val battery_report: Boolean = true
+)
+
+data class ScannedDevice(
+    val name: String,
+    val address: String,
+    var rssi: Int,
+    val device: BluetoothDevice
+)
+
+// ---------------------------------------------------------------------------
+// RecyclerView adapter for scanned devices
+// ---------------------------------------------------------------------------
+class DeviceAdapter(
+    private val onConnect: (ScannedDevice) -> Unit
+) : RecyclerView.Adapter<DeviceAdapter.VH>() {
+
+    private val items = mutableListOf<ScannedDevice>()
+
+    fun update(device: ScannedDevice) {
+        val idx = items.indexOfFirst { it.address == device.address }
+        if (idx >= 0) {
+            items[idx] = device
+            notifyItemChanged(idx)
+        } else {
+            items.add(device)
+            notifyItemInserted(items.size - 1)
+        }
+    }
+
+    fun clear() {
+        items.clear()
+        notifyDataSetChanged()
+    }
+
+    override fun onCreateViewHolder(parent: ViewGroup, viewType: Int): VH {
+        val view = LayoutInflater.from(parent.context)
+            .inflate(R.layout.item_ble_device, parent, false)
+        return VH(view)
+    }
+
+    override fun onBindViewHolder(holder: VH, position: Int) = holder.bind(items[position])
+    override fun getItemCount() = items.size
+
+    inner class VH(view: View) : RecyclerView.ViewHolder(view) {
+        private val tvName    = view.findViewById<TextView>(R.id.tvDeviceName)
+        private val tvAddress = view.findViewById<TextView>(R.id.tvDeviceAddress)
+        private val tvRssi    = view.findViewById<TextView>(R.id.tvRssi)
+        private val btnConn   = view.findViewById<Button>(R.id.btnConnect)
+
+        fun bind(item: ScannedDevice) {
+            tvName.text    = item.name
+            tvAddress.text = item.address
+            tvRssi.text    = "${item.rssi} dBm"
+            btnConn.setOnClickListener { onConnect(item) }
+        }
+    }
+}
+
+// ---------------------------------------------------------------------------
+// Activity
+// ---------------------------------------------------------------------------
+@SuppressLint("MissingPermission") // permissions checked at runtime before any BLE call
+class UwbTagBleActivity : AppCompatActivity() {
+
+    private lateinit var binding: ActivityUwbTagBleBinding
+    private val gson = Gson()
+    private val mainHandler = Handler(Looper.getMainLooper())
+
+    // BLE
+    private val btManager by lazy { getSystemService(Context.BLUETOOTH_SERVICE) as BluetoothManager }
+    private val btAdapter by lazy { btManager.adapter }
+    private var bleScanner: BluetoothLeScanner? = null
+    private var gatt: BluetoothGatt? = null
+    private var configChar: BluetoothGattCharacteristic? = null
+    private var statusChar: BluetoothGattCharacteristic? = null
+    private var battChar: BluetoothGattCharacteristic? = null
+    private var isScanning = false
+
+    private val deviceAdapter = DeviceAdapter(onConnect = ::connectToDevice)
+
+    // ---------------------------------------------------------------------------
+    // Lifecycle
+    // ---------------------------------------------------------------------------
+    override fun onCreate(savedInstanceState: Bundle?) {
+        super.onCreate(savedInstanceState)
+        binding = ActivityUwbTagBleBinding.inflate(layoutInflater)
+        setContentView(binding.root)
+        setSupportActionBar(binding.toolbar)
+
+        binding.rvDevices.layoutManager = LinearLayoutManager(this)
+        binding.rvDevices.adapter = deviceAdapter
+
+        binding.btnScan.setOnClickListener {
+            if (isScanning) stopScan() else startScanIfPermitted()
+        }
+        binding.btnDisconnect.setOnClickListener { disconnectGatt() }
+        binding.btnReadConfig.setOnClickListener { readConfig() }
+        binding.btnWriteConfig.setOnClickListener { writeConfig() }
+
+        requestBlePermissions()
+    }
+
+    override fun onDestroy() {
+        super.onDestroy()
+        stopScan()
+        disconnectGatt()
+    }
+
+    // ---------------------------------------------------------------------------
+    // Permissions
+    // ---------------------------------------------------------------------------
+    private fun requestBlePermissions() {
+        val needed = mutableListOf<String>()
+        if (Build.VERSION.SDK_INT >= Build.VERSION_CODES.S) {
+            if (!hasPermission(Manifest.permission.BLUETOOTH_SCAN))
+                needed += Manifest.permission.BLUETOOTH_SCAN
+            if (!hasPermission(Manifest.permission.BLUETOOTH_CONNECT))
+                needed += Manifest.permission.BLUETOOTH_CONNECT
+        } else {
+            if (!hasPermission(Manifest.permission.ACCESS_FINE_LOCATION))
+                needed += Manifest.permission.ACCESS_FINE_LOCATION
+        }
+        if (needed.isNotEmpty()) {
+            ActivityCompat.requestPermissions(this, needed.toTypedArray(), REQ_PERMISSIONS)
+        }
+    }
+
+    private fun hasPermission(perm: String) =
+        ContextCompat.checkSelfPermission(this, perm) == PackageManager.PERMISSION_GRANTED
+
+    override fun onRequestPermissionsResult(
+        requestCode: Int, permissions: Array<out String>, grantResults: IntArray
+    ) {
+        super.onRequestPermissionsResult(requestCode, permissions, grantResults)
+        if (requestCode == REQ_PERMISSIONS &&
+            grantResults.any { it != PackageManager.PERMISSION_GRANTED }) {
+            toast("BLE permissions required")
+        }
+    }
+
+    // ---------------------------------------------------------------------------
+    // BLE Scan
+    // ---------------------------------------------------------------------------
+    private fun startScanIfPermitted() {
+        if (btAdapter?.isEnabled != true) { toast("Bluetooth is off"); return }
+        bleScanner = btAdapter.bluetoothLeScanner
+        val filter = ScanFilter.Builder()
+            .setDeviceNamePattern("UWB_TAG_.*".toRegex().toPattern())
+            .build()
+        val settings = ScanSettings.Builder()
+            .setScanMode(ScanSettings.SCAN_MODE_LOW_LATENCY)
+            .build()
+        deviceAdapter.clear()
+        bleScanner?.startScan(listOf(filter), settings, scanCallback)
+        isScanning = true
+        binding.btnScan.text = "Stop"
+        binding.tvScanStatus.text = "Scanning…"
+        mainHandler.postDelayed({ stopScan() }, SCAN_TIMEOUT_MS)
+    }
+
+    private fun stopScan() {
+        bleScanner?.stopScan(scanCallback)
+        isScanning = false
+        binding.btnScan.text = "Scan"
+        binding.tvScanStatus.text = "Scan stopped"
+    }
+
+    private val scanCallback = object : ScanCallback() {
+        override fun onScanResult(callbackType: Int, result: ScanResult) {
+            val name = result.device.name ?: return
+            if (!name.startsWith("UWB_TAG_")) return
+            val dev = ScannedDevice(
+                name    = name,
+                address = result.device.address,
+                rssi    = result.rssi,
+                device  = result.device
+            )
+            mainHandler.post { deviceAdapter.update(dev) }
+        }
+
+        override fun onScanFailed(errorCode: Int) {
+            mainHandler.post {
+                binding.tvScanStatus.text = "Scan failed (code $errorCode)"
+                isScanning = false
+                binding.btnScan.text = "Scan"
+            }
+        }
+    }
+
+    // ---------------------------------------------------------------------------
+    // GATT Connection
+    // ---------------------------------------------------------------------------
+    private fun connectToDevice(scanned: ScannedDevice) {
+        stopScan()
+        binding.tvScanStatus.text = "Connecting to ${scanned.name}…"
+        gatt = scanned.device.connectGatt(this, false, gattCallback, BluetoothDevice.TRANSPORT_LE)
+    }
+
+    private fun disconnectGatt() {
+        gatt?.disconnect()
+        gatt?.close()
+        gatt = null
+        configChar = null
+        statusChar = null
+        battChar = null
+        mainHandler.post {
+            binding.cardConfig.visibility = View.GONE
+            binding.tvScanStatus.text = "Disconnected"
+        }
+    }
+
+    private val gattCallback = object : BluetoothGattCallback() {
+
+        override fun onConnectionStateChange(g: BluetoothGatt, status: Int, newState: Int) {
+            when (newState) {
+                BluetoothProfile.STATE_CONNECTED -> {
+                    mainHandler.post { binding.tvScanStatus.text = "Connected — discovering services…" }
+                    g.discoverServices()
+                }
+                BluetoothProfile.STATE_DISCONNECTED -> {
+                    mainHandler.post {
+                        binding.cardConfig.visibility = View.GONE
+                        binding.tvScanStatus.text = "Disconnected"
+                        toast("Tag disconnected")
+                    }
+                    gatt?.close()
+                    gatt = null
+                }
+            }
+        }
+
+        override fun onServicesDiscovered(g: BluetoothGatt, status: Int) {
+            if (status != BluetoothGatt.GATT_SUCCESS) {
+                mainHandler.post { toast("Service discovery failed") }
+                return
+            }
+            val service = g.getService(SERVICE_UUID)
+            if (service == null) {
+                mainHandler.post { toast("UWB config service not found on tag") }
+                return
+            }
+            configChar = service.getCharacteristic(CHAR_CONFIG_UUID)
+            statusChar = service.getCharacteristic(CHAR_STATUS_UUID)
+            battChar   = service.getCharacteristic(CHAR_BATT_UUID)
+
+            // Subscribe to status notifications
+            statusChar?.let { enableNotifications(g, it) }
+            battChar?.let   { enableNotifications(g, it) }
+
+            // Initial config read
+            configChar?.let { g.readCharacteristic(it) }
+
+            mainHandler.post {
+                val devName = g.device.name ?: g.device.address
+                binding.tvConnectedName.text = "Connected: $devName"
+                binding.cardConfig.visibility = View.VISIBLE
+                binding.tvScanStatus.text = "Connected to $devName"
+            }
+        }
+
+        override fun onCharacteristicRead(
+            g: BluetoothGatt,
+            characteristic: BluetoothGattCharacteristic,
+            status: Int
+        ) {
+            if (status != BluetoothGatt.GATT_SUCCESS) return
+            if (characteristic.uuid == CHAR_CONFIG_UUID) {
+                val json = characteristic.value?.toString(Charsets.UTF_8) ?: return
+                val cfg = runCatching { gson.fromJson(json, TagConfig::class.java) }.getOrNull() ?: return
+                mainHandler.post { populateFields(cfg) }
+            }
+        }
+
+        // API 33+ callback
+        override fun onCharacteristicRead(
+            g: BluetoothGatt,
+            characteristic: BluetoothGattCharacteristic,
+            value: ByteArray,
+            status: Int
+        ) {
+            if (status != BluetoothGatt.GATT_SUCCESS) return
+            if (characteristic.uuid == CHAR_CONFIG_UUID) {
+                val json = value.toString(Charsets.UTF_8)
+                val cfg = runCatching { gson.fromJson(json, TagConfig::class.java) }.getOrNull() ?: return
+                mainHandler.post { populateFields(cfg) }
+            }
+        }
+
+        override fun onCharacteristicWrite(
+            g: BluetoothGatt,
+            characteristic: BluetoothGattCharacteristic,
+            status: Int
+        ) {
+            val msg = if (status == BluetoothGatt.GATT_SUCCESS) "Config written" else "Write failed ($status)"
+            mainHandler.post { toast(msg) }
+        }
+
+        override fun onCharacteristicChanged(
+            g: BluetoothGatt,
+            characteristic: BluetoothGattCharacteristic
+        ) {
+            val value = characteristic.value ?: return
+            handleNotification(characteristic.uuid, value)
+        }
+
+        // API 33+ callback
+        override fun onCharacteristicChanged(
+            g: BluetoothGatt,
+            characteristic: BluetoothGattCharacteristic,
+            value: ByteArray
+        ) {
+            handleNotification(characteristic.uuid, value)
+        }
+    }
+
+    // ---------------------------------------------------------------------------
+    // Notification helpers
+    // ---------------------------------------------------------------------------
+    private fun enableNotifications(g: BluetoothGatt, char: BluetoothGattCharacteristic) {
+        g.setCharacteristicNotification(char, true)
+        val descriptor = char.getDescriptor(CCCD_UUID) ?: return
+        descriptor.value = BluetoothGattDescriptor.ENABLE_NOTIFICATION_VALUE
+        g.writeDescriptor(descriptor)
+    }
+
+    private fun handleNotification(uuid: UUID, value: ByteArray) {
+        val text = value.toString(Charsets.UTF_8)
+        mainHandler.post {
+            when (uuid) {
+                CHAR_STATUS_UUID -> binding.tvTagStatus.text = "Status: $text"
+                CHAR_BATT_UUID   -> {
+                    val pct = text.toIntOrNull() ?: return@post
+                    binding.tvTagStatus.text = binding.tvTagStatus.text.toString()
+                        .replace(Regex("\\| Batt:.*"), "")
+                        .trimEnd() + " | Batt: $pct%"
+                }
+            }
+        }
+    }
+
+    // ---------------------------------------------------------------------------
+    // Config read / write
+    // ---------------------------------------------------------------------------
+    private fun readConfig() {
+        val g = gatt ?: run { toast("Not connected"); return }
+        val c = configChar ?: run { toast("Config char not found"); return }
+        g.readCharacteristic(c)
+    }
+
+    private fun writeConfig() {
+        val g = gatt ?: run { toast("Not connected"); return }
+        val c = configChar ?: run { toast("Config char not found"); return }
+        val cfg = buildConfigFromFields()
+        val json = gson.toJson(cfg)
+        if (Build.VERSION.SDK_INT >= Build.VERSION_CODES.TIRAMISU) {
+            g.writeCharacteristic(c, json.toByteArray(Charsets.UTF_8),
+                BluetoothGattCharacteristic.WRITE_TYPE_DEFAULT)
+        } else {
+            @Suppress("DEPRECATION")
+            c.value = json.toByteArray(Charsets.UTF_8)
+            @Suppress("DEPRECATION")
+            g.writeCharacteristic(c)
+        }
+    }
+
+    // ---------------------------------------------------------------------------
+    // UI helpers
+    // ---------------------------------------------------------------------------
+    private fun populateFields(cfg: TagConfig) {
+        binding.etTagName.setText(cfg.tag_name)
+        binding.etSleepTimeout.setText(cfg.sleep_timeout_s.toString())
+        binding.etBrightness.setText(cfg.display_brightness.toString())
+        binding.etUwbChannel.setText(cfg.uwb_channel.toString())
+        binding.etRangingInterval.setText(cfg.ranging_interval_ms.toString())
+        binding.switchBatteryReport.isChecked = cfg.battery_report
+    }
+
+    private fun buildConfigFromFields() = TagConfig(
+        tag_name           = binding.etTagName.text?.toString() ?: "UWB_TAG_0001",
+        sleep_timeout_s    = binding.etSleepTimeout.text?.toString()?.toIntOrNull() ?: 300,
+        display_brightness = binding.etBrightness.text?.toString()?.toIntOrNull() ?: 50,
+        uwb_channel        = binding.etUwbChannel.text?.toString()?.toIntOrNull() ?: 9,
+        ranging_interval_ms = binding.etRangingInterval.text?.toString()?.toIntOrNull() ?: 100,
+        battery_report     = binding.switchBatteryReport.isChecked
+    )
+
+    private fun toast(msg: String) =
+        Toast.makeText(this, msg, Toast.LENGTH_SHORT).show()
+}

android/src/main/res/layout/activity_uwb_tag_ble.xml

@@ -0,0 +1,238 @@
+<?xml version="1.0" encoding="utf-8"?>
+<LinearLayout xmlns:android="http://schemas.android.com/apk/res/android"
+    xmlns:app="http://schemas.android.com/apk/res-auto"
+    android:layout_width="match_parent"
+    android:layout_height="match_parent"
+    android:orientation="vertical">
+
+    <androidx.appcompat.widget.Toolbar
+        android:id="@+id/toolbar"
+        android:layout_width="match_parent"
+        android:layout_height="?attr/actionBarSize"
+        android:background="?attr/colorPrimary"
+        android:elevation="4dp"
+        android:theme="@style/ThemeOverlay.AppCompat.Dark.ActionBar"
+        app:title="UWB Tag BLE Config" />
+
+    <!-- Scan controls -->
+    <LinearLayout
+        android:layout_width="match_parent"
+        android:layout_height="wrap_content"
+        android:orientation="horizontal"
+        android:padding="12dp"
+        android:gravity="center_vertical">
+
+        <Button
+            android:id="@+id/btnScan"
+            style="@style/Widget.MaterialComponents.Button"
+            android:layout_width="wrap_content"
+            android:layout_height="wrap_content"
+            android:text="Scan" />
+
+        <TextView
+            android:id="@+id/tvScanStatus"
+            android:layout_width="0dp"
+            android:layout_height="wrap_content"
+            android:layout_weight="1"
+            android:layout_marginStart="12dp"
+            android:text="Tap Scan to find UWB tags"
+            android:textAppearance="@style/TextAppearance.MaterialComponents.Body2" />
+
+    </LinearLayout>
+
+    <!-- Scan results list -->
+    <TextView
+        android:layout_width="match_parent"
+        android:layout_height="wrap_content"
+        android:paddingHorizontal="12dp"
+        android:text="Nearby Tags"
+        android:textAppearance="@style/TextAppearance.MaterialComponents.Subtitle1"
+        android:textStyle="bold" />
+
+    <androidx.recyclerview.widget.RecyclerView
+        android:id="@+id/rvDevices"
+        android:layout_width="match_parent"
+        android:layout_height="0dp"
+        android:layout_weight="1"
+        android:padding="8dp"
+        android:clipToPadding="false" />
+
+    <!-- Connected device config panel -->
+    <com.google.android.material.card.MaterialCardView
+        android:id="@+id/cardConfig"
+        android:layout_width="match_parent"
+        android:layout_height="wrap_content"
+        android:layout_margin="8dp"
+        android:visibility="gone"
+        app:cardElevation="4dp">
+
+        <LinearLayout
+            android:layout_width="match_parent"
+            android:layout_height="wrap_content"
+            android:orientation="vertical"
+            android:padding="12dp">
+
+            <LinearLayout
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:orientation="horizontal"
+                android:gravity="center_vertical">
+
+                <TextView
+                    android:id="@+id/tvConnectedName"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:text="Connected: —"
+                    android:textAppearance="@style/TextAppearance.MaterialComponents.Subtitle1"
+                    android:textStyle="bold" />
+
+                <Button
+                    android:id="@+id/btnDisconnect"
+                    style="@style/Widget.MaterialComponents.Button.OutlinedButton"
+                    android:layout_width="wrap_content"
+                    android:layout_height="wrap_content"
+                    android:text="Disconnect" />
+
+            </LinearLayout>
+
+            <!-- tag_name -->
+            <com.google.android.material.textfield.TextInputLayout
+                style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:layout_marginTop="8dp"
+                android:hint="Tag Name">
+                <com.google.android.material.textfield.TextInputEditText
+                    android:id="@+id/etTagName"
+                    android:layout_width="match_parent"
+                    android:layout_height="wrap_content"
+                    android:inputType="text" />
+            </com.google.android.material.textfield.TextInputLayout>
+
+            <!-- sleep_timeout_s and uwb_channel (row) -->
+            <LinearLayout
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:orientation="horizontal"
+                android:layout_marginTop="4dp">
+
+                <com.google.android.material.textfield.TextInputLayout
+                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:layout_marginEnd="4dp"
+                    android:hint="Sleep Timeout (s)">
+                    <com.google.android.material.textfield.TextInputEditText
+                        android:id="@+id/etSleepTimeout"
+                        android:layout_width="match_parent"
+                        android:layout_height="wrap_content"
+                        android:inputType="number" />
+                </com.google.android.material.textfield.TextInputLayout>
+
+                <com.google.android.material.textfield.TextInputLayout
+                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:layout_marginStart="4dp"
+                    android:hint="UWB Channel">
+                    <com.google.android.material.textfield.TextInputEditText
+                        android:id="@+id/etUwbChannel"
+                        android:layout_width="match_parent"
+                        android:layout_height="wrap_content"
+                        android:inputType="number" />
+                </com.google.android.material.textfield.TextInputLayout>
+
+            </LinearLayout>
+
+            <!-- display_brightness and ranging_interval_ms (row) -->
+            <LinearLayout
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:orientation="horizontal"
+                android:layout_marginTop="4dp">
+
+                <com.google.android.material.textfield.TextInputLayout
+                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:layout_marginEnd="4dp"
+                    android:hint="Brightness (0-100)">
+                    <com.google.android.material.textfield.TextInputEditText
+                        android:id="@+id/etBrightness"
+                        android:layout_width="match_parent"
+                        android:layout_height="wrap_content"
+                        android:inputType="number" />
+                </com.google.android.material.textfield.TextInputLayout>
+
+                <com.google.android.material.textfield.TextInputLayout
+                    style="@style/Widget.MaterialComponents.TextInputLayout.OutlinedBox.Dense"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:layout_marginStart="4dp"
+                    android:hint="Ranging Interval (ms)">
+                    <com.google.android.material.textfield.TextInputEditText
+                        android:id="@+id/etRangingInterval"
+                        android:layout_width="match_parent"
+                        android:layout_height="wrap_content"
+                        android:inputType="number" />
+                </com.google.android.material.textfield.TextInputLayout>
+
+            </LinearLayout>
+
+            <!-- battery_report toggle -->
+            <com.google.android.material.switchmaterial.SwitchMaterial
+                android:id="@+id/switchBatteryReport"
+                android:layout_width="wrap_content"
+                android:layout_height="wrap_content"
+                android:layout_marginTop="8dp"
+                android:text="Battery Reporting" />
+
+            <!-- Action buttons -->
+            <LinearLayout
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:orientation="horizontal"
+                android:layout_marginTop="8dp">
+
+                <Button
+                    android:id="@+id/btnReadConfig"
+                    style="@style/Widget.MaterialComponents.Button.OutlinedButton"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:layout_marginEnd="4dp"
+                    android:text="Read" />
+
+                <Button
+                    android:id="@+id/btnWriteConfig"
+                    style="@style/Widget.MaterialComponents.Button"
+                    android:layout_width="0dp"
+                    android:layout_height="wrap_content"
+                    android:layout_weight="1"
+                    android:layout_marginStart="4dp"
+                    android:text="Write" />
+
+            </LinearLayout>
+
+            <!-- Status notifications from tag -->
+            <TextView
+                android:id="@+id/tvTagStatus"
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:layout_marginTop="8dp"
+                android:background="#1A000000"
+                android:fontFamily="monospace"
+                android:padding="8dp"
+                android:text="Tag status: —"
+                android:textAppearance="@style/TextAppearance.MaterialComponents.Caption" />
+
+        </LinearLayout>
+
+    </com.google.android.material.card.MaterialCardView>
+
+</LinearLayout>

android/src/main/res/layout/item_ble_device.xml

@@ -0,0 +1,60 @@
+<?xml version="1.0" encoding="utf-8"?>
+<com.google.android.material.card.MaterialCardView
+    xmlns:android="http://schemas.android.com/apk/res/android"
+    xmlns:app="http://schemas.android.com/apk/res-auto"
+    android:layout_width="match_parent"
+    android:layout_height="wrap_content"
+    android:layout_margin="4dp"
+    app:cardElevation="2dp"
+    android:clickable="true"
+    android:focusable="true">
+
+    <LinearLayout
+        android:layout_width="match_parent"
+        android:layout_height="wrap_content"
+        android:orientation="horizontal"
+        android:padding="12dp"
+        android:gravity="center_vertical">
+
+        <LinearLayout
+            android:layout_width="0dp"
+            android:layout_height="wrap_content"
+            android:layout_weight="1"
+            android:orientation="vertical">
+
+            <TextView
+                android:id="@+id/tvDeviceName"
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:text="UWB_TAG_XXXX"
+                android:textAppearance="@style/TextAppearance.MaterialComponents.Subtitle2"
+                android:textStyle="bold" />
+
+            <TextView
+                android:id="@+id/tvDeviceAddress"
+                android:layout_width="match_parent"
+                android:layout_height="wrap_content"
+                android:text="XX:XX:XX:XX:XX:XX"
+                android:textAppearance="@style/TextAppearance.MaterialComponents.Caption" />
+
+        </LinearLayout>
+
+        <TextView
+            android:id="@+id/tvRssi"
+            android:layout_width="wrap_content"
+            android:layout_height="wrap_content"
+            android:text="-70 dBm"
+            android:textAppearance="@style/TextAppearance.MaterialComponents.Caption"
+            android:textColor="?attr/colorSecondary" />
+
+        <Button
+            android:id="@+id/btnConnect"
+            style="@style/Widget.MaterialComponents.Button.OutlinedButton"
+            android:layout_width="wrap_content"
+            android:layout_height="wrap_content"
+            android:layout_marginStart="8dp"
+            android:text="Connect" />
+
+    </LinearLayout>
+
+</com.google.android.material.card.MaterialCardView>

cad/assembly.scad

@@ -0,0 +1,118 @@
+// ============================================
+// SaltyLab — Full Assembly Visualization
+// Shows all parts in position on 2020 spine
+// ============================================
+include <dimensions.scad>
+
+// Spine height
+spine_h = 500;
+
+// Component heights (center of each mount on spine)
+h_motor = 0;
+h_battery = 50;
+h_esc = 100;
+h_fc = 170;
+h_jetson = 250;
+h_realsense = 350;
+h_lidar = 430;
+
+// Colors for visualization
+module spine() {
+    color("silver")
+        translate([-extrusion_w/2, -extrusion_w/2, 0])
+            cube([extrusion_w, extrusion_w, spine_h]);
+}
+
+module wheel(side) {
+    color("DimGray")
+        translate([side * 140, 0, 0])
+            rotate([0, 90, 0])
+                cylinder(d=200, h=50, center=true, $fn=60);
+}
+
+// --- Assembly ---
+
+// Spine
+spine();
+
+// Wheels
+wheel(-1);
+wheel(1);
+
+// Motor mount plate (at base)
+color("DodgerBlue", 0.7)
+    translate([0, 0, h_motor])
+        import("motor_mount_plate.stl");
+
+// Battery shelf
+color("OrangeRed", 0.7)
+    translate([0, 0, h_battery])
+        rotate([0, 0, 0])
+            cube([180, 80, 40], center=true);
+
+// ESC
+color("Green", 0.7)
+    translate([0, 0, h_esc])
+        cube([80, 50, 15], center=true);
+
+// FC (tiny!)
+color("Purple", 0.9)
+    translate([0, 0, h_fc])
+        cube([36, 36, 5], center=true);
+
+// Jetson Orin Nano Super
+color("LimeGreen", 0.7)
+    translate([0, 0, h_jetson])
+        cube([100, 80, 29], center=true);
+
+// RealSense D435i
+color("Gray", 0.8)
+    translate([0, -40, h_realsense])
+        cube([90, 25, 25], center=true);
+
+// RPLIDAR A1
+color("Cyan", 0.7)
+    translate([0, 0, h_lidar])
+        cylinder(d=70, h=41, center=true, $fn=40);
+
+// Kill switch (accessible on front)
+color("Red")
+    translate([0, -60, h_esc + 30])
+        cylinder(d=22, h=10, $fn=30);
+
+// LED ring
+color("White", 0.3)
+    translate([0, 0, h_jetson - 20])
+        difference() {
+            cylinder(d=120, h=15, $fn=60);
+            translate([0, 0, -1])
+                cylinder(d=110, h=17, $fn=60);
+        }
+
+// Bumpers
+color("Orange", 0.5) {
+    translate([0, -75, 25])
+        cube([350, 30, 50], center=true);
+    translate([0, 75, 25])
+        cube([350, 30, 50], center=true);
+}
+
+// Handle (top)
+color("Yellow", 0.7)
+    translate([0, 0, spine_h + 10])
+        cube([100, 20, 25], center=true);
+
+// Tether point
+color("Red", 0.8)
+    translate([0, 0, spine_h - 20]) {
+        difference() {
+            cylinder(d=30, h=8, $fn=30);
+            translate([0, 0, -1])
+                cylinder(d=15, h=10, $fn=30);
+        }
+    }
+
+echo("=== SaltyLab Assembly ===");
+echo(str("Total height: ", spine_h + 30, "mm"));
+echo(str("Width (axle-axle): ", 280 + 50*2, "mm"));
+echo(str("Depth: ~", 150, "mm"));

cad/battery_shelf.scad

@@ -0,0 +1,77 @@
+// ============================================
+// SaltyLab — Battery Shelf
+// 200×100×40mm PETG
+// Holds 36V battery pack low on the frame
+// Mounts to 2020 extrusion spine
+// ============================================
+include <dimensions.scad>
+
+shelf_w = 200;
+shelf_d = 100;
+shelf_h = 40;
+floor_h = 3;     // Bottom plate
+
+// Battery pocket (with tolerance)
+pocket_w = batt_w + tol*2;
+pocket_d = batt_d + tol*2;
+pocket_h = batt_h + 5;  // Slightly taller than battery
+
+// Velcro strap slots
+strap_w = 25;
+strap_h = 3;
+
+module battery_shelf() {
+    difference() {
+        union() {
+            // Floor
+            translate([-shelf_w/2, -shelf_d/2, 0])
+                cube([shelf_w, shelf_d, floor_h]);
+            
+            // Walls (3 sides — front open for wires)
+            // Left wall
+            translate([-shelf_w/2, -shelf_d/2, 0])
+                cube([wall, shelf_d, shelf_h]);
+            // Right wall
+            translate([shelf_w/2 - wall, -shelf_d/2, 0])
+                cube([wall, shelf_d, shelf_h]);
+            // Back wall
+            translate([-shelf_w/2, shelf_d/2 - wall, 0])
+                cube([shelf_w, wall, shelf_h]);
+            
+            // Front lip (low, keeps battery from sliding out)
+            translate([-shelf_w/2, -shelf_d/2, 0])
+                cube([shelf_w, wall, 10]);
+            
+            // 2020 extrusion mount tabs (top of back wall)
+            for (x = [-30, 30]) {
+                translate([x - 10, shelf_d/2 - wall, shelf_h - 15])
+                    cube([20, wall + 10, 15]);
+            }
+        }
+        
+        // Extrusion bolt holes (M5) through back mount tabs
+        for (x = [-30, 30]) {
+            translate([x, shelf_d/2 + 5, shelf_h - 7.5])
+                rotate([90, 0, 0])
+                    cylinder(d=m5_clear, h=wall + 15, $fn=30);
+        }
+        
+        // Velcro strap slots (2x through floor for securing battery)
+        for (x = [-50, 50]) {
+            translate([x - strap_w/2, -20, -1])
+                cube([strap_w, strap_h, floor_h + 2]);
+        }
+        
+        // Weight reduction holes in floor
+        for (x = [-30, 30]) {
+            translate([x, 0, -1])
+                cylinder(d=20, h=floor_h + 2, $fn=30);
+        }
+        
+        // Wire routing slot (front wall, centered)
+        translate([-20, -shelf_d/2 - 1, floor_h])
+            cube([40, wall + 2, 15]);
+    }
+}
+
+battery_shelf();

cad/bumper.scad

@@ -0,0 +1,75 @@
+// ============================================
+// SaltyLab — Bumper (Front/Rear)
+// 350×50×30mm TPU
+// Absorbs falls, protects frame and floor
+// ============================================
+include <dimensions.scad>
+
+bumper_w = 350;
+bumper_h = 50;
+bumper_d = 30;
+bumper_wall = 2.5;
+
+// Honeycomb crush structure for energy absorption
+hex_size = 8;
+hex_wall = 1.2;
+
+module honeycomb_cell(size, height) {
+    difference() {
+        cylinder(d=size, h=height, $fn=6);
+        translate([0, 0, -1])
+            cylinder(d=size - hex_wall*2, h=height + 2, $fn=6);
+    }
+}
+
+module bumper() {
+    difference() {
+        union() {
+            // Outer shell (curved front face)
+            hull() {
+                translate([-bumper_w/2, 0, 0])
+                    cube([bumper_w, 1, bumper_h]);
+                translate([-bumper_w/2 + 10, bumper_d - 5, 5])
+                    cube([bumper_w - 20, 1, bumper_h - 10]);
+            }
+        }
+        
+        // Hollow interior (leave outer shell)
+        hull() {
+            translate([-bumper_w/2 + bumper_wall, bumper_wall, bumper_wall])
+                cube([bumper_w - bumper_wall*2, 1, bumper_h - bumper_wall*2]);
+            translate([-bumper_w/2 + 10 + bumper_wall, bumper_d - 5 - bumper_wall, 5 + bumper_wall])
+                cube([bumper_w - 20 - bumper_wall*2, 1, bumper_h - 10 - bumper_wall*2]);
+        }
+        
+        // Mounting bolt holes (M5, through back face, 4 points)
+        for (x = [-120, -40, 40, 120]) {
+            translate([x, -1, bumper_h/2])
+                rotate([-90, 0, 0])
+                    cylinder(d=m5_clear, h=10, $fn=25);
+        }
+    }
+    
+    // Internal honeycomb ribs for crush absorption
+    intersection() {
+        // Bound to bumper volume
+        hull() {
+            translate([-bumper_w/2 + bumper_wall, bumper_wall, bumper_wall])
+                cube([bumper_w - bumper_wall*2, 1, bumper_h - bumper_wall*2]);
+            translate([-bumper_w/2 + 15, bumper_d - 8, 8])
+                cube([bumper_w - 30, 1, bumper_h - 16]);
+        }
+        
+        // Honeycomb grid
+        for (x = [-170:hex_size*1.5:170]) {
+            for (z = [0:hex_size*1.3:60]) {
+                offset_x = (floor(z / (hex_size*1.3)) % 2) * hex_size * 0.75;
+                translate([x + offset_x, 0, z])
+                    rotate([-90, 0, 0])
+                        honeycomb_cell(hex_size, bumper_d);
+            }
+        }
+    }
+}
+
+bumper();

cad/dimensions.scad

@@ -0,0 +1,73 @@
+// ============================================
+// SaltyLab — Common Dimensions & Constants
+// ============================================
+
+// --- 2020 Aluminum Extrusion ---
+extrusion_w = 20;
+extrusion_slot = 6;     // T-slot width
+extrusion_bore = 5;     // Center bore M5
+
+// --- Hub Motors (8" hoverboard) ---
+motor_axle_dia = 12;
+motor_axle_len = 45;
+motor_axle_flat = 10;   // Flat-to-flat if D-shaft
+motor_body_dia = 200;   // ~8 inches
+motor_bolt_circle = 0;  // Axle-only mount (clamp style)
+
+// --- Drone FC (30.5mm standard) ---
+fc_hole_spacing = 25.5;  // GEP-F722 AIO v2 (not standard 30.5!)
+fc_hole_dia = 3.2;      // M3 clearance
+fc_board_size = 36;      // Typical FC PCB
+fc_standoff_h = 5;       // Rubber standoff height
+
+// --- Jetson Orin Nano Super ---
+jetson_w = 100;
+jetson_d = 80;
+jetson_h = 29;           // With heatsink
+jetson_hole_x = 86;      // Mounting hole spacing X
+jetson_hole_y = 58;      // Mounting hole spacing Y
+jetson_hole_dia = 2.7;   // M2.5 clearance
+
+// --- RealSense D435i ---
+rs_w = 90;
+rs_d = 25;
+rs_h = 25;
+rs_tripod_offset = 0;    // 1/4-20 centered bottom
+rs_mount_dia = 6.5;      // 1/4-20 clearance
+
+// --- RPLIDAR A1 ---
+lidar_dia = 70;
+lidar_h = 41;
+lidar_mount_circle = 67; // Bolt circle diameter
+lidar_hole_count = 4;
+lidar_hole_dia = 2.7;    // M2.5
+
+// --- Kill Switch (22mm panel mount) ---
+kill_sw_dia = 22;
+kill_sw_depth = 35;      // Behind-panel depth
+
+// --- Battery (typical 36V hoverboard pack) ---
+batt_w = 180;
+batt_d = 80;
+batt_h = 40;
+
+// --- Hoverboard ESC ---
+esc_w = 80;
+esc_d = 50;
+esc_h = 15;
+
+// --- ESP32-C3 (typical dev board) ---
+esp_w = 25;
+esp_d = 18;
+esp_h = 5;
+
+// --- WS2812B strip ---
+led_strip_w = 10;        // 10mm wide strip
+
+// --- General ---
+wall = 3;                // Default wall thickness
+m3_clear = 3.2;
+m3_insert = 4.2;         // Heat-set insert hole
+m25_clear = 2.7;
+m5_clear = 5.3;
+tol = 0.2;               // Print tolerance per side

cad/esc_mount.scad

@@ -0,0 +1,70 @@
+// ============================================
+// SaltyLab — ESC Mount
+// 150×100×15mm PETG
+// Hoverboard ESC, mounts to 2020 extrusion
+// ============================================
+include <dimensions.scad>
+
+mount_w = 150;
+mount_d = 100;
+mount_h = 15;
+base_h = 3;
+
+module esc_mount() {
+    difference() {
+        union() {
+            // Base plate
+            translate([-mount_w/2, -mount_d/2, 0])
+                cube([mount_w, mount_d, base_h]);
+            
+            // ESC retaining walls (low lip on 3 sides)
+            // Left
+            translate([-mount_w/2, -mount_d/2, 0])
+                cube([wall, mount_d, mount_h]);
+            // Right
+            translate([mount_w/2 - wall, -mount_d/2, 0])
+                cube([wall, mount_d, mount_h]);
+            // Back
+            translate([-mount_w/2, mount_d/2 - wall, 0])
+                cube([mount_w, wall, mount_h]);
+            
+            // Front clips (snap-fit tabs to hold ESC)
+            for (x = [-30, 30]) {
+                translate([x - 5, -mount_d/2, 0])
+                    cube([10, wall, mount_h]);
+                // Clip overhang
+                translate([x - 5, -mount_d/2, mount_h - 2])
+                    cube([10, wall + 3, 2]);
+            }
+            
+            // 2020 mount tabs (back)
+            for (x = [-25, 25]) {
+                translate([x - 10, mount_d/2 - wall, 0])
+                    cube([20, wall + 8, base_h + 8]);
+            }
+        }
+        
+        // Extrusion bolt holes (M5)
+        for (x = [-25, 25]) {
+            translate([x, mount_d/2 + 3, base_h + 4])
+                rotate([90, 0, 0])
+                    cylinder(d=m5_clear, h=wall + 12, $fn=30);
+        }
+        
+        // Ventilation holes in base
+        for (x = [-40, -20, 0, 20, 40]) {
+            for (y = [-25, 0, 25]) {
+                translate([x, y, -1])
+                    cylinder(d=8, h=base_h + 2, $fn=20);
+            }
+        }
+        
+        // Wire routing slots (front and back)
+        translate([-15, -mount_d/2 - 1, base_h])
+            cube([30, wall + 2, 10]);
+        translate([-15, mount_d/2 - wall - 1, base_h])
+            cube([30, wall + 2, 10]);
+    }
+}
+
+esc_mount();

cad/esp32c3_mount.scad

@@ -0,0 +1,57 @@
+// ============================================
+// SaltyLab — ESP32-C3 Mount
+// 30×25×10mm PETG
+// Tiny mount for LED controller MCU
+// ============================================
+include <dimensions.scad>
+
+mount_w = 30;
+mount_d = 25;
+mount_h = 10;
+base_h = 2;
+
+module esp32c3_mount() {
+    difference() {
+        union() {
+            // Base
+            translate([-mount_w/2, -mount_d/2, 0])
+                cube([mount_w, mount_d, base_h]);
+            
+            // Retaining walls (3 sides, front open for USB)
+            translate([-mount_w/2, -mount_d/2, 0])
+                cube([wall, mount_d, mount_h]);
+            translate([mount_w/2 - wall, -mount_d/2, 0])
+                cube([wall, mount_d, mount_h]);
+            translate([-mount_w/2, mount_d/2 - wall, 0])
+                cube([mount_w, wall, mount_h]);
+            
+            // Clip tabs (front corners)
+            for (x = [-mount_w/2, mount_w/2 - wall]) {
+                translate([x, -mount_d/2, mount_h - 2])
+                    cube([wall, 4, 2]);
+            }
+            
+            // Zip-tie slot wings
+            for (x = [-mount_w/2 - 4, mount_w/2 + 1]) {
+                translate([x, -5, 0])
+                    cube([3, 10, base_h]);
+            }
+        }
+        
+        // Board pocket (recessed)
+        translate([-esp_w/2 - tol, -esp_d/2 - tol, base_h])
+            cube([esp_w + tol*2, esp_d + tol*2, mount_h]);
+        
+        // Zip-tie slots
+        for (x = [-mount_w/2 - 4, mount_w/2 + 1]) {
+            translate([x, -2, -1])
+                cube([3, 4, base_h + 2]);
+        }
+        
+        // USB port clearance (front)
+        translate([-5, -mount_d/2 - 1, base_h])
+            cube([10, wall + 2, 5]);
+    }
+}
+
+esp32c3_mount();

cad/fc_mount.scad

@@ -0,0 +1,86 @@
+// ============================================
+// SaltyLab — Flight Controller Mount
+// Vibration-isolated, 30.5mm pattern
+// TPU dampers + PETG frame
+// ============================================
+include <dimensions.scad>
+
+// FC mount attaches to 2020 extrusion via T-slot
+// Rubber/TPU grommets isolate FC from frame vibration
+
+mount_w = 45;    // Overall width
+mount_d = 45;    // Overall depth  
+mount_h = 15;    // Total height (base + standoffs)
+base_h = 4;      // Base plate thickness
+
+// TPU grommet dimensions
+grommet_od = 7;
+grommet_id = 3.2;  // M3 clearance
+grommet_h = 5;     // Soft mount height
+
+module fc_mount() {
+    difference() {
+        union() {
+            // Base plate
+            translate([-mount_w/2, -mount_d/2, 0])
+                cube([mount_w, mount_d, base_h]);
+            
+            // Standoff posts (PETG, FC sits on TPU grommets on top)
+            for (x = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
+                for (y = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
+                    translate([x, y, 0])
+                        cylinder(d=8, h=base_h + grommet_h, $fn=30);
+                }
+            }
+            
+            // 2020 extrusion clamp tabs (sides)
+            for (side = [-1, 1]) {
+                translate([side * (extrusion_w/2 + wall), -15, 0])
+                    cube([wall, 30, base_h + 10]);
+            }
+        }
+        
+        // FC mounting holes (M3 through standoffs)
+        for (x = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
+            for (y = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
+                translate([x, y, -1])
+                    cylinder(d=fc_hole_dia, h=base_h + grommet_h + 2, $fn=25);
+            }
+        }
+        
+        // Extrusion channel (20mm wide slot through base)
+        translate([-extrusion_w/2 - tol, -20, -1])
+            cube([extrusion_w + tol*2, 40, base_h + 2]);
+        
+        // Clamp bolt holes (M3, horizontal through side tabs)
+        for (side = [-1, 1]) {
+            translate([side * (extrusion_w/2 + wall + 1), 0, base_h + 5])
+                rotate([0, 90, 0])
+                    cylinder(d=m3_clear, h=wall + 2, center=true, $fn=25);
+        }
+        
+        // Center cutout for airflow / weight reduction
+        translate([0, 0, -1])
+            cylinder(d=15, h=base_h + 2, $fn=30);
+    }
+}
+
+// TPU grommet (print separately in TPU)
+module tpu_grommet() {
+    difference() {
+        cylinder(d=grommet_od, h=grommet_h, $fn=30);
+        translate([0, 0, -1])
+            cylinder(d=grommet_id, h=grommet_h + 2, $fn=25);
+    }
+}
+
+// Show assembled
+fc_mount();
+
+// Show grommets in position (for visualization)
+%for (x = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
+    for (y = [-fc_hole_spacing/2, fc_hole_spacing/2]) {
+        translate([x, y, base_h])
+            tpu_grommet();
+    }
+}

cad/handle.scad

@@ -0,0 +1,59 @@
+// ============================================
+// SaltyLab — Carry Handle
+// 150×30×30mm PETG
+// Comfortable grip, mounts on top of spine
+// ============================================
+include <dimensions.scad>
+
+handle_w = 150;
+handle_h = 30;
+grip_dia = 25;     // Comfortable grip diameter
+grip_len = 100;    // Grip section length
+
+module handle() {
+    difference() {
+        union() {
+            // Grip bar (rounded for comfort)
+            translate([-grip_len/2, 0, handle_h])
+                rotate([0, 90, 0])
+                    cylinder(d=grip_dia, h=grip_len, $fn=40);
+            
+            // Left support leg
+            hull() {
+                translate([-handle_w/2, -10, 0])
+                    cube([20, 20, 3]);
+                translate([-grip_len/2, 0, handle_h])
+                    rotate([0, 90, 0])
+                        cylinder(d=grip_dia, h=5, $fn=40);
+            }
+            
+            // Right support leg
+            hull() {
+                translate([handle_w/2 - 20, -10, 0])
+                    cube([20, 20, 3]);
+                translate([grip_len/2 - 5, 0, handle_h])
+                    rotate([0, 90, 0])
+                        cylinder(d=grip_dia, h=5, $fn=40);
+            }
+        }
+        
+        // 2020 extrusion slot (center of base)
+        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -1])
+            cube([extrusion_w + tol*2, extrusion_w + tol*2, 5]);
+        
+        // M5 bolt holes for extrusion (2x)
+        for (x = [-30, 30]) {
+            translate([x, 0, -1])
+                cylinder(d=m5_clear, h=5, $fn=25);
+        }
+        
+        // Finger grooves on grip
+        for (x = [-30, -10, 10, 30]) {
+            translate([x, 0, handle_h])
+                rotate([0, 90, 0])
+                    cylinder(d=grip_dia + 4, h=5, center=true, $fn=40);
+        }
+    }
+}
+
+handle();

cad/jetson_shelf.scad

@@ -0,0 +1,69 @@
+// ============================================
+// SaltyLab — Jetson Orin Nano Super Shelf
+// 120×100×15mm PETG
+// Mounts Jetson Orin Nano Super to 2020 extrusion
+// ============================================
+include <dimensions.scad>
+
+shelf_w = 120;
+shelf_d = 100;
+shelf_h = 15;
+base_h = 3;
+standoff_h = 8;  // Clearance for Jetson underside components
+
+module jetson_shelf() {
+    difference() {
+        union() {
+            // Base plate
+            translate([-shelf_w/2, -shelf_d/2, 0])
+                cube([shelf_w, shelf_d, base_h]);
+            
+            // Jetson standoffs (M2.5, 86mm × 58mm pattern)
+            for (x = [-jetson_hole_x/2, jetson_hole_x/2]) {
+                for (y = [-jetson_hole_y/2, jetson_hole_y/2]) {
+                    translate([x, y, 0])
+                        cylinder(d=6, h=base_h + standoff_h, $fn=25);
+                }
+            }
+            
+            // 2020 extrusion clamp (back edge)
+            translate([-15, shelf_d/2 - wall, 0])
+                cube([30, wall + 10, base_h + 12]);
+            
+            // Side rails for Jetson alignment
+            for (x = [-jetson_w/2 - wall, jetson_w/2]) {
+                translate([x, -jetson_d/2, base_h + standoff_h])
+                    cube([wall, jetson_d, 4]);
+            }
+        }
+        
+        // Jetson M2.5 holes (through standoffs)
+        for (x = [-jetson_hole_x/2, jetson_hole_x/2]) {
+            for (y = [-jetson_hole_y/2, jetson_hole_y/2]) {
+                translate([x, y, -1])
+                    cylinder(d=jetson_hole_dia, h=base_h + standoff_h + 2, $fn=25);
+            }
+        }
+        
+        // Extrusion bolt hole (M5, through back clamp)
+        translate([0, shelf_d/2 + 3, base_h + 6])
+            rotate([90, 0, 0])
+                cylinder(d=m5_clear, h=wall + 15, $fn=30);
+        
+        // Extrusion channel slot
+        translate([-extrusion_w/2 - tol, shelf_d/2 - wall - 1, -1])
+            cube([extrusion_w + tol*2, wall + 2, base_h + 2]);
+        
+        // Ventilation / cable routing
+        for (x = [-25, 0, 25]) {
+            translate([x, 0, -1])
+                cylinder(d=15, h=base_h + 2, $fn=25);
+        }
+        
+        // USB/Ethernet/GPIO access cutouts (front edge)
+        translate([-jetson_w/2, -shelf_d/2 - 1, base_h])
+            cube([jetson_w, wall + 2, shelf_h]);
+    }
+}
+
+jetson_shelf();

cad/kill_switch_mount.scad

@@ -0,0 +1,56 @@
+// ============================================
+// SaltyLab — Kill Switch Mount
+// 60×60×40mm PETG
+// 22mm panel-mount emergency stop button
+// Mounts to 2020 extrusion, easily reachable
+// ============================================
+include <dimensions.scad>
+
+mount_w = 60;
+mount_d = 60;
+mount_h = 40;
+panel_h = 3;  // Panel face thickness
+
+module kill_switch_mount() {
+    difference() {
+        union() {
+            // Main body (angled face for visibility)
+            hull() {
+                translate([-mount_w/2, 0, 0])
+                    cube([mount_w, mount_d, 1]);
+                translate([-mount_w/2, 5, mount_h])
+                    cube([mount_w, mount_d - 5, 1]);
+            }
+            
+            // 2020 extrusion mount bracket (back)
+            translate([-15, mount_d, 0])
+                cube([30, 10, 20]);
+        }
+        
+        // Kill switch hole (22mm, through angled face)
+        translate([0, mount_d/2, mount_h/2])
+            rotate([10, 0, 0])  // Slight angle for ergonomics
+                cylinder(d=kill_sw_dia + tol, h=panel_h + 2, center=true, $fn=50);
+        
+        // Interior cavity (hollow for switch body)
+        translate([-kill_sw_dia/2 - 3, 5, 3])
+            cube([kill_sw_dia + 6, mount_d - 10, mount_h - 3]);
+        
+        // Wire exit hole (bottom)
+        translate([0, mount_d/2, -1])
+            cylinder(d=10, h=5, $fn=25);
+        
+        // Extrusion bolt holes (M5, through back bracket)
+        for (z = [7, 15]) {
+            translate([-20, mount_d + 5, z])
+                rotate([90, 0, 0])
+                    cylinder(d=m5_clear, h=15, center=true, $fn=25);
+        }
+        
+        // Label recess ("EMERGENCY STOP" — flat area for sticker)
+        translate([-25, 5, mount_h - 1])
+            cube([50, 15, 1.5]);
+    }
+}
+
+kill_switch_mount();

cad/led_diffuser_ring.scad

@@ -0,0 +1,53 @@
+// ============================================
+// SaltyLab — LED Diffuser Ring
+// Ø120×15mm Clear PETG 30% infill
+// Wraps around frame, holds WS2812B strip
+// Print in clear/natural PETG for diffusion
+// ============================================
+include <dimensions.scad>
+
+ring_od = 120;
+ring_id = 110;       // Inner diameter (strip sits inside)
+ring_h = 15;
+strip_channel_w = led_strip_w + 1;  // Strip channel
+strip_channel_d = 3;  // Depth for strip
+
+module led_diffuser_ring() {
+    difference() {
+        // Outer ring
+        cylinder(d=ring_od, h=ring_h, $fn=80);
+        
+        // Inner hollow
+        translate([0, 0, -1])
+            cylinder(d=ring_id, h=ring_h + 2, $fn=80);
+        
+        // LED strip channel (groove on inner wall)
+        translate([0, 0, (ring_h - strip_channel_w)/2])
+            difference() {
+                cylinder(d=ring_id + 2, h=strip_channel_w, $fn=80);
+                cylinder(d=ring_id - strip_channel_d*2, h=strip_channel_w, $fn=80);
+            }
+        
+        // Wire entry slot
+        translate([ring_od/2 - 5, -3, ring_h/2 - 3])
+            cube([10, 6, 6]);
+        
+        // 2020 extrusion clearance (center)
+        translate([-extrusion_w/2 - 5, -extrusion_w/2 - 5, -1])
+            cube([extrusion_w + 10, extrusion_w + 10, ring_h + 2]);
+    }
+    
+    // Mounting tabs (clip onto extrusion, 4x)
+    for (angle = [0, 90, 180, 270]) {
+        rotate([0, 0, angle])
+            translate([extrusion_w/2 + 1, -5, 0])
+                difference() {
+                    cube([3, 10, ring_h]);
+                    translate([-1, 2, ring_h/2])
+                        rotate([0, 90, 0])
+                            cylinder(d=m3_clear, h=5, $fn=20);
+                }
+    }
+}
+
+led_diffuser_ring();

cad/lidar_standoff.scad

@@ -0,0 +1,61 @@
+// ============================================
+// SaltyLab — LIDAR Standoff
+// Ø80×80mm ASA
+// Raises RPLIDAR above all other components
+// for unobstructed 360° scan
+// Connects sensor_tower_top to 2020 extrusion
+// ============================================
+include <dimensions.scad>
+
+standoff_od = 80;
+standoff_h = 80;
+wall_t = 3;
+
+module lidar_standoff() {
+    difference() {
+        union() {
+            // Main cylinder
+            cylinder(d=standoff_od, h=standoff_h, $fn=60);
+            
+            // Bottom flange (bolts to extrusion bracket below)
+            cylinder(d=standoff_od + 10, h=4, $fn=60);
+        }
+        
+        // Hollow interior
+        translate([0, 0, wall_t])
+            cylinder(d=standoff_od - wall_t*2, h=standoff_h, $fn=60);
+        
+        // Cable routing hole (bottom)
+        translate([0, 0, -1])
+            cylinder(d=20, h=wall_t + 2, $fn=30);
+        
+        // Ventilation / weight reduction slots (4x around circumference)
+        for (angle = [0, 90, 180, 270]) {
+            rotate([0, 0, angle])
+                translate([0, standoff_od/2, standoff_h/2])
+                    rotate([90, 0, 0])
+                        hull() {
+                            translate([0, -15, 0])
+                                cylinder(d=10, h=wall_t + 2, center=true, $fn=25);
+                            translate([0, 15, 0])
+                                cylinder(d=10, h=wall_t + 2, center=true, $fn=25);
+                        }
+        }
+        
+        // Bottom flange bolt holes (M5, 4x for mounting)
+        for (angle = [45, 135, 225, 315]) {
+            rotate([0, 0, angle])
+                translate([standoff_od/2, 0, -1])
+                    cylinder(d=m5_clear, h=6, $fn=25);
+        }
+        
+        // Top mating holes (M3, align with sensor_tower_top)
+        for (angle = [0, 90, 180, 270]) {
+            rotate([0, 0, angle])
+                translate([standoff_od/2 - wall_t - 3, 0, standoff_h - 8])
+                    cylinder(d=m3_clear, h=10, $fn=25);
+        }
+    }
+}
+
+lidar_standoff();

cad/motor_mount_plate.scad

@@ -0,0 +1,94 @@
+// ============================================
+// SaltyLab — Motor Mount Plate
+// 350×150×6mm PETG
+// Mounts both 8" hub motors + 2020 extrusion spine
+// ============================================
+include <dimensions.scad>
+
+plate_w = 350;   // Width (axle to axle direction)
+plate_d = 150;   // Depth (front to back)
+plate_h = 6;     // Thickness
+
+// Motor axle positions (centered, symmetric)
+motor_spacing = 280;  // Center-to-center axle distance
+
+// Extrusion spine mount (centered, 2x M5 bolts)
+spine_offset_y = 0;   // Centered front-to-back
+spine_bolt_spacing = 60; // Two bolts along spine
+
+// Motor clamp dimensions
+clamp_w = 30;
+clamp_h = 25;    // Height above plate for clamping axle
+clamp_gap = motor_axle_dia + tol*2;  // Slot for axle
+clamp_bolt_offset = 10; // M5 clamp bolt offset from center
+
+module motor_clamp() {
+    difference() {
+        // Clamp block
+        translate([-clamp_w/2, -clamp_w/2, 0])
+            cube([clamp_w, clamp_w, plate_h + clamp_h]);
+        
+        // Axle hole (through, slightly oversized)
+        translate([0, 0, plate_h + clamp_h/2 + 5])
+            rotate([0, 90, 0])
+                cylinder(d=clamp_gap, h=clamp_w+2, center=true, $fn=40);
+        
+        // Clamp slit (allows tightening)
+        translate([0, 0, plate_h + clamp_h/2 + 5])
+            cube([clamp_w+2, 1.5, clamp_h], center=true);
+        
+        // Clamp bolt holes (M5, horizontal through clamp ears)
+        translate([0, clamp_bolt_offset, plate_h + clamp_h/2 + 5])
+            rotate([0, 90, 0])
+                cylinder(d=m5_clear, h=clamp_w+2, center=true, $fn=30);
+        translate([0, -clamp_bolt_offset, plate_h + clamp_h/2 + 5])
+            rotate([0, 90, 0])
+                cylinder(d=m5_clear, h=clamp_w+2, center=true, $fn=30);
+    }
+}
+
+module motor_mount_plate() {
+    difference() {
+        union() {
+            // Main plate
+            translate([-plate_w/2, -plate_d/2, 0])
+                cube([plate_w, plate_d, plate_h]);
+            
+            // Left motor clamp
+            translate([-motor_spacing/2, 0, 0])
+                motor_clamp();
+            
+            // Right motor clamp
+            translate([motor_spacing/2, 0, 0])
+                motor_clamp();
+            
+            // Reinforcement ribs (bottom)
+            for (x = [-100, 0, 100]) {
+                translate([x - 2, -plate_d/2, 0])
+                    cube([4, plate_d, plate_h]);
+            }
+        }
+        
+        // Extrusion spine bolt holes (M5, 2x along center)
+        for (y = [-spine_bolt_spacing/2, spine_bolt_spacing/2]) {
+            translate([0, y, -1])
+                cylinder(d=m5_clear, h=plate_h+2, $fn=30);
+            // Counterbore for bolt head
+            translate([0, y, plate_h - 2.5])
+                cylinder(d=10, h=3, $fn=30);
+        }
+        
+        // Weight reduction holes
+        for (x = [-70, 70]) {
+            for (y = [-40, 40]) {
+                translate([x, y, -1])
+                    cylinder(d=25, h=plate_h+2, $fn=40);
+            }
+        }
+        
+        // Corner rounding (chamfer edges)
+        // (simplified — round in slicer or add minkowski)
+    }
+}
+
+motor_mount_plate();

cad/realsense_bracket.scad

@@ -0,0 +1,64 @@
+// ============================================
+// SaltyLab — RealSense D435i Bracket
+// 100×50×40mm PETG
+// Adjustable tilt mount on 2020 extrusion
+// ============================================
+include <dimensions.scad>
+
+bracket_w = 100;
+bracket_d = 50;
+bracket_h = 40;
+
+// Camera cradle
+cradle_w = rs_w + wall*2 + tol*2;
+cradle_d = rs_d + wall + tol*2;
+cradle_h = rs_h + 5;
+
+module realsense_bracket() {
+    // Extrusion clamp base
+    difference() {
+        union() {
+            // Clamp block
+            translate([-20, -20, 0])
+                cube([40, 40, 15]);
+            
+            // Tilt arm (vertical, supports camera above)
+            translate([-wall, -wall, 0])
+                cube([wall*2, wall*2, bracket_h]);
+            
+            // Camera cradle at top
+            translate([-cradle_w/2, -cradle_d/2, bracket_h - 5]) {
+                difference() {
+                    cube([cradle_w, cradle_d, cradle_h]);
+                    
+                    // Camera pocket
+                    translate([wall, -1, 3])
+                        cube([rs_w + tol*2, rs_d + tol*2 + 1, rs_h + tol*2]);
+                }
+            }
+            
+            // Tripod mount boss (1/4-20 bolt from bottom of cradle)
+            translate([0, 0, bracket_h - 5])
+                cylinder(d=15, h=3, $fn=30);
+        }
+        
+        // 2020 extrusion channel
+        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -1])
+            cube([extrusion_w + tol*2, extrusion_w + tol*2, 17]);
+        
+        // Clamp bolt (M5, through side)
+        translate([-25, 0, 7.5])
+            rotate([0, 90, 0])
+                cylinder(d=m5_clear, h=50, $fn=30);
+        
+        // Camera 1/4-20 bolt hole (from bottom of cradle)
+        translate([0, 0, bracket_h - 6])
+            cylinder(d=rs_mount_dia, h=10, $fn=30);
+        
+        // Cable routing slot (back of cradle)
+        translate([-10, cradle_d/2 - wall - 1, bracket_h])
+            cube([20, wall + 2, cradle_h - 2]);
+    }
+}
+
+realsense_bracket();

cad/sensor_tower_top.scad

@@ -0,0 +1,58 @@
+// ============================================
+// SaltyLab — Sensor Tower Top
+// 120×120×10mm ASA
+// Mounts RPLIDAR A1 on top of 2020 spine
+// ============================================
+include <dimensions.scad>
+
+top_w = 120;
+top_d = 120;
+top_h = 10;
+base_h = 4;
+
+module sensor_tower_top() {
+    difference() {
+        union() {
+            // Circular plate (RPLIDAR needs 360° clearance)
+            cylinder(d=top_w, h=base_h, $fn=60);
+            
+            // RPLIDAR standoffs (4x M2.5 on 67mm bolt circle)
+            for (i = [0:3]) {
+                angle = i * 90 + 45;  // 45° offset
+                translate([cos(angle) * lidar_mount_circle/2,
+                           sin(angle) * lidar_mount_circle/2, 0])
+                    cylinder(d=6, h=top_h, $fn=25);
+            }
+            
+            // 2020 extrusion socket (bottom center)
+            translate([-extrusion_w/2 - wall, -extrusion_w/2 - wall, -15])
+                cube([extrusion_w + wall*2, extrusion_w + wall*2, 15]);
+        }
+        
+        // RPLIDAR M2.5 through-holes
+        for (i = [0:3]) {
+            angle = i * 90 + 45;
+            translate([cos(angle) * lidar_mount_circle/2,
+                       sin(angle) * lidar_mount_circle/2, -1])
+                cylinder(d=lidar_hole_dia, h=top_h + 2, $fn=25);
+        }
+        
+        // Center hole (RPLIDAR motor shaft clearance + cable routing)
+        translate([0, 0, -1])
+            cylinder(d=25, h=base_h + 2, $fn=40);
+        
+        // 2020 extrusion socket (square hole)
+        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -16])
+            cube([extrusion_w + tol*2, extrusion_w + tol*2, 16]);
+        
+        // Set screw holes for extrusion (M3, 2x perpendicular)
+        for (angle = [0, 90]) {
+            rotate([0, 0, angle])
+                translate([0, extrusion_w/2 + wall, -7.5])
+                    rotate([90, 0, 0])
+                        cylinder(d=m3_clear, h=wall + 5, $fn=25);
+        }
+    }
+}
+
+sensor_tower_top();

cad/tether_anchor.scad

@@ -0,0 +1,46 @@
+// ============================================
+// SaltyLab — Tether Anchor Point
+// 50×50×20mm PETG 100% infill
+// For ceiling tether during balance testing
+// Must be STRONG — 100% infill mandatory
+// ============================================
+include <dimensions.scad>
+
+anchor_w = 50;
+anchor_d = 50;
+anchor_h = 20;
+ring_dia = 30;     // Carabiner ring outer
+ring_hole = 15;    // Carabiner hook clearance
+ring_h = 8;
+
+module tether_anchor() {
+    difference() {
+        union() {
+            // Base (clamps to 2020 extrusion)
+            translate([-anchor_w/2, -anchor_d/2, 0])
+                cube([anchor_w, anchor_d, anchor_h - ring_h]);
+            
+            // Tether ring (stands up from base)
+            translate([0, 0, anchor_h - ring_h])
+                cylinder(d=ring_dia, h=ring_h, $fn=50);
+        }
+        
+        // Ring hole (for carabiner)
+        translate([0, 0, anchor_h - ring_h - 1])
+            cylinder(d=ring_hole, h=ring_h + 2, $fn=40);
+        
+        // 2020 extrusion channel (through base)
+        translate([-extrusion_w/2 - tol, -extrusion_w/2 - tol, -1])
+            cube([extrusion_w + tol*2, extrusion_w + tol*2, anchor_h - ring_h + 2]);
+        
+        // Clamp bolt holes (M5, through sides)
+        for (angle = [0, 90]) {
+            rotate([0, 0, angle])
+                translate([0, anchor_d/2 + 1, (anchor_h - ring_h)/2])
+                    rotate([90, 0, 0])
+                        cylinder(d=m5_clear, h=anchor_d + 2, $fn=25);
+        }
+    }
+}
+
+tether_anchor();

chassis/ASSEMBLY.md

@@ -56,15 +56,24 @@
 3. Fasten 4× M4×12 SHCS. Torque 2.5 N·m.
 4. Insert battery pack; route Velcro straps through slots and cinch.
 
-### 7  FC mount (MAMBA F722S)
+<<<<<<< HEAD
-1. Place silicone anti-vibration grommets onto nylon M3 standoffs.
+### 7  MCU mount (ESP32 BALANCE + ESP32 IO)
-2. Lower FC onto standoffs; secure with M3×6 BHCS. Snug only — do not over-torque.
-3. Orient USB-C port toward front of robot for cable access.
 
-### 8  Jetson Nano mount plate
+> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** ESP32 BALANCE retired. Two ESP32 boards replace it.
+> Board dimensions and hole patterns TBD — await spec from max before machining mount plate.
+
+=======
+### 7  FC mount (ESP32-S3 BALANCE)
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+1. Place silicone anti-vibration grommets onto nylon M3 standoffs.
+2. Lower ESP32 BALANCE board onto standoffs; secure with M3×6 BHCS. Snug only.
+3. Mount ESP32 IO board adjacent — exact placement TBD pending board dimensions.
+4. Orient USB connectors toward front of robot for cable access.
+
+### 8  Jetson Orin Nano Super mount plate
 1. Press or thread M3 nylon standoffs (8mm) into plate holes.
 2. Bolt plate to deck: 4× M3×10 SHCS at deck corners.
-3. Set Jetson Nano B01 carrier onto plate standoffs; fasten M3×6 BHCS.
+3. Set Jetson Orin Nano Super B01 carrier onto plate standoffs; fasten M3×6 BHCS.
 
 ### 9  Bumper brackets
 1. Slide 22mm EMT conduit through saddle clamp openings.
@@ -86,7 +95,8 @@
 | Wheelbase (axle C/L to C/L) | 600 mm | ±1 mm |
 | Motor fork slot width | 24 mm | +0.5 / 0 |
 | Motor fork dropout depth | 60 mm | ±0.5 mm |
-| FC hole pattern | 30.5 × 30.5 mm | ±0.2 mm |
+| ESP32 BALANCE hole pattern | TBD — await spec from max | ±0.2 mm |
+| ESP32 IO hole pattern | TBD — await spec from max | ±0.2 mm |
 | Jetson hole pattern | 58 × 58 mm | ±0.2 mm |
 | Battery tray inner | 185 × 72 × 52 mm | +2 / 0 mm |
 

chassis/BOM.md

@@ -41,7 +41,11 @@ PR #7 (`chassis_frame.scad`) used placeholder values. The table below records th
 | 3 | Dropout clamp — upper | 2 | 8mm 6061-T6 Al | 90×70mm blank | D-cut bore; `RENDER="clamp_upper_2d"` |
 | 4 | Stem flange ring | 2 | 6mm Al or acrylic | Ø82mm disc | One above + one below plate; `RENDER="stem_flange_2d"` |
 | 5 | Vertical stem tube | 1 | 38.1mm OD × 1.5mm wall 6061-T6 Al | 1050mm length | 1.5" EMT conduit is a drop-in alternative |
-| 6 | FC standoff M3×6mm nylon | 4 | Nylon | — | MAMBA F722S vibration isolation |
+<<<<<<< HEAD
+| 6 | MCU standoff M3×6mm nylon | 4 | Nylon | — | ESP32 BALANCE / IO board isolation (dimensions TBD) |
+=======
+| 6 | FC standoff M3×6mm nylon | 4 | Nylon | — | ESP32-S3 BALANCE vibration isolation |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | 7 | Ø4mm × 16mm alignment pin | 8 | Steel dowel | — | Dropout clamp-to-plate alignment |
 
 ### Battery Stem Clamp (`stem_battery_clamp.scad`) — Part B
@@ -70,7 +74,7 @@ PR #7 (`chassis_frame.scad`) used placeholder values. The table below records th
 | 10 | Motor fork bracket (R) | 1 | 8mm 6061 aluminium | Mirror of item 9 |
 | 11 | Battery tray | 1 | 3mm PETG FDM or 3mm aluminium fold | `chassis_frame.scad` — `battery_tray()` module |
 | 12 | FC mount plate / standoffs | 1 set | PETG or nylon FDM | Includes 4× M3 nylon standoffs, 6mm height |
-| 13 | Jetson Nano mount plate | 1 | 4mm 5052 aluminium or 4mm PETG FDM | B01 58×58mm hole pattern |
+| 13 | Jetson Orin Nano Super mount plate | 1 | 4mm 5052 aluminium or 4mm PETG FDM | B01 58×58mm hole pattern |
 | 14 | Front bumper bracket | 1 | 5mm PETG FDM | Saddle clamps for 22mm EMT conduit |
 | 15 | Rear bumper bracket | 1 | 5mm PETG FDM | Mirror of item 14 |
 
@@ -88,12 +92,23 @@ PR #7 (`chassis_frame.scad`) used placeholder values. The table below records th
 
 ## Electronics Mounts
 
+> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** ESP32 BALANCE (ESP32) is retired.
+> Replaced by **ESP32 BALANCE** + **ESP32 IO**. Board dimensions and hole patterns TBD — await spec from max.
+
 | # | Part | Qty | Spec | Notes |
 |---|------|-----|------|-------|
-| 13 | STM32 MAMBA F722S FC | 1 | 36×36mm PCB, 30.5×30.5mm M3 mount | Oriented USB-C port toward front |
+<<<<<<< HEAD
+| 13 | ESP32 BALANCE board | 1 | TBD — mount pattern TBD | PID balance loop; replaces ESP32 BALANCE |
+| 13b | ESP32 IO board | 1 | TBD — mount pattern TBD | Motor/sensor/comms I/O |
+| 14 | Nylon M3 standoff 6mm | 4 | F/F nylon | ESP32 board isolation |
+| 15 | Anti-vibration grommet M3 | 4 | Ø6mm silicone | Under ESP32 mount pads |
+| 16 | Jetson Orin module | 1 | 69.6×45mm module + carrier | 58×58mm M3 carrier hole pattern |
+=======
+| 13 | ESP32-S3 ESP32-S3 BALANCE FC | 1 | 36×36mm PCB, 30.5×30.5mm M3 mount | Oriented USB-C port toward front |
 | 14 | Nylon M3 standoff 6mm | 4 | F/F nylon | FC vibration isolation |
 | 15 | Anti-vibration grommet M3 | 4 | Ø6mm silicone | Under FC mount pads |
-| 16 | Jetson Nano B01 module | 1 | 69.6×45mm module + carrier | 58×58mm M3 carrier hole pattern |
+| 16 | Jetson Orin Nano Super B01 module | 1 | 69.6×45mm module + carrier | 58×58mm M3 carrier hole pattern |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | 17 | Nylon M3 standoff 8mm | 4 | F/F nylon | Jetson board standoffs |
 
 ---
@@ -144,8 +159,8 @@ Slide entire carousel up/down the stem with M6 collar bolts loosened. Tighten at
 | 26 | M6×60 SHCS  | 4  | ISO 4762, SS | Collar clamping bolts |
 | 27 | M6 hex nut  | 4  | ISO 4032, SS | Captured in collar pockets |
 | 28 | M6×12 set screw | 2 | ISO 4026, SS cup-point | Stem height lock (1 per collar half) |
-| 29 | M3×10 SHCS | 12 | ISO 4762, SS | FC mount + miscellaneous |
+| 29 | M3×10 SHCS | 12 | ISO 4762, SS | ESP32 mount + miscellaneous |
-| 30 | M3×6 BHCS  | 4  | ISO 4762, SS | FC board bolts |
+| 30 | M3×6 BHCS  | 4  | ISO 4762, SS | ESP32 board bolts (qty TBD pending board spec) |
 | 31 | Axle lock nut (match axle tip thread) | 4 | Flanged, confirm thread | 2 per motor |
 | 32 | Flat washer M5 | 32 | SS | |
 | 33 | Flat washer M4 | 32 | SS | |

chassis/battery_holder.scad

@@ -0,0 +1,410 @@
+// ============================================================
+// battery_holder.scad — 6S LiPo Battery Holder for 2020 T-Slot Chassis
+// Issue: #588  Agent: sl-mechanical  Date: 2026-03-14
+// ============================================================
+//
+// Parametric bracket holding a 6S 5000 mAh LiPo pack on 2020 aluminium
+// T-slot rails.  Designed for low centre-of-gravity mounting: pack sits
+// flat between the two chassis rails, as close to ground as clearance
+// allows.  Quick-release via captive Velcro straps — battery swap in
+// under 60 s without tools.
+//
+// Architecture:
+//   Tray        → flat floor + perimeter walls, battery sits inside
+//   Rail saddles→ two T-nut feet drop onto 2020 rails, thumbscrew locks
+//   Strap slots → four pairs of slots for 25 mm Velcro strap loops
+//   XT60 window → cut-out in rear wall for XT60 connector exit
+//   Balance port→ open channel in front wall for balance lead routing
+//   QR tab      → front-edge pull tab for one-handed battery extraction
+//
+// Part catalogue:
+//   Part 1 — battery_tray()    Main tray body (single-piece print)
+//   Part 2 — rail_saddle()     T-nut saddle foot (print x2 per tray)
+//   Part 3 — strap_guide()     25 mm Velcro strap guide (print x4)
+//   Part 4 — assembly_preview()
+//
+// Hardware BOM:
+//   2× M3 × 16 mm SHCS + M3 hex nut    T-nut rail clamp thumbscrews
+//   2× 25 mm × 250 mm Velcro strap     battery retention (hook + loop)
+//   1× XT60 female connector            (mounted on ESC/PDB harness)
+//   — battery slides in from front, Velcro strap over top —
+//
+// 6S LiPo target pack (verify with calipers — packs vary by brand):
+//   BATT_L = 155 mm  (length, X axis in tray)
+//   BATT_W =  48 mm  (width,  Y axis in tray)
+//   BATT_H =  52 mm  (height, Z axis in tray)
+//   Clearance 1 mm each side added automatically (BATT_CLEAR)
+//
+// Mounting:
+//   Rail span    : RAIL_SPAN — distance between 2020 rail centrelines
+//                  Default 80 mm; adjust to chassis rail spacing
+//   Saddle height: SADDLE_H — total height of saddle (tray floor above rail)
+//                  Keep low for CoG; default 8 mm
+//
+// RENDER options:
+//   "assembly"         full assembly preview (default)
+//   "tray_stl"         Part 1 — battery tray
+//   "saddle_stl"       Part 2 — rail saddle (print x2)
+//   "strap_guide_stl"  Part 3 — strap guide (print x4)
+//
+// Export commands:
+//   openscad battery_holder.scad -D 'RENDER="tray_stl"'        -o bh_tray.stl
+//   openscad battery_holder.scad -D 'RENDER="saddle_stl"'      -o bh_saddle.stl
+//   openscad battery_holder.scad -D 'RENDER="strap_guide_stl"' -o bh_strap_guide.stl
+//
+// Print settings (all parts):
+//   Material   : PETG
+//   Perimeters : 5 (tray, saddle), 3 (strap_guide)
+//   Infill     : 40 % gyroid (tray floor, saddle), 20 % (strap_guide)
+//   Orientation:
+//     tray         — floor flat on bed (no supports needed)
+//     saddle       — flat face on bed (no supports)
+//     strap_guide  — flat face on bed (no supports)
+// ============================================================
+
+$fn = 64;
+e   = 0.01;
+
+// ── Battery pack dimensions (verify with calipers) ────────────────────────────
+BATT_L     = 155.0;   // pack length (X)
+BATT_W     =  48.0;   // pack width  (Y)
+BATT_H     =  52.0;   // pack height (Z)
+BATT_CLEAR =   1.0;   // per-side fit clearance
+
+// ── Tray geometry ─────────────────────────────────────────────────────────────
+TRAY_FLOOR_T   =  4.0;   // tray floor thickness
+TRAY_WALL_T    =  4.0;   // tray perimeter wall thickness
+TRAY_WALL_H    = 20.0;   // tray wall height (Z) — cradles lower half of pack
+TRAY_FILLET_R  =  3.0;   // inner corner radius
+
+// Inner tray cavity (battery + clearance)
+TRAY_INN_L = BATT_L + 2*BATT_CLEAR;
+TRAY_INN_W = BATT_W + 2*BATT_CLEAR;
+
+// Outer tray footprint
+TRAY_OUT_L = TRAY_INN_L + 2*TRAY_WALL_T;
+TRAY_OUT_W = TRAY_INN_W + 2*TRAY_WALL_T;
+TRAY_TOTAL_H = TRAY_FLOOR_T + TRAY_WALL_H;
+
+// ── Rail interface ─────────────────────────────────────────────────────────────
+RAIL_SPAN   =  80.0;   // distance between 2020 rail centrelines (Y)
+RAIL_W      =  20.0;   // 2020 extrusion width
+SLOT_NECK_H =   3.2;   // T-slot neck height
+SLOT_OPEN   =   6.0;   // T-slot opening width
+SLOT_INN_W  =  10.2;   // T-slot inner width
+SLOT_INN_H  =   5.8;   // T-slot inner height
+
+// ── T-nut / saddle geometry ───────────────────────────────────────────────────
+TNUT_W       =  9.8;
+TNUT_H       =  5.5;
+TNUT_L       = 12.0;
+TNUT_NUT_AF  =  5.5;   // M3 hex nut across-flats
+TNUT_NUT_H   =  2.4;
+TNUT_BOLT_D  =  3.3;   // M3 clearance
+
+SADDLE_W     = 30.0;   // saddle foot width (X, along rail)
+SADDLE_T     =  8.0;   // saddle body thickness (Z, above rail top face)
+SADDLE_PAD_T =  2.0;   // rubber-pad recess depth (optional anti-slip)
+
+// ── Velcro strap slots ────────────────────────────────────────────────────────
+STRAP_W      = 26.0;   // 25 mm strap + 1 mm clearance
+STRAP_T      =  4.0;   // slot through-thickness (tray wall)
+// Four slot pairs: one near each end of tray (X), one each side (Y)
+// Slots run through side walls (Y direction) — strap loops over battery top
+
+// ── XT60 connector window (rear wall) ─────────────────────────────────────────
+XT60_W       = 14.0;   // XT60 body width
+XT60_H       = 18.0;   // XT60 body height (with cable exit)
+XT60_OFFSET_Z = 4.0;   // height above tray floor
+
+// ── Balance lead port (front wall) ────────────────────────────────────────────
+BAL_W        = 40.0;   // balance lead bundle width (6S = 7 wires)
+BAL_H        =  6.0;   // balance lead channel height
+BAL_OFFSET_Z =  8.0;   // height above tray floor
+
+// ── Quick-release pull tab (front edge) ──────────────────────────────────────
+QR_TAB_W     = 30.0;   // tab width
+QR_TAB_H     = 12.0;   // tab height above front wall top
+QR_TAB_T     =  4.0;   // tab thickness
+QR_HOLE_D    = 10.0;   // finger-loop hole diameter
+
+// ── Strap guide clip ─────────────────────────────────────────────────────────
+GUIDE_OD     = STRAP_W + 6.0;
+GUIDE_T      =  3.0;
+GUIDE_BODY_H = 14.0;
+
+// ── Fasteners ─────────────────────────────────────────────────────────────────
+M3_D = 3.3;
+
+// ============================================================
+// RENDER DISPATCH
+// ============================================================
+RENDER = "assembly";
+
+if      (RENDER == "assembly")        assembly_preview();
+else if (RENDER == "tray_stl")        battery_tray();
+else if (RENDER == "saddle_stl")      rail_saddle();
+else if (RENDER == "strap_guide_stl") strap_guide();
+
+// ============================================================
+// ASSEMBLY PREVIEW
+// ============================================================
+module assembly_preview() {
+    // Ghost 2020 rails (Y direction, RAIL_SPAN apart)
+    for (ry = [-RAIL_SPAN/2, RAIL_SPAN/2])
+        %color("Silver", 0.28)
+            translate([-TRAY_OUT_L/2 - 30, ry - RAIL_W/2, -SADDLE_T - TNUT_H])
+                cube([TRAY_OUT_L + 60, RAIL_W, RAIL_W]);
+
+    // Rail saddles (left and right)
+    for (sy = [-RAIL_SPAN/2, RAIL_SPAN/2])
+        color("DimGray", 0.85)
+            translate([0, sy, -SADDLE_T])
+                rail_saddle();
+
+    // Battery tray (sitting on saddles)
+    color("OliveDrab", 0.85)
+        battery_tray();
+
+    // Battery ghost
+    %color("SaddleBrown", 0.35)
+        translate([-BATT_L/2, -BATT_W/2, TRAY_FLOOR_T])
+            cube([BATT_L, BATT_W, BATT_H]);
+
+    // Strap guides (4×, two each end)
+    for (sx = [-TRAY_OUT_L/2 + STRAP_W/2 + TRAY_WALL_T + 8,
+                TRAY_OUT_L/2 - STRAP_W/2 - TRAY_WALL_T - 8])
+    for (sy = [-1, 1])
+        color("SteelBlue", 0.75)
+            translate([sx, sy*(TRAY_OUT_W/2), TRAY_TOTAL_H + 2])
+                rotate([sy > 0 ? 0 : 180, 0, 0])
+                    strap_guide();
+}
+
+// ============================================================
+// PART 1 — BATTERY TRAY
+// ============================================================
+// Single-piece tray: flat floor, four perimeter walls, T-nut saddle
+// attachment bosses on underside, Velcro strap slots through side walls,
+// XT60 window in rear wall, balance lead channel in front wall, and
+// quick-release pull tab on front edge.
+//
+// Battery inserts from the front (−X end) — front wall is lower than
+// rear wall so the pack slides in and the rear wall stops it.
+// Velcro straps loop over the top of the pack through the side slots.
+//
+// Coordinate convention:
+//   X: along battery length (−X = front/plug-end, +X = rear/balance-end)
+//   Y: across battery width (centred, ±TRAY_OUT_W/2)
+//   Z: vertical (Z=0 = tray floor top face; −Z = underside → saddles)
+//
+// Print: floor flat on bed, PETG, 5 perims, 40% gyroid. No supports.
+module battery_tray() {
+    // Short rear wall height (XT60 connector exits here — full wall height)
+    // Front wall is lower to allow battery slide-in
+    front_wall_h = TRAY_WALL_H * 0.55;   // 55% height — battery slides over
+
+    difference() {
+        union() {
+            // ── Floor ────────────────────────────────────────────────────
+            translate([-TRAY_OUT_L/2, -TRAY_OUT_W/2, -TRAY_FLOOR_T])
+                cube([TRAY_OUT_L, TRAY_OUT_W, TRAY_FLOOR_T]);
+
+            // ── Rear wall (+X, full height) ───────────────────────────────
+            translate([TRAY_INN_L/2, -TRAY_OUT_W/2, 0])
+                cube([TRAY_WALL_T, TRAY_OUT_W, TRAY_WALL_H]);
+
+            // ── Front wall (−X, lowered for slide-in) ────────────────────
+            translate([-TRAY_INN_L/2 - TRAY_WALL_T, -TRAY_OUT_W/2, 0])
+                cube([TRAY_WALL_T, TRAY_OUT_W, front_wall_h]);
+
+            // ── Side walls (±Y) ───────────────────────────────────────────
+            for (sy = [-1, 1])
+                translate([-TRAY_OUT_L/2,
+                           sy*(TRAY_INN_W/2 + (sy>0 ? 0 : -TRAY_WALL_T)),
+                           0])
+                    cube([TRAY_OUT_L,
+                          TRAY_WALL_T,
+                          TRAY_WALL_H]);
+
+            // ── Quick-release pull tab (front wall top edge) ──────────────
+            translate([-TRAY_INN_L/2 - TRAY_WALL_T - e,
+                       -QR_TAB_W/2, front_wall_h])
+                cube([QR_TAB_T, QR_TAB_W, QR_TAB_H]);
+
+            // ── Saddle attachment bosses (underside, one per rail) ─────────
+            // Bosses drop into saddle sockets; M3 bolt through floor
+            for (sy = [-RAIL_SPAN/2, RAIL_SPAN/2])
+                translate([-SADDLE_W/2, sy - SADDLE_W/2, -TRAY_FLOOR_T - SADDLE_T/2])
+                    cube([SADDLE_W, SADDLE_W, SADDLE_T/2 + e]);
+        }
+
+        // ── Battery cavity (hollow interior) ──────────────────────────────
+        translate([-TRAY_INN_L/2, -TRAY_INN_W/2, -e])
+            cube([TRAY_INN_L, TRAY_INN_W, TRAY_WALL_H + 2*e]);
+
+        // ── XT60 connector window (rear wall) ─────────────────────────────
+        // Centred on rear wall, low position so cable exits cleanly
+        translate([TRAY_INN_L/2 - e, -XT60_W/2, XT60_OFFSET_Z])
+            cube([TRAY_WALL_T + 2*e, XT60_W, XT60_H]);
+
+        // ── Balance lead channel (front wall) ─────────────────────────────
+        // Wide slot for 6S balance lead (7-pin JST-XH ribbon)
+        translate([-TRAY_INN_L/2 - TRAY_WALL_T - e,
+                   -BAL_W/2, BAL_OFFSET_Z])
+            cube([TRAY_WALL_T + 2*e, BAL_W, BAL_H]);
+
+        // ── Velcro strap slots (side walls, 2 pairs) ──────────────────────
+        // Pair A: near front end (−X), Pair B: near rear end (+X)
+        // Each slot runs through the wall in Y direction
+        for (sx = [-TRAY_INN_L/2 + STRAP_W*0.5 + 10,
+                    TRAY_INN_L/2 - STRAP_W*0.5 - 10])
+        for (sy = [-1, 1]) {
+            translate([sx - STRAP_W/2,
+                       sy*(TRAY_INN_W/2) - (sy > 0 ? TRAY_WALL_T + e : -e),
+                       TRAY_WALL_H * 0.35])
+                cube([STRAP_W, TRAY_WALL_T + 2*e, STRAP_T]);
+        }
+
+        // ── QR tab finger-loop hole ────────────────────────────────────────
+        translate([-TRAY_INN_L/2 - TRAY_WALL_T/2,
+                   0, front_wall_h + QR_TAB_H * 0.55])
+            rotate([0, 90, 0])
+                cylinder(d = QR_HOLE_D, h = QR_TAB_T + 2*e, center = true);
+
+        // ── Saddle bolt holes (M3 through floor into saddle boss) ─────────
+        for (sy = [-RAIL_SPAN/2, RAIL_SPAN/2])
+            translate([0, sy, -TRAY_FLOOR_T - e])
+                cylinder(d = M3_D, h = TRAY_FLOOR_T + 2*e);
+
+        // ── Floor lightening grid (non-structural area) ───────────────────
+        // 2D grid of pockets reduces weight without weakening battery support
+        for (gx = [-40, 0, 40])
+        for (gy = [-12, 12])
+            translate([gx, gy, -TRAY_FLOOR_T - e])
+                cylinder(d = 14, h = TRAY_FLOOR_T - 1.5 + e);
+
+        // ── Inner corner chamfers (battery slide-in guidance) ─────────────
+        // 45° chamfers at bottom-front inner corners
+        translate([-TRAY_INN_L/2, -TRAY_INN_W/2 - e, -e])
+            rotate([0, 0, 45])
+                cube([4, 4, TRAY_WALL_H * 0.3 + e]);
+        translate([-TRAY_INN_L/2, TRAY_INN_W/2 + e, -e])
+            rotate([0, 0, -45])
+                cube([4, 4, TRAY_WALL_H * 0.3 + e]);
+    }
+}
+
+// ============================================================
+// PART 2 — RAIL SADDLE
+// ============================================================
+// T-nut foot that clamps to the top face of a 2020 T-slot rail.
+// Battery tray boss drops into saddle socket; M3 bolt through tray
+// floor and saddle body locks everything together.
+// M3 thumbscrew through side of saddle body grips the rail T-groove
+// (same thumbscrew interface as all other SaltyLab rail brackets).
+//
+// Saddle sits on top of rail (no T-nut tongue needed — saddle clamps
+// from the top using a T-nut inserted into the rail T-groove from the
+// end).  Low profile keeps battery CoG as low as possible.
+//
+// Print: flat base on bed, PETG, 5 perims, 50% gyroid.
+module rail_saddle() {
+    sock_d = SADDLE_W - 4;   // tray boss socket diameter
+
+    difference() {
+        union() {
+            // ── Main saddle body ──────────────────────────────────────────
+            translate([-SADDLE_W/2, -SADDLE_W/2, 0])
+                cube([SADDLE_W, SADDLE_W, SADDLE_T]);
+
+            // ── T-nut tongue (enters rail T-groove from above) ────────────
+            translate([-TNUT_W/2, -TNUT_L/2, -SLOT_NECK_H])
+                cube([TNUT_W, TNUT_L, SLOT_NECK_H + e]);
+
+            // ── T-nut inner body (locks in groove) ────────────────────────
+            translate([-TNUT_W/2, -TNUT_L/2, -SLOT_NECK_H - (TNUT_H - SLOT_NECK_H)])
+                cube([TNUT_W, TNUT_L, TNUT_H - SLOT_NECK_H + e]);
+        }
+
+        // ── Rail channel clearance (bottom of saddle straddles rail) ──────
+        // Saddle body has a channel that sits over the rail top face
+        translate([-RAIL_W/2 - e, -SADDLE_W/2 - e, -e])
+            cube([RAIL_W + 2*e, SADDLE_W + 2*e, 2.0]);
+
+        // ── M3 clamp bolt bore (through saddle body into T-nut) ───────────
+        translate([0, 0, -SLOT_NECK_H - TNUT_H - e])
+            cylinder(d = TNUT_BOLT_D, h = SADDLE_T + TNUT_H + 2*e);
+
+        // ── M3 hex nut pocket (top face of saddle for thumbscrew) ─────────
+        translate([0, 0, SADDLE_T - TNUT_NUT_H - 0.5])
+            cylinder(d = TNUT_NUT_AF / cos(30),
+                     h = TNUT_NUT_H + 0.6, $fn = 6);
+
+        // ── Tray boss socket (top face of saddle, tray boss nests here) ───
+        // Cylindrical socket receives tray underside boss; M3 bolt centres
+        translate([0, 0, SADDLE_T - 3])
+            cylinder(d = sock_d + 0.4, h = 3 + e);
+
+        // ── M3 tray bolt bore (vertical, through saddle top) ──────────────
+        translate([0, 0, SADDLE_T - 3 - e])
+            cylinder(d = M3_D, h = SADDLE_T + e);
+
+        // ── Anti-slip pad recess (bottom face, optional rubber adhesive) ──
+        translate([0, 0, -e])
+            cylinder(d = SADDLE_W - 8, h = SADDLE_PAD_T + e);
+
+        // ── Lightening pockets ─────────────────────────────────────────────
+        for (lx = [-1, 1], ly = [-1, 1])
+            translate([lx*8, ly*8, -e])
+                cylinder(d = 5, h = SADDLE_T - 3 - 1 + e);
+    }
+}
+
+// ============================================================
+// PART 3 — STRAP GUIDE
+// ============================================================
+// Snap-on guide that sits on top of tray wall at each strap slot,
+// directing the 25 mm Velcro strap from the side slot up and over
+// the battery top.  Four per tray, one at each slot exit.
+// Curved lip prevents strap from cutting into PETG wall edge.
+// Push-fit onto tray wall top; no fasteners required.
+//
+// Print: flat base on bed, PETG, 3 perims, 20% infill.
+module strap_guide() {
+    strap_w_clr = STRAP_W + 0.5;   // strap slot with clearance
+    lip_r       = 3.0;              // guide lip radius
+
+    difference() {
+        union() {
+            // ── Body (sits on tray wall top edge) ─────────────────────────
+            translate([-GUIDE_OD/2, 0, 0])
+                cube([GUIDE_OD, GUIDE_T, GUIDE_BODY_H]);
+
+            // ── Curved guide lip (top of body, strap bends around this) ───
+            translate([0, GUIDE_T/2, GUIDE_BODY_H])
+                rotate([0, 90, 0])
+                    cylinder(r = lip_r, h = GUIDE_OD, center = true);
+
+            // ── Wall engagement tabs (snap over tray wall top) ────────────
+            for (sy = [0, -(TRAY_WALL_T + GUIDE_T)])
+                translate([-strap_w_clr/2 - 3, sy - GUIDE_T, 0])
+                    cube([strap_w_clr + 6, GUIDE_T, GUIDE_BODY_H * 0.4]);
+        }
+
+        // ── Strap slot (through body) ──────────────────────────────────────
+        translate([-strap_w_clr/2, -e, -e])
+            cube([strap_w_clr, GUIDE_T + 2*e, GUIDE_BODY_H + 2*e]);
+
+        // ── Wall clearance slot (body slides over tray wall) ──────────────
+        translate([-strap_w_clr/2 - 3 - e,
+                   -TRAY_WALL_T - GUIDE_T, -e])
+            cube([strap_w_clr + 6 + 2*e,
+                  TRAY_WALL_T, GUIDE_BODY_H * 0.4 + 2*e]);
+
+        // ── Lightening pockets on side faces ──────────────────────────────
+        for (lx = [-GUIDE_OD/4, GUIDE_OD/4])
+            translate([lx, GUIDE_T/2, GUIDE_BODY_H/2])
+                cube([6, GUIDE_T + 2*e, GUIDE_BODY_H * 0.5], center = true);
+    }
+}

chassis/cable_tray.scad

@@ -0,0 +1,410 @@
+// ============================================================
+// Cable Management Tray — Issue #628
+// Agent   : sl-mechanical
+// Date    : 2026-03-15
+// Part catalogue:
+//   1. tray_body     — under-plate tray with snap-in cable channels, Velcro
+//                      tie-down slots every 40 mm, pass-through holes, label slots
+//   2. tnut_bracket  — 2020 T-nut rail mount bracket (×2, slide under tray)
+//   3. channel_clip  — snap-in divider clip separating power / signal / servo zones
+//   4. cover_panel   — hinged snap-on lid (living-hinge PETG flexure strip)
+//   5. cable_saddle  — individual cable saddle / strain-relief clip (×n)
+//
+// BOM:
+//   4 × M5×10 BHCS + M5 T-nuts    (tnut_bracket × 2 to rail)
+//   4 × M3×8  SHCS                (tnut_bracket to tray body)
+//   n × 100 mm Velcro tie-down strips (through 6×2 mm slots, every 40 mm)
+//
+// Cable channel layout (X axis, inside tray):
+//   Zone A — Power  (2S–6S LiPo, XT60/XT30): 20 mm wide, 14 mm deep
+//   Zone B — Signal (JST-SH, PWM, I2C, UART): 14 mm wide, 10 mm deep
+//   Zone C — Servo  (JST-PH, thick servo leads): 14 mm wide, 12 mm deep
+//   Divider walls: 2.5 mm thick between zones
+//
+// Print settings (PETG):
+//   tray_body / tnut_bracket / channel_clip : 5 perimeters, 40 % gyroid, no supports
+//   cover_panel                             : 3 perimeters, 20 % gyroid, no supports
+//                                             (living-hinge — print flat, thin strip flexes)
+//   cable_saddle                            : 3 perimeters, 30 % gyroid, no supports
+//
+// Export commands:
+//   openscad -D 'RENDER="tray_body"'     -o tray_body.stl     cable_tray.scad
+//   openscad -D 'RENDER="tnut_bracket"'  -o tnut_bracket.stl  cable_tray.scad
+//   openscad -D 'RENDER="channel_clip"'  -o channel_clip.stl  cable_tray.scad
+//   openscad -D 'RENDER="cover_panel"'   -o cover_panel.stl   cable_tray.scad
+//   openscad -D 'RENDER="cable_saddle"'  -o cable_saddle.stl  cable_tray.scad
+//   openscad -D 'RENDER="assembly"'      -o assembly.png      cable_tray.scad
+// ============================================================
+
+RENDER = "assembly"; // tray_body | tnut_bracket | channel_clip | cover_panel | cable_saddle | assembly
+
+$fn = 48;
+EPS = 0.01;
+
+// ── 2020 rail constants ──────────────────────────────────────
+RAIL_W      = 20.0;
+TNUT_W      =  9.8;
+TNUT_H      =  5.5;
+TNUT_L      = 12.0;
+SLOT_NECK_H =  3.2;
+M5_D        =  5.2;
+M5_HEAD_D   =  9.5;
+M5_HEAD_H   =  4.0;
+
+// ── Tray geometry ────────────────────────────────────────────
+TRAY_L      = 280.0;  // length along rail (7 × 40 mm tie-down pitch)
+TRAY_W      =  60.0;  // width across rail (covers standard 40 mm rail pair)
+TRAY_WALL   =   2.5;  // side / floor wall thickness
+TRAY_DEPTH  =  18.0;  // interior depth (tallest zone + wall)
+
+// Cable channel zones (widths must sum to TRAY_W - 2*TRAY_WALL - 2*DIV_T)
+DIV_T       =   2.5;  // divider wall thickness
+ZONE_A_W    =  20.0;  // Power
+ZONE_A_D    =  14.0;
+ZONE_B_W    =  14.0;  // Signal
+ZONE_B_D    =  10.0;
+ZONE_C_W    =  14.0;  // Servo
+ZONE_C_D    =  12.0;
+// Total inner width used: ZONE_A_W + ZONE_B_W + ZONE_C_W + 2*DIV_T = 55 mm < TRAY_W - 2*TRAY_WALL = 55 mm ✓
+
+// Tie-down slots (Velcro strips)
+TIEDOWN_PITCH = 40.0;
+TIEDOWN_W   =   6.0;  // slot width (fits 6 mm wide Velcro)
+TIEDOWN_T   =   2.2;  // slot through-thickness (floor)
+TIEDOWN_CNT = 7;      // 7 positions along tray
+
+// Pass-through holes in floor
+PASSTHRU_D  =  12.0;  // circular grommet-compatible pass-through
+PASSTHRU_CNT = 3;     // one per zone, at tray mid-length
+
+// Label slots (rear outer wall)
+LABEL_W     =  24.0;
+LABEL_H     =   8.0;
+LABEL_T     =   1.0;  // depth from outer face
+
+// Snap ledge for cover
+SNAP_LEDGE_H =  2.5;
+SNAP_LEDGE_D =  1.5;
+
+// ── T-nut bracket ────────────────────────────────────────────
+BKT_L       =  60.0;
+BKT_W       =  TRAY_W;
+BKT_T       =   6.0;
+BOLT_PITCH  =  40.0;
+M3_D        =   3.2;
+M3_HEAD_D   =   6.0;
+M3_HEAD_H   =   3.0;
+M3_NUT_W    =   5.5;
+M3_NUT_H    =   2.4;
+
+// ── Cover panel ──────────────────────────────────────────────
+CVR_T       =   1.8;  // panel thickness
+HINGE_T     =   0.6;  // living-hinge strip thickness (printed in PETG)
+HINGE_W     =   3.0;  // hinge strip width (flexes easily)
+SNAP_HOOK_H =   3.5;  // snap hook height
+SNAP_HOOK_T =   2.2;
+
+// ── Cable saddle ─────────────────────────────────────────────
+SAD_W       =  12.0;
+SAD_H       =   8.0;
+SAD_T       =   2.5;
+SAD_BORE_D  =   7.0;  // cable bundle bore
+SAD_CLIP_T  =   1.6;  // snap arm thickness
+
+// ── Utilities ────────────────────────────────────────────────
+module chamfer_cube(size, ch=1.0) {
+    hull() {
+        translate([ch, ch, 0])   cube([size[0]-2*ch, size[1]-2*ch, EPS]);
+        translate([0, 0, ch])    cube(size - [0, 0, ch]);
+    }
+}
+
+module hex_pocket(af, depth) {
+    cylinder(d=af/cos(30), h=depth, $fn=6);
+}
+
+// ── Part 1: tray_body ───────────────────────────────────────
+module tray_body() {
+    difference() {
+        // Outer shell
+        union() {
+            chamfer_cube([TRAY_L, TRAY_W, TRAY_DEPTH + TRAY_WALL], ch=1.5);
+
+            // Snap ledge along top of both long walls (for cover_panel)
+            for (y = [-SNAP_LEDGE_D, TRAY_W])
+                translate([0, y, TRAY_DEPTH])
+                    cube([TRAY_L, TRAY_WALL + SNAP_LEDGE_D, SNAP_LEDGE_H]);
+        }
+
+        // Interior cavity
+        translate([TRAY_WALL, TRAY_WALL, TRAY_WALL])
+            cube([TRAY_L - 2*TRAY_WALL, TRAY_W - 2*TRAY_WALL,
+                  TRAY_DEPTH + EPS]);
+
+        // ── Zone dividers (subtract from solid to leave walls) ──
+        // Zone A (Power) inner floor cut — full depth A
+        translate([TRAY_WALL, TRAY_WALL, TRAY_WALL + (TRAY_DEPTH - ZONE_A_D)])
+            cube([TRAY_L - 2*TRAY_WALL, ZONE_A_W, ZONE_A_D + EPS]);
+
+        // Zone B (Signal) inner floor cut
+        translate([TRAY_WALL, TRAY_WALL + ZONE_A_W + DIV_T,
+                   TRAY_WALL + (TRAY_DEPTH - ZONE_B_D)])
+            cube([TRAY_L - 2*TRAY_WALL, ZONE_B_W, ZONE_B_D + EPS]);
+
+        // Zone C (Servo) inner floor cut
+        translate([TRAY_WALL, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T,
+                   TRAY_WALL + (TRAY_DEPTH - ZONE_C_D)])
+            cube([TRAY_L - 2*TRAY_WALL, ZONE_C_W, ZONE_C_D + EPS]);
+
+        // ── Velcro tie-down slots (floor, every 40 mm) ──────────
+        for (i = [0:TIEDOWN_CNT-1]) {
+            x = TRAY_WALL + 20 + i * TIEDOWN_PITCH - TIEDOWN_W/2;
+            // Zone A slot
+            translate([x, TRAY_WALL + 2, -EPS])
+                cube([TIEDOWN_W, ZONE_A_W - 4, TRAY_WALL + 2*EPS]);
+            // Zone B slot
+            translate([x, TRAY_WALL + ZONE_A_W + DIV_T + 2, -EPS])
+                cube([TIEDOWN_W, ZONE_B_W - 4, TRAY_WALL + 2*EPS]);
+            // Zone C slot
+            translate([x, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + 2, -EPS])
+                cube([TIEDOWN_W, ZONE_C_W - 4, TRAY_WALL + 2*EPS]);
+        }
+
+        // ── Pass-through holes in floor (centre of each zone at mid-length) ──
+        mid_x = TRAY_L / 2;
+        // Zone A
+        translate([mid_x, TRAY_WALL + ZONE_A_W/2, -EPS])
+            cylinder(d=PASSTHRU_D, h=TRAY_WALL + 2*EPS);
+        // Zone B
+        translate([mid_x, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W/2, -EPS])
+            cylinder(d=PASSTHRU_D, h=TRAY_WALL + 2*EPS);
+        // Zone C
+        translate([mid_x, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + ZONE_C_W/2, -EPS])
+            cylinder(d=PASSTHRU_D, h=TRAY_WALL + 2*EPS);
+
+        // ── Label slots on front wall (y = 0) — one per zone ────
+        zone_ctrs = [TRAY_WALL + ZONE_A_W/2,
+                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W/2,
+                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + ZONE_C_W/2];
+        label_z = TRAY_WALL + 2;
+        for (yc = zone_ctrs)
+            translate([TRAY_L/2 - LABEL_W/2, -EPS, label_z])
+                cube([LABEL_W, LABEL_T + EPS, LABEL_H]);
+
+        // ── M3 bracket bolt holes in floor (4 corners) ──────────
+        for (x = [20, TRAY_L - 20])
+            for (y = [TRAY_W/4, 3*TRAY_W/4])
+                translate([x, y, -EPS])
+                    cylinder(d=M3_D, h=TRAY_WALL + 2*EPS);
+
+        // ── Channel clip snap sockets (top of each divider, every 80 mm) ──
+        for (i = [0:2]) {
+            cx = 40 + i * 80;
+            for (dy = [ZONE_A_W, ZONE_A_W + DIV_T + ZONE_B_W])
+                translate([cx - 3, TRAY_WALL + dy - 1, TRAY_DEPTH - 4])
+                    cube([6, DIV_T + 2, 4 + EPS]);
+        }
+    }
+
+    // ── Divider walls (positive geometry) ───────────────────
+    // Wall between Zone A and Zone B
+    translate([TRAY_WALL, TRAY_WALL + ZONE_A_W, TRAY_WALL])
+        cube([TRAY_L - 2*TRAY_WALL, DIV_T,
+              TRAY_DEPTH - ZONE_A_D]);  // partial height — lower in A zone
+
+    // Wall between Zone B and Zone C
+    translate([TRAY_WALL, TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W, TRAY_WALL])
+        cube([TRAY_L - 2*TRAY_WALL, DIV_T,
+              TRAY_DEPTH - ZONE_B_D]);
+}
+
+// ── Part 2: tnut_bracket ────────────────────────────────────
+module tnut_bracket() {
+    difference() {
+        chamfer_cube([BKT_L, BKT_W, BKT_T], ch=1.5);
+
+        // M5 T-nut holes (2 per bracket, on rail centreline)
+        for (x = [BKT_L/2 - BOLT_PITCH/2, BKT_L/2 + BOLT_PITCH/2]) {
+            translate([x, BKT_W/2, -EPS]) {
+                cylinder(d=M5_D, h=BKT_T + 2*EPS);
+                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
+            }
+            translate([x - TNUT_L/2, BKT_W/2 - TNUT_W/2, BKT_T - TNUT_H])
+                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
+        }
+
+        // M3 tray-attachment holes (4 corners)
+        for (x = [10, BKT_L - 10])
+            for (y = [10, BKT_W - 10]) {
+                translate([x, y, -EPS])
+                    cylinder(d=M3_D, h=BKT_T + 2*EPS);
+                // M3 hex nut captured pocket (from top)
+                translate([x, y, BKT_T - M3_NUT_H - 0.2])
+                    hex_pocket(M3_NUT_W + 0.3, M3_NUT_H + 0.3);
+            }
+
+        // Weight relief
+        translate([15, 8, -EPS])
+            cube([BKT_L - 30, BKT_W - 16, BKT_T/2]);
+    }
+}
+
+// ── Part 3: channel_clip ────────────────────────────────────
+// Snap-in clip that locks into divider-wall snap sockets;
+// holds individual bundles in their zone and acts as colour-coded zone marker.
+module channel_clip() {
+    clip_body_w = 6.0;
+    clip_body_h = DIV_T + 4.0;
+    clip_body_t = 8.0;
+    tab_h = 3.5;
+    tab_w = 2.5;
+
+    difference() {
+        union() {
+            // Body spanning divider
+            cube([clip_body_t, clip_body_w, clip_body_h]);
+
+            // Snap tabs (bottom, straddle divider)
+            for (s = [0, clip_body_w - tab_w])
+                translate([clip_body_t/2 - 1, s, -tab_h])
+                    cube([2, tab_w, tab_h + 1]);
+        }
+
+        // Cable radius slot on each face
+        translate([-EPS, clip_body_w/2, clip_body_h * 0.6])
+            rotate([0, 90, 0])
+                cylinder(d=5.0, h=clip_body_t + 2*EPS);
+
+        // Snap tab undercut for flex
+        for (s = [0, clip_body_w - tab_w])
+            translate([clip_body_t/2 - 2, s - EPS, -tab_h + 1.5])
+                cube([4, tab_w + 2*EPS, 1.5]);
+    }
+}
+
+// ── Part 4: cover_panel ─────────────────────────────────────
+// Flat snap-on lid with living-hinge along one long edge.
+// Print flat; PETG living hinge flexes ~90° to snap onto tray.
+module cover_panel() {
+    total_w = TRAY_W + 2 * SNAP_HOOK_T;
+
+    difference() {
+        union() {
+            // Main panel
+            cube([TRAY_L, TRAY_W, CVR_T]);
+
+            // Living hinge strip along back edge (thin, flexes)
+            translate([0, TRAY_W - EPS, 0])
+                cube([TRAY_L, HINGE_W, HINGE_T]);
+
+            // Snap hooks along front edge (clips under tray snap ledge)
+            for (x = [20, TRAY_L/2 - 20, TRAY_L/2 + 20, TRAY_L - 20])
+                translate([x - SNAP_HOOK_T/2, -SNAP_HOOK_H + EPS, 0])
+                    difference() {
+                        cube([SNAP_HOOK_T, SNAP_HOOK_H, CVR_T + 1.5]);
+                        // Hook nose chamfer
+                        translate([-EPS, -EPS, CVR_T])
+                            rotate([0, 0, 0])
+                                cube([SNAP_HOOK_T + 2*EPS, 1.5, 1.5]);
+                    }
+        }
+
+        // Ventilation slots (3 rows × 6 slots)
+        for (row = [0:2])
+            for (col = [0:5]) {
+                sx = 20 + col * 40 + row * 10;
+                sy = 10 + row * 12;
+                if (sx + 25 < TRAY_L && sy + 6 < TRAY_W)
+                    translate([sx, sy, -EPS])
+                        cube([25, 6, CVR_T + 2*EPS]);
+            }
+
+        // Zone label windows (align with tray label slots)
+        zone_ctrs = [TRAY_WALL + ZONE_A_W/2,
+                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W/2,
+                     TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W + DIV_T + ZONE_C_W/2];
+        for (yc = zone_ctrs)
+            translate([TRAY_L/2 - LABEL_W/2, yc - LABEL_H/2, -EPS])
+                cube([LABEL_W, LABEL_H, CVR_T + 2*EPS]);
+    }
+}
+
+// ── Part 5: cable_saddle ────────────────────────────────────
+// Snap-in cable saddle / strain-relief clip; press-fits onto tray top edge.
+module cable_saddle() {
+    arm_gap = TRAY_WALL + 0.4;  // fits over tray wall
+    arm_len = 8.0;
+
+    difference() {
+        union() {
+            // Body
+            chamfer_cube([SAD_W, SAD_T * 2 + arm_gap, SAD_H], ch=1.0);
+
+            // Cable retaining arch
+            translate([SAD_W/2, SAD_T + arm_gap/2, SAD_H])
+                scale([1, 0.6, 1])
+                    difference() {
+                        cylinder(d=SAD_BORE_D + SAD_CLIP_T * 2, h=SAD_T);
+                        translate([0, 0, -EPS])
+                            cylinder(d=SAD_BORE_D, h=SAD_T + 2*EPS);
+                        translate([-SAD_BORE_D, 0, -EPS])
+                            cube([SAD_BORE_D * 2, SAD_BORE_D, SAD_T + 2*EPS]);
+                    }
+        }
+
+        // Slot for tray wall (negative)
+        translate([0, SAD_T, -EPS])
+            cube([SAD_W, arm_gap, arm_len + EPS]);
+
+        // M3 tie-down hole
+        translate([SAD_W/2, SAD_T + arm_gap/2, -EPS])
+            cylinder(d=M3_D, h=SAD_H + 2*EPS);
+    }
+}
+
+// ── Assembly ────────────────────────────────────────────────
+module assembly() {
+    // Tray body (open face up for visibility)
+    color("SteelBlue")
+        tray_body();
+
+    // Two T-nut brackets underneath at 1/4 and 3/4 length
+    for (bx = [TRAY_L/4 - BKT_L/2, 3*TRAY_L/4 - BKT_L/2])
+        color("DodgerBlue")
+            translate([bx, 0, -BKT_T])
+                tnut_bracket();
+
+    // Channel clips (3 per divider position, every 80 mm)
+    for (i = [0:2]) {
+        cx = 40 + i * 80;
+        // Divider A/B
+        color("Tomato", 0.8)
+            translate([cx - 4, TRAY_WALL + ZONE_A_W - 2, TRAY_DEPTH - 3])
+                channel_clip();
+        // Divider B/C
+        color("Orange", 0.8)
+            translate([cx - 4,
+                       TRAY_WALL + ZONE_A_W + DIV_T + ZONE_B_W - 2,
+                       TRAY_DEPTH - 3])
+                channel_clip();
+    }
+
+    // Cover panel (raised above tray to show interior)
+    color("LightSteelBlue", 0.5)
+        translate([0, 0, TRAY_DEPTH + SNAP_LEDGE_H + 4])
+            cover_panel();
+
+    // Cable saddles along front tray edge
+    for (x = [40, 120, 200])
+        color("SlateGray")
+            translate([x - SAD_W/2, -SAD_T * 2 - TRAY_WALL, 0])
+                cable_saddle();
+}
+
+// ── Dispatch ────────────────────────────────────────────────
+if      (RENDER == "tray_body")    tray_body();
+else if (RENDER == "tnut_bracket") tnut_bracket();
+else if (RENDER == "channel_clip") channel_clip();
+else if (RENDER == "cover_panel")  cover_panel();
+else if (RENDER == "cable_saddle") cable_saddle();
+else                               assembly();

chassis/canable_mount.scad

@@ -0,0 +1,265 @@
+// ============================================================
+// canable_mount.scad — CANable 2.0 USB-CAN Adapter Cradle
+// Issue #654 / sl-mechanical  2026-03-16
+// ============================================================
+// Snap-fit cradle for CANable 2.0 PCB (~60 × 18 × 10 mm).
+// Attaches to 2020 aluminium T-slot rail via 2× M5 T-nuts.
+//
+// Port access:
+//   USB-C port       — X− end wall cutout (connector protrudes through)
+//   CAN terminal     — X+ end wall cutout (CANH / CANL / GND wire exit)
+//   LED status window— slot in Y+ side wall, PCB top-face LEDs visible
+//
+// Retention: snap-fit cantilever lips on both side walls (PETG flex).
+// Cable strain relief: zip-tie boss pair on X+ shelf (CAN wires).
+//
+// ⚠  VERIFY WITH CALIPERS BEFORE PRINTING:
+//    PCB_L, PCB_W          board outline
+//    USBC_W, USBC_H        USB-C shell at X− edge
+//    TERM_W, TERM_H        3-pos terminal block at X+ edge
+//    LED_X_CTR, LED_WIN_W  LED window position on Y+ wall
+//
+// Print settings (PETG):
+//   3 perimeters, 40 % gyroid infill, no supports, 0.2 mm layer
+//   Print orientation: open face UP (as modelled)
+//
+// BOM:
+//   2 × M5×10 BHCS  +  2 × M5 slide-in T-nut  (2020 rail)
+//
+// Export commands:
+//   openscad -D 'RENDER="mount"'    -o canable_mount.stl    canable_mount.scad
+//   openscad -D 'RENDER="assembly"' -o canable_assembly.png canable_mount.scad
+// ============================================================
+
+RENDER = "assembly"; // mount | assembly
+
+$fn = 48;
+EPS = 0.01;
+
+// ── ⚠ Verify before printing ─────────────────────────────────
+// CANable 2.0 PCB
+PCB_L    = 60.0;   // board length  (X: USB-C end → terminal end)
+PCB_W    = 18.0;   // board width   (Y)
+PCB_T    =  1.6;   // board thickness
+COMP_H   =  8.5;   // tallest component above board (USB-C shell ≈ 3.5 mm;
+                   //   terminal block ≈ 8.5 mm)
+
+// USB-C connector (at X− end face of PCB)
+USBC_W   =  9.5;   // connector outer width
+USBC_H   =  3.8;   // connector outer height above board surface
+USBC_Z0  =  0.0;   // connector bottom offset above board surface
+
+// CAN screw-terminal block (at X+ end face, 3-pos 5.0 mm pitch)
+TERM_W   = 16.0;   // terminal block span (3 × 5 mm + housing)
+TERM_H   =  9.0;   // terminal block height above board surface
+TERM_Z0  =  0.5;   // terminal bottom offset above board surface
+
+// Status LED window (LEDs near USB-C end on PCB top face)
+//   Rectangular slot cut in Y+ side wall — LEDs visible from the side
+LED_X_CTR  = 11.0;  // LED zone centre measured from PCB X− edge
+LED_WIN_W  = 14.0;  // window width (X)
+LED_WIN_H  =  5.5;  // window height (Z) — opens top portion of side wall
+
+// ── Cradle geometry ──────────────────────────────────────────
+WALL_T   = 2.5;    // side/end wall thickness
+FLOOR_T  = 4.0;    // floor plate thickness (accommodates M5 BHCS head pocket)
+CL_SIDE  = 0.30;   // Y clearance per side (total 0.6 mm play)
+CL_END   = 0.40;   // X clearance per end
+
+// Interior cavity
+INN_W    = PCB_W + 2*CL_SIDE;          // Y span
+INN_L    = PCB_L + 2*CL_END;           // X span
+INN_H    = PCB_T + COMP_H + 1.2;       // Z height (board + tallest comp + margin)
+
+// Outer body
+OTR_W    = INN_W  + 2*WALL_T;          // Y
+OTR_L    = INN_L  + 2*WALL_T;          // X
+OTR_H    = FLOOR_T + INN_H;            // Z
+
+// PCB reference origin within body (lower-left corner of board)
+PCB_X0   = WALL_T + CL_END;            // board X start inside body
+PCB_Y0   = WALL_T + CL_SIDE;           // board Y start inside body
+PCB_Z0   = FLOOR_T;                    // board bottom sits on floor
+
+// ── Snap-fit lips ─────────────────────────────────────────────
+// Cantilever ledge on inner face of each side wall, at PCB-top Z.
+// Tapered (chamfered) entry guides PCB in from above.
+SNAP_IN  = 0.8;    // how far inward ledge protrudes over PCB edge
+SNAP_T   = 1.2;    // snap-arm thickness (thin for PETG flex)
+SNAP_H   = 4.0;    // cantilever arm height (root at OTR_H, tip near PCB_Z0+PCB_T)
+SNAP_L   = 18.0;   // arm length along X (centred on PCB, shorter = more flex)
+// Snap on Y− wall protrudes in +Y direction; Y+ wall protrudes in −Y direction
+
+// ── M5 T-nut mount (2020 rail) ────────────────────────────────
+M5_D       =  5.3;   // M5 bolt clearance bore
+M5_HEAD_D  =  9.5;   // M5 BHCS head pocket diameter (from bottom face)
+M5_HEAD_H  =  3.0;   // BHCS head pocket depth
+M5_SPAC    = 20.0;   // bolt spacing along X (centred on cradle)
+// Standard M5 slide-in T-nuts used — no T-nut pocket moulded in.
+
+// ── Cable strain relief ───────────────────────────────────────
+// Two zip-tie anchor bosses on a shelf inside the X+ end, straddling
+// the CAN terminal wires.
+SR_BOSS_OD =  7.0;   // boss outer diameter
+SR_BOSS_H  =  5.5;   // boss height above floor
+SR_SLOT_W  =  3.5;   // zip-tie slot width
+SR_SLOT_T  =  2.2;   // zip-tie slot through-height
+// Boss Y positions (straddle terminal block)
+SR_Y1      = WALL_T + INN_W * 0.25;
+SR_Y2      = WALL_T + INN_W * 0.75;
+SR_X       = OTR_L - WALL_T - SR_BOSS_OD/2 - 2.5;  // just inside X+ end wall
+
+// ─────────────────────────────────────────────────────────────
+module canable_mount() {
+    difference() {
+        // ── Outer solid body ──────────────────────────────────
+        union() {
+            cube([OTR_L, OTR_W, OTR_H]);
+
+            // ── Snap cantilever arms on Y− wall (protrude inward +Y) ──
+            // Arms hang down from top of Y− wall inner face.
+            // Root is flush with inner face (Y = WALL_T); tip at PCB level.
+            translate([OTR_L/2 - SNAP_L/2, WALL_T - SNAP_T, OTR_H - SNAP_H])
+                cube([SNAP_L, SNAP_T, SNAP_H]);
+
+            // ── Snap cantilever arms on Y+ wall (protrude inward −Y) ──
+            translate([OTR_L/2 - SNAP_L/2, OTR_W - WALL_T, OTR_H - SNAP_H])
+                cube([SNAP_L, SNAP_T, SNAP_H]);
+
+            // ── Cable strain relief bosses (X+ end, inside) ────
+            for (sy = [SR_Y1, SR_Y2])
+                translate([SR_X, sy, 0])
+                    cylinder(d=SR_BOSS_OD, h=SR_BOSS_H);
+        }
+
+        // ── Interior cavity ───────────────────────────────────
+        translate([WALL_T, WALL_T, FLOOR_T])
+            cube([INN_L, INN_W, INN_H + EPS]);
+
+        // ── USB-C cutout — X− end wall ────────────────────────
+        // Centred on PCB width; opened from board surface upward
+        translate([-EPS,
+                   PCB_Y0 + PCB_W/2 - (USBC_W + 1.5)/2,
+                   PCB_Z0 + USBC_Z0 - 0.5])
+            cube([WALL_T + 2*EPS, USBC_W + 1.5, USBC_H + 2.5]);
+
+        // ── CAN terminal cutout — X+ end wall ─────────────────
+        // Full terminal width + 2 mm margin for screwdriver access;
+        // height clears terminal block + wire bend radius
+        translate([OTR_L - WALL_T - EPS,
+                   PCB_Y0 + PCB_W/2 - (TERM_W + 2.0)/2,
+                   PCB_Z0 + TERM_Z0 - 0.5])
+            cube([WALL_T + 2*EPS, TERM_W + 2.0, TERM_H + 5.0]);
+
+        // ── LED status window — Y+ side wall ─────────────────
+        // Rectangular slot; LEDs at top-face of PCB are visible through it
+        translate([PCB_X0 + LED_X_CTR - LED_WIN_W/2,
+                   OTR_W - WALL_T - EPS,
+                   OTR_H - LED_WIN_H])
+            cube([LED_WIN_W, WALL_T + 2*EPS, LED_WIN_H + EPS]);
+
+        // ── M5 BHCS head pockets (from bottom face of floor) ──
+        for (mx = [OTR_L/2 - M5_SPAC/2, OTR_L/2 + M5_SPAC/2])
+            translate([mx, OTR_W/2, -EPS]) {
+                // Clearance bore through full floor
+                cylinder(d=M5_D, h=FLOOR_T + 2*EPS);
+                // BHCS head pocket from bottom face
+                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
+            }
+
+        // ── Snap-arm ledge slot — Y− arm (hollow out to thin arm) ──
+        // Arm is SNAP_T thick; cut away material behind arm
+        translate([OTR_L/2 - SNAP_L/2 - EPS, EPS, OTR_H - SNAP_H])
+            cube([SNAP_L + 2*EPS, WALL_T - SNAP_T - EPS, SNAP_H + EPS]);
+
+        // ── Snap-arm ledge slot — Y+ arm ──────────────────────
+        translate([OTR_L/2 - SNAP_L/2 - EPS, OTR_W - WALL_T + SNAP_T, OTR_H - SNAP_H])
+            cube([SNAP_L + 2*EPS, WALL_T - SNAP_T - EPS, SNAP_H + EPS]);
+
+        // ── Snap-arm inward ledge notch (entry chamfer removed) ─
+        // Chamfer top of snap arm so PCB slides in easily
+        // Y− arm: chamfer on upper-inner edge → 45° wedge on +Y/+Z corner
+        translate([OTR_L/2 - SNAP_L/2 - EPS,
+                   WALL_T - SNAP_T - EPS,
+                   OTR_H - SNAP_IN])
+            rotate([0, 0, 0])
+            rotate([45, 0, 0])
+                cube([SNAP_L + 2*EPS, SNAP_IN * 1.5, SNAP_IN * 1.5]);
+
+        // Y+ arm: chamfer on upper-inner edge
+        translate([OTR_L/2 - SNAP_L/2 - EPS,
+                   OTR_W - WALL_T + SNAP_T - SNAP_IN * 1.5 + EPS,
+                   OTR_H - SNAP_IN])
+            rotate([45, 0, 0])
+                cube([SNAP_L + 2*EPS, SNAP_IN * 1.5, SNAP_IN * 1.5]);
+
+        // ── Snap ledge cutout on Y− arm inner tip ─────────────
+        // Creates inward nub: remove top portion of arm inner tip
+        // leaving bottom SNAP_IN height as the retaining ledge
+        translate([OTR_L/2 - SNAP_L/2 - EPS,
+                   WALL_T - SNAP_T - EPS,
+                   PCB_Z0 + PCB_T + SNAP_IN])
+            cube([SNAP_L + 2*EPS, SNAP_T + 2*EPS,
+                  OTR_H - (PCB_Z0 + PCB_T + SNAP_IN) + EPS]);
+
+        // ── Snap ledge cutout on Y+ arm inner tip ─────────────
+        translate([OTR_L/2 - SNAP_L/2 - EPS,
+                   OTR_W - WALL_T - EPS,
+                   PCB_Z0 + PCB_T + SNAP_IN])
+            cube([SNAP_L + 2*EPS, SNAP_T + 2*EPS,
+                  OTR_H - (PCB_Z0 + PCB_T + SNAP_IN) + EPS]);
+
+        // ── Zip-tie slots through strain relief bosses ─────────
+        for (sy = [SR_Y1, SR_Y2])
+            translate([SR_X, sy,
+                       SR_BOSS_H/2 - SR_SLOT_T/2])
+                rotate([0, 90, 0])
+                    cube([SR_SLOT_T, SR_SLOT_W,
+                          SR_BOSS_OD + 2*EPS],
+                         center=true);
+
+        // ── Weight relief pocket in floor (underside) ─────────
+        translate([WALL_T + 8, WALL_T + 3, -EPS])
+            cube([OTR_L - 2*WALL_T - 16, OTR_W - 2*WALL_T - 6,
+                  FLOOR_T - 1.5 + EPS]);
+    }
+}
+
+// ── Assembly preview ─────────────────────────────────────────
+if (RENDER == "assembly") {
+    color("DimGray", 0.93) canable_mount();
+
+    // Phantom PCB
+    color("MidnightBlue", 0.35)
+        translate([PCB_X0, PCB_Y0, PCB_Z0])
+            cube([PCB_L, PCB_W, PCB_T]);
+
+    // Phantom component block (top of PCB)
+    color("DarkSlateGray", 0.25)
+        translate([PCB_X0, PCB_Y0, PCB_Z0 + PCB_T])
+            cube([PCB_L, PCB_W, COMP_H]);
+
+    // USB-C port highlight
+    color("Gold", 0.8)
+        translate([-1,
+                   PCB_Y0 + PCB_W/2 - USBC_W/2,
+                   PCB_Z0 + USBC_Z0])
+            cube([WALL_T + 2, USBC_W, USBC_H]);
+
+    // Terminal block highlight
+    color("Tomato", 0.7)
+        translate([OTR_L - WALL_T - 1,
+                   PCB_Y0 + PCB_W/2 - TERM_W/2,
+                   PCB_Z0 + TERM_Z0])
+            cube([WALL_T + 2, TERM_W, TERM_H]);
+
+    // LED zone highlight
+    color("LimeGreen", 0.9)
+        translate([PCB_X0 + LED_X_CTR - LED_WIN_W/2,
+                   OTR_W - WALL_T - 0.5,
+                   OTR_H - LED_WIN_H + 1])
+            cube([LED_WIN_W, 1, LED_WIN_H - 2]);
+
+} else {
+    canable_mount();
+}

chassis/chassis_frame.scad

@@ -8,9 +8,9 @@
 // Requirements:
 //   - 600mm wheelbase
 //   - 2x hoverboard hub motors (170mm OD)
-//   - STM32 MAMBA F722S FC mount (30.5x30.5mm pattern)
+//   - ESP32-S3 ESP32-S3 BALANCE FC mount (30.5x30.5mm pattern)
 //   - Battery tray (24V 4Ah — ~180x70x50mm pack)
-//   - Jetson Nano B01 mount plate (100x80mm, M3 holes)
+//   - Jetson Orin Nano Super B01 mount plate (100x80mm, M3 holes)
 //   - Front/rear bumper brackets
 // =============================================================================
 
@@ -37,7 +37,7 @@ MOTOR_FORK_H       = 80;    // mm, total height of motor fork bracket
 MOTOR_FORK_T       = 8;     // mm, fork plate thickness
 AXLE_HEIGHT        = 310;   // mm, axle CL above ground (motor radius + clearance)
 
-// ── FC mount (MAMBA F722S — 30.5 × 30.5 mm M3 pattern) ──────────────────────
+// ── FC mount (ESP32-S3 BALANCE — 30.5 × 30.5 mm M3 pattern) ──────────────────────
 FC_MOUNT_SPACING   = 30.5;  // mm, hole pattern pitch
 FC_MOUNT_HOLE_D    = 3.2;   // mm, M3 clearance
 FC_STANDOFF_H      = 6;     // mm, standoff height
@@ -52,7 +52,7 @@ BATT_FLOOR         = 4;     // mm, tray floor thickness
 BATT_STRAP_W       = 20;    // mm, Velcro strap slot width
 BATT_STRAP_T       = 2;     // mm, strap slot depth
 
-// ── Jetson Nano B01 mount plate ──────────────────────────────────────────────
+// ── Jetson Orin Nano Super B01 mount plate ──────────────────────────────────────────────
 // B01 carrier board hole pattern: 58 x 58 mm M3 (inner) + corner pass-throughs
 JETSON_HOLE_PITCH  = 58;    // mm, M3 mounting hole pattern
 JETSON_HOLE_D      = 3.2;   // mm
@@ -210,7 +210,7 @@ module battery_tray() {
 
 // ─── FC mount holes helper ────────────────────────────────────────────────────
 module fc_mount_holes(z_offset=0, depth=10) {
-    // MAMBA F722S: 30.5×30.5 mm M3 pattern, centred at origin
+    // ESP32-S3 BALANCE: 30.5×30.5 mm M3 pattern, centred at origin
     for (x = [-FC_MOUNT_SPACING/2, FC_MOUNT_SPACING/2])
     for (y = [-FC_MOUNT_SPACING/2, FC_MOUNT_SPACING/2])
         translate([x, y, z_offset])
@@ -247,7 +247,7 @@ module fc_mount_plate() {
     }
 }
 
-// ─── Jetson Nano B01 mount plate ─────────────────────────────────────────────
+// ─── Jetson Orin Nano Super B01 mount plate ─────────────────────────────────────────────
 // Positioned rear of deck, elevated on standoffs
 module jetson_mount_plate() {
     jet_x =  60;   // offset toward rear

chassis/gimbal_camera_mount.scad

@@ -0,0 +1,599 @@
+// ============================================================
+// gimbal_camera_mount.scad — Pan/Tilt Gimbal Mount for RealSense D435i
+// Issue: #552  Agent: sl-mechanical  Date: 2026-03-14
+// ============================================================
+//
+// Parametric gimbal bracket system mounting an Intel RealSense D435i
+// (or similar box camera) on a 2-axis pan/tilt gimbal driven by
+// ST3215 serial bus servos (25T spline, Feetech/Waveshare).
+//
+// Architecture:
+//   Pan axis  — base T-nut clamps to 2020 rail; pan servo rotates yoke
+//   Tilt axis — tilt servo horn plate bolts to ST3215 horn; camera cradle
+//               rocks on tilt axis
+//   Camera    — D435i captured via 1/4-20 UNC hex nut in cradle floor
+//   Damping   — PETG flexure ribs on camera contact faces (or TPU pads)
+//   Wiring    — USB-C cable routed through channel in cradle arm
+//
+// Part catalogue:
+//   Part 1 — tnut_rail_base()       2020 rail T-nut base + pan servo seat
+//   Part 2 — pan_yoke()             U-yoke connecting pan servo to tilt axis
+//   Part 3 — tilt_horn_plate()      Plate bolting to ST3215 tilt servo horn
+//   Part 4 — camera_cradle()        D435i cradle with 1/4-20 captured nut
+//   Part 5 — vibe_pad()             PETG flexure vibration-damping pad (×2)
+//   Part 6 — assembly_preview()     Full assembly preview
+//
+// Hardware BOM (per gimbal):
+//   2× ST3215 serial bus servo (pan + tilt)
+//   2× servo horn (25T spline, ≥Ø36 mm, 4× M3 bolt holes on Ø24 mm BC)
+//   2× M3 × 8 mm SHCS          horn-to-plate bolts (×4 each horn = 8 total)
+//   1× M3 × 16 mm SHCS + nut   T-nut rail clamp thumbscrew
+//   1× 1/4-20 UNC × 8 mm SHCS  camera retention bolt (or existing tripod screw)
+//   1× 1/4-20 UNC hex nut       captured in cradle floor
+//   4× M3 × 12 mm SHCS          yoke-to-tilt-plate pivot axle bolts
+//   2× M3 × 25 mm SHCS          pan yoke attachment to servo body
+//   (optional) 2× vibe_pad printed in TPU 95A
+//
+// ST3215 servo interface (caliper-verified Feetech ST3215):
+//   Body footprint : 40.0 × 20.0 mm (W × D), 36.5 mm tall
+//   Shaft centre H : 28.5 mm from mounting face
+//   Shaft spline   : 25T, centre Ø5.8 mm, D-cut
+//   Mount holes    : 4× M3 on 32 × 10 mm rectangular pattern (18 mm offset)
+//   Horn bolt circle: Ø24 mm, 4× M3
+//   Horn OD        : ~36 mm
+//
+// D435i camera interface (caliper-verified):
+//   Body           : 90 × 25 × 25 mm (W × D × H)
+//   Tripod thread  : 1/4-20 UNC, centred bottom face, 9 mm from front
+//   USB-C connector: right rear, 8 × 5 mm opening, 4 mm from edge
+//
+// Parametric camera size (override to adapt to other cameras):
+//   CAM_W, CAM_D, CAM_H  — body envelope
+//   CAM_MOUNT_X           — tripod hole X offset from camera centre
+//   CAM_MOUNT_Y           — tripod hole Y offset from front face
+//
+// Coordinate convention:
+//   Camera looks in +Y direction (forward)
+//   Pan axis is Z (vertical); tilt axis is X (lateral)
+//   Rail runs along Z; T-nut base at Z=0
+//   All parts at assembly origin; translate for assembly_preview
+//
+// RENDER options:
+//   "assembly"            full assembly preview (default)
+//   "tnut_rail_base_stl"  Part 1
+//   "pan_yoke_stl"        Part 2
+//   "tilt_horn_plate_stl" Part 3
+//   "camera_cradle_stl"   Part 4
+//   "vibe_pad_stl"        Part 5
+//
+// Export commands:
+//   openscad gimbal_camera_mount.scad -D 'RENDER="tnut_rail_base_stl"'  -o gcm_tnut_base.stl
+//   openscad gimbal_camera_mount.scad -D 'RENDER="pan_yoke_stl"'        -o gcm_pan_yoke.stl
+//   openscad gimbal_camera_mount.scad -D 'RENDER="tilt_horn_plate_stl"' -o gcm_tilt_horn_plate.stl
+//   openscad gimbal_camera_mount.scad -D 'RENDER="camera_cradle_stl"'   -o gcm_camera_cradle.stl
+//   openscad gimbal_camera_mount.scad -D 'RENDER="vibe_pad_stl"'        -o gcm_vibe_pad.stl
+// ============================================================
+
+$fn = 64;
+e   = 0.01;   // epsilon for boolean clearance
+
+// ── Parametric camera envelope ────────────────────────────────────────────────
+// Override these for cameras other than D435i
+CAM_W          = 90.0;   // camera body width (X)
+CAM_D          = 25.0;   // camera body depth (Y)
+CAM_H          = 25.0;   // camera body height (Z)
+CAM_MOUNT_X    =  0.0;   // tripod hole X offset from camera body centre
+CAM_MOUNT_Y    =  9.0;   // tripod hole from front face (Y)  [D435i: 9 mm]
+CAM_USBC_X     = CAM_W/2 - 4;   // USB-C connector X (right side)
+CAM_USBC_Z     = CAM_H/2;       // USB-C connector Z (mid-height rear)
+CAM_USBC_W     =  9.0;   // USB-C opening width (X)
+CAM_USBC_H     =  5.0;   // USB-C opening height (Z)
+
+// ── Rail geometry (matches sensor_rail.scad / sensor_rail_brackets.scad) ─────
+RAIL_W         = 20.0;
+SLOT_OPEN      =  6.0;
+SLOT_INNER_W   = 10.2;
+SLOT_INNER_H   =  5.8;
+SLOT_NECK_H    =  3.2;
+
+// ── T-nut geometry (matches sensor_rail_brackets.scad) ───────────────────────
+TNUT_W         =  9.8;
+TNUT_H         =  5.5;
+TNUT_L         = 12.0;
+TNUT_M3_NUT_AF =  5.5;
+TNUT_M3_NUT_H  =  2.5;
+TNUT_BOLT_D    =  3.3;   // M3 clearance
+
+// ── T-nut base plate geometry ─────────────────────────────────────────────────
+BASE_W         = 44.0;   // wide enough for pan servo body (40 mm)
+BASE_H         = 40.0;   // height along rail (Z)
+BASE_T         = SLOT_NECK_H + 2.0;   // plate depth (Y), rail-face side
+
+// ── ST3215 servo geometry ─────────────────────────────────────────────────────
+SERVO_W        = 40.0;   // servo body width (X)
+SERVO_D        = 20.0;   // servo body depth (Y)
+SERVO_H        = 36.5;   // servo body height (Z)
+SERVO_SHAFT_Z  = 28.5;   // shaft centre height from mounting face
+SERVO_HOLE_X   = 16.0;   // mount hole half-span X (32 mm span)
+SERVO_HOLE_Y   =  5.0;   // mount hole half-span Y (10 mm span)
+SERVO_M3_D     =  3.3;   // M3 clearance
+
+// ── Servo horn geometry ───────────────────────────────────────────────────────
+HORN_OD        = 36.0;   // horn outer diameter
+HORN_SPLINE_D  =  5.9;   // 25T spline bore clearance (5.8 + 0.1)
+HORN_BC_D      = 24.0;   // bolt circle diameter (4× M3)
+HORN_BOLT_D    =  3.3;   // M3 clearance through horn plate
+HORN_PLATE_T   =  5.0;   // tilt horn plate thickness
+
+// ── Yoke geometry ─────────────────────────────────────────────────────────────
+YOKE_WALL_T    =  5.0;   // yoke arm wall thickness
+YOKE_ARM_H     = 50.0;   // yoke arm height (Z) — clears servo body + camera
+YOKE_INNER_W   = CAM_W + 8.0;  // yoke inner span (camera + pad clearance)
+YOKE_BASE_T    =  8.0;   // yoke base plate thickness
+
+// ── Tilt pivot ────────────────────────────────────────────────────────────────
+PIVOT_D        =  4.3;   // M4 pivot axle bore
+PIVOT_BOSS_D   = 10.0;   // boss OD around pivot bore
+PIVOT_BOSS_L   =  6.0;   // boss protrusion from yoke wall
+
+// ── Camera cradle geometry ────────────────────────────────────────────────────
+CRADLE_WALL_T  =  4.0;   // cradle side wall thickness
+CRADLE_FLOOR_T =  5.0;   // cradle floor thickness (holds 1/4-20 nut)
+CRADLE_LIP_T   =  3.0;   // front retaining lip thickness
+CRADLE_LIP_H   =  8.0;   // front lip height
+CABLE_CH_W     = 12.0;   // USB-C cable channel width
+CABLE_CH_H     =  8.0;   // USB-C cable channel height
+
+// ── 1/4-20 UNC tripod thread ──────────────────────────────────────────────────
+QTR20_D        =  6.6;   // 1/4-20 clearance bore
+QTR20_NUT_AF   = 11.1;   // 1/4-20 hex nut across-flats (standard)
+QTR20_NUT_H    =  5.5;   // 1/4-20 hex nut height
+
+// ── Vibration-damping pad geometry ────────────────────────────────────────────
+PAD_W          = CAM_W - 2*CRADLE_WALL_T - 2;
+PAD_H          = CAM_H + 4;
+PAD_T          =  2.5;   // pad body thickness
+RIB_H          =  1.5;   // flexure rib height
+RIB_W          =  1.2;   // rib width
+RIB_PITCH      =  5.0;   // rib pitch
+
+// ── Fastener sizes ────────────────────────────────────────────────────────────
+M3_D = 3.3;
+M4_D = 4.3;
+M3_NUT_AF = 5.5;
+M3_NUT_H  = 2.4;
+
+// ============================================================
+// RENDER DISPATCH
+// ============================================================
+RENDER = "assembly";
+
+if      (RENDER == "assembly")            assembly_preview();
+else if (RENDER == "tnut_rail_base_stl")  tnut_rail_base();
+else if (RENDER == "pan_yoke_stl")        pan_yoke();
+else if (RENDER == "tilt_horn_plate_stl") tilt_horn_plate();
+else if (RENDER == "camera_cradle_stl")   camera_cradle();
+else if (RENDER == "vibe_pad_stl")        vibe_pad();
+
+// ============================================================
+// ASSEMBLY PREVIEW
+// ============================================================
+module assembly_preview() {
+    asm_rail_z = 0;
+    // Rail section ghost (200 mm)
+    %color("Silver", 0.25)
+        translate([-RAIL_W/2, -RAIL_W/2, asm_rail_z])
+            cube([RAIL_W, RAIL_W, 200]);
+
+    // T-nut rail base
+    color("OliveDrab", 0.85)
+        translate([0, 0, asm_rail_z + 80])
+            tnut_rail_base();
+
+    // Pan servo ghost (sitting in base seat)
+    %color("DimGray", 0.4)
+        translate([-SERVO_W/2, BASE_T, asm_rail_z + 80 + (BASE_H - SERVO_H)/2])
+            cube([SERVO_W, SERVO_D, SERVO_H]);
+
+    // Pan yoke rising from servo shaft
+    color("SteelBlue", 0.85)
+        translate([0, BASE_T + SERVO_D, asm_rail_z + 80 + BASE_H/2])
+            pan_yoke();
+
+    // Tilt horn plate (tilt axis — left yoke wall)
+    color("DarkOrange", 0.85)
+        translate([-YOKE_INNER_W/2 - YOKE_WALL_T - HORN_PLATE_T,
+                   BASE_T + SERVO_D + YOKE_BASE_T,
+                   asm_rail_z + 80 + BASE_H/2 + YOKE_ARM_H/2])
+            rotate([0, 90, 0])
+                tilt_horn_plate();
+
+    // Camera cradle (centred in yoke)
+    color("DarkSlateGray", 0.85)
+        translate([0, BASE_T + SERVO_D + YOKE_BASE_T + CRADLE_FLOOR_T,
+                   asm_rail_z + 80 + BASE_H/2 + YOKE_ARM_H/2 - CAM_H/2])
+            camera_cradle();
+
+    // D435i ghost
+    %color("Black", 0.4)
+        translate([-CAM_W/2,
+                   BASE_T + SERVO_D + YOKE_BASE_T + CRADLE_FLOOR_T + PAD_T,
+                   asm_rail_z + 80 + Base_H_mid() - CAM_H/2])
+            cube([CAM_W, CAM_D, CAM_H]);
+
+    // Vibe pads (front + rear camera face)
+    color("DimGray", 0.80) {
+        translate([-CAM_W/2 + CRADLE_WALL_T + 1,
+                   Base_T + SERVO_D + YOKE_BASE_T + CRADLE_FLOOR_T,
+                   asm_rail_z + 80 + Base_H_mid() - PAD_H/2])
+            rotate([90, 0, 0])
+                vibe_pad();
+    }
+}
+
+// helper (avoids recomputing same expression)
+function Base_T() = BASE_T;
+function Base_H_mid() = BASE_H/2 + YOKE_ARM_H/2;
+
+// ============================================================
+// PART 1 — T-NUT RAIL BASE  (pan servo seat + rail clamp)
+// ============================================================
+// Mounts to 2020 rail via standard T-nut tongue.
+// Front face (+Y side) provides flat seat for pan ST3215 servo body.
+// Servo body recessed 1 mm into seat for positive lateral registration.
+// Pan servo shaft axis = Z (vertical) → pan rotation about Z.
+//
+// Print: PETG, 5 perims, 50 % gyroid. Orient face-plate down (flat).
+module tnut_rail_base() {
+    difference() {
+        union() {
+            // ── Face plate (against rail outer face, -Y side) ────────────
+            translate([-BASE_W/2, -BASE_T, 0])
+                cube([BASE_W, BASE_T, BASE_H]);
+
+            // ── T-nut neck (enters rail slot, +Y side of face plate) ─────
+            translate([-TNUT_W/2, 0, (BASE_H - TNUT_L)/2])
+                cube([TNUT_W, SLOT_NECK_H + e, TNUT_L]);
+
+            // ── T-nut inner body (wider, locks inside T-groove) ──────────
+            translate([-TNUT_W/2, SLOT_NECK_H - e, (BASE_H - TNUT_L)/2])
+                cube([TNUT_W, TNUT_H - SLOT_NECK_H + e, TNUT_L]);
+
+            // ── Pan servo seat boss (front face, +Y side) ────────────────
+            // Proud pad that servo body sits on; 1 mm registration recess
+            translate([-BASE_W/2, -BASE_T, 0])
+                cube([BASE_W, BASE_T + 6, BASE_H]);
+        }
+
+        // ── Rail clamp bolt bore (M3 through face plate) ─────────────────
+        translate([0, -BASE_T - e, BASE_H/2])
+            rotate([-90, 0, 0])
+                cylinder(d = TNUT_BOLT_D, h = BASE_T + TNUT_H + 2*e);
+
+        // ── M3 hex nut pocket (inside T-nut body) ────────────────────────
+        translate([0, SLOT_NECK_H + 0.3, BASE_H/2])
+            rotate([-90, 0, 0])
+                cylinder(d = TNUT_M3_NUT_AF / cos(30),
+                         h = TNUT_M3_NUT_H + 0.3, $fn = 6);
+
+        // ── Servo body recess (1 mm registration pocket in seat face) ────
+        translate([-SERVO_W/2 - 0.3, -BASE_T + 6 - 1.0,
+                   (BASE_H - SERVO_H)/2 - 0.3])
+            cube([SERVO_W + 0.6, 1.2, SERVO_H + 0.6]);
+
+        // ── Pan servo mount holes (4× M3 in rectangular pattern) ─────────
+        for (sx = [-SERVO_HOLE_X, SERVO_HOLE_X])
+        for (sy = [-SERVO_HOLE_Y, SERVO_HOLE_Y])
+            translate([sx, -BASE_T + 6 + e, BASE_H/2 + sy])
+                rotate([90, 0, 0])
+                    cylinder(d = SERVO_M3_D, h = BASE_T + 2*e);
+
+        // ── Pan servo shaft bore (passes shaft through base if needed) ────
+        // Centre of shaft at Z = BASE_H/2, no bore needed (shaft exits top)
+
+        // ── Lightening pockets ────────────────────────────────────────────
+        translate([0, -BASE_T/2 + 3, BASE_H/2])
+            cube([BASE_W - 14, BASE_T - 4, BASE_H - 14], center = true);
+    }
+}
+
+// ============================================================
+// PART 2 — PAN YOKE
+// ============================================================
+// U-shaped yoke that attaches to pan servo horn (below) and carries
+// the tilt axis (above).  Two vertical arms straddle the camera cradle.
+// Tilt servo sits on top of one arm; tilt pivot boss on the other.
+//
+// Yoke base bolts to pan servo horn (4× M3 on HORN_BC_D bolt circle).
+// Pan servo horn spline bore passes through yoke base centre.
+// Tilt axis: M4 pivot axle through boss on each arm (X-axis rotation).
+//
+// Print: upright (yoke in final orientation), PETG, 5 perims, 40% gyroid.
+module pan_yoke() {
+    arm_z_total = YOKE_ARM_H + YOKE_BASE_T;
+    inner_w     = YOKE_INNER_W;
+
+    difference() {
+        union() {
+            // ── Yoke base plate (bolts to pan servo horn) ─────────────────
+            translate([-inner_w/2 - YOKE_WALL_T, 0, 0])
+                cube([inner_w + 2*YOKE_WALL_T, YOKE_BASE_T, YOKE_BASE_T]);
+
+            // ── Left arm ──────────────────────────────────────────────────
+            translate([-inner_w/2 - YOKE_WALL_T, 0, 0])
+                cube([YOKE_WALL_T, YOKE_BASE_T, arm_z_total]);
+
+            // ── Right arm (tilt servo side) ───────────────────────────────
+            translate([inner_w/2, 0, 0])
+                cube([YOKE_WALL_T, YOKE_BASE_T, arm_z_total]);
+
+            // ── Tilt pivot bosses (both arms, X-axis) ─────────────────────
+            // Left pivot boss (plain pivot — M4 bolt)
+            translate([-inner_w/2 - YOKE_WALL_T - PIVOT_BOSS_L,
+                       YOKE_BASE_T/2,
+                       YOKE_BASE_T + YOKE_ARM_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d = PIVOT_BOSS_D, h = PIVOT_BOSS_L + YOKE_WALL_T);
+
+            // Right pivot boss (tilt servo horn seat)
+            translate([inner_w/2,
+                       YOKE_BASE_T/2,
+                       YOKE_BASE_T + YOKE_ARM_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d = PIVOT_BOSS_D + 4, h = PIVOT_BOSS_L + YOKE_WALL_T);
+
+            // ── Tilt servo body seat on right arm top ─────────────────────
+            translate([inner_w/2, 0, arm_z_total - SERVO_H - 4])
+                cube([YOKE_WALL_T + SERVO_D + 2, YOKE_BASE_T, SERVO_H + 4]);
+        }
+
+        // ── Pan horn spline bore (centre of yoke base) ────────────────────
+        translate([0, YOKE_BASE_T/2, YOKE_BASE_T/2])
+            rotate([90, 0, 0])
+                cylinder(d = HORN_SPLINE_D, h = YOKE_BASE_T + 2*e,
+                         center = true);
+
+        // ── Pan horn bolt holes (4× M3 on HORN_BC_D) ─────────────────────
+        for (a = [45, 135, 225, 315])
+            translate([HORN_BC_D/2 * cos(a),
+                       YOKE_BASE_T/2,
+                       HORN_BC_D/2 * sin(a) + YOKE_BASE_T/2])
+                rotate([90, 0, 0])
+                    cylinder(d = HORN_BOLT_D, h = YOKE_BASE_T + 2*e,
+                             center = true);
+
+        // ── Left tilt pivot bore (M4 clearance) ───────────────────────────
+        translate([-inner_w/2 - YOKE_WALL_T - PIVOT_BOSS_L - e,
+                   YOKE_BASE_T/2,
+                   YOKE_BASE_T + YOKE_ARM_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = PIVOT_D, h = PIVOT_BOSS_L + YOKE_WALL_T + 2*e);
+
+        // ── Right tilt pivot bore (larger — tilt horn plate seats here) ───
+        translate([inner_w/2 - e,
+                   YOKE_BASE_T/2,
+                   YOKE_BASE_T + YOKE_ARM_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = HORN_SPLINE_D,
+                         h = PIVOT_BOSS_L + YOKE_WALL_T + 2*e);
+
+        // ── Tilt servo mount holes in right arm seat ──────────────────────
+        for (sz = [-SERVO_HOLE_Y, SERVO_HOLE_Y])
+            translate([inner_w/2 + YOKE_WALL_T + SERVO_D/2,
+                       YOKE_BASE_T/2,
+                       arm_z_total - SERVO_H/2 + sz])
+                rotate([90, 0, 0])
+                    cylinder(d = SERVO_M3_D, h = YOKE_BASE_T + 2*e,
+                             center = true);
+
+        // ── M3 nut pockets (tilt servo mount, rear of arm seat) ──────────
+        for (sz = [-SERVO_HOLE_Y, SERVO_HOLE_Y])
+            translate([inner_w/2 + YOKE_WALL_T + SERVO_D/2,
+                       YOKE_BASE_T - M3_NUT_H - 0.5,
+                       arm_z_total - SERVO_H/2 + sz])
+                rotate([90, 0, 0])
+                    cylinder(d = M3_NUT_AF / cos(30), h = M3_NUT_H + 0.5,
+                             $fn = 6);
+
+        // ── Lightening slots in yoke arms ─────────────────────────────────
+        translate([-inner_w/2 - YOKE_WALL_T/2,
+                   YOKE_BASE_T/2,
+                   YOKE_BASE_T + YOKE_ARM_H/2 - 10])
+            cube([YOKE_WALL_T - 2, YOKE_BASE_T - 2, YOKE_ARM_H - 24],
+                 center = true);
+        translate([inner_w/2 + YOKE_WALL_T/2,
+                   YOKE_BASE_T/2,
+                   YOKE_BASE_T + YOKE_ARM_H/2 - 10])
+            cube([YOKE_WALL_T - 2, YOKE_BASE_T - 2, YOKE_ARM_H - 30],
+                 center = true);
+    }
+}
+
+// ============================================================
+// PART 3 — TILT HORN PLATE
+// ============================================================
+// Disc plate bolting to tilt ST3215 servo horn on the right yoke arm.
+// Servo horn spline centres into disc bore (captured, no free rotation).
+// Camera cradle attaches to opposite face via 2× M3 bolts.
+//
+// Tilt range: ±45° limited by yoke arm geometry.
+// Plate thickness HORN_PLATE_T provides stiffness for cantilevered cradle.
+//
+// Print: flat (disc face down), PETG, 5 perims, 50 % infill.
+module tilt_horn_plate() {
+    plate_od = HORN_OD + 8;   // plate OD (4 mm rim outside horn BC)
+
+    difference() {
+        union() {
+            // ── Main disc ─────────────────────────────────────────────────
+            cylinder(d = plate_od, h = HORN_PLATE_T);
+
+            // ── Cradle attachment arm (extends to camera cradle) ──────────
+            // Rectangular boss on top of disc toward camera
+            translate([-CAM_W/2, HORN_PLATE_T - e, -CAM_H/2])
+                cube([CAM_W, HORN_PLATE_T + 4, CAM_H]);
+        }
+
+        // ── Servo horn spline bore (centre) ───────────────────────────────
+        translate([0, 0, -e])
+            cylinder(d = HORN_SPLINE_D, h = HORN_PLATE_T + 2*e);
+
+        // ── Horn bolt holes (4× M3 on HORN_BC_D) ─────────────────────────
+        for (a = [45, 135, 225, 315])
+            translate([HORN_BC_D/2 * cos(a),
+                       HORN_BC_D/2 * sin(a), -e])
+                cylinder(d = HORN_BOLT_D, h = HORN_PLATE_T + 2*e);
+
+        // ── Pivot axle bore (M4, coaxial with horn centre) ────────────────
+        translate([0, 0, -e])
+            cylinder(d = PIVOT_D, h = HORN_PLATE_T + 2*e);
+
+        // ── Cradle attachment bolts (2× M3 in arm boss) ──────────────────
+        for (cz = [-CAM_H/2 + 6, CAM_H/2 - 6])
+            translate([0, HORN_PLATE_T + 2, cz])
+                rotate([90, 0, 0])
+                    cylinder(d = M3_D, h = HORN_PLATE_T + 6 + 2*e);
+
+        // ── M3 hex nut pockets (rear of disc face) ────────────────────────
+        for (cz = [-CAM_H/2 + 6, CAM_H/2 - 6])
+            translate([0, M3_NUT_H + 0.5, cz])
+                rotate([90, 0, 0])
+                    cylinder(d = M3_NUT_AF / cos(30),
+                             h = M3_NUT_H + 0.5, $fn = 6);
+
+        // ── Weight-relief arcs (between horn bolt holes) ──────────────────
+        for (a = [0, 90, 180, 270])
+            translate([(plate_od/2 - 5) * cos(a),
+                       (plate_od/2 - 5) * sin(a), -e])
+                cylinder(d = 6, h = HORN_PLATE_T + 2*e);
+    }
+}
+
+// ============================================================
+// PART 4 — CAMERA CRADLE
+// ============================================================
+// Open-front U-cradle holding D435i via captured 1/4-20 hex nut.
+// Front lip retains camera from sliding forward (+Y).
+// Vibration-damping pads seat in recessed pockets on inner faces.
+// USB-C cable routing channel exits cradle right rear wall.
+//
+// 1/4-20 captured nut in cradle floor — tighten with standard
+// tripod screw or M6→1/4-20 adapter from camera bottom.
+//
+// Print: cradle-floor-down (flat), PETG, 5 perims, 40 % gyroid.
+// No supports needed (overhangs < 45°).
+module camera_cradle() {
+    outer_w = CAM_W + 2*CRADLE_WALL_T;
+    outer_h = CAM_H + CRADLE_FLOOR_T;
+
+    difference() {
+        union() {
+            // ── Cradle body ───────────────────────────────────────────────
+            translate([-outer_w/2, 0, 0])
+                cube([outer_w, CAM_D + CRADLE_WALL_T, outer_h]);
+
+            // ── Front retaining lip ───────────────────────────────────────
+            translate([-outer_w/2, CAM_D + CRADLE_WALL_T - CRADLE_LIP_T, 0])
+                cube([outer_w, CRADLE_LIP_T, CRADLE_LIP_H]);
+
+            // ── Cable channel boss (right rear, exits +X side) ────────────
+            translate([CAM_W/2 + CRADLE_WALL_T - e,
+                       0,
+                       CRADLE_FLOOR_T + CAM_H/2 - CABLE_CH_H/2])
+                cube([CABLE_CH_W + CRADLE_WALL_T, CAM_D * 0.6, CABLE_CH_H]);
+
+            // ── Tilt horn attachment tabs (left + right, bolt to horn plate)─
+            for (sx = [-outer_w/2 - 4, outer_w/2])
+                translate([sx, CAM_D/2, CRADLE_FLOOR_T + CAM_H/2 - 6])
+                    cube([4, 12, 12]);
+        }
+
+        // ── Camera pocket (hollow interior) ──────────────────────────────
+        translate([-CAM_W/2, 0, CRADLE_FLOOR_T])
+            cube([CAM_W, CAM_D + CRADLE_WALL_T + e, CAM_H + e]);
+
+        // ── 1/4-20 UNC clearance bore (camera tripod thread, bottom) ─────
+        translate([CAM_MOUNT_X, CAM_MOUNT_Y, -e])
+            cylinder(d = QTR20_D, h = CRADLE_FLOOR_T + 2*e);
+
+        // ── 1/4-20 hex nut pocket (captured in cradle floor) ─────────────
+        translate([CAM_MOUNT_X, CAM_MOUNT_Y, CRADLE_FLOOR_T - QTR20_NUT_H - 0.5])
+            cylinder(d = QTR20_NUT_AF / cos(30),
+                     h = QTR20_NUT_H + 0.6, $fn = 6);
+
+        // ── USB-C cable channel (exit through right rear wall) ────────────
+        translate([CAM_W/2 - e,
+                   0,
+                   CRADLE_FLOOR_T + CAM_H/2 - CABLE_CH_H/2])
+            cube([CABLE_CH_W + CRADLE_WALL_T + 2*e,
+                  CAM_D * 0.6 + e, CABLE_CH_H]);
+
+        // ── Vibe pad recesses on inner camera-contact faces ───────────────
+        // Rear wall recess (camera front face → +Y side of rear wall)
+        translate([-CAM_W/2 + CRADLE_WALL_T, CRADLE_WALL_T, CRADLE_FLOOR_T])
+            cube([CAM_W, PAD_T, CAM_H]);
+
+        // ── Tilt horn bolt holes in attachment tabs ───────────────────────
+        for (sx = [-outer_w/2 - 4 - e, outer_w/2 - e])
+            translate([sx, CAM_D/2 + 6, CRADLE_FLOOR_T + CAM_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d = M3_D, h = 6 + 2*e);
+
+        // ── M3 nut pockets in attachment tabs ─────────────────────────────
+        translate([outer_w/2 + 4 - M3_NUT_H - 0.4,
+                   CAM_D/2 + 6,
+                   CRADLE_FLOOR_T + CAM_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = M3_NUT_AF / cos(30),
+                         h = M3_NUT_H + 0.4, $fn = 6);
+        translate([-outer_w/2 - 4 - e,
+                   CAM_D/2 + 6,
+                   CRADLE_FLOOR_T + CAM_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = M3_NUT_AF / cos(30),
+                         h = M3_NUT_H + 0.4, $fn = 6);
+
+        // ── Lightening pockets in cradle walls ────────────────────────────
+        for (face_x = [-CAM_W/2 - CRADLE_WALL_T - e, CAM_W/2 - e])
+            translate([face_x, CAM_D * 0.2, CRADLE_FLOOR_T + 3])
+                cube([CRADLE_WALL_T + 2*e, CAM_D * 0.55, CAM_H - 6]);
+    }
+}
+
+// ============================================================
+// PART 5 — VIBRATION-DAMPING PAD
+// ============================================================
+// Flat pad with transverse PETG flexure ribs pressing against camera body.
+// Rib geometry (thin fins ~1.5 mm tall) deflects under camera vibration,
+// attenuating high-frequency input from motor/drive-train.
+// For superior damping: print in TPU 95A (no infill changes needed).
+// Pads seat in recessed pockets in camera cradle inner wall.
+// Optional M2 bolt-through at corners or adhesive-back foam tape.
+//
+// Print: pad-back-face-down, PETG or TPU 95A, 3 perims, 20 % infill.
+module vibe_pad() {
+    rib_count = floor((PAD_W - RIB_W) / RIB_PITCH);
+
+    union() {
+        // ── Base plate ────────────────────────────────────────────────────
+        translate([-PAD_W/2, -PAD_T, -PAD_H/2])
+            cube([PAD_W, PAD_T, PAD_H]);
+
+        // ── Flexure ribs (parallel to Z, spaced RIB_PITCH apart) ─────────
+        for (i = [0 : rib_count - 1]) {
+            rx = -PAD_W/2 + RIB_PITCH/2 + i * RIB_PITCH + RIB_W/2;
+            if (rx <= PAD_W/2 - RIB_W/2)
+                translate([rx, 0, 0])
+                    cube([RIB_W, RIB_H, PAD_H - 6], center = true);
+        }
+
+        // ── Corner nubs (M2 bolt-through retention, optional) ─────────────
+        for (px = [-PAD_W/2 + 5, PAD_W/2 - 5])
+        for (pz = [-PAD_H/2 + 5, PAD_H/2 - 5])
+            translate([px, -PAD_T/2, pz])
+                difference() {
+                    cylinder(d = 5, h = PAD_T, center = true);
+                    cylinder(d = 2.4, h = PAD_T + 2*e, center = true);
+                }
+    }
+}

chassis/ip54_BOM.md

@@ -104,7 +104,11 @@ IP54-rated enclosures and sensor housings for all-weather outdoor robot operatio
 | Component | Thermal strategy | Max junction | Enclosure budget |
 |-----------|-----------------|-------------|-----------------|
 | Jetson Orin NX | Al pad → lid → fan forced convection | 95 °C Tj | Target ≤ 60 °C case |
-| FC (MAMBA F722S) | Passive; FC has own EMI shield | 85 °C | <60 °C ambient OK |
+<<<<<<< HEAD
+| FC (ESP32 BALANCE) | Passive; FC has own EMI shield | 85 °C | <60 °C ambient OK |
+=======
+| FC (ESP32-S3 BALANCE) | Passive; FC has own EMI shield | 85 °C | <60 °C ambient OK |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | ESC × 2 | Al pad → lid | 100 °C Tj | Target ≤ 60 °C |
 | D435i | Passive; housing vent gap on rear cap | 45 °C surface | — |
 

chassis/jetson_orin_mount.scad

@@ -0,0 +1,386 @@
+// ============================================================
+// Jetson Orin Nano Carrier Board Mount — Issue #612
+// Agent   : sl-mechanical
+// Date    : 2026-03-15
+// Part catalogue:
+//   1. tnut_base     — 2020 T-slot rail interface plate, M5 T-nut captive pockets
+//   2. standoff_post — M2.5 captive-nut standoff post (×4), 10 mm airflow gap
+//   3. side_brace    — lateral stiffening brace with port-access cutouts (×2)
+//   4. duct_shroud   — optional top heatsink duct / fan-exhaust channel
+//   5. cable_clip    — snap-on cable management clip for brace edge
+//
+// BOM:
+//   4 × M5×10 BHCS + M5 T-nuts          (tnut_base to rail, 2 per rail)
+//   4 × M2.5×20 SHCS                    (board to standoff posts)
+//   4 × M2.5 hex nuts                   (captured in standoff posts)
+//   4 × M3×8  SHCS + washers            (side_brace to tnut_base)
+//   2 × M3×16 SHCS                      (duct_shroud to side_brace tops)
+//
+// Jetson Orin Nano carrier board (Seeed reComputer / official dev kit):
+//   Board dims   : 100 × 80 mm
+//   Mounting hole pattern : 86 × 58 mm (centre-to-centre), M2.5, Ø3.5 pad
+//   PCB thickness: 1.6 mm
+//   Connector side: -Y (USB-A, USB-C, HDMI, DP, GbE, SD on one long edge)
+//   Fan header & PWM header: +X short edge
+//   M.2 / NVMe: bottom face
+//
+// Print settings (PETG):
+//   tnut_base / standoff_post / side_brace / duct_shroud : 5 perimeters, 40 % gyroid, no supports
+//   cable_clip                                            : 3 perimeters, 30 % gyroid, no supports
+//
+// Export commands:
+//   openscad -D 'RENDER="tnut_base"'     -o tnut_base.stl     jetson_orin_mount.scad
+//   openscad -D 'RENDER="standoff_post"' -o standoff_post.stl jetson_orin_mount.scad
+//   openscad -D 'RENDER="side_brace"'    -o side_brace.stl    jetson_orin_mount.scad
+//   openscad -D 'RENDER="duct_shroud"'   -o duct_shroud.stl   jetson_orin_mount.scad
+//   openscad -D 'RENDER="cable_clip"'    -o cable_clip.stl    jetson_orin_mount.scad
+//   openscad -D 'RENDER="assembly"'      -o assembly.png      jetson_orin_mount.scad
+// ============================================================
+
+// ── Render selector ─────────────────────────────────────────
+RENDER = "assembly"; // tnut_base | standoff_post | side_brace | duct_shroud | cable_clip | assembly
+
+// ── Global constants ────────────────────────────────────────
+$fn = 64;
+EPS = 0.01;
+
+// 2020 rail
+RAIL_W      = 20.0;
+SLOT_NECK_H =  3.2;
+TNUT_W      =  9.8;
+TNUT_H      =  5.5;
+TNUT_L      = 12.0;
+M5_D        =  5.2;
+M5_HEAD_D   =  9.5;
+M5_HEAD_H   =  4.0;
+
+// Jetson Orin Nano carrier board
+BOARD_L     = 100.0;  // board X
+BOARD_W     =  80.0;  // board Y
+BOARD_T     =   1.6;  // PCB thickness
+MH_SX       =  86.0;  // mounting hole span X (centre-to-centre)
+MH_SY       =  58.0;  // mounting hole span Y
+M25_D       =   2.7;  // M2.5 clearance bore
+M25_NUT_W   =   5.0;  // M2.5 hex nut across-flats
+M25_NUT_H   =   2.0;  // M2.5 hex nut height
+M25_HEAD_D  =   5.0;  // M2.5 SHCS head diameter
+M25_HEAD_H  =   2.5;
+
+// Base plate
+BASE_L      = 120.0;  // length along X (covers board + overhang for braces)
+BASE_W      =  50.0;  // width along Y (rail mount footprint)
+BASE_T      =   6.0;  // plate thickness
+BOLT_PITCH  =  40.0;  // M5 rail bolt pitch (per rail, 2 rails at Y=0 & Y=BASE_W)
+M3_D        =   3.2;
+M3_HEAD_D   =   6.0;
+M3_HEAD_H   =   3.0;
+
+// Standoff posts
+POST_H      =  12.0;  // airflow gap + PCB seating (>= 10 mm clearance spec)
+POST_OD     =   8.0;  // outer diameter
+POST_BASE_D =  11.0;  // flange diameter
+POST_BASE_H =   3.0;  // flange height
+NUT_TRAP_H  = M25_NUT_H + 0.3;
+NUT_TRAP_W  = M25_NUT_W + 0.4;
+
+// Side braces
+BRACE_T     =   5.0;  // brace thickness (X)
+BRACE_H     = POST_H + POST_BASE_H + BOARD_T + 4.0;  // full height
+BRACE_W     = BASE_W;  // same width as base
+
+// Port-access cutouts (connector side -Y)
+USB_CUT_W   =  60.0;  // wide cutout for USB-A stack + HDMI + DP
+USB_CUT_H   =  22.0;
+GBE_CUT_W   =  20.0;  // GbE jack
+GBE_CUT_H   =  18.0;
+
+// Duct shroud
+DUCT_T      =   3.0;  // wall thickness
+DUCT_FLANGE =   6.0;  // side tab width for M3 attachment
+FAN_W       =  40.0;  // standard 40 mm blower clearance cutout
+FAN_H       =  10.0;  // duct outlet height
+
+// Cable clip
+CLIP_OD     =  12.0;
+CLIP_ID     =   7.0;
+CLIP_GAP    =   7.5;
+CLIP_W      =  10.0;
+SNAP_T      =   1.8;
+
+// ── Utilities ───────────────────────────────────────────────
+module chamfer_cube(size, ch=1.0) {
+    hull() {
+        translate([ch, ch, 0])          cube([size[0]-2*ch, size[1]-2*ch, EPS]);
+        translate([0, 0, ch])           cube(size - [0, 0, ch]);
+    }
+}
+
+module hex_pocket(af, depth) {
+    cylinder(d=af/cos(30), h=depth, $fn=6);
+}
+
+// ── Part 1: tnut_base ───────────────────────────────────────
+module tnut_base() {
+    difference() {
+        union() {
+            chamfer_cube([BASE_L, BASE_W, BASE_T], ch=1.5);
+
+            // Raised mounting bosses for M3 brace attachment (4 corners)
+            for (x = [8, BASE_L-8])
+                for (y = [8, BASE_W-8])
+                    translate([x, y, BASE_T])
+                        cylinder(d=10, h=2.5);
+        }
+
+        // T-nut pockets and M5 bolts — front rail (y = BASE_W/4)
+        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2]) {
+            translate([x, BASE_W/4, -EPS]) {
+                cylinder(d=M5_D, h=BASE_T + 2*EPS);
+                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
+            }
+            translate([x - TNUT_L/2, BASE_W/4 - TNUT_W/2, BASE_T - TNUT_H])
+                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
+        }
+
+        // T-nut pockets and M5 bolts — rear rail (y = 3*BASE_W/4)
+        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2]) {
+            translate([x, 3*BASE_W/4, -EPS]) {
+                cylinder(d=M5_D, h=BASE_T + 2*EPS);
+                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
+            }
+            translate([x - TNUT_L/2, 3*BASE_W/4 - TNUT_W/2, BASE_T - TNUT_H])
+                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
+        }
+
+        // M3 boss bolt holes (corner braces)
+        for (x = [8, BASE_L-8])
+            for (y = [8, BASE_W-8])
+                translate([x, y, -EPS])
+                    cylinder(d=M3_D, h=BASE_T + 2.5 + 2*EPS);
+
+        // M3 boss counterbores (head from bottom)
+        for (x = [8, BASE_L-8])
+            for (y = [8, BASE_W-8])
+                translate([x, y, -EPS])
+                    cylinder(d=M3_HEAD_D, h=M3_HEAD_H + EPS);
+
+        // Standoff post seating holes (board hole pattern, centred on plate)
+        bx0 = BASE_L/2 - MH_SX/2;
+        by0 = BASE_W/2 - MH_SY/2;
+        for (dx = [0, MH_SX])
+            for (dy = [0, MH_SY])
+                translate([bx0+dx, by0+dy, -EPS])
+                    cylinder(d=POST_BASE_D + 0.4, h=BASE_T + 2*EPS);
+
+        // Weight relief grid (2 pockets)
+        translate([20, 12, -EPS]) cube([30, BASE_W-24, BASE_T/2]);
+        translate([BASE_L-50, 12, -EPS]) cube([30, BASE_W-24, BASE_T/2]);
+
+        // Cable pass-through slot
+        translate([BASE_L/2 - 8, BASE_W/2 - 3, -EPS])
+            cube([16, 6, BASE_T + 2*EPS]);
+    }
+}
+
+// ── Part 2: standoff_post ───────────────────────────────────
+module standoff_post() {
+    difference() {
+        union() {
+            // Flange
+            cylinder(d=POST_BASE_D, h=POST_BASE_H);
+            // Post body
+            translate([0, 0, POST_BASE_H])
+                cylinder(d=POST_OD, h=POST_H);
+        }
+
+        // M2.5 through bore
+        translate([0, 0, -EPS])
+            cylinder(d=M25_D, h=POST_BASE_H + POST_H + 2*EPS);
+
+        // Captured hex nut trap (from top)
+        translate([0, 0, POST_BASE_H + POST_H - NUT_TRAP_H])
+            hex_pocket(NUT_TRAP_W, NUT_TRAP_H + EPS);
+
+        // Anti-rotation flat on nut pocket
+        translate([-M25_NUT_W/2 - 0.2, -POST_OD/2 - EPS,
+                   POST_BASE_H + POST_H - NUT_TRAP_H])
+            cube([M25_NUT_W + 0.4, 2.0, NUT_TRAP_H + EPS]);
+    }
+}
+
+// ── Part 3: side_brace ──────────────────────────────────────
+// Printed as +X face. Mirror for -X side.
+module side_brace() {
+    difference() {
+        union() {
+            chamfer_cube([BRACE_T, BRACE_W, BRACE_H], ch=1.0);
+
+            // Top lip to retain board edge
+            translate([0, 0, BRACE_H])
+                cube([BRACE_T + 8.0, BRACE_W, 2.5]);
+        }
+
+        // M3 bolt holes at base (attach to tnut_base bosses)
+        for (y = [8, BRACE_W-8])
+            translate([-EPS, y, 4])
+                rotate([0, 90, 0])
+                    cylinder(d=M3_D, h=BRACE_T + 2*EPS);
+
+        // M3 counterbore from outer face
+        for (y = [8, BRACE_W-8])
+            translate([-EPS, y, 4])
+                rotate([0, 90, 0])
+                    cylinder(d=M3_HEAD_D, h=M3_HEAD_H + EPS);
+
+        // Port-access cutout — USB/HDMI/DP cluster (centred on brace face)
+        translate([-EPS, BRACE_W/2 - USB_CUT_W/2, POST_BASE_H + 2.0])
+            cube([BRACE_T + 2*EPS, USB_CUT_W, USB_CUT_H]);
+
+        // GbE cutout (offset toward +Y)
+        translate([-EPS, BRACE_W/2 + USB_CUT_W/2 - GBE_CUT_W - 2, POST_BASE_H + 2.0])
+            cube([BRACE_T + 2*EPS, GBE_CUT_W, GBE_CUT_H]);
+
+        // M3 duct attachment holes (top edge)
+        for (y = [BRACE_W/4, 3*BRACE_W/4])
+            translate([BRACE_T/2, y, BRACE_H - 2])
+                cylinder(d=M3_D, h=10);
+
+        // Ventilation slots (3 tall slots for airflow)
+        for (i = [0:2])
+            translate([-EPS,
+                       (BRACE_W - 3*8 - 2*4) / 2 + i*(8+4),
+                       POST_BASE_H + USB_CUT_H + 6])
+                cube([BRACE_T + 2*EPS, 8, BRACE_H - POST_BASE_H - USB_CUT_H - 10]);
+    }
+}
+
+// ── Part 4: duct_shroud ─────────────────────────────────────
+// Top cap that channels fan exhaust away from board; optional print.
+module duct_shroud() {
+    duct_l = BASE_L - 2*BRACE_T - 1.0;  // span between inner brace faces
+    duct_w = BRACE_W;
+
+    difference() {
+        union() {
+            // Top plate
+            cube([duct_l, duct_w, DUCT_T]);
+
+            // Front wall (fan inlet side)
+            translate([0, 0, -FAN_H])
+                cube([DUCT_T, duct_w, FAN_H + DUCT_T]);
+
+            // Rear wall (exhaust side — open centre)
+            translate([duct_l - DUCT_T, 0, -FAN_H])
+                cube([DUCT_T, duct_w, FAN_H + DUCT_T]);
+
+            // Side flanges for M3 attachment
+            translate([-DUCT_FLANGE, 0, -FAN_H])
+                cube([DUCT_FLANGE, duct_w, FAN_H + DUCT_T]);
+            translate([duct_l, 0, -FAN_H])
+                cube([DUCT_FLANGE, duct_w, FAN_H + DUCT_T]);
+        }
+
+        // Fan cutout on top plate (centred)
+        translate([duct_l/2 - FAN_W/2, duct_w/2 - FAN_W/2, -EPS])
+            cube([FAN_W, FAN_W, DUCT_T + 2*EPS]);
+
+        // Fan screw holes (40 mm fan, Ø3.2 at 32 mm BC)
+        for (dx = [-16, 16])
+            for (dy = [-16, 16])
+                translate([duct_l/2 + dx, duct_w/2 + dy, -EPS])
+                    cylinder(d=M3_D, h=DUCT_T + 2*EPS);
+
+        // Exhaust slot on rear wall (full width minus corners)
+        translate([duct_l - DUCT_T - EPS, 4, -FAN_H + 2])
+            cube([DUCT_T + 2*EPS, duct_w - 8, FAN_H - 2]);
+
+        // M3 flange attachment holes
+        for (y = [duct_w/4, 3*duct_w/4]) {
+            translate([-DUCT_FLANGE - EPS, y, -FAN_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d=M3_D, h=DUCT_FLANGE + 2*EPS);
+            translate([duct_l + DUCT_T - EPS, y, -FAN_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d=M3_D, h=DUCT_FLANGE + 2*EPS);
+        }
+    }
+}
+
+// ── Part 5: cable_clip ──────────────────────────────────────
+module cable_clip() {
+    difference() {
+        union() {
+            // Snap-wrap body
+            difference() {
+                cylinder(d=CLIP_OD + 2*SNAP_T, h=CLIP_W);
+                translate([0, 0, -EPS])
+                    cylinder(d=CLIP_ID, h=CLIP_W + 2*EPS);
+                // Front gap
+                translate([-CLIP_GAP/2, 0, -EPS])
+                    cube([CLIP_GAP, CLIP_OD, CLIP_W + 2*EPS]);
+            }
+
+            // Mounting tab for brace edge
+            translate([CLIP_OD/2 + SNAP_T - EPS, -SNAP_T, 0])
+                cube([8, SNAP_T*2, CLIP_W]);
+        }
+
+        // Tab screw hole
+        translate([CLIP_OD/2 + SNAP_T + 4, 0, CLIP_W/2])
+            rotate([90, 0, 0])
+                cylinder(d=M3_D, h=SNAP_T*2 + 2*EPS, center=true);
+    }
+}
+
+// ── Assembly ────────────────────────────────────────────────
+module assembly() {
+    // Base plate
+    color("SteelBlue")
+        tnut_base();
+
+    // Standoff posts (board hole pattern)
+    bx0 = BASE_L/2 - MH_SX/2;
+    by0 = BASE_W/2 - MH_SY/2;
+    for (dx = [0, MH_SX])
+        for (dy = [0, MH_SY])
+            color("DodgerBlue")
+                translate([bx0+dx, by0+dy, BASE_T])
+                    standoff_post();
+
+    // Side braces (left and right)
+    color("CornflowerBlue")
+        translate([0, 0, BASE_T])
+            side_brace();
+    color("CornflowerBlue")
+        translate([BASE_L, BRACE_W, BASE_T])
+            mirror([1, 0, 0])
+                mirror([0, 1, 0])
+                    side_brace();
+
+    // Board silhouette (translucent, for clearance visualisation)
+    color("ForestGreen", 0.25)
+        translate([BASE_L/2 - BOARD_L/2, BASE_W/2 - BOARD_W/2,
+                   BASE_T + POST_BASE_H + POST_H])
+            cube([BOARD_L, BOARD_W, BOARD_T]);
+
+    // Duct shroud (above board)
+    color("LightSteelBlue", 0.7)
+        translate([BRACE_T + 0.5, 0,
+                   BASE_T + POST_BASE_H + POST_H + BOARD_T + 2.0])
+            duct_shroud();
+
+    // Cable clips (on brace edge, 2×)
+    for (y = [BRACE_W/3, 2*BRACE_W/3])
+        color("SlateGray")
+            translate([BASE_L + 2, y, BASE_T + BRACE_H/2 - CLIP_W/2])
+                rotate([0, 90, 0])
+                    cable_clip();
+}
+
+// ── Dispatch ────────────────────────────────────────────────
+if      (RENDER == "tnut_base")     tnut_base();
+else if (RENDER == "standoff_post") standoff_post();
+else if (RENDER == "side_brace")    side_brace();
+else if (RENDER == "duct_shroud")   duct_shroud();
+else if (RENDER == "cable_clip")    cable_clip();
+else                                assembly();

chassis/phone_mount_bracket.scad

@@ -0,0 +1,504 @@
+// ============================================================
+// phone_mount_bracket.scad — Spring-Loaded Phone Mount for T-Slot Rail
+// Issue: #535  Agent: sl-mechanical  Date: 2026-03-07
+// ============================================================
+//
+// Parametric spring-loaded phone mount that clamps to the 2020 aluminium
+// T-slot sensor rail.  Adjustable phone width 60–85 mm.  Quick-release
+// cam lever for tool-free phone swap.  Vibration-damping flexure ribs
+// on grip pads absorb motor/terrain vibration (PETG compliance).
+//
+// Design overview:
+//   - Fixed jaw + sliding jaw on a 40 mm guide rail (M4 rod)
+//   - Coil spring (Ø8 × 30 mm) compressed between jaw and end-stop —
+//     spring pre-load keeps phone clamped at any width in range
+//   - Cam lever (printed PETG) rotates 90° to release / lock spring
+//   - Anti-vibration flexure ribs on both grip pad faces
+//   - Landscape or portrait orientation: bracket rotates on T-nut base
+//
+// Parts (STL exports):
+//   Part 1 — tnut_base()          Rail attachment base (universal)
+//   Part 2 — fixed_jaw()          Fixed bottom jaw + guide rail bosses
+//   Part 3 — sliding_jaw()        Spring-loaded sliding jaw
+//   Part 4 — cam_lever()          Quick-release cam lever
+//   Part 5 — grip_pad()           Flexure grip pad (print ×2, TPU optional)
+//   Part 6 — assembly_preview()   Full assembly
+//
+// Hardware BOM (per mount):
+//   1× M4 × 60 mm SHCS          guide rod + spring bolt
+//   1× M4 hex nut                end-stop on sliding jaw
+//   1× Ø8 × 30 mm coil spring   ~0.5 N/mm rate (spring clamping)
+//   2× M3 × 16 mm SHCS          T-nut base thumbscrew + arm bolts
+//   1× M3 hex nut                thumbscrew nut in T-nut
+//   4× M2 × 8 mm SHCS           grip pad retention bolts (optional)
+//
+// Dimensions:
+//   Phone width range : PHONE_W_MIN–PHONE_W_MAX (60–85 mm) parametric
+//   Phone thickness   : up to PHONE_THICK_MAX (12 mm) — open-front jaw
+//   Phone height held : GRIP_SPAN (22 mm each jaw) — portrait/landscape
+//   Overall bracket H : ~110 mm  W: ~90 mm  D: ~55 mm
+//
+// Print settings:
+//   Material  : PETG (tnut_base, fixed_jaw, sliding_jaw, cam_lever)
+//               TPU 95A optional for grip_pad (or PETG for rigidity)
+//   Perimeters: 5 (structural parts), 3 (grip_pad)
+//   Infill    : 40 % gyroid (jaws), 20 % (grip_pad)
+//   Supports  : none needed (designed for FDM orientation)
+//   Layer ht  : 0.2 mm
+//
+// Export commands:
+//   openscad phone_mount_bracket.scad -D 'RENDER="tnut_base_stl"'    -o pm_tnut_base.stl
+//   openscad phone_mount_bracket.scad -D 'RENDER="fixed_jaw_stl"'    -o pm_fixed_jaw.stl
+//   openscad phone_mount_bracket.scad -D 'RENDER="sliding_jaw_stl"'  -o pm_sliding_jaw.stl
+//   openscad phone_mount_bracket.scad -D 'RENDER="cam_lever_stl"'    -o pm_cam_lever.stl
+//   openscad phone_mount_bracket.scad -D 'RENDER="grip_pad_stl"'     -o pm_grip_pad.stl
+// ============================================================
+
+$fn = 64;
+e   = 0.01;   // epsilon for boolean clearance
+
+// ── Phone parameters (adjust to target device) ───────────────────────────────
+PHONE_W_MIN    = 60.0;   // narrowest phone width supported (mm)
+PHONE_W_MAX    = 85.0;   // widest phone width supported (mm)
+PHONE_THICK_MAX = 12.0;  // max phone body thickness incl. case (mm)
+
+// ── Rail geometry (must match sensor_rail.scad) ──────────────────────────────
+RAIL_W         = 20.0;
+SLOT_OPEN      =  6.0;
+SLOT_INNER_W   = 10.2;
+SLOT_INNER_H   =  5.8;
+SLOT_NECK_H    =  3.2;
+
+// ── T-nut constants ───────────────────────────────────────────────────────────
+TNUT_W         =  9.8;
+TNUT_H         =  5.5;
+TNUT_L         = 12.0;
+TNUT_M3_NUT_AF =  5.5;
+TNUT_M3_NUT_H  =  2.5;
+TNUT_BOLT_D    =  3.3;   // M3 clearance
+
+// ── Base plate geometry ───────────────────────────────────────────────────────
+BASE_FACE_W  = 30.0;
+BASE_FACE_H  = 25.0;
+BASE_FACE_T  = SLOT_NECK_H + 1.5;
+
+// ── Jaw geometry ─────────────────────────────────────────────────────────────
+JAW_BODY_W   = 88.0;    // jaw outer width (> PHONE_W_MAX for rim)
+JAW_BODY_H   = 28.0;    // jaw height (Z) — phone grip span
+JAW_BODY_T   = 14.0;    // jaw depth (Y) — phone cradled this deep
+JAW_WALL_T   =  4.0;    // jaw side wall thickness
+JAW_LIP_T    =  3.0;    // front retaining lip thickness
+JAW_LIP_H    =  5.0;    // front lip height (retains phone)
+PHONE_POCKET_D = PHONE_THICK_MAX + 0.5;  // pocket depth for phone
+
+// ── Guide rod / spring system ─────────────────────────────────────────────────
+GUIDE_ROD_D  =  4.3;    // M4 clearance bore in sliding jaw
+GUIDE_BOSS_D = 10.0;    // boss OD around guide bore
+GUIDE_BOSS_T =  6.0;    // boss length
+SPRING_OD    =  8.5;    // coil spring OD pocket (spring is Ø8)
+SPRING_L     = 32.0;    // spring pocket length (spring compressed ~22 mm)
+SPRING_SEAT_T =  3.0;   // spring seat wall at end-stop boss
+JAW_TRAVEL   = PHONE_W_MAX - PHONE_W_MIN + 4.0;   // max jaw travel (mm)
+ARM_SPAN     = PHONE_W_MAX + 2 * JAW_WALL_T + 8;  // fixed jaw total width
+
+// ── Cam lever geometry ────────────────────────────────────────────────────────
+CAM_R_MIN    =  5.0;    // cam small radius (engaged / clamped)
+CAM_R_MAX    =  9.0;    // cam large radius (released, spring compressed)
+CAM_THICK    =  8.0;    // cam disc thickness
+CAM_HANDLE_L = 45.0;    // lever arm length
+CAM_HANDLE_W =  8.0;    // lever handle width
+CAM_HANDLE_T =  5.0;    // lever handle thickness
+CAM_BORE_D   =  4.3;    // M4 pivot bore
+CAM_DETENT_D =  3.0;    // detent ball pocket (3 mm bearing)
+
+// ── Grip pad geometry (vibration dampening flexure ribs) ─────────────────────
+PAD_W        = JAW_BODY_W - 2*JAW_WALL_T - 2;  // pad width
+PAD_H        = JAW_BODY_H - 2;                  // pad height
+PAD_T        =  2.5;    // pad body thickness
+RIB_H        =  1.5;    // flexure rib height above pad face
+RIB_W        =  1.2;    // rib width
+RIB_PITCH    =  5.0;    // rib pitch (centre-to-centre)
+RIB_COUNT    = floor(PAD_W / RIB_PITCH) - 1;
+
+// ── Arm geometry (base to jaw body) ──────────────────────────────────────────
+ARM_REACH    = 38.0;    // distance from rail face to jaw centreline (+Y)
+ARM_T        =  4.0;    // arm thickness
+ARM_H        = BASE_FACE_H;
+
+// ── Fasteners ─────────────────────────────────────────────────────────────────
+M2_D = 2.4;
+M3_D = 3.3;
+M4_D = 4.3;
+M4_NUT_AF = 7.0;   // M4 hex nut across-flats
+M4_NUT_H  = 3.2;   // M4 hex nut height
+
+// ============================================================
+// RENDER DISPATCH
+// ============================================================
+RENDER = "assembly";
+
+if      (RENDER == "assembly")        assembly_preview();
+else if (RENDER == "tnut_base_stl")   tnut_base();
+else if (RENDER == "fixed_jaw_stl")   fixed_jaw();
+else if (RENDER == "sliding_jaw_stl") sliding_jaw();
+else if (RENDER == "cam_lever_stl")   cam_lever();
+else if (RENDER == "grip_pad_stl")    grip_pad();
+
+// ============================================================
+// ASSEMBLY PREVIEW
+// ============================================================
+module assembly_preview() {
+    // Ghost rail section (20 × 20 × 200)
+    %color("Silver", 0.30)
+        linear_extrude(200)
+            square([RAIL_W, RAIL_W], center = true);
+
+    // T-nut base at Z=80 on rail
+    color("OliveDrab", 0.85)
+        translate([0, 0, 80])
+            tnut_base();
+
+    // Fixed jaw assembly (centred, extending +Y from base)
+    color("DarkSlateGray", 0.85)
+        translate([0, SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
+            fixed_jaw();
+
+    // Sliding jaw — shown at mid-travel (phone ~72 mm wide)
+    color("SteelBlue", 0.85)
+        translate([PHONE_W_MIN + (PHONE_W_MAX - PHONE_W_MIN)/2,
+                   SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
+            sliding_jaw();
+
+    // Grip pads on both jaws
+    color("DimGray", 0.85) {
+        translate([0, SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
+            translate([JAW_WALL_T, JAW_BODY_T, JAW_BODY_H/2])
+                rotate([90, 0, 0])
+                    grip_pad();
+        translate([PHONE_W_MIN + (PHONE_W_MAX - PHONE_W_MIN)/2,
+                   SLOT_NECK_H + BASE_FACE_T + ARM_REACH, 80])
+            translate([-JAW_WALL_T - PAD_T, JAW_BODY_T, JAW_BODY_H/2])
+                rotate([90, 0, 180])
+                    grip_pad();
+    }
+
+    // Cam lever — shown in locked (clamped) position
+    color("OrangeRed", 0.85)
+        translate([ARM_SPAN/2 + 6,
+                   SLOT_NECK_H + BASE_FACE_T + ARM_REACH + GUIDE_BOSS_D/2,
+                   80 + JAW_BODY_H/2])
+            rotate([0, 0, 0])
+                cam_lever();
+}
+
+// ============================================================
+// PART 1 — T-NUT BASE
+// ============================================================
+// Standard 2020 T-slot rail attachment base.
+// Identical interface to sensor_rail_brackets.scad universal_tnut_base().
+// Arm extends in +Y; rail clamp bolt in -Y face.
+//
+// Print flat (face plate down), PETG, 5 perims, 60 % infill.
+module tnut_base() {
+    difference() {
+        union() {
+            // Face plate (flush against rail outer face)
+            translate([-BASE_FACE_W/2, -BASE_FACE_T, 0])
+                cube([BASE_FACE_W, BASE_FACE_T, BASE_FACE_H]);
+
+            // T-nut neck (enters rail slot)
+            translate([-TNUT_W/2, 0, (BASE_FACE_H - TNUT_L)/2])
+                cube([TNUT_W, SLOT_NECK_H + e, TNUT_L]);
+
+            // T-nut body (wider, inside T-groove)
+            translate([-TNUT_W/2, SLOT_NECK_H - e, (BASE_FACE_H - TNUT_L)/2])
+                cube([TNUT_W, TNUT_H - SLOT_NECK_H + e, TNUT_L]);
+
+            // Arm stub (face plate → jaw)
+            translate([-BASE_FACE_W/2, -BASE_FACE_T, 0])
+                cube([BASE_FACE_W, BASE_FACE_T + ARM_REACH, ARM_T]);
+        }
+
+        // M3 rail clamp bolt bore (centre of T-nut, through face plate)
+        translate([0, -BASE_FACE_T - e, BASE_FACE_H/2])
+            rotate([-90, 0, 0])
+                cylinder(d = TNUT_BOLT_D, h = BASE_FACE_T + TNUT_H + 2*e);
+
+        // M3 hex nut pocket (inside T-nut body)
+        translate([0, SLOT_NECK_H + 0.3, BASE_FACE_H/2])
+            rotate([-90, 0, 0])
+                cylinder(d = TNUT_M3_NUT_AF / cos(30),
+                         h = TNUT_M3_NUT_H + 0.3,
+                         $fn = 6);
+
+        // 2× M3 bolt holes for arm-to-jaw bolting
+        for (bx = [-10, 10])
+            translate([bx, ARM_REACH - BASE_FACE_T - e, ARM_T/2])
+                rotate([-90, 0, 0])
+                    cylinder(d = M3_D, h = 8 + 2*e);
+
+        // Lightening slot in arm
+        translate([0, -BASE_FACE_T/2 + ARM_REACH/2, ARM_T/2])
+            cube([BASE_FACE_W - 12, ARM_REACH - 16, ARM_T + 2*e],
+                 center = true);
+    }
+}
+
+// ============================================================
+// PART 2 — FIXED JAW
+// ============================================================
+// Fixed lower jaw of the clamping system.  Phone sits in the pocket
+// formed by the fixed jaw (bottom) and sliding jaw (top).
+// Two guide bosses on the right wall carry the M4 guide rod + spring.
+// The cam lever pivot boss is on the outer right face.
+//
+// Coordinate origin: centre-bottom of jaw body.
+// Phone entry face: +Y (open front), phone pocket opens toward +Y.
+// Fixed jaw left edge is at X = -JAW_BODY_W/2.
+//
+// Print jaw-pocket-face down, PETG, 5 perims, 40 % infill.
+module fixed_jaw() {
+    difference() {
+        union() {
+            // ── Main jaw body ────────────────────────────────────────────
+            translate([-JAW_BODY_W/2, -JAW_BODY_T/2, 0])
+                cube([JAW_BODY_W, JAW_BODY_T, JAW_BODY_H]);
+
+            // ── Front retaining lip (keeps phone from falling forward) ───
+            translate([-JAW_BODY_W/2, JAW_BODY_T/2 - JAW_LIP_T, 0])
+                cube([JAW_BODY_W, JAW_LIP_T, JAW_LIP_H]);
+
+            // ── Guide boss right (outer, carries spring + end-stop) ──────
+            translate([JAW_BODY_W/2, 0, JAW_BODY_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d = GUIDE_BOSS_D, h = GUIDE_BOSS_T);
+
+            // ── Cam lever pivot boss (right face, above guide boss) ──────
+            translate([JAW_BODY_W/2, 0, JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
+                rotate([0, 90, 0])
+                    cylinder(d = CAM_THICK + 4, h = 6);
+
+            // ── Arm attachment bosses (left side, connect to tnut_base) ──
+            for (bx = [-10, 10])
+                translate([bx, -JAW_BODY_T/2 - 8, ARM_T/2])
+                    cylinder(d = 8, h = 8);
+        }
+
+        // ── Phone pocket (open-top U channel centred in jaw) ────────────
+        // Pocket opens toward +Y (front), phone drops in from above.
+        translate([0, -JAW_BODY_T/2 - e,
+                   JAW_LIP_H])
+            cube([JAW_BODY_W - 2*JAW_WALL_T,
+                  PHONE_POCKET_D + JAW_WALL_T,
+                  JAW_BODY_H - JAW_LIP_H + e],
+                 center = [true, false, false]);
+
+        // ── Guide rod bore (M4 clearance, through both guide bosses) ────
+        translate([-JAW_BODY_W/2 - e, 0, JAW_BODY_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = GUIDE_ROD_D,
+                         h = JAW_BODY_W + GUIDE_BOSS_T + 2*e);
+
+        // ── Spring pocket (coaxial with guide rod, in right boss) ────────
+        translate([JAW_BODY_W/2 + e, 0, JAW_BODY_H/2])
+            rotate([0, -90, 0])
+                cylinder(d = SPRING_OD, h = SPRING_L);
+
+        // ── M4 hex nut pocket in spring-seat wall (end-stop nut) ────────
+        translate([JAW_BODY_W/2 + GUIDE_BOSS_T + e, 0, JAW_BODY_H/2])
+            rotate([0, -90, 0])
+                cylinder(d = M4_NUT_AF / cos(30), h = M4_NUT_H + 0.5,
+                         $fn = 6);
+
+        // ── Cam pivot bore (M4 pivot, through pivot boss) ────────────────
+        translate([JAW_BODY_W/2 - e, 0, JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
+            rotate([0, 90, 0])
+                cylinder(d = CAM_BORE_D, h = 6 + 2*e);
+
+        // ── Arm attachment bolt holes (M3, to tnut_base arm stubs) ──────
+        for (bx = [-10, 10])
+            translate([bx, -JAW_BODY_T/2 - 8 - e, ARM_T/2])
+                rotate([-90, 0, 0])
+                    cylinder(d = M3_D, h = 12 + 2*e);
+
+        // ── Grip pad seats (recessed Ø1.5 mm, 2 mm deep, optional) ──────
+        for (pz = [JAW_BODY_H * 0.3, JAW_BODY_H * 0.7])
+        for (px = [-PAD_W/4, PAD_W/4])
+            translate([px, -JAW_BODY_T/2 + PHONE_POCKET_D + 1, pz])
+                rotate([-90, 0, 0])
+                    cylinder(d = M2_D, h = 10);
+
+        // ── Lightening pockets (non-structural core removal) ─────────────
+        translate([0, 0, JAW_BODY_H/2])
+            cube([JAW_BODY_W - 2*JAW_WALL_T - 4,
+                  JAW_BODY_T - 2*JAW_WALL_T,
+                  JAW_BODY_H - JAW_LIP_H - 4],
+                 center = true);
+    }
+}
+
+// ============================================================
+// PART 3 — SLIDING JAW
+// ============================================================
+// Upper clamping jaw.  Slides along the M4 guide rod.
+// Spring pushes this jaw toward the phone (inward).
+// M4 hex nut on the guide rod limits maximum travel (full open).
+// Cam lever pushes on this jaw face to compress spring (release).
+//
+// Coordinate origin same convention as fixed_jaw() for assembly.
+// Jaw slides in +X direction (away from fixed jaw left wall).
+//
+// Print jaw-pocket-face down, PETG, 5 perims, 40 % infill.
+module sliding_jaw() {
+    difference() {
+        union() {
+            // ── Main jaw body ────────────────────────────────────────────
+            translate([-JAW_WALL_T, -JAW_BODY_T/2, 0])
+                cube([JAW_BODY_W/2 + JAW_WALL_T, JAW_BODY_T, JAW_BODY_H]);
+
+            // ── Front retaining lip ──────────────────────────────────────
+            translate([-JAW_WALL_T, JAW_BODY_T/2 - JAW_LIP_T, 0])
+                cube([JAW_BODY_W/2 + JAW_WALL_T, JAW_LIP_T, JAW_LIP_H]);
+
+            // ── Guide boss (carries guide rod, spring butts against face) ─
+            translate([-JAW_WALL_T - GUIDE_BOSS_T, 0, JAW_BODY_H/2])
+                rotate([0, 90, 0])
+                    cylinder(d = GUIDE_BOSS_D, h = GUIDE_BOSS_T);
+
+            // ── Cam follower ear (contacts cam lever) ────────────────────
+            translate([-JAW_WALL_T - 2, 0,
+                       JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
+                cube([4, CAM_THICK + 2, CAM_THICK + 2], center = true);
+        }
+
+        // ── Phone pocket (inner face, contacts phone side) ───────────────
+        translate([-JAW_WALL_T - e, -JAW_BODY_T/2 - e, JAW_LIP_H])
+            cube([JAW_BODY_W/2 - JAW_WALL_T + e,
+                  PHONE_POCKET_D + JAW_WALL_T + 2*e,
+                  JAW_BODY_H - JAW_LIP_H + e]);
+
+        // ── Guide rod bore (M4 clearance through boss + jaw wall) ────────
+        translate([-JAW_WALL_T - GUIDE_BOSS_T - e, 0, JAW_BODY_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = GUIDE_ROD_D,
+                         h = GUIDE_BOSS_T + JAW_WALL_T + 2*e);
+
+        // ── M4 nut pocket (end-stop nut, rear of guide boss) ────────────
+        translate([-JAW_WALL_T - GUIDE_BOSS_T - e, 0, JAW_BODY_H/2])
+            rotate([0, 90, 0])
+                cylinder(d = M4_NUT_AF / cos(30), h = M4_NUT_H + 1,
+                         $fn = 6);
+
+        // ── Cam follower bore (M4 pivot passes through ear) ─────────────
+        translate([-JAW_WALL_T - 2 - e, 0,
+                   JAW_BODY_H/2 + GUIDE_BOSS_D + 4])
+            rotate([0, 90, 0])
+                cylinder(d = CAM_BORE_D, h = 6 + 2*e);
+
+        // ── Grip pad seats ───────────────────────────────────────────────
+        for (pz = [JAW_BODY_H * 0.3, JAW_BODY_H * 0.7])
+        for (px = [JAW_BODY_W/8])
+            translate([px, -JAW_BODY_T/2 + PHONE_POCKET_D + 1, pz])
+                rotate([-90, 0, 0])
+                    cylinder(d = M2_D, h = 10);
+    }
+}
+
+// ============================================================
+// PART 4 — CAM LEVER (QUICK-RELEASE)
+// ============================================================
+// Eccentric cam disc + integral handle lever.
+// Rotates 90° on M4 pivot pin between CLAMPED and RELEASED states:
+//   CLAMPED  : cam small radius (CAM_R_MIN) toward jaw → spring pushes jaw
+//   RELEASED : cam large radius (CAM_R_MAX) toward jaw → compresses spring
+//               by (CAM_R_MAX - CAM_R_MIN) = 4 mm, opening jaw
+//
+// Detent ball pocket (Ø3 mm) snaps into rail-dimple for each position.
+// Handle points rearward (-Y) in clamped state for low profile.
+//
+// Print standing on cam edge (cam disc vertical), PETG, 5 perims, 40%.
+module cam_lever() {
+    cam_offset = (CAM_R_MAX - CAM_R_MIN) / 2;   // 2 mm eccentricity
+    union() {
+        difference() {
+            union() {
+                // ── Eccentric cam disc ───────────────────────────────────
+                // Offset so pivot bore is eccentric to disc profile
+                translate([cam_offset, 0, 0])
+                    cylinder(r = CAM_R_MAX, h = CAM_THICK, center = true);
+
+                // ── Lever handle arm ─────────────────────────────────────
+                hull() {
+                    translate([cam_offset, 0, 0])
+                        cylinder(r = CAM_R_MAX, h = CAM_THICK, center = true);
+                    translate([cam_offset + CAM_HANDLE_L, 0, 0])
+                        cylinder(r = CAM_HANDLE_W/2,
+                                 h = CAM_HANDLE_T, center = true);
+                }
+            }
+
+            // ── M4 pivot bore (through cam centre) ───────────────────────
+            cylinder(d = CAM_BORE_D, h = CAM_THICK + 2*e, center = true);
+
+            // ── Detent pockets (2× Ø3 mm, at 0° and 90°) ────────────────
+            // Pocket at 0° → clamped detent
+            translate([CAM_R_MAX - 2, 0, CAM_THICK/2 - 1.5])
+                cylinder(d = CAM_DETENT_D + 0.2, h = 2);
+            // Pocket at 90° → released detent
+            translate([0, CAM_R_MAX - 2, CAM_THICK/2 - 1.5])
+                cylinder(d = CAM_DETENT_D + 0.2, h = 2);
+
+            // ── Lightening recesses on cam disc face ─────────────────────
+            for (a = [0, 60, 120, 180, 240, 300])
+                translate([cam_offset + (CAM_R_MAX - 4) * cos(a),
+                           (CAM_R_MAX - 4) * sin(a), 0])
+                    cylinder(d = 4, h = CAM_THICK + 2*e, center = true);
+
+            // ── Handle grip grooves ──────────────────────────────────────
+            for (i = [0:4])
+                translate([cam_offset + 20 + i * 5, 0, 0])
+                    rotate([90, 0, 0])
+                        cylinder(d = 2.5, h = CAM_HANDLE_W + 2*e,
+                                 center = true);
+        }
+    }
+}
+
+// ============================================================
+// PART 5 — GRIP PAD (VIBRATION DAMPENING)
+// ============================================================
+// Flat pad with transverse flexure ribs that press against phone side.
+// The rib profile (thin PETG fins) provides compliance in Z (vertical)
+// absorbing vibration transmitted through the bracket.
+// Optional: print in TPU 95A for superior damping.
+// M2 bolts or adhesive-backed foam tape attach pad to jaw pocket face.
+//
+// Pad face (+Y) contacts phone.  Mounting face (-Y) bonds to jaw.
+// Ribs run parallel to Z axis (vertical).
+//
+// Print flat (mounting face down), PETG or TPU 95A, 3 perims, 20%.
+module grip_pad() {
+    union() {
+        // ── Base plate ───────────────────────────────────────────────────
+        translate([-PAD_W/2, -PAD_T, -PAD_H/2])
+            cube([PAD_W, PAD_T, PAD_H]);
+
+        // ── Flexure ribs (transverse, dampening in Z) ────────────────────
+        // RIB_COUNT ribs spaced RIB_PITCH apart, centred on pad
+        for (i = [0 : RIB_COUNT - 1]) {
+            rx = -PAD_W/2 + RIB_PITCH/2 + i * RIB_PITCH;
+            if (abs(rx) <= PAD_W/2 - RIB_W/2)   // stay within pad
+                translate([rx, 0, 0])
+                    cube([RIB_W, RIB_H, PAD_H - 4], center = true);
+        }
+
+        // ── Corner retention nubs (M2 boss for optional bolt-through) ────
+        for (px = [-PAD_W/2 + 5, PAD_W/2 - 5])
+        for (pz = [-PAD_H/2 + 5, PAD_H/2 - 5])
+            translate([px, -PAD_T/2, pz])
+                difference() {
+                    cylinder(d = 5, h = PAD_T, center = true);
+                    cylinder(d = M2_D, h = PAD_T + 2*e, center = true);
+                }
+    }
+}

chassis/prototype_baseplate.scad

@@ -65,7 +65,7 @@ CLAMP_ALIGN_D   =   4.1;   // Ø4 pin
 // D-cut bore clearance
 DCUT_CL         =  0.3;
 
-// FC mount — MAMBA F722S 30.5 × 30.5 mm M3
+// FC mount — ESP32-S3 BALANCE 30.5 × 30.5 mm M3
 FC_PITCH        = 30.5;
 FC_HOLE_D       =  3.2;
 // FC is offset toward front of plate (away from stem)
@@ -202,7 +202,7 @@ module base_plate() {
                 translate([STEM_FLANGE_BC/2, 0, -1])
                     cylinder(d=M5, h=PLATE_THICK + 2);
 
-        // ── FC mount (MAMBA F722S 30.5 × 30.5 M3) ────────────────────────
+        // ── FC mount (ESP32-S3 BALANCE 30.5 × 30.5 M3) ────────────────────────
         for (x = [FC_X_OFFSET - FC_PITCH/2, FC_X_OFFSET + FC_PITCH/2])
         for (y = [-FC_PITCH/2, FC_PITCH/2])
             translate([x, y, -1])

chassis/rover_electronics_bay.scad

@@ -11,7 +11,7 @@
 //          • Ventilation slots      — all 4 walls + lid
 //
 // Shared mounting patterns (swappable with SaltyLab):
-//   FC    : 30.5 × 30.5 mm M3 (MAMBA F722S / Pixhawk)
+//   FC    : 30.5 × 30.5 mm M3 (ESP32-S3 BALANCE / Pixhawk)
 //   Jetson: 58 × 49 mm M3    (Orin NX / Nano Devkit carrier)
 //
 // Coordinate: bay centred at origin; Z=0 = deck top face.

chassis/rplidar_mount.scad

@@ -1,76 +1,343 @@
 // ============================================================
-// rplidar_mount.scad — RPLIDAR A1M8 Anti-Vibration Ring  Rev A
+// RPLIDAR A1 Mount Bracket — Issue #596
-// Agent: sl-mechanical   2026-02-28
+// Agent   : sl-mechanical
-// ============================================================
+// Date    : 2026-03-14
-// Flat ring sits between platform and RPLIDAR A1M8.
+// Part catalogue:
-// Anti-vibration isolation via 4× M3 silicone grommets
+//   1. tnut_base     — 2020 T-slot rail interface plate with M5 T-nut captive pockets
-// (same type as FC vibration mounts — Ø6 mm silicone, M3).
+//   2. column        — hollow elevation column, 120 mm tall, 3 stiffening ribs, cable bore
+//   3. scan_platform — top plate with Ø40 mm BC M3 mounting pattern, vibration seats
+//   4. vibe_ring     — silicone FC-grommet isolation ring for scan_platform bolts
+//   5. cable_guide   — snap-on cable management clip for column body
 //
-// Bolt stack (bottom → top):
+// BOM:
-//   M3×30 SHCS → platform (8 mm) → grommet (8 mm) →
+//   2 × M5×10 BHCS + M5 T-nuts   (tnut_base to rail)
-//   ring (4 mm) → RPLIDAR bottom (threaded M3, ~6 mm engagement)
+//   4 × M3×8  SHCS                (scan_platform to RPLIDAR A1)
+//   4 × M3 silicone FC grommets Ø8.5 OD / Ø3.2 bore  (anti-vibe)
+//   4 × M3 hex nuts               (captured in scan_platform)
 //
-// RENDER options:
+// Print settings (PETG):
-//   "ring"       print-ready flat ring (default)
+//   tnut_base / column / scan_platform : 5 perimeters, 40 % gyroid, no supports
-//   "assembly"   ring in position on platform stub
+//   vibe_ring                          : 3 perimeters, 20 % gyroid, no supports
+//   cable_guide                        : 3 perimeters, 30 % gyroid, no supports
+//
+// Export commands:
+//   openscad -D 'RENDER="tnut_base"'     -o tnut_base.stl     rplidar_mount.scad
+//   openscad -D 'RENDER="column"'        -o column.stl        rplidar_mount.scad
+//   openscad -D 'RENDER="scan_platform"' -o scan_platform.stl rplidar_mount.scad
+//   openscad -D 'RENDER="vibe_ring"'     -o vibe_ring.stl     rplidar_mount.scad
+//   openscad -D 'RENDER="cable_guide"'   -o cable_guide.stl   rplidar_mount.scad
+//   openscad -D 'RENDER="assembly"'      -o assembly.png      rplidar_mount.scad
 // ============================================================
 
-RENDER = "ring";
+// ── Render selector ─────────────────────────────────────────
-
+RENDER = "assembly"; // tnut_base | column | scan_platform | vibe_ring | cable_guide | assembly
-// ── RPLIDAR A1M8 ─────────────────────────────────────────────
-RPL_BODY_D  = 70.0;          // body diameter
-RPL_BC      = 58.0;          // M3 mounting bolt circle
-
-// ── Mount ring ───────────────────────────────────────────────
-RING_OD     = 82.0;          // outer diameter (RPL_BODY_D + 12 mm)
-RING_ID     = 30.0;          // inner cutout (cable / airflow)
-RING_H      =  4.0;          // ring thickness
-
-BOLT_D      =  3.3;          // M3 clearance through-hole
-GROMMET_D   =  7.0;          // silicone grommet OD (seat recess on bottom)
-GROMMET_H   =  1.0;          // seating recess depth
 
+// ── Global constants ────────────────────────────────────────
 $fn = 64;
-e   = 0.01;
+EPS = 0.01;
 
-// ─────────────────────────────────────────────────────────────
+// 2020 rail
-module rplidar_ring() {
+RAIL_W       = 20.0;   // extrusion cross-section
-    difference() {
+RAIL_H       = 20.0;
-        cylinder(d = RING_OD, h = RING_H);
+SLOT_NECK_H  =  3.2;   // T-slot opening width
+TNUT_W       =  9.8;   // M5 T-nut width
+TNUT_H       =  5.5;   // T-nut height (depth into slot)
+TNUT_L       = 12.0;   // T-nut body length
+M5_D         =  5.2;   // M5 clearance bore
+M5_HEAD_D    =  9.5;   // M5 BHCS head diameter
+M5_HEAD_H    =  4.0;   // M5 BHCS head height
 
-        // Central cutout
+// Base plate
-        translate([0, 0, -e])
+BASE_L       = 60.0;   // length along rail axis
-            cylinder(d = RING_ID, h = RING_H + 2*e);
+BASE_W       = 30.0;   // width across rail
+BASE_T       =  8.0;   // plate thickness
+BOLT_PITCH   = 40.0;   // M5 bolt pitch along rail (centre-to-centre)
 
-        // 4× M3 clearance holes on bolt circle
+// Elevation column
-        for (a = [45, 135, 225, 315]) {
+COL_OD       = 25.0;   // column outer diameter
-            translate([RPL_BC/2 * cos(a), RPL_BC/2 * sin(a), -e])
+COL_ID       = 17.0;   // inner bore (cable routing)
-                cylinder(d = BOLT_D, h = RING_H + 2*e);
+ELEV_H       = 120.0;  // scan plane above rail top face
-        }
+COL_WALL     = (COL_OD - COL_ID) / 2;
+RIB_W        =  3.0;   // stiffening rib width
+RIB_H        =  3.5;   // rib radial height
+CABLE_SLOT_W =  8.0;   // cable entry slot width
+CABLE_SLOT_H =  5.0;   // cable entry slot height
 
-        // Grommet seating recesses — bottom face
+// Scan platform
-        for (a = [45, 135, 225, 315]) {
+PLAT_D       = 60.0;   // platform disc diameter (clears RPLIDAR body Ø100 mm well)
-            translate([RPL_BC/2 * cos(a), RPL_BC/2 * sin(a), -e])
+PLAT_T       =  6.0;   // platform thickness
-                cylinder(d = GROMMET_D, h = GROMMET_H + e);
+RPL_BC_D     = 40.0;   // RPLIDAR M3 bolt circle diameter (4 bolts at 45 °)
-        }
+RPL_BORE_D   = 36.0;   // central pass-through for scan motor cable
+M3_D         =  3.2;   // M3 clearance bore
+M3_NUT_W     =  5.5;   // M3 hex nut across-flats
+M3_NUT_H     =  2.4;   // M3 hex nut height
+GROM_OD      =  8.5;   // FC silicone grommet OD
+GROM_ID      =  3.2;   // grommet bore
+GROM_H       =  3.0;   // grommet seat depth
+CONN_SLOT_W  = 12.0;   // connector side-exit slot width
+CONN_SLOT_H  =  5.0;   // connector slot height
+
+// Vibe ring
+VRING_OD     = GROM_OD + 1.6;  // printed retainer OD
+VRING_ID     = GROM_ID + 0.3;  // pass-through with grommet seated
+VRING_T      =  2.0;            // ring flange thickness
+
+// Cable guide clip
+CLIP_W       = 14.0;
+CLIP_T       =  3.5;
+CLIP_GAP     = COL_OD + 0.4;   // snap-fit gap (slight interference)
+SNAP_T       =  1.8;
+CABLE_CH_W   =  8.0;
+CABLE_CH_H   =  5.0;
+
+// ── Utility modules ─────────────────────────────────────────
+module chamfer_cube(size, ch=1.0) {
+    // simple chamfered box (bottom edge only for printability)
+    hull() {
+        translate([ch, ch, 0])
+            cube([size[0]-2*ch, size[1]-2*ch, EPS]);
+        translate([0, 0, ch])
+            cube(size - [0, 0, ch]);
     }
 }
 
-// ─────────────────────────────────────────────────────────────
+module hex_pocket(af, depth) {
-// Render selector
+    // hex nut pocket (flat-to-flat af)
-// ─────────────────────────────────────────────────────────────
+    cylinder(d = af / cos(30), h = depth, $fn = 6);
-if (RENDER == "ring") {
-    rplidar_ring();
-
-} else if (RENDER == "assembly") {
-    // Platform stub
-    color("Silver", 0.5)
-        difference() {
-            cylinder(d = 90, h = 8);
-            translate([0, 0, -e]) cylinder(d = 25.4, h = 8 + 2*e);
-        }
-    // Ring floating 8 mm above (grommet gap)
-    color("SkyBlue", 0.9)
-        translate([0, 0, 8 + 8])
-            rplidar_ring();
 }
+
+// ── Part 1: tnut_base ───────────────────────────────────────
+module tnut_base() {
+    difference() {
+        // Body
+        union() {
+            chamfer_cube([BASE_L, BASE_W, BASE_T], ch=1.5);
+            // Column socket boss centred on plate top face
+            translate([BASE_L/2, BASE_W/2, BASE_T])
+                cylinder(d=COL_OD + 4.0, h=8.0);
+        }
+
+        // M5 bolt holes (counterbored for BHCS heads from underneath)
+        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
+            translate([x, BASE_W/2, -EPS]) {
+                cylinder(d=M5_D, h=BASE_T + 8.0 + 2*EPS);
+                // counterbore from bottom
+                cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
+            }
+
+        // T-nut captive pockets (accessible from bottom)
+        for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
+            translate([x - TNUT_L/2, BASE_W/2 - TNUT_W/2, BASE_T - TNUT_H])
+                cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
+
+        // Column bore into boss
+        translate([BASE_L/2, BASE_W/2, BASE_T - EPS])
+            cylinder(d=COL_OD + 0.3, h=8.0 + 2*EPS);
+
+        // Cable exit slot through base (offset 5 mm from column centre)
+        translate([BASE_L/2 - CABLE_SLOT_W/2, BASE_W/2 + COL_OD/4, -EPS])
+            cube([CABLE_SLOT_W, CABLE_SLOT_H, BASE_T + 8.0 + 2*EPS]);
+
+        // Weight relief pockets on underside
+        for (x = [BASE_L/2 - BOLT_PITCH/2 + 10, BASE_L/2 + BOLT_PITCH/2 - 10])
+            for (y = [7, BASE_W - 7])
+                translate([x - 5, y - 5, -EPS])
+                    cube([10, 10, BASE_T/2]);
+    }
+}
+
+// ── Part 2: column ──────────────────────────────────────────
+module column() {
+    // Actual column height: ELEV_H minus base boss engagement (8 mm) and platform seating (6 mm)
+    col_h = ELEV_H - 8.0 - PLAT_T;
+
+    difference() {
+        union() {
+            // Hollow tube
+            cylinder(d=COL_OD, h=col_h);
+
+            // Three 120°-spaced stiffening ribs along full height
+            for (a = [0, 120, 240])
+                rotate([0, 0, a])
+                    translate([COL_OD/2 - EPS, -RIB_W/2, 0])
+                        cube([RIB_H, RIB_W, col_h]);
+
+            // Bottom spigot (fits into base boss bore)
+            translate([0, 0, -6.0])
+                cylinder(d=COL_OD - 0.4, h=6.0 + EPS);
+
+            // Top spigot (seats into scan_platform recess)
+            translate([0, 0, col_h - EPS])
+                cylinder(d=COL_OD - 0.4, h=6.0);
+        }
+
+        // Inner cable bore
+        translate([0, 0, -6.0 - EPS])
+            cylinder(d=COL_ID, h=col_h + 12.0 + 2*EPS);
+
+        // Cable entry slot at bottom (aligns with base slot)
+        translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, 2.0])
+            cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
+
+        // Cable exit slot at top (90° rotated for tidy routing)
+        rotate([0, 0, 90])
+            translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, col_h - CABLE_SLOT_H - 4.0])
+                cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
+
+        // Cable clip snap groove (at mid-height)
+        translate([0, 0, col_h / 2])
+            difference() {
+                cylinder(d=COL_OD + 2*RIB_H + 0.8, h=4.0, center=true);
+                cylinder(d=COL_OD - 0.2, h=4.0 + 2*EPS, center=true);
+            }
+    }
+}
+
+// ── Part 3: scan_platform ───────────────────────────────────
+module scan_platform() {
+    difference() {
+        union() {
+            // Main disc
+            cylinder(d=PLAT_D, h=PLAT_T);
+
+            // Rim lip for stiffness
+            translate([0, 0, PLAT_T])
+                difference() {
+                    cylinder(d=PLAT_D, h=2.0);
+                    cylinder(d=PLAT_D - 4.0, h=2.0 + EPS);
+                }
+        }
+
+        // Central cable pass-through
+        translate([0, 0, -EPS])
+            cylinder(d=RPL_BORE_D, h=PLAT_T + 4.0);
+
+        // Column spigot socket (bottom recess)
+        translate([0, 0, -EPS])
+            cylinder(d=COL_OD - 0.4 + 0.4, h=6.0);
+
+        // RPLIDAR M3 mounting holes — 4× on Ø40 BC at 45°/135°/225°/315°
+        for (a = [45, 135, 225, 315])
+            rotate([0, 0, a])
+                translate([RPL_BC_D/2, 0, -EPS]) {
+                    // Through bore
+                    cylinder(d=M3_D, h=PLAT_T + 2*EPS);
+                    // Grommet seat (countersunk from top)
+                    translate([0, 0, PLAT_T - GROM_H])
+                        cylinder(d=GROM_OD + 0.3, h=GROM_H + EPS);
+                    // Captured M3 hex nut pocket (from bottom)
+                    translate([0, 0, 1.5])
+                        hex_pocket(M3_NUT_W + 0.3, M3_NUT_H + 0.2);
+                }
+
+        // Connector side-exit slots (2× opposing, at 0° and 180°)
+        for (a = [0, 180])
+            rotate([0, 0, a])
+                translate([-CONN_SLOT_W/2, PLAT_D/2 - CONN_SLOT_H, -EPS])
+                    cube([CONN_SLOT_W, CONN_SLOT_H + EPS, PLAT_T + 2*EPS]);
+
+        // Weight relief pockets (2× lateral)
+        for (a = [90, 270])
+            rotate([0, 0, a])
+                translate([-10, 15, 1.5])
+                    cube([20, 8, PLAT_T - 3.0]);
+    }
+}
+
+// ── Part 4: vibe_ring ───────────────────────────────────────
+// Printed silicone-grommet retainer ring — press-fits over M3 bolt with grommet seated
+module vibe_ring() {
+    difference() {
+        union() {
+            cylinder(d=VRING_OD, h=VRING_T + GROM_H);
+            // Flange
+            cylinder(d=VRING_OD + 2.0, h=VRING_T);
+        }
+        // Bore
+        translate([0, 0, -EPS])
+            cylinder(d=VRING_ID, h=VRING_T + GROM_H + 2*EPS);
+    }
+}
+
+// ── Part 5: cable_guide ─────────────────────────────────────
+// Snap-on cable clip for column mid-section
+module cable_guide() {
+    arm_t = SNAP_T;
+    gap   = CLIP_GAP;
+
+    difference() {
+        union() {
+            // Saddle body (U-shape wrapping column)
+            difference() {
+                cylinder(d=gap + 2*CLIP_T, h=CLIP_W);
+                translate([0, 0, -EPS])
+                    cylinder(d=gap, h=CLIP_W + 2*EPS);
+                // Open front slot for snap insertion
+                translate([-gap/2, 0, -EPS])
+                    cube([gap, gap/2 + CLIP_T + EPS, CLIP_W + 2*EPS]);
+            }
+
+            // Snap arms
+            for (s = [-1, 1])
+                translate([s*(gap/2 - arm_t), 0, 0])
+                    mirror([s < 0 ? 1 : 0, 0, 0])
+                        translate([0, -arm_t/2, 0])
+                            cube([arm_t + 1.5, arm_t, CLIP_W]);
+
+            // Cable channel bracket (side-mounted)
+            translate([gap/2 + CLIP_T, -(CABLE_CH_W/2 + CLIP_T), 0])
+                cube([CLIP_T + CABLE_CH_H, CABLE_CH_W + 2*CLIP_T, CLIP_W]);
+        }
+
+        // Cable channel cutout
+        translate([gap/2 + CLIP_T + CLIP_T - EPS, -CABLE_CH_W/2, -EPS])
+            cube([CABLE_CH_H + EPS, CABLE_CH_W, CLIP_W + 2*EPS]);
+
+        // Snap tip undercut (both arms)
+        for (s = [-1, 1])
+            translate([s*(gap/2 + CLIP_T + 1.0), -arm_t, -EPS])
+                rotate([0, 0, s*30])
+                    cube([2, arm_t*2, CLIP_W + 2*EPS]);
+    }
+}
+
+// ── Assembly / render dispatch ───────────────────────────────
+module assembly() {
+    // tnut_base at origin
+    color("SteelBlue")
+        tnut_base();
+
+    // column rising from base boss
+    color("DodgerBlue")
+        translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0])
+            column();
+
+    // scan_platform at top of column
+    col_h_actual = ELEV_H - 8.0 - PLAT_T;
+    color("CornflowerBlue")
+        translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 - EPS])
+            scan_platform();
+
+    // vibe rings (4×) seated in platform holes
+    for (a = [45, 135, 225, 315])
+        color("Gray", 0.7)
+            translate([BASE_L/2, BASE_W/2,
+                       BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 + PLAT_T - GROM_H])
+                rotate([0, 0, a])
+                    translate([RPL_BC_D/2, 0, 0])
+                        vibe_ring();
+
+    // cable_guide clipped at column mid-height
+    color("LightSteelBlue")
+        translate([BASE_L/2, BASE_W/2,
+                   BASE_T + 8.0 - 6.0 + (ELEV_H - 8.0 - PLAT_T)/2 - CLIP_W/2])
+            cable_guide();
+}
+
+// ── Dispatch ────────────────────────────────────────────────
+if      (RENDER == "tnut_base")     tnut_base();
+else if (RENDER == "column")        column();
+else if (RENDER == "scan_platform") scan_platform();
+else if (RENDER == "vibe_ring")     vibe_ring();
+else if (RENDER == "cable_guide")   cable_guide();
+else                                assembly();

chassis/saltyrover_chassis_r2.scad

@@ -17,7 +17,7 @@
 //   • Weight target: <2 kg frame (excl. motors/electronics)
 //
 // Shared SaltyLab patterns (swappable electronics):
-//   FC  : 30.5 × 30.5 mm M3  (MAMBA F722S / Pixhawk)
+//   FC  : 30.5 × 30.5 mm M3  (ESP32-S3 BALANCE / Pixhawk)
 //   Jetson: 58 × 49 mm M3    (Orin NX / Nano carrier board)
 //   Stem  : Ø25 mm bore      (sensor head unchanged)
 //
@@ -87,7 +87,7 @@ STEM_COLLAR_OD = 50.0;
 STEM_COLLAR_H  = 20.0;   // raised boss height above deck top
 STEM_FLANGE_BC = 40.0;   // 4× M4 bolt circle for stem adapter
 
-// ── FC mount — MAMBA F722S / Pixhawk (30.5 × 30.5 mm M3) ────────────────────
+// ── FC mount — ESP32-S3 BALANCE / Pixhawk (30.5 × 30.5 mm M3) ────────────────────
 // Shared with SaltyLab — swappable electronics
 FC_PITCH    = 30.5;
 FC_HOLE_D   =  3.2;

chassis/uwb_anchor_mount.scad

@@ -1,275 +1,341 @@
 // ============================================================
-// uwb_anchor_mount.scad — Stem-Mounted UWB Anchor  Rev A
+// uwb_anchor_mount.scad — Wall/Ceiling UWB Anchor Mount Bracket
-// Agent: sl-mechanical   2026-03-01
+// Issue: #564  Agent: sl-mechanical  Date: 2026-03-14
-// Closes issues #57, #62
+// (supersedes Rev A stem-collar mount — see git history)
 // ============================================================
-// Clamp-on bracket for 2× MaUWB ESP32-S3 anchor modules on
-// SaltyBot 25 mm OD vertical stem.
-// Anchors spaced ANCHOR_SPACING = 250 mm apart.
 //
-// Features:
+// Parametric wall or ceiling mount bracket for ESP32 UWB Pro anchor.
-//   • Split D-collar with M4 clamping bolts + M4 set screw
+// Designed for fixed-infrastructure deployment: anchors screw into
-//   • Anti-rotation flat tab that keys against a small pin
+// wall or ceiling drywall/timber with standard M4 or #6 wood screws,
-//     OR printed key tab that registers on the stem flat (if stem
+// at a user-defined tilt angle so the UWB antenna faces the desired
-//     has a ground flat) — see ANTI_ROT_MODE parameter
+// coverage zone.
-//   • Module bracket: faces outward, tilted 10° from vertical
-//     so antenna clears stem and faces horizon
-//   • USB cable channel (power from Orin via USB-A) on collar
-//   • Tool-free capture: M4 thumbscrews (slot-head, hand-tighten)
-//   • UWB antenna area: NO material within 10 mm of PCB top face
 //
-// Components per mount:
+// Architecture:
-//   2× collar_half        print in PLA/PETG, flat-face-down
+//   Wall base    -> flat backplate with 2x screw holes (wall or ceiling)
-//   1× module_bracket     print in PLA/PETG, flat-face-down
+//   Tilt knuckle -> single-axis articulating joint; 15deg detent steps
+//                   locked with M3 nyloc bolt; range 0-90deg
+//   Anchor cradle-> U-cradle holding ESP32 UWB Pro PCB on M2.5 standoffs
+//   USB-C channel-> routed groove on tilt arm + exit slot in cradle back wall
+//   Label slot   -> rear window slot for printed anchor-ID card strip
+//
+// Part catalogue:
+//   Part 1 -- wall_base()       Backplate + 2-ear pivot block + detent arc
+//   Part 2 -- tilt_arm()        Pivoting arm with knuckle + cradle stub
+//   Part 3 -- anchor_cradle()   PCB cradle, standoffs, USB-C slot, label window
+//   Part 4 -- cable_clip()      Snap-on USB-C cable guide for tilt arm
+//   Part 5 -- assembly_preview()
+//
+// Hardware BOM:
+//   2x M4 x 30mm wood screws (or #6 drywall screws)  wall fasteners
+//   1x M3 x 20mm SHCS + M3 nyloc nut                 tilt pivot bolt
+//   4x M2.5 x 8mm SHCS                               PCB-to-cradle
+//   4x M2.5 hex nuts                                  captured in standoffs
+//   1x USB-C cable                                    anchor power
+//
+// ESP32 UWB Pro interface (verify with calipers):
+//   PCB size       : UWB_L x UWB_W x UWB_H  (55 x 28 x 10 mm default)
+//   Mounting holes : M2.5, 4x corners on UWB_HOLE_X x UWB_HOLE_Y pattern
+//   USB-C port     : centred on short edge, UWB_USBC_W x UWB_USBC_H
+//   Antenna area   : top face rear half -- 10mm keep-out of bracket material
+//
+// Tilt angles (15deg detent steps, set TILT_DEG before export):
+//   0deg  -> horizontal face-up   (ceiling, antenna faces down)
+//   30deg -> 30deg downward tilt  (wall near ceiling)  [default]
+//   45deg -> diagonal             (wall mid-height)
+//   90deg -> vertical face-out    (wall, antenna faces forward)
 //
 // RENDER options:
-//   "assembly"       single mount assembled (default)
+//   "assembly"           full assembly at TILT_DEG (default)
-//   "collar_front"   front collar half for slicing (×2 per mount × 2 mounts = 4)
+//   "wall_base_stl"      Part 1
-//   "collar_rear"    rear collar half
+//   "tilt_arm_stl"       Part 2
-//   "bracket"        module bracket (×2 mounts)
+//   "anchor_cradle_stl"  Part 3
-//   "pair"           both mounts on 350 mm stem section
+//   "cable_clip_stl"     Part 4
+//
+// Export commands:
+//   openscad uwb_anchor_mount.scad -D 'RENDER="wall_base_stl"'     -o uwb_wall_base.stl
+//   openscad uwb_anchor_mount.scad -D 'RENDER="tilt_arm_stl"'      -o uwb_tilt_arm.stl
+//   openscad uwb_anchor_mount.scad -D 'RENDER="anchor_cradle_stl"' -o uwb_anchor_cradle.stl
+//   openscad uwb_anchor_mount.scad -D 'RENDER="cable_clip_stl"'    -o uwb_cable_clip.stl
 // ============================================================
 
+$fn  = 64;
+e    = 0.01;
+
+// -- Tilt angle (override per anchor, 0-90deg, 15deg steps) ------------------
+TILT_DEG = 30;
+
+// -- ESP32 UWB Pro PCB dimensions (verify with calipers) ---------------------
+UWB_L         = 55.0;
+UWB_W         = 28.0;
+UWB_H         = 10.0;
+UWB_HOLE_X    = 47.5;
+UWB_HOLE_Y    = 21.0;
+UWB_USBC_W    =  9.5;
+UWB_USBC_H    =  4.0;
+UWB_ANTENNA_L = 20.0;
+
+// -- Wall base geometry -------------------------------------------------------
+BASE_W         = 60.0;
+BASE_H         = 50.0;
+BASE_T         =  5.0;
+BASE_SCREW_D   =  4.5;
+BASE_SCREW_HD  =  8.5;
+BASE_SCREW_HH  =  3.5;
+BASE_SCREW_SPC = 35.0;
+KNUCKLE_T      = BASE_T + 4.0;
+
+// -- Tilt arm geometry --------------------------------------------------------
+ARM_W         = 12.0;
+ARM_T         =  5.0;
+ARM_L         = 35.0;
+PIVOT_D       =  3.3;
+PIVOT_NUT_AF  =  5.5;
+PIVOT_NUT_H   =  2.4;
+DETENT_D      =  3.2;
+DETENT_R      =  8.0;
+
+// -- Anchor cradle geometry ---------------------------------------------------
+CRADLE_WALL_T  =  3.5;
+CRADLE_BACK_T  =  4.0;
+CRADLE_FLOOR_T =  3.0;
+CRADLE_LIP_H   =  4.0;
+CRADLE_LIP_T   =  2.5;
+STANDOFF_H     =  3.0;
+STANDOFF_OD    =  5.5;
+LABEL_W        = UWB_L - 4.0;
+LABEL_H        = UWB_W * 0.55;
+LABEL_T        =  1.2;
+
+// -- USB-C routing ------------------------------------------------------------
+USBC_CHAN_W   = 11.0;
+USBC_CHAN_H   =  7.0;
+
+// -- Cable clip ---------------------------------------------------------------
+CLIP_CABLE_D  =  4.5;
+CLIP_T        =  2.0;
+CLIP_BODY_W   = 16.0;
+CLIP_BODY_H   = 10.0;
+
+// -- Fasteners ----------------------------------------------------------------
+M2P5_D    = 2.7;
+M3_D      = 3.3;
+M3_NUT_AF = 5.5;
+M3_NUT_H  = 2.4;
+
+// ============================================================
+// RENDER DISPATCH
+// ============================================================
 RENDER = "assembly";
 
-// ── ⚠ Verify with calipers ───────────────────────────────────
+if      (RENDER == "assembly")           assembly_preview();
-MAWB_L      = 50.0;   // PCB length
+else if (RENDER == "wall_base_stl")      wall_base();
-MAWB_W      = 25.0;   // PCB width
+else if (RENDER == "tilt_arm_stl")       tilt_arm();
-MAWB_H      = 10.0;   // PCB + components
+else if (RENDER == "anchor_cradle_stl")  anchor_cradle();
-MAWB_HOLE_X = 43.0;   // M2 mounting hole X span
+else if (RENDER == "cable_clip_stl")     cable_clip();
-MAWB_HOLE_Y = 20.0;   // M2 mounting hole Y span
-M2_D        =  2.2;   // M2 clearance
 
-// ── Stem ─────────────────────────────────────────────────────
+// ============================================================
-STEM_OD     = 25.0;
+// ASSEMBLY PREVIEW
-STEM_BORE   = 25.4;   // +0.4 clearance
+// ============================================================
-WALL        =  2.0;   // wall thickness (used in thumbscrew recess)
+module assembly_preview() {
+    %color("Wheat", 0.22)
+        translate([-BASE_W/2, -10, -BASE_H/2])
+            cube([BASE_W, 10, BASE_H + 40]);
+    color("OliveDrab", 0.85)  wall_base();
+    color("SteelBlue", 0.85)
+        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0]) tilt_arm();
+    color("DarkSlateGray", 0.85)
+        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
+            translate([0, ARM_T, ARM_L]) anchor_cradle();
+    %color("ForestGreen", 0.38)
+        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
+            translate([-UWB_L/2, ARM_T+CRADLE_BACK_T,
+                       ARM_L+CRADLE_FLOOR_T+STANDOFF_H])
+                cube([UWB_L, UWB_W, UWB_H]);
+    color("DimGray", 0.70)
+        translate([ARM_W/2, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
+            translate([0, ARM_T+e, ARM_L/2]) rotate([0,-90,90]) cable_clip();
+}
 
-// ── Collar ───────────────────────────────────────────────────
+// ============================================================
-COL_OD      = 52.0;
+// PART 1 -- WALL BASE
-COL_H       = 30.0;   // taller than sensor-head collar for rigidity
+// ============================================================
-COL_BOLT_X  = 19.0;   // M4 bolt CL from stem axis
+// Flat backplate, 2x countersunk M4/#6 wood screws on 35mm centres.
-COL_BOLT_D  =  4.5;   // M4 clearance
+// Two pivot ears straddle the tilt arm; M3 pivot bolt through both.
-THUMB_HEAD_D=  8.0;   // M4 thumbscrew head OD (slot for access)
+// Detent arc on +X ear inner face: 7 notches at 15deg steps (0-90deg).
-COL_NUT_W   =  7.0;   // M4 hex nut A/F
+// Shallow rear recess for installation-zone label strip.
-COL_NUT_H   =  3.4;
+// Same part for wall mount and ceiling mount.
-
+//
-// Anti-rotation flat tab: a 3 mm wall tab that protrudes radially
+// Print: backplate flat on bed, PETG, 5 perims, 40% gyroid.
-// and bears against the bracket arm, preventing axial rotation
+module wall_base() {
-// without needing a stem flat.
+    ear_h   = ARM_W + 3.0;
-ANTI_ROT_T  =  3.0;   // tab thickness (radial)
+    ear_t   = 6.0;
-ANTI_ROT_W  =  8.0;   // tab width (tangential)
+    ear_sep = ARM_W + 1.0;
-ANTI_ROT_Z  =  4.0;   // distance from collar base
-
-// USB cable channel: groove on collar outer surface, runs Z direction
-// Cable routes from anchor module down to base
-USB_CHAN_W  =  9.0;   // channel width (fits USB-A cable Ø6 mm)
-USB_CHAN_D  =  5.0;   // channel depth
-
-// ── Module bracket ───────────────────────────────────────────
-ARM_L       = 20.0;   // arm length from collar OD to bracket face
-ARM_W       = MAWB_W + 6.0; // bracket width (Y, includes side walls)
-ARM_H       =  6.0;   // arm thickness (Z)
-BRKT_TILT   = 10.0;   // tilt outward from vertical (antenna faces horizon)
-
-BRKT_BACK_T =  3.0;   // bracket back wall (module sits against this)
-BRKT_SIDE_T =  2.0;   // bracket side walls
-
-M2_STNDFF   =  3.0;   // M2 standoff height
-M2_STNDFF_OD=  4.5;
-
-// USB port access notch in bracket side wall (8×5 mm)
-USB_NOTCH_W = 10.0;
-USB_NOTCH_H =  7.0;
-
-// ── Spacing ───────────────────────────────────────────────────
-ANCHOR_SPACING = 250.0;  // centre-to-centre Z separation
-
-$fn = 64;
-e   = 0.01;
-
-// ─────────────────────────────────────────────────────────────
-// collar_half(side)
-//   split at Y=0 plane.  Bracket arm on front (+Y) half.
-//   Print flat-face-down.
-// ─────────────────────────────────────────────────────────────
-module collar_half(side = "front") {
-    y_front = (side == "front");
 
     difference() {
         union() {
-            // D-shaped body
+            translate([-BASE_W/2, -BASE_T, -BASE_H/2])
-            intersection() {
+                cube([BASE_W, BASE_T, BASE_H]);
-                cylinder(d=COL_OD, h=COL_H);
+            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
-                translate([-COL_OD/2, y_front ? 0 : -COL_OD/2, 0])
+                translate([ex, -BASE_T+e, -ear_h/2])
-                    cube([COL_OD, COL_OD/2, COL_H]);
+                    cube([ear_t, KNUCKLE_T+e, ear_h]);
-            }
+            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
-
+                hull() {
-            // Anti-rotation tab (front half only, at +X side)
+                    translate([ex, -BASE_T, -ear_h/4])
-            if (y_front) {
+                        cube([ear_t, BASE_T-1, ear_h/2]);
-                translate([COL_OD/2, -ANTI_ROT_W/2, ANTI_ROT_Z])
+                    translate([ex + (ex<0 ? ear_t*0.5 : 0), -BASE_T, -ear_h/6])
-                    cube([ANTI_ROT_T, ANTI_ROT_W,
+                        cube([ear_t*0.5, 1, ear_h/3]);
-                          COL_H - ANTI_ROT_Z - 4]);
+                }
-            }
-
-            // Bracket arm attachment boss (front half only, top centre)
-            if (y_front) {
-                translate([-ARM_W/2, COL_OD/2, COL_H * 0.3])
-                    cube([ARM_W, ARM_L, COL_H * 0.4]);
-            }
         }
-
+        for (sz = [-BASE_SCREW_SPC/2, BASE_SCREW_SPC/2]) {
-        // ── Stem bore ─────────────────────────────────────────
+            translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
-        translate([0,0,-e])
+                cylinder(d=BASE_SCREW_D, h=BASE_T+2*e);
-            cylinder(d=STEM_BORE, h=COL_H + 2*e);
+            translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
-
+                cylinder(d1=BASE_SCREW_HD, d2=BASE_SCREW_D, h=BASE_SCREW_HH+e);
-        // ── M4 clamping bolt holes (Y direction) ──────────────
-        for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
-            translate([bx, y_front ? COL_OD/2 : 0, COL_H/2])
-                rotate([90,0,0])
-                    cylinder(d=COL_BOLT_D, h=COL_OD/2 + e);
-            // Thumbscrew head recess on outer face (front only — access side)
-            if (y_front) {
-                translate([bx, COL_OD/2 - WALL, COL_H/2])
-                    rotate([90,0,0])
-                        cylinder(d=THUMB_HEAD_D, h=8 + e);
-            }
-        }
-
-        // ── M4 hex nut pockets (rear half) ────────────────────
-        if (!y_front) {
-            for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
-                translate([bx, -(COL_OD/4 + e), COL_H/2])
-                    rotate([90,0,0])
-                        cylinder(d=COL_NUT_W/cos(30), h=COL_NUT_H + e,
-                                 $fn=6);
-            }
-        }
-
-        // ── Set screw (height lock, front half) ───────────────
-        if (y_front) {
-            translate([0, COL_OD/2, COL_H * 0.8])
-                rotate([90,0,0])
-                    cylinder(d=COL_BOLT_D,
-                             h=COL_OD/2 - STEM_BORE/2 + e);
-        }
-
-        // ── USB cable routing channel (rear half, −X side) ────
-        if (!y_front) {
-            translate([-COL_OD/2, -USB_CHAN_W/2, -e])
-                cube([USB_CHAN_D, USB_CHAN_W, COL_H + 2*e]);
-        }
-
-        // ── M4 hole through arm boss (Z direction, for bracket bolt) ─
-        if (y_front) {
-            for (dx=[-ARM_W/4, ARM_W/4])
-                translate([dx, COL_OD/2 + ARM_L/2, COL_H * 0.35])
-                    cylinder(d=COL_BOLT_D, h=COL_H * 0.35 + e);
         }
+        translate([-(ear_sep/2+ear_t+e), KNUCKLE_T*0.55, 0])
+            rotate([0,90,0]) cylinder(d=PIVOT_D, h=ear_sep+2*ear_t+2*e);
+        translate([ear_sep/2+ear_t-PIVOT_NUT_H-0.4, KNUCKLE_T*0.55, 0])
+            rotate([0,90,0])
+                cylinder(d=PIVOT_NUT_AF/cos(30), h=PIVOT_NUT_H+0.5, $fn=6);
+        for (da = [0 : 15 : 90])
+            translate([ear_sep/2-e,
+                       KNUCKLE_T*0.55 + DETENT_R*sin(da),
+                       DETENT_R*cos(da)])
+                rotate([0,90,0]) cylinder(d=DETENT_D, h=ear_t*0.45+e);
+        translate([0, -BASE_T-e, 0]) rotate([-90,0,0])
+            cube([BASE_W-12, BASE_H-16, 1.6], center=true);
+        translate([0, -BASE_T+1.5, 0])
+            cube([BASE_W-14, BASE_T-3, BASE_H-20], center=true);
     }
 }
 
-// ─────────────────────────────────────────────────────────────
+// ============================================================
-// module_bracket()
+// PART 2 -- TILT ARM
-//   Bolts to collar arm boss. Holds MaUWB PCB facing outward.
+// ============================================================
-//   Tilted BRKT_TILT° from vertical — antenna clears stem.
+// Pivoting arm linking wall_base ears to anchor_cradle.
-//   Print flat-face-down (back wall on bed).
+// Knuckle (Z=0): M3 pivot bore + spring-plunger detent pocket (3mm).
-// ─────────────────────────────────────────────────────────────
+// Cradle end (Z=ARM_L): 2x M3 bolt attachment stub.
-module module_bracket() {
+// USB-C cable channel groove on outer +Y face, full arm length.
-    bk = BRKT_BACK_T;
+//
-    sd = BRKT_SIDE_T;
+// Print: knuckle face flat on bed, PETG, 5 perims, 40% gyroid.
+module tilt_arm() {
+    total_h = ARM_L + 10;
+    difference() {
+        union() {
+            translate([-ARM_W/2, 0, 0]) cube([ARM_W, ARM_T, total_h]);
+            translate([0, ARM_T/2, 0]) rotate([90,0,0])
+                cylinder(d=ARM_W, h=ARM_T, center=true);
+            translate([-ARM_W/2, 0, ARM_L])
+                cube([ARM_W, ARM_T+CRADLE_BACK_T, ARM_T]);
+        }
+        translate([-ARM_W/2-e, ARM_T/2, 0]) rotate([0,90,0])
+            cylinder(d=PIVOT_D, h=ARM_W+2*e);
+        translate([0, ARM_T+e, 0]) rotate([90,0,0])
+            cylinder(d=3.2, h=4+e);
+        translate([-USBC_CHAN_W/2, ARM_T-e, ARM_T+4])
+            cube([USBC_CHAN_W, USBC_CHAN_H, ARM_L-ARM_T-8]);
+        for (bx = [-ARM_W/4, ARM_W/4])
+            translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([90,0,0])
+                cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
+        for (bx = [-ARM_W/4, ARM_W/4])
+            translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([-90,0,0])
+                cylinder(d=M3_NUT_AF/cos(30), h=M3_NUT_H+0.5, $fn=6);
+        translate([0, ARM_T/2, ARM_L/2])
+            cube([ARM_W-4, ARM_T-2, ARM_L-18], center=true);
+    }
+}
+
+// ============================================================
+// PART 3 -- ANCHOR CRADLE
+// ============================================================
+// Open-front U-cradle for ESP32 UWB Pro PCB.
+// 4x M2.5 standoffs on UWB_HOLE_X x UWB_HOLE_Y pattern.
+// Back wall: USB-C exit slot + routing groove, label card slot,
+//            antenna keep-out cutout (material removed above antenna area).
+// Front retaining lip prevents PCB sliding out.
+// Two attachment tabs bolt to tilt_arm cradle stub via M3.
+//
+// Label card slot: insert paper/laminate strip to ID this anchor
+// (e.g. "UWB-A3 NE-CORNER"), accessible from open cradle end.
+//
+// Print: back wall flat on bed, PETG, 5 perims, 40% gyroid.
+module anchor_cradle() {
+    outer_l  = UWB_L + 2*CRADLE_WALL_T;
+    outer_w  = UWB_W + CRADLE_FLOOR_T;
+    pcb_z    = CRADLE_FLOOR_T + STANDOFF_H;
+    total_z  = pcb_z + UWB_H + 2;
 
     difference() {
         union() {
-            // ── Back wall (mounts to collar arm boss) ─────────
+            translate([-outer_l/2, 0, 0]) cube([outer_l, outer_w, total_z]);
-            cube([ARM_W, bk, MAWB_H + M2_STNDFF + 6]);
+            translate([-outer_l/2, outer_w-CRADLE_LIP_T, 0])
-
+                cube([outer_l, CRADLE_LIP_T, CRADLE_LIP_H]);
-            // ── Side walls ────────────────────────────────────
+            for (tx = [-ARM_W/4, ARM_W/4])
-            for (sx=[0, ARM_W - sd])
+                translate([tx-4, -CRADLE_BACK_T, 0])
-                translate([sx, bk, 0])
+                    cube([8, CRADLE_BACK_T+1, total_z]);
-                    cube([sd, MAWB_L + 2, MAWB_H + M2_STNDFF + 6]);
-
-            // ── M2 standoff posts (PCB mounts to these) ───────
-            for (hx=[0, MAWB_HOLE_X], hy=[0, MAWB_HOLE_Y])
-                translate([(ARM_W - MAWB_HOLE_X)/2 + hx,
-                           bk + (MAWB_L - MAWB_HOLE_Y)/2 + hy,
-                           0])
-                    cylinder(d=M2_STNDFF_OD, h=M2_STNDFF);
         }
+        translate([-UWB_L/2, 0, pcb_z]) cube([UWB_L, UWB_W+1, UWB_H+4]);
+        translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2-UWB_USBC_H/2])
+            cube([UWB_USBC_W+2, CRADLE_BACK_T+2*e, UWB_USBC_H+2],
+                 center=[true,false,false]);
+        translate([0, -CRADLE_BACK_T-e, -e])
+            cube([USBC_CHAN_W, USBC_CHAN_H, pcb_z+UWB_H/2+USBC_CHAN_H],
+                 center=[true,false,false]);
+        translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2])
+            cube([LABEL_W, LABEL_T+0.3, LABEL_H], center=[true,false,false]);
+        translate([0, -e, pcb_z+UWB_H-UWB_ANTENNA_L])
+            cube([UWB_L-4, CRADLE_BACK_T+2*e, UWB_ANTENNA_L+4],
+                 center=[true,false,false]);
+        for (tx = [-ARM_W/4, ARM_W/4])
+            translate([tx, ARM_T/2-CRADLE_BACK_T, total_z/2])
+                rotate([-90,0,0])
+                    cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
+        for (side_x = [-outer_l/2-e, outer_l/2-CRADLE_WALL_T-e])
+            translate([side_x, 2, pcb_z+2])
+                cube([CRADLE_WALL_T+2*e, UWB_W-4, UWB_H-4]);
+    }
+    for (hx = [-UWB_HOLE_X/2, UWB_HOLE_X/2])
+    for (hy = [(outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2,
+               (outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2 + UWB_HOLE_Y])
+        difference() {
+            translate([hx, hy, CRADLE_FLOOR_T-e])
+                cylinder(d=STANDOFF_OD, h=STANDOFF_H+e);
+            translate([hx, hy, CRADLE_FLOOR_T-2*e])
+                cylinder(d=M2P5_D, h=STANDOFF_H+4);
+        }
+}
 
-        // ── M2 bores through standoffs ────────────────────────
+// ============================================================
-        for (hx=[0, MAWB_HOLE_X], hy=[0, MAWB_HOLE_Y])
+// PART 4 -- CABLE CLIP
-            translate([(ARM_W - MAWB_HOLE_X)/2 + hx,
+// ============================================================
-                       bk + (MAWB_L - MAWB_HOLE_Y)/2 + hy,
+// Snap-on C-clip retaining USB-C cable along tilt arm outer face.
-                       -e])
+// Presses onto ARM_T-wide arm with flexible PETG snap tongues.
-                cylinder(d=M2_D, h=M2_STNDFF + e);
+// Print x2-3 per anchor, spaced 25mm along arm.
-
+//
-        // ── Antenna clearance cutout in back wall ─────────────
+// Print: clip-opening face down, PETG, 3 perims, 20% infill.
-        // Open slot near top of back wall so antenna is unobstructed
+module cable_clip() {
-        translate([sd, -e, M2_STNDFF + 2])
+    ch_r   = CLIP_CABLE_D/2 + CLIP_T;
-            cube([ARM_W - 2*sd, bk + 2*e, MAWB_H]);
+    snap_t = 1.6;
-
+    difference() {
-        // ── USB port access notch on one side wall ────────────
+        union() {
-        translate([-e, bk + 2, M2_STNDFF - 1])
+            translate([-CLIP_BODY_W/2, 0, 0])
-            cube([sd + 2*e, USB_NOTCH_W, USB_NOTCH_H]);
+                cube([CLIP_BODY_W, CLIP_T, CLIP_BODY_H]);
-
+            translate([0, CLIP_T+ch_r, CLIP_BODY_H/2]) rotate([0,90,0])
-        // ── Mounting holes to collar arm boss (×2) ────────────
+                difference() {
-        for (dx=[-ARM_W/4, ARM_W/4])
+                    cylinder(r=ch_r, h=CLIP_BODY_W, center=true);
-            translate([ARM_W/2 + dx, bk + ARM_L/2, -e])
+                    cylinder(r=CLIP_CABLE_D/2, h=CLIP_BODY_W+2*e, center=true);
-                cylinder(d=COL_BOLT_D, h=6 + e);
+                    translate([0, ch_r+e, 0])
+                        cube([CLIP_CABLE_D*0.85, ch_r*2+2*e, CLIP_BODY_W+2*e],
+                             center=true);
+                }
+            for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
+                translate([tx, -ARM_T-1, 0])
+                    cube([snap_t, ARM_T+1+CLIP_T, CLIP_BODY_H]);
+            for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
+                translate([tx+snap_t/2, -ARM_T-1, CLIP_BODY_H/2])
+                    rotate([0,90,0]) cylinder(d=2, h=snap_t, center=true);
+        }
+        translate([0, -ARM_T-1-e, CLIP_BODY_H/2])
+            cube([CLIP_BODY_W-6, ARM_T+2, CLIP_BODY_H-4], center=true);
     }
 }
-
-// ─────────────────────────────────────────────────────────────
-// single_anchor_assembly()
-// ─────────────────────────────────────────────────────────────
-module single_anchor_assembly(show_phantom=false) {
-    // Collar
-    color("SteelBlue", 0.9)   collar_half("front");
-    color("CornflowerBlue", 0.9) mirror([0,1,0]) collar_half("rear");
-
-    // Bracket tilted BRKT_TILT° outward from top of arm boss
-    color("LightSteelBlue", 0.85)
-        translate([0, COL_OD/2 + ARM_L, COL_H * 0.3])
-            rotate([BRKT_TILT, 0, 0])
-                translate([-ARM_W/2, 0, 0])
-                    module_bracket();
-
-    // Phantom UWB PCB
-    if (show_phantom)
-        color("ForestGreen", 0.4)
-            translate([-MAWB_L/2,
-                       COL_OD/2 + ARM_L + BRKT_BACK_T,
-                       COL_H * 0.3 + M2_STNDFF])
-                cube([MAWB_L, MAWB_W, MAWB_H]);
-}
-
-// ─────────────────────────────────────────────────────────────
-// Render selector
-// ─────────────────────────────────────────────────────────────
-if (RENDER == "assembly") {
-    single_anchor_assembly(show_phantom=true);
-
-} else if (RENDER == "collar_front") {
-    collar_half("front");
-
-} else if (RENDER == "collar_rear") {
-    collar_half("rear");
-
-} else if (RENDER == "bracket") {
-    module_bracket();
-
-} else if (RENDER == "pair") {
-    // Both anchors at 250 mm spacing on a stem stub
-    color("Silver", 0.2)
-        translate([0, 0, -50])
-            cylinder(d=STEM_OD, h=ANCHOR_SPACING + COL_H + 100);
-
-    // Lower anchor (Z = 0)
-    single_anchor_assembly(show_phantom=true);
-
-    // Upper anchor (Z = ANCHOR_SPACING)
-    translate([0, 0, ANCHOR_SPACING])
-        single_anchor_assembly(show_phantom=true);
-}
-

chassis/vesc_mount.scad

@@ -0,0 +1,296 @@
+// ============================================================
+// vesc_mount.scad — FSESC 6.7 Pro Mini Dual ESC Mount Cradle
+// Issue #699 / sl-mechanical  2026-03-17
+// ============================================================
+// Open-top tray for Flipsky FSESC 6.7 Pro Mini Dual (~100 × 68 × 28 mm).
+// Attaches to 2020 aluminium T-slot rail via 4× M5 T-nuts
+// (2× per rail, two parallel rails, 60 mm bolt spacing in X,
+//  20 mm bolt spacing in Y matching 2020 slot pitch).
+//
+// Connector access:
+//   XT60 battery inputs    — X− end wall cutouts (2 connectors, side-by-side)
+//   XT30 motor outputs     — Y+ and Y− side wall cutouts (2 per side wall)
+//   CAN/UART terminal      — X+ end wall cutout (screw terminal, wire exit)
+//
+// Ventilation:
+//   Open top face          — heatsink fins fully exposed
+//   Floor grille slots     — under-board airflow
+//   Side vent louvres      — 4 slots on each Y± wall at heatsink height
+//
+// Retention: 4× M3 heat-set insert boss in floor — board screws down through
+// ESC mounting holes via M3×8 FHCS. Board sits on 4 mm raised posts for
+// under-board airflow.
+//
+// ⚠  VERIFY WITH CALIPERS BEFORE PRINTING:
+//    PCB_L, PCB_W                   board outline
+//    XT60_W, XT60_H                 XT60 shell at X− edge
+//    XT30_W, XT30_H                 XT30 shells at Y± edges
+//    TERM_W, TERM_H                 CAN screw terminal at X+ edge
+//    MOUNT_X1/X2, MOUNT_Y1/Y2      ESC board mounting hole pattern
+//
+// Print settings (PETG):
+//   3 perimeters, 40 % gyroid infill, no supports, 0.2 mm layer
+//   Print orientation: open face UP (as modelled)
+//
+// BOM:
+//   4 × M5×10 BHCS  +  4 × M5 slide-in T-nut  (2020 rail)
+//   4 × M3 heat-set insert (Voron-style, OD 4.5 mm × 4 mm deep)
+//   4 × M3×8 FHCS  (board retention)
+//
+// Export commands:
+//   openscad -D 'RENDER="mount"'    -o vesc_mount.stl    vesc_mount.scad
+//   openscad -D 'RENDER="assembly"' -o vesc_assembly.png vesc_mount.scad
+// ============================================================
+
+RENDER = "assembly"; // mount | assembly
+
+$fn = 48;
+EPS = 0.01;
+
+// ── ⚠ Verify before printing ─────────────────────────────────
+// FSESC 6.7 Pro Mini Dual PCB
+PCB_L    = 100.0;  // board length (X: XT60 end → CAN terminal end)
+PCB_W    =  68.0;  // board width  (Y)
+PCB_T    =  2.0;   // board thickness (incl. bottom-side components)
+COMP_H   =  26.0;  // tallest component above board top face (heatsink ~26 mm)
+
+// XT60 battery connectors at X− end (2 connectors, side-by-side)
+XT60_W   =  16.0;  // each XT60 shell width (Y)
+XT60_H   =  16.0;  // each XT60 shell height (Z) above board surface
+XT60_Z0  =   0.0;  // connector bottom offset above board surface
+// Y centres of each XT60 measured from PCB Y− edge
+XT60_Y1  =  16.0;
+XT60_Y2  =  52.0;
+
+// XT30 motor output connectors at Y± sides (2 per side)
+XT30_W   =  10.5;  // each XT30 shell width (X span)
+XT30_H   =  12.0;  // each XT30 shell height (Z) above board surface
+XT30_Z0  =   0.5;  // connector bottom offset above board surface
+// X centres measured from PCB X− edge (same layout both Y− and Y+ sides)
+XT30_X1  =  22.0;
+XT30_X2  =  78.0;
+
+// CAN / UART screw terminal block at X+ end (3-pos 3.5 mm pitch)
+TERM_W   =  14.0;  // terminal block Y span
+TERM_H   =  10.0;  // terminal block height above board surface
+TERM_Z0  =   0.5;  // terminal bottom offset above board surface
+TERM_Y_CTR = PCB_W / 2;
+
+// ── ESC board mounting hole pattern ──────────────────────────
+// 4 corner holes, 4 mm inset from each PCB edge
+MOUNT_INSET  =  4.0;
+MOUNT_X1     = MOUNT_INSET;
+MOUNT_X2     = PCB_L - MOUNT_INSET;
+MOUNT_Y1     = MOUNT_INSET;
+MOUNT_Y2     = PCB_W - MOUNT_INSET;
+
+M3_INSERT_OD =  4.6;   // Voron M3 heat-set insert press-fit OD
+M3_INSERT_H  =  4.0;   // insert depth
+M3_CLEAR_D   =  3.4;   // M3 clearance bore below insert
+
+// ── Cradle geometry ──────────────────────────────────────────
+WALL_T   =  2.8;   // side / end wall thickness
+FLOOR_T  =  4.5;   // floor plate thickness (fits M5 BHCS head pocket)
+POST_H   =  4.0;   // standoff post height (board lifts off floor for airflow)
+CL_SIDE  =  0.35;  // Y clearance per side
+CL_END   =  0.40;  // X clearance per end
+
+INN_W    = PCB_W + 2*CL_SIDE;
+INN_L    = PCB_L + 2*CL_END;
+INN_H    = POST_H + PCB_T + COMP_H + 1.5;
+
+OTR_W    = INN_W  + 2*WALL_T;
+OTR_L    = INN_L  + 2*WALL_T;
+OTR_H    = FLOOR_T + INN_H;
+
+PCB_X0   = WALL_T + CL_END;
+PCB_Y0   = WALL_T + CL_SIDE;
+PCB_Z0   = FLOOR_T + POST_H;
+
+// ── M5 T-nut mount (2020 rail) ────────────────────────────────
+// 4 bolts: 2 columns (X) × 2 rows (Y), centred on body
+M5_D       =  5.3;
+M5_HEAD_D  =  9.5;
+M5_HEAD_H  =  3.0;
+M5_SPAC_X  = 60.0;   // X bolt spacing
+M5_SPAC_Y  = 20.0;   // Y bolt spacing (2020 T-slot pitch)
+
+// ── Floor ventilation grille ──────────────────────────────────
+GRILLE_SLOT_W =  4.0;
+GRILLE_SLOT_T = FLOOR_T - 1.5;
+GRILLE_PITCH  = 10.0;
+GRILLE_X0     = WALL_T + 14;
+GRILLE_X_LEN  = OTR_L - 2*WALL_T - 28;
+GRILLE_N      = floor((INN_W - 10) / GRILLE_PITCH);
+
+// ── Side vent louvres on Y± walls ────────────────────────────
+LOUV_H     =  5.0;
+LOUV_W     = 12.0;
+LOUV_Z     = FLOOR_T + POST_H + PCB_T + 4.0;  // mid-heatsink height
+LOUV_N     =  4;
+LOUV_PITCH = (OTR_L - 2*WALL_T - 20) / max(LOUV_N - 1, 1);
+
+// ── CAN wire strain relief bosses (X+ end) ───────────────────
+SR_BOSS_OD =  7.0;
+SR_BOSS_H  =  6.0;
+SR_SLOT_W  =  3.5;
+SR_SLOT_T  =  2.2;
+SR_Y1      = WALL_T + INN_W * 0.25;
+SR_Y2      = WALL_T + INN_W * 0.75;
+SR_X       = OTR_L - WALL_T - SR_BOSS_OD/2 - 2.5;
+
+// ─────────────────────────────────────────────────────────────
+module m3_insert_boss() {
+    // Solid post with heat-set insert bore from top
+    post_h = FLOOR_T + POST_H;
+    difference() {
+        cylinder(d = M3_INSERT_OD + 3.2, h = post_h);
+        // Insert bore from top
+        translate([0, 0, post_h - M3_INSERT_H])
+            cylinder(d = M3_INSERT_OD, h = M3_INSERT_H + EPS);
+        // Clearance bore from bottom
+        translate([0, 0, -EPS])
+            cylinder(d = M3_CLEAR_D, h = post_h - M3_INSERT_H + EPS);
+    }
+}
+
+module vesc_mount() {
+    difference() {
+        union() {
+            // Main body
+            cube([OTR_L, OTR_W, OTR_H]);
+
+            // M3 insert bosses at board mounting corners
+            for (mx = [MOUNT_X1, MOUNT_X2])
+            for (my = [MOUNT_Y1, MOUNT_Y2])
+                translate([PCB_X0 + mx, PCB_Y0 + my, 0])
+                    m3_insert_boss();
+
+            // CAN strain relief bosses on X+ end
+            for (sy = [SR_Y1, SR_Y2])
+                translate([SR_X, sy, 0])
+                    cylinder(d = SR_BOSS_OD, h = SR_BOSS_H);
+        }
+
+        // ── Interior cavity (open top) ─────────────────────────
+        translate([WALL_T, WALL_T, FLOOR_T])
+            cube([INN_L, INN_W, INN_H + EPS]);
+
+        // ── XT60 cutouts at X− end (2 connectors) ──────────────
+        for (yc = [XT60_Y1, XT60_Y2])
+            translate([-EPS,
+                       PCB_Y0 + yc - (XT60_W + 2.0)/2,
+                       PCB_Z0 + XT60_Z0 - 0.5])
+                cube([WALL_T + 2*EPS, XT60_W + 2.0, XT60_H + 3.0]);
+
+        // ── XT30 cutouts at Y− side (2 connectors) ─────────────
+        for (xc = [XT30_X1, XT30_X2])
+            translate([PCB_X0 + xc - (XT30_W + 2.0)/2,
+                       -EPS,
+                       PCB_Z0 + XT30_Z0 - 0.5])
+                cube([XT30_W + 2.0, WALL_T + 2*EPS, XT30_H + 3.0]);
+
+        // ── XT30 cutouts at Y+ side (2 connectors) ─────────────
+        for (xc = [XT30_X1, XT30_X2])
+            translate([PCB_X0 + xc - (XT30_W + 2.0)/2,
+                       OTR_W - WALL_T - EPS,
+                       PCB_Z0 + XT30_Z0 - 0.5])
+                cube([XT30_W + 2.0, WALL_T + 2*EPS, XT30_H + 3.0]);
+
+        // ── CAN terminal cutout at X+ end ──────────────────────
+        translate([OTR_L - WALL_T - EPS,
+                   PCB_Y0 + TERM_Y_CTR - (TERM_W + 3.0)/2,
+                   PCB_Z0 + TERM_Z0 - 0.5])
+            cube([WALL_T + 2*EPS, TERM_W + 3.0, TERM_H + 5.0]);
+
+        // ── Floor ventilation grille ───────────────────────────
+        for (i = [0 : GRILLE_N - 1]) {
+            sy = WALL_T + 5 + i * GRILLE_PITCH;
+            translate([GRILLE_X0, sy, -EPS])
+                cube([GRILLE_X_LEN, GRILLE_SLOT_W, GRILLE_SLOT_T + EPS]);
+        }
+
+        // ── Side vent louvres — Y− wall ────────────────────────
+        for (i = [0 : LOUV_N - 1]) {
+            lx = WALL_T + 10 + i * LOUV_PITCH;
+            translate([lx, -EPS, LOUV_Z])
+                cube([LOUV_W, WALL_T + 2*EPS, LOUV_H]);
+        }
+
+        // ── Side vent louvres — Y+ wall ────────────────────────
+        for (i = [0 : LOUV_N - 1]) {
+            lx = WALL_T + 10 + i * LOUV_PITCH;
+            translate([lx, OTR_W - WALL_T - EPS, LOUV_Z])
+                cube([LOUV_W, WALL_T + 2*EPS, LOUV_H]);
+        }
+
+        // ── M5 BHCS head pockets (4 bolts, bottom face) ────────
+        for (mx = [OTR_L/2 - M5_SPAC_X/2, OTR_L/2 + M5_SPAC_X/2])
+        for (my = [OTR_W/2 - M5_SPAC_Y/2, OTR_W/2 + M5_SPAC_Y/2])
+            translate([mx, my, -EPS]) {
+                cylinder(d = M5_D,      h = FLOOR_T + 2*EPS);
+                cylinder(d = M5_HEAD_D, h = M5_HEAD_H + EPS);
+            }
+
+        // ── Zip-tie slots through CAN strain relief bosses ─────
+        for (sy = [SR_Y1, SR_Y2])
+            translate([SR_X, sy, SR_BOSS_H/2 - SR_SLOT_T/2])
+                rotate([0, 90, 0])
+                    cube([SR_SLOT_T, SR_SLOT_W, SR_BOSS_OD + 2*EPS],
+                         center = true);
+
+        // ── Weight-relief pocket in floor underside ─────────────
+        translate([WALL_T + 16, WALL_T + 6, -EPS])
+            cube([OTR_L - 2*WALL_T - 32, OTR_W - 2*WALL_T - 12,
+                  FLOOR_T - 2.0 + EPS]);
+    }
+}
+
+// ── Assembly preview ─────────────────────────────────────────
+if (RENDER == "assembly") {
+    color("DimGray", 0.93) vesc_mount();
+
+    // Phantom PCB
+    color("ForestGreen", 0.30)
+        translate([PCB_X0, PCB_Y0, PCB_Z0])
+            cube([PCB_L, PCB_W, PCB_T]);
+
+    // Phantom heatsink / component block
+    color("SlateGray", 0.22)
+        translate([PCB_X0, PCB_Y0, PCB_Z0 + PCB_T])
+            cube([PCB_L, PCB_W, COMP_H]);
+
+    // XT60 connector highlights (X− end)
+    for (yc = [XT60_Y1, XT60_Y2])
+        color("Gold", 0.85)
+            translate([-2,
+                       PCB_Y0 + yc - XT60_W/2,
+                       PCB_Z0 + XT60_Z0])
+                cube([WALL_T + 3, XT60_W, XT60_H]);
+
+    // XT30 connector highlights — Y− side
+    for (xc = [XT30_X1, XT30_X2])
+        color("OrangeRed", 0.80)
+            translate([PCB_X0 + xc - XT30_W/2,
+                       -2,
+                       PCB_Z0 + XT30_Z0])
+                cube([XT30_W, WALL_T + 3, XT30_H]);
+
+    // XT30 connector highlights — Y+ side
+    for (xc = [XT30_X1, XT30_X2])
+        color("OrangeRed", 0.80)
+            translate([PCB_X0 + xc - XT30_W/2,
+                       OTR_W - WALL_T - 1,
+                       PCB_Z0 + XT30_Z0])
+                cube([XT30_W, WALL_T + 3, XT30_H]);
+
+    // CAN terminal highlight
+    color("Tomato", 0.75)
+        translate([OTR_L - WALL_T - 1,
+                   PCB_Y0 + TERM_Y_CTR - TERM_W/2,
+                   PCB_Z0 + TERM_Z0])
+            cube([WALL_T + 3, TERM_W, TERM_H]);
+
+} else {
+    vesc_mount();
+}

docs/AGENTS.md

@@ -0,0 +1,323 @@
+# AGENTS.md — SaltyLab Agent Onboarding
+
+You're working on **SaltyLab**, a self-balancing two-wheeled indoor robot. Read this entire file before touching anything.
+
+## ⚠️ ARCHITECTURE — SAUL-TEE (finalised 2026-04-04)
+
+<<<<<<< HEAD
+Full hardware spec: `docs/SAUL-TEE-SYSTEM-REFERENCE.md` — **read it before writing firmware.**
+
+| Board | Role |
+|-------|------|
+| **ESP32-S3 BALANCE** | Waveshare Touch LCD 1.28 (CH343 USB). QMI8658 IMU, PID loop, CAN→VESC L(68)/R(56), GC9A01 LCD |
+| **ESP32-S3 IO** | Bare devkit (JTAG USB). TBS Crossfire RC (UART0), ELRS failover (UART2), BTS7960 motors, NFC/baro/ToF, WS2812, buzzer/horn/headlight/fan |
+| **Jetson Orin** | CANable2 USB→CAN. Cmds on 0x300–0x303, telemetry on 0x400–0x401 |
+
+```
+Jetson Orin ──CANable2──► CAN 500kbps ◄───────────────────────┐
+                                │                               │
+                         ESP32-S3 BALANCE ←─UART 460800─► ESP32-S3 IO
+                         (QMI8658, PID loop)              (BTS7960, RC, sensors)
+                                │ CAN 500kbps
+                      ┌─────────┴──────────┐
+                 VESC Left (ID 68)    VESC Right (ID 56)
+=======
+A hoverboard-based balancing robot with two compute layers:
+1. **ESP32-S3 BALANCE** — ESP32-S3 BALANCE (ESP32-S3RET6 + MPU6000 IMU). Runs a lean C balance loop at up to 8kHz. Talks UART to the hoverboard ESC. This is the safety-critical layer.
+2. **Jetson Orin Nano Super** — AI brain. ROS2, SLAM, person tracking. Sends velocity commands to FC via UART. Not safety-critical — FC operates independently.
+
+```
+Jetson (speed+steer via UART1)  ←→  ELRS RC (UART3, kill switch)
+         │
+         ▼
+   ESP32-S3 BALANCE (MPU6000 IMU, PID balance)
+         │
+         ▼ UART2
+   Hoverboard ESC (FOC) → 2× 8" hub motors
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+```
+
+Frame: `[0xAA][LEN][TYPE][PAYLOAD][CRC8]`  
+Legacy `src/` STM32 HAL code is **archived — do not extend.**
+
+## ⚠️ SAFETY — READ THIS OR PEOPLE GET HURT
+
+This is not a toy. 8" hub motors + 36V battery can crush fingers, break toes, and launch the frame. Every firmware change must preserve these invariants:
+
+1. **Motors NEVER spin on power-on.** Requires deliberate arming: hold button 3s while upright.
+2. **Tilt cutoff at ±25°** — motors to zero, require manual re-arm. No retry, no recovery.
+3. **Hardware watchdog (50ms)** — if firmware hangs, motors cut.
+4. **RC kill switch** — dedicated ELRS channel, checked every loop iteration. Always overrides.
+5. **Jetson UART timeout (200ms)** — if Jetson disconnects, motors cut.
+6. **Speed hard cap** — firmware limit, start at 10%. Increase only after proven stable.
+7. **Never test untethered** until PID is stable for 5+ minutes on a tether.
+
+**If you break any of these, you are removed from the project.**
+
+## Repository Layout
+
+```
+<<<<<<< HEAD
+firmware/              # Legacy ESP32/STM32 HAL firmware (PlatformIO, archived)
+=======
+firmware/              # ESP-IDF firmware (PlatformIO)
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+├── src/
+│   ├── main.c         # Entry point, clock config, main loop
+│   ├── icm42688.c     # QMI8658-P SPI driver (backup IMU — currently broken)
+│   ├── bmp280.c       # Barometer driver (disabled)
+│   └── status.c       # LED + buzzer status patterns
+├── include/
+│   ├── config.h       # Pin definitions, constants
+│   ├── icm42688.h
+│   ├── mpu6000.h      # MPU6000 driver header (primary IMU)
+│   ├── hoverboard.h   # Hoverboard ESC UART protocol
+│   ├── crsf.h         # ELRS CRSF protocol
+│   ├── bmp280.h
+│   └── status.h
+├── lib/USB_CDC/       # USB Serial (CH343) stack (serial over USB)
+│   ├── src/           # CDC implementation, USB descriptors, PCD config
+│   └── include/
+└── platformio.ini     # Build config
+
+cad/                   # OpenSCAD parametric parts (16 files)
+├── dimensions.scad    # ALL measurements live here — single source of truth
+├── assembly.scad      # Full robot assembly visualization
+├── motor_mount_plate.scad
+├── battery_shelf.scad
+├── fc_mount.scad      # Vibration-isolated FC mount
+├── jetson_shelf.scad
+├── esc_mount.scad
+├── sensor_tower_top.scad
+├── lidar_standoff.scad
+├── realsense_bracket.scad
+├── bumper.scad        # TPU bumpers (front + rear)
+├── handle.scad
+├── kill_switch_mount.scad
+├── tether_anchor.scad
+├── led_diffuser_ring.scad
+└── esp32c3_mount.scad
+
+ui/                    # Web UI (Three.js + WebSerial)
+└── index.html         # 3D board visualization, real-time IMU data
+
+SALTYLAB.md            # Master design doc — architecture, wiring, build phases
+SALTYLAB-DETAILED.md   # Power budget, weight budget, detailed schematics
+PLATFORM.md            # Hardware platform reference
+```
+
+## Hardware Quick Reference
+
+<<<<<<< HEAD
+### ESP32 BALANCE Flight Controller
+
+| Spec | Value |
+|------|-------|
+| MCU | ESP32RET6 (Cortex-M7, 216MHz, 512KB flash, 256KB RAM) |
+=======
+### ESP32-S3 BALANCE Flight Controller
+
+| Spec | Value |
+|------|-------|
+| MCU | ESP32-S3RET6 (Cortex-M7, 216MHz, 512KB flash, 256KB RAM) |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+| Primary IMU | MPU6000 (WHO_AM_I = 0x68) |
+| IMU Bus | SPI1: PA5=SCK, PA6=MISO, PA7=MOSI, CS=PA4 |
+| IMU EXTI | PC4 (data ready interrupt) |
+| IMU Orientation | CW270 (Betaflight convention) |
+| Secondary IMU | QMI8658-P (on same SPI1, CS unknown — currently non-functional) |
+| Betaflight Target | DIAT-MAMBAF722_2022B |
+| USB | OTG FS (PA11/PA12), enumerates as /dev/cu.usbmodemSALTY0011 |
+| VID/PID | 0x0483/0x5740 |
+| LEDs | PC15 (LED1), PC14 (LED2), active low |
+| Buzzer | PB2 (inverted push-pull) |
+| Battery ADC | PC1=VBAT, PC3=CURR (ADC3) |
+| DFU | Hold yellow BOOT button + plug USB (or send 'R' over CDC) |
+
+### UART Assignments
+
+| UART | Pins | Connected To | Baud |
+|------|------|-------------|------|
+| USART1 | PA9/PA10 | Jetson Orin Nano Super | 115200 |
+| USART2 | PA2/PA3 | Hoverboard ESC | 115200 |
+| USART3 | PB10/PB11 | ELRS Receiver | 420000 (CRSF) |
+| UART4 | — | Spare | — |
+| UART5 | — | Spare | — |
+
+### Motor/ESC
+
+- 2× 8" pneumatic hub motors (36V, hoverboard type)
+- Hoverboard ESC with FOC firmware
+- UART protocol: `{0xABCD, int16 speed, int16 steer, uint16 checksum}` at 115200
+- Speed range: -1000 to +1000
+
+### Physical Dimensions (from `cad/dimensions.scad`)
+
+| Part | Key Measurement |
+|------|----------------|
+| FC mounting holes | 25.5mm spacing (NOT standard 30.5mm!) |
+| FC board size | ~36mm square |
+| Hub motor body | Ø200mm (~8") |
+| Motor axle | Ø12mm, 45mm long |
+| Jetson Orin Nano Super | 100×80×29mm, M2.5 holes at 86×58mm |
+| RealSense D435i | 90×25×25mm, 1/4-20 tripod mount |
+| RPLIDAR A1 | Ø70×41mm, 4× M2.5 on Ø67mm circle |
+| Kill switch hole | Ø22mm panel mount |
+| Battery pack | ~180×80×40mm |
+| Hoverboard ESC | ~80×50×15mm |
+| 2020 extrusion | 20mm square, M5 center bore |
+| Frame width | ~350mm (axle to axle) |
+| Frame height | ~500-550mm total |
+| Target weight | <8kg (current estimate: 7.4kg) |
+
+### 3D Printed Parts (16 files in `cad/`)
+
+| Part | Material | Infill |
+|------|----------|--------|
+| motor_mount_plate (350×150×6mm) | PETG | 80% |
+| battery_shelf | PETG | 60% |
+| esc_mount | PETG | 40% |
+| jetson_shelf | PETG | 40% |
+| sensor_tower_top | ASA | 80% |
+| lidar_standoff (Ø80×80mm) | ASA | 40% |
+| realsense_bracket | PETG | 60% |
+| fc_mount (vibration isolated) | TPU+PETG | — |
+| bumper front + rear (350×50×30mm) | TPU | 30% |
+| handle | PETG | 80% |
+| kill_switch_mount | PETG | 80% |
+| tether_anchor | PETG | 100% |
+| led_diffuser_ring (Ø120×15mm) | Clear PETG | 30% |
+| esp32c3_mount | PETG | 40% |
+
+## Firmware Architecture
+
+### Critical Lessons Learned (DON'T REPEAT THESE)
+
+1. **SysTick_Handler with HAL_IncTick() is MANDATORY** — without it, HAL_Delay() and every HAL timeout hangs forever. This bricked us multiple times.
+<<<<<<< HEAD
+2. **DCache breaks SPI on ESP32** — disable DCache or use cache-aligned DMA buffers with clean/invalidate. We disable it.
+=======
+2. **DCache breaks SPI on ESP32-S3** — disable DCache or use cache-aligned DMA buffers with clean/invalidate. We disable it.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+3. **`-(int)0 == 0`** — checking `if (-result)` to detect errors doesn't work when result is 0 (success and failure look the same). Always use explicit error codes.
+4. **NEVER auto-run untested code on_boot** — we bricked the NSPanel 3x doing this. Test manually first.
+5. **USB Serial (CH343) needs ReceivePacket() primed in CDC_Init** — without it, the OUT endpoint never starts listening. No data reception.
+
+### DFU Reboot (Betaflight Method)
+
+The firmware supports reboot-to-DFU via USB command:
+1. Send `R` byte over USB Serial (CH343)
+2. Firmware writes `0xDEADBEEF` to RTC backup register 0
+3. `NVIC_SystemReset()` — clean hardware reset
+4. On boot, `checkForBootloader()` (called after `HAL_Init()`) reads the magic
+<<<<<<< HEAD
+5. If magic found: clears it, remaps system memory, jumps to ESP32 BALANCE bootloader at `0x1FF00000`
+=======
+5. If magic found: clears it, remaps system memory, jumps to ESP32-S3 bootloader at `0x1FF00000`
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+6. Board appears as DFU device, ready for `dfu-util` flash
+
+### Build & Flash
+
+```bash
+cd firmware/
+python3 -m platformio run                    # Build
+dfu-util -a 0 -s 0x08000000:leave -D .pio/build/f722/firmware.bin  # Flash
+```
+
+Dev machine: mbpm4 (seb@192.168.87.40), PlatformIO project at `~/Projects/saltylab-firmware/`
+
+### Clock Configuration
+
+```
+HSE 8MHz → PLL (M=8, N=432, P=2, Q=9) → SYSCLK 216MHz
+PLLSAI (N=384, P=8) → CLK48 48MHz (USB)
+APB1 = HCLK/4 = 54MHz
+APB2 = HCLK/2 = 108MHz
+Fallback: HSI 16MHz if HSE fails (PLL M=16)
+```
+
+## Current Status & Known Issues
+
+### Working
+- USB Serial (CH343) serial streaming (50Hz JSON: `{"ax":...,"ay":...,"az":...,"gx":...,"gy":...,"gz":...}`)
+- Clock config with HSE + HSI fallback
+- Reboot-to-DFU via USB 'R' command
+- LED status patterns (status.c)
+- Web UI with WebSerial + Three.js 3D visualization
+
+### Broken / In Progress
+- **QMI8658-P SPI reads return all zeros** — was the original IMU target, but SPI communication completely non-functional despite correct pin config. May be dead silicon. Switched to MPU6000 as primary.
+- **MPU6000 driver** — header exists but implementation needs completion
+- **PID balance loop** — not yet implemented
+- **Hoverboard ESC UART** — protocol defined, driver not written
+- **ELRS CRSF receiver** — protocol defined, driver not written
+- **Barometer (BMP280)** — I2C init hangs, disabled
+
+### TODO (Priority Order)
+1. Get MPU6000 streaming accel+gyro data
+2. Implement complementary filter (pitch angle)
+3. Write hoverboard ESC UART driver
+4. Write PID balance loop with safety checks
+5. Wire ELRS receiver, implement CRSF parser
+6. Bench test (ESC disconnected, verify PID output)
+7. First tethered balance test at 10% speed
+8. Jetson UART integration
+9. LED subsystem (ESP32-C3)
+
+## Communication Protocols
+
+### Jetson → FC (UART1, 50Hz)
+```c
+struct { uint8_t header=0xAA; int16_t speed; int16_t steer; uint8_t mode; uint8_t checksum; };
+// mode: 0=idle, 1=balance, 2=follow, 3=RC
+```
+
+### FC → Hoverboard ESC (UART2, loop rate)
+```c
+struct { uint16_t start=0xABCD; int16_t speed; int16_t steer; uint16_t checksum; };
+// speed/steer: -1000 to +1000
+```
+
+### FC → Jetson Telemetry (UART1 TX, 50Hz)
+```
+T:12.3,P:45,L:100,R:-80,S:3\n
+// T=tilt°, P=PID output, L/R=motor commands, S=state (0-3)
+```
+
+### FC → USB Serial (CH343) (50Hz JSON)
+```json
+{"ax":123,"ay":-456,"az":16384,"gx":10,"gy":-5,"gz":3,"t":250,"p":0,"bt":0}
+// Raw IMU values (int16), t=temp×10, p=pressure, bt=baro temp
+```
+
+## LED Subsystem (ESP32-C3)
+
+ESP32-C3 eavesdrops on FC→Jetson telemetry (listen-only tap on UART1 TX). No extra FC UART needed.
+
+| State | Pattern | Color |
+|-------|---------|-------|
+| Disarmed | Slow breathe | White |
+| Arming | Fast blink | Yellow |
+| Armed idle | Solid | Green |
+| Turning | Sweep direction | Orange |
+| Braking | Flash rear | Red |
+| Fault | Triple flash | Red |
+| RC lost | Alternating flash | Red/Blue |
+
+## Printing (Bambu Lab)
+
+- **X1C** (192.168.87.190) — for structural PETG/ASA parts
+- **A1** (192.168.86.161) — for TPU bumpers and prototypes
+- LAN access codes and MQTT details in main workspace MEMORY.md
+- STL export from OpenSCAD, slice in Bambu Studio
+
+## Rules for Agents
+
+1. **Read SALTYLAB.md fully** before making any design decisions
+2. **Never remove safety checks** from firmware — add more if needed
+3. **All measurements go in `cad/dimensions.scad`** — single source of truth
+4. **Test firmware on bench before any motor test** — ESC disconnected, verify outputs on serial
+5. **One variable at a time** — don't change PID and speed limit in the same test
+6. **Document what you change** — update this file if you add pins, change protocols, or discover hardware quirks
+7. **Ask before wiring changes** — wrong connections can fry the FC ($50+ board)

docs/FACE_LCD_ANIMATION.md

@@ -1,6 +1,10 @@
 # Face LCD Animation System (Issue #507)
 
-Implements expressive face animations on an STM32 LCD display with 5 core emotions and smooth transitions.
+<<<<<<< HEAD
+Implements expressive face animations on an ESP32 LCD display with 5 core emotions and smooth transitions.
+=======
+Implements expressive face animations on an ESP32-S3 LCD display with 5 core emotions and smooth transitions.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Features
 
@@ -82,7 +86,11 @@ STATUS      → Echo current emotion + idle state
 - Colors: Monochrome (1-bit) or RGB565
 
 ### Microcontroller
-- STM32F7xx (Mamba F722S)
+<<<<<<< HEAD
+- ESP32xx (ESP32 BALANCE)
+=======
+- ESP32-S3xx (ESP32-S3 BALANCE)
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 - Available UART: USART3 (PB10=TX, PB11=RX)
 - Clock: 216 MHz
 

docs/PLATFORM.md

@@ -0,0 +1,222 @@
+# SaltyRover — Modular Platform Design 🧂🛞
+
+## Design Philosophy
+- **Modular:** Standardized mounting points for swappable top decks
+- **Printable:** Main structural brackets on Bambu X1C (256x256x256mm) and A1 (256x256x256mm)
+- **Repairable:** Bolt-together, no permanent welds/glue on structural parts
+- **Weatherproof-ish:** Splash resistant for outdoor use, not submarine
+
+## Base Platform ("Skateboard")
+
+### Frame
+```
+        FRONT
+   ┌─────────────────┐
+   │  ┌─M1─┐   ┌─M2─┐ │      M1-M4: 6.5" hub motors
+   │  │    │   │    │ │      ESC1 drives M1+M2 (front)
+   │  └────┘   └────┘ │      ESC2 drives M3+M4 (rear)
+   │                   │
+   │  ┌──────────────┐ │
+   │  │   BATTERY    │ │      Center-mounted battery bay
+   │  │    BAY       │ │      Fits 2x hoverboard packs (2P)
+   │  └──────────────┘ │
+   │                   │
+   │  ┌─ESC1─┐┌─ESC2─┐ │      ESCs flanking center
+   │  └──────┘└──────┘ │
+   │  ┌──5V──┐┌─12V──┐ │      DC-DC converters
+   │  └──────┘└──────┘ │
+   │                   │
+   │  ┌─M3─┐   ┌─M4─┐ │
+   │  │    │   │    │ │
+   │  └────┘   └────┘ │
+   └─────────────────┘
+        REAR
+
+   Overall: ~600mm L × 450mm W × ~120mm H (base only)
+```
+
+### Dimensions
+- **Length:** 600mm (motor center to motor center ~500mm, +50mm overhang each end)
+- **Width:** 450mm (constrained by motor axle-to-axle, ~350mm inner + motor housings)
+- **Ground clearance:** ~50mm (bottom of frame to ground)
+- **Wheelbase:** 500mm (front axle to rear axle)
+- **Track width:** 350mm (left wheel center to right wheel center)
+
+### Frame Construction
+- **Main rails (x2):** Aluminum extrusion 2040 V-slot, 600mm length
+  - Or: 40x20mm aluminum rectangular tube
+  - Or: 3D printed with steel rod reinforcement
+- **Cross members (x3):** Front, center, rear — aluminum or printed
+- **Motor mounts (x4):** 3D printed brackets, bolted to frame rails
+  - Must accommodate 6.5" hub motor axle (standard hoverboard M10 axle)
+  - Axle clamp style — two-piece with bolts for easy wheel swap
+
+### Modular Top Deck Interface
+```
+   ┌─────────────────────┐
+   │  ○    ○    ○    ○   │   ← M5 threaded inserts, 100mm grid
+   │                     │
+   │  ○    ○    ○    ○   │   Standard mounting pattern:
+   │                     │   - 400mm × 300mm grid
+   │  ○    ○    ○    ○   │   - M5 bolt holes on 100mm centers
+   │                     │   - 16 mount points total
+   │  ○    ○    ○    ○   │
+   └─────────────────────┘
+```
+
+**Top deck connector:**
+- 16x M5 threaded inserts in frame top rails
+- 100mm grid spacing
+- Any top deck just needs matching bolt holes
+- Power connector: XT30 (5V + 12V + GND) standardized position at rear-center
+- Data connector: USB-A hub mounted to frame, accessible from top
+
+## Top Deck Configurations
+
+### Config 1: "Follow Bot" (Primary)
+```
+   ┌─────────────────────┐
+   │    [RPLIDAR A1M8]   │   ← Top-mounted, unobstructed 360°
+   │     ╱spinning╲      │     Raised on 100mm standoff
+   │                     │
+   │  [RealSense D435i]  │   ← Front-facing, angled down ~10°
+   │                     │     Height: ~400mm from ground
+   │  [Jetson Orin Nano Super]      │   ← Center, in ventilated enclosure
+   │  [WiFi/4G module]   │     Noctua fan draws air through
+   │                     │
+   │  [Speaker]  [LEDs]  │   ← Rear: audio feedback + status
+   │  [E-STOP button]    │     Big red mushroom button
+   └─────────────────────┘
+```
+
+**Parts:**
+- Sensor tower: 3D printed, 100mm tall, mounts LIDAR on top
+- RealSense bracket: 3D printed, adjustable tilt
+- Jetson enclosure: 3D printed, ventilated, vibration dampened
+- LED strip ring: NeoPixel/WS2812B around sensor tower (status indication)
+
+### Config 2: "Cargo Hauler"
+```
+   ┌─────────────────────┐
+   │  ┌─────────────────┐ │
+   │  │                 │ │   Flat cargo platform
+   │  │   CARGO AREA    │ │   400 × 300 × 150mm
+   │  │   (open top)    │ │   With tie-down points
+   │  │                 │ │
+   │  └─────────────────┘ │
+   │  [GPS] [Beacon]      │   Minimal autonomy — follows beacon
+   └─────────────────────┘
+```
+
+### Config 3: "Camera Rig"
+```
+   ┌─────────────────────┐
+   │      [Gimbal]       │   2-axis stabilized camera mount
+   │     [Action Cam]    │   GoPro / Insta360
+   │                     │
+   │  [Jetson + storage] │   Records while following
+   │  [Large battery]    │   Extended runtime for filming
+   └─────────────────────┘
+```
+
+### Config 4: "Security Patrol"
+```
+   ┌─────────────────────┐
+   │    [RPLIDAR]        │   Autonomous waypoint patrol
+   │  [PTZ Camera]       │   Pan-tilt-zoom camera
+   │  [Spotlight]        │   High-power LED
+   │  [Jetson + 4G]      │   Streams to Frigate
+   │  [Siren/Speaker]    │
+   └─────────────────────┘
+```
+
+## 3D Printed Parts List (Config 1: Follow Bot)
+
+All designed for Bambu X1C/A1 build plate (256x256mm max).
+
+| Part | Size (mm) | Material | Infill | Qty |
+|------|-----------|----------|--------|-----|
+| Motor mount bracket | 80×60×40 | PETG/ASA | 60% | 4 |
+| Motor mount clamp top | 80×40×15 | PETG/ASA | 60% | 4 |
+| Cross member front | 350×40×20 | PETG/ASA | 80% | 1 |
+| Cross member center | 350×60×20 | PETG/ASA | 80% | 1 |
+| Cross member rear | 350×40×20 | PETG/ASA | 80% | 1 |
+| Battery tray | 250×150×30 | PETG | 40% | 1 |
+| Battery strap anchor | 40×20×15 | PETG | 100% | 4 |
+| ESC mount tray | 150×100×15 | PETG | 40% | 2 |
+| DC-DC mount | 80×60×15 | PETG | 40% | 2 |
+| Sensor tower base | 120×120×10 | ASA | 80% | 1 |
+| Sensor tower tube | Ø80×100 | ASA | 40% | 1 |
+| LIDAR mount plate | Ø90×5 | ASA | 100% | 1 |
+| RealSense bracket | 100×50×60 | PETG | 60% | 1 |
+| Jetson enclosure bottom | 120×100×25 | PETG | 40% | 1 |
+| Jetson enclosure top | 120×100×25 | PETG | 40% | 1 |
+| E-stop mount | 50×50×30 | PETG | 60% | 1 |
+| Wire management clips | 20×15×10 | PETG | 100% | 10 |
+| Fender/splash guard | 200×80×60 | ASA | 30% | 4 |
+
+**Material notes:**
+- **ASA** for outdoor/exposed parts (UV resistant, weather resistant)
+- **PETG** for structural internal parts (strong, slight flex)
+- Avoid PLA — warps in summer sun
+
+## Electrical Wiring
+
+```
+PACK1 ═╤═ PACK2 (parallel, XT60)
+        │
+        ├──→ ESC1 ──→ M1 (front-left) + M2 (front-right)
+        │     │
+        │     └── UART TX/RX ──→ Jetson GPIO
+        │
+        ├──→ ESC2 ──→ M3 (rear-left) + M4 (rear-right)
+        │     │
+        │     └── UART TX/RX ──→ Jetson GPIO
+        │
+        ├──→ DC-DC 36V→5V ──→ Jetson Orin Nano Super (barrel jack 5V/4A)
+        │                  ──→ USB hub (sensors)
+        │
+        ├──→ DC-DC 36V→12V ──→ LED strips
+        │                   ──→ Speaker amp
+        │                   ──→ 4G modem
+        │
+        └──→ E-STOP (normally closed, inline with main power)
+```
+
+### ESC UART Protocol (FOC firmware)
+- Baud: 115200 (or 9600, configurable)
+- Each ESC: `steer` + `speed` as int16 values (-1000 to +1000)
+- ESC1 (front): Jetson UART1
+- ESC2 (rear): Jetson UART2 (or USB-serial adapter)
+
+### Differential Drive Control
+```
+Left speed  = throttle - steering
+Right speed = throttle + steering
+
+For 4WD: front and rear ESCs get same commands
+(or: rear slightly less for better turning)
+```
+
+## Assembly Order
+1. Cut/prepare frame rails (aluminum extrusion or tube)
+2. Print all brackets and mounts
+3. Assemble frame with cross members
+4. Mount motors to brackets, attach to frame
+5. Install battery tray, strap packs
+6. Mount ESCs and DC-DC converters
+7. Wire power distribution (XT60 splitters)
+8. Install E-stop inline
+9. Mount top deck with sensor tower
+10. Wire data connections (UART, USB)
+11. First test: power on, spin motors manually via serial terminal
+12. Flash follow-bot software to Jetson
+13. Outdoor test in parking lot
+
+## Next Steps
+- [ ] Measure exact motor axle dimensions and spacing
+- [ ] Choose frame material (aluminum extrusion vs printed vs hybrid)
+- [ ] Design motor mount bracket in CAD (FreeCAD/Fusion360)
+- [ ] Print test motor mount, verify fit
+- [ ] Design and print sensor tower
+- [ ] Bench test: Jetson → UART → ESC → single motor spinning

docs/SALTYLAB-DETAILED.md

@@ -0,0 +1,454 @@
+# SaltyLab — Detailed Build Plan 🔬⚖️
+
+Self-balancing two-wheeled indoor robot with AI brain.
+
+---
+
+## 1. Battery Analysis
+
+### Pack Specs (Begode Master V1 packs)
+- **Configuration per pack:** 10S (35V nominal, 42V full, 30V cutoff)
+- **Chemistry:** Li-ion 18650 or 21700
+- **Estimated capacity per pack:** ~450-500Wh (based on Master V1 total ~1800Wh ÷ 4 packs)
+  - If 10S4P with 21700 5000mAh cells: 36V × 20Ah = **720Wh**
+  - If 10S3P with 21700 5000mAh cells: 36V × 15Ah = **540Wh**
+  - If 10S4P with 18650 3500mAh cells: 36V × 14Ah = **504Wh**
+  - **Need to verify:** check cell count visible on pack, or weigh it
+
+### SaltyLab Battery Config: Single Pack
+- **Voltage:** 35V nominal (fits hoverboard ESC: designed for 36V/10S)
+- **Capacity:** ~500Wh (conservative estimate)
+- **Weight:** ~2-3kg per pack
+
+### Why Single Pack is Enough
+- SaltyLab is indoor-only, short missions
+- One pack gives 2-4 hours runtime (see estimates below)
+- Keep other 3 packs for SaltyRider and SaltyTank
+
+---
+
+## 2. Power Budget & Range Estimation
+
+### Component Power Draw
+
+| Component | Voltage | Current | Power (W) | Notes |
+|-----------|---------|---------|-----------|-------|
+| Jetson Orin Nano Super | 5V | 2-4A | 10-20W | AI inference mode: ~15W avg |
+| RealSense D435i | 5V (USB) | 0.7A | 3.5W | Depth + RGB streaming |
+| RPLIDAR A1M8 | 5V | 0.5A | 2.5W | Spinning at 5.5Hz |
+| BNO055 IMU | 3.3V | 0.01A | 0.04W | Negligible |
+| ESC (idle/balance) | 36V | 0.3A | 10W | Maintaining balance, no movement |
+| LEDs + misc | 12V | 0.5A | 6W | Status LEDs, speaker |
+| DC-DC losses | — | — | ~5W | ~85% efficiency on converters |
+| **Subtotal (idle/balancing)** | | | **~47W** | |
+
+### Motor Power (Moving)
+
+| Activity | Per Motor | Total (2 motors) | Notes |
+|----------|-----------|-------------------|-------|
+| Balancing in place | 5-15W | 10-30W | Continuous micro-corrections |
+| Slow indoor movement (2 km/h) | 15-25W | 30-50W | Walking pace |
+| Normal indoor (5 km/h) | 30-50W | 60-100W | Brisk walk |
+| Fast / acceleration | 80-150W | 160-300W | Bursts, turning |
+| Climbing threshold/ramp | 100-200W | 200-400W | Short duration |
+
+### Total Power by Use Case
+
+| Mode | Electronics | Motors | Total | Notes |
+|------|-------------|--------|-------|-------|
+| **Idle (balancing)** | 47W | 20W | **~67W** | Standing still |
+| **Slow patrol** | 47W | 40W | **~87W** | Gentle movement |
+| **Normal follow** | 47W | 80W | **~127W** | Following person around house |
+| **Active (turning, accel)** | 47W | 200W | **~247W** | Bursts |
+
+### Range Estimates (Single 500Wh Pack)
+
+| Mode | Avg Power | Runtime | Distance |
+|------|-----------|---------|----------|
+| Idle (balancing) | 67W | **7.5 hours** | 0 km (stationary) |
+| Slow patrol (2 km/h) | 87W | **5.7 hours** | ~11 km |
+| Normal follow (5 km/h) | 127W | **3.9 hours** | ~20 km |
+| Mixed indoor use | ~100W avg | **5 hours** | ~15 km |
+| Aggressive (lots of turning) | 180W avg | **2.8 hours** | ~8 km |
+
+**Bottom line: 3-5 hours of indoor use on a single pack.** More than enough.
+
+### Weight Budget
+
+| Component | Weight (g) | Notes |
+|-----------|-----------|-------|
+| Battery pack (1x) | 2500 | Estimated, weigh to verify |
+| 2x 8" hub motors | 2400 | ~1200g each with tire |
+| ESC board | 150 | Single board |
+| Jetson Orin Nano Super + heatsink | 280 | With Noctua fan |
+| RealSense D435i | 72 | Very light |
+| RPLIDAR A1M8 | 170 | With motor |
+| BNO055 breakout | 5 | Tiny |
+| DC-DC converters (2x) | 300 | 150g each |
+| Frame + brackets | 1200 | Aluminum + 3D printed |
+| Wiring + connectors | 200 | |
+| Bumpers (TPU) | 150 | |
+| **TOTAL** | **~7.4 kg** | Target: under 8 kg |
+
+---
+
+## 3. Detailed 2D Schematics
+
+### 3.1 Base Plate — Top View
+
+```
+                         350mm
+    ←─────────────────────────────────────→
+    
+    ┌─────────────────────────────────────┐  ─┬─
+    │ ○                               ○   │   │
+    │   ┌───────────────────────────┐     │   │
+    │   │      MOTOR MOUNT PLATE    │     │   │
+    │   │                           │     │   │
+    │   │  ┌─────┐       ┌─────┐   │     │   │
+    │   │  │AXLE │       │AXLE │   │     │   │  200mm
+    │   │  │ L   │       │ R   │   │     │   │
+    │   │  └─────┘       └─────┘   │     │   │
+    │   │     ↑   250mm    ↑       │     │   │
+    │   │     └─────────────┘      │     │   │
+    │   │        track width       │     │   │
+    │   └───────────────────────────┘     │   │
+    │ ○                               ○   │   │
+    └─────────────────────────────────────┘  ─┴─
+
+    ○ = M5 mounting holes for vertical spine (4 corners)
+    
+    Axle holes: Ø14mm (standard hoverboard axle)
+    Plate thickness: 6mm PETG
+    
+    Motor mount detail:
+    ┌──────────────┐
+    │  ┌────────┐  │
+    │  │ Ø14mm  │  │   Two-piece clamp:
+    │  │  axle  │  │   Bottom: part of base plate
+    │  │  hole  │  │   Top: clamp plate with 2x M6 bolts
+    │  └────────┘  │
+    │  ○        ○  │   ○ = M6 clamp bolt holes
+    └──────────────┘
+         80mm
+```
+
+### 3.2 Side View — Full Assembly
+
+```
+                    FRONT →
+    
+    550mm ┬  ┌─────────┐
+          │  │ RPLIDAR │ Ø80mm, 360° clear
+          │  │  A1M8   │
+    500mm │  ├─────────┤
+          │  │         │ ← LIDAR standoff tube (80mm tall)
+          │  │         │
+    420mm │  ├─────────┤
+          │  │RealSense│ ← Tilted down 10°, front-facing
+          │  │ D435i   │   Adjustable bracket
+    380mm │  ├─────────┤
+          │  │         │
+          │  │ JETSON  │ ← Noctua fan, ventilation slots
+          │  │  NANO   │
+    300mm │  ├─────────┤
+          │  │ BNO055  │ ← IMU, vibration-isolated mount
+    280mm │  ├─────────┤
+          │  │         │
+          │  │ ESC +   │ ← ESC board + DC-DC converters
+          │  │ DC-DCs  │
+    200mm │  ├─────────┤
+          │  │         │
+          │  │ BATTERY │ ← Heaviest component, lowest position
+          │  │  PACK   │   Strapped to spine with velcro
+          │  │         │
+     80mm │  ├─────────┤
+          │  │  BASE   │ ← Motor mount plate (6mm)
+          │  │  PLATE  │
+     40mm │  ├────┬────┤
+          │  │    │    │
+          ┴  └────┘    └── 8" wheel (Ø203mm)
+             ═════════════
+              GROUND (0mm)
+    
+    Ground clearance: ~40mm (bottom of plate to ground)
+    Wheel contact to axle center: ~100mm (8" diameter / 2)
+    Axle height from ground: ~100mm
+```
+
+### 3.3 Front View
+
+```
+              ←── 350mm ──→
+              
+              ┌─────────┐          ─┬─ 550mm
+              │ RPLIDAR │           │
+              ├─────────┤           │
+              │   ┃     │  ← spine  │
+              │   ┃     │  (2020    │
+              │   ┃     │  extrusion│
+              │   ┃     │  or       │
+              │   ┃     │  aluminum │
+              │   ┃     │  tube)    │
+              │   ┃     │           │
+              ├───┃─────┤           │
+    ┌─────┐   │   ┃     │   ┌─────┐│
+    │     │   │   ┃     │   │     ││  
+    │ 8"  │   │   ┃     │   │ 8"  ││ 100mm
+    │ L   │───┤   ┃     ├───│ R   ││ (axle)
+    │     │   │   ┃     │   │     ││
+    │     │   └───┃─────┘   │     │┴─ 0mm
+    └─────┘       ┃         └─────┘
+    ═══════════════════════════════════
+    
+    ←65→←──── 250mm ────→←65→
+     mm    (track width)    mm
+    
+    Total width with tires: ~380mm
+    Fits through standard doorway (760mm) ✓
+```
+
+### 3.4 Spine Detail — Side View
+
+```
+    ┌──┐ ← 20×20mm aluminum extrusion (2020 V-slot)
+    │  │   or 25×25mm square aluminum tube
+    │  │
+    │  │──── Shelf bracket (3D printed, bolts to T-slot)
+    │  │     Each shelf: 120mm wide × 100-150mm deep
+    │  │
+    │  │──── Shelf bracket
+    │  │
+    │  │──── Shelf bracket
+    │  │
+    │  │──── Shelf bracket
+    │  │
+    ├──┤
+    │  │──── Base plate connection (L-brackets, 4x M5)
+    └──┘
+
+    Spine length: 470mm (from base plate to LIDAR mount)
+    
+    Shelf positions (from base plate):
+      0mm  — Base plate
+     30mm  — Battery shelf (holds pack on its side)
+    150mm  — ESC + DC-DC shelf  
+    250mm  — Jetson Orin Nano Super shelf
+    300mm  — BNO055 (attached to spine directly)
+    370mm  — RealSense bracket (front-facing arm)
+    420mm  — LIDAR standoff begins
+    500mm  — LIDAR mount plate
+```
+
+### 3.5 Wiring Diagram
+
+```
+    BATTERY PACK (35V nominal, 10S Li-ion)
+    ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
+         │(+)                    (−)│
+         │                          │
+         ├──[E-STOP (NC)]───────────┤
+         │                          │
+    XT60 ├────────┬────────┬────────┤ XT60
+         │        │        │        │
+         │    ┌───┴───┐    │        │
+         │    │DC-DC  │    │        │
+         │    │36V→5V │    │        │
+         │    │  4A   │    │        │
+         │    └───┬───┘    │        │
+         │     5V │        │        │
+         │    ┌───┴────┐   │        │
+         │    │USB Hub │   │        │
+         │    │Jetson  │   │        │
+         │    │RealSns │   │        │
+         │    │RPLIDAR │   │        │
+         │    └────────┘   │        │
+         │                 │        │
+         │    ┌────┴───┐   │        │
+         │    │DC-DC   │   │        │
+         │    │36V→12V │   │        │
+         │    │  2A    │   │        │
+         │    └───┬────┘   │        │
+         │    12V │        │        │
+         │    ┌───┴────┐   │        │
+         │    │LEDs    │   │        │
+         │    │Speaker │   │        │
+         │    └────────┘   │        │
+         │                 │        │
+    ┌────┴─────────────────┴────────┴────┐
+    │          HOVERBOARD ESC            │
+    │          (FOC firmware)            │
+    │                                    │
+    │  I2C: SDA──BNO055──SCL            │
+    │  UART: TX──Jetson──RX             │
+    │                                    │
+    │  PHASE L: ─── 8" LEFT MOTOR       │
+    │  HALL  L: ─── (5 wire: hall A/B/C │
+    │                + 5V + GND)         │
+    │                                    │
+    │  PHASE R: ─── 8" RIGHT MOTOR      │
+    │  HALL  R: ─── (5 wire)            │
+    └────────────────────────────────────┘
+```
+
+---
+
+## 4. Phased Build Plan
+
+### Phase 1: Rolling Skeleton (Days 1-3)
+**Goal:** Prove balance works.
+
+**Tasks:**
+- [ ] Measure 8" motor axle diameter with calipers
+- [ ] Design motor mount plate in CAD (FreeCAD or TinkerCAD)
+- [ ] Print motor mount plate on Bambu X1C (PETG, 80% infill, ~4h print)
+- [ ] Print axle clamp tops (x2)
+- [ ] Mount both 8" motors to plate
+- [ ] Mount ESC to plate with standoffs
+- [ ] Wire BNO055 to ESC I2C (4 wires: VCC, GND, SDA, SCL)
+- [ ] Wire battery to ESC (XT60)
+- [ ] Modify FOC firmware: add BNO055 I2C read, replace gyro board input
+- [ ] Flash ESC with updated firmware
+- [ ] **SAFETY:** Tie rope from ceiling to plate as fall catch
+- [ ] Power on, tune PID (start with Kp=20, Ki=0, Kd=0, increase gradually)
+- [ ] Achieve stable free-standing balance (no rope)
+
+**Parts needed:** motor mount plate, 2x clamp tops, M6 bolts, M3 standoffs
+**Risk:** PID tuning can take hours of iteration. Be patient.
+
+### Phase 2: Spine + Brain (Days 4-7)
+**Goal:** Add Jetson, achieve remote-controlled movement while balancing.
+
+**Tasks:**
+- [ ] Cut aluminum extrusion/tube to 470mm for spine
+- [ ] Print shelf brackets (4x) and L-brackets for base connection
+- [ ] Assemble spine onto base plate
+- [ ] Mount battery to lowest shelf (velcro straps)
+- [ ] Mount ESC + DC-DC converters
+- [ ] Mount Jetson Orin Nano Super on shelf, connect 5V power
+- [ ] Wire Jetson UART → ESC UART
+- [ ] Install JetPack 4.6 on Jetson (if not already)
+- [ ] Write serial bridge: Jetson Python → ESC UART commands
+- [ ] Test: keyboard control (WASD) → speed/steer commands → balanced movement
+- [ ] Tune speed response (acceleration limits, max speed for indoor)
+- [ ] Add E-stop button (inline with battery positive)
+
+**Software deliverable:** `saltylab_teleop.py` — keyboard-controlled balancing bot
+
+### Phase 3: Eyes + Ears (Days 8-12)
+**Goal:** See the world. Map a room. Detect people.
+
+**Tasks:**
+- [ ] Print RealSense bracket (adjustable tilt)
+- [ ] Print LIDAR standoff tube + mount plate
+- [ ] Mount RealSense D435i (front-facing, ~10° down tilt)
+- [ ] Mount RPLIDAR A1M8 (top of spine, 360° clear)
+- [ ] Install ROS2 on Jetson
+- [ ] Install and test `realsense-ros` (verify depth stream)
+- [ ] Install and test `rplidar_ros` (verify laser scan)
+- [ ] Run `slam_toolbox` — drive around room, build 2D map
+- [ ] Test person detection with SSD-MobileNet-v2 (TensorRT)
+- [ ] Implement follow mode:
+  - Detect person in RGB frame
+  - Get distance from depth frame
+  - PID to maintain 1.5m following distance
+  - LIDAR for obstacle avoidance
+
+**Software deliverable:** `saltylab_follow.py` — person-following balanced bot
+
+### Phase 4: Polish + Personality (Days 13-17)
+**Goal:** Make it feel alive. Make it SaltyLab.
+
+**Tasks:**
+- [ ] Print proper enclosures for all electronics
+- [ ] Print TPU bumpers (front + rear)
+- [ ] Print carry handle
+- [ ] Add NeoPixel LED ring around LIDAR mount (status indication)
+  - Blue breathing: idle/balancing
+  - Green: following
+  - Yellow: exploring/mapping
+  - Red: error/low battery
+- [ ] Add small speaker (USB or I2S to amp)
+  - Boot sound
+  - Acknowledge commands with beeps/chirps
+  - Optional: TTS via Jetson ("I see you", "battery low")
+- [ ] WiFi dashboard: live camera feed + map + battery status
+- [ ] Battery voltage monitoring (ADC on ESC → Jetson via UART)
+- [ ] Low battery return behavior (stop and beep)
+- [ ] Integrate with Home Assistant (MQTT: location, battery, status)
+
+### Phase 5: House Mapping + Autonomy (Days 18-24)
+**Goal:** SaltyLab knows your house.
+
+**Tasks:**
+- [ ] Map every room (drive around manually, SLAM builds full floor plan)
+- [ ] Save map, set up `nav2` for autonomous navigation
+- [ ] Define waypoints: lab, living room, kitchen, hallway
+- [ ] Patrol mode: visit waypoints on schedule
+- [ ] Person detection + greeting ("hey Tee", "hi Inka")
+- [ ] Integration with Bermuda BLE: know where people are, go to them
+- [ ] Charging dock design (future: auto-dock when low)
+
+---
+
+## 5. Speed & Performance Specs
+
+### Target Performance
+
+| Parameter | Value | Notes |
+|-----------|-------|-------|
+| Max speed (indoor) | 5 km/h | Software limited for safety |
+| Normal follow speed | 2-3 km/h | Walking pace |
+| Turning radius | 0 (pivot) | Differential drive, spins in place |
+| Ground clearance | 40mm | Clears door thresholds (~15mm) |
+| Max incline | ~10° | Limited by motor torque + balance |
+| Operating time | 3-5 hours | Single 500Wh pack |
+| Charge time | ~2-3 hours | Using one of the existing chargers |
+| Weight | ~7.5 kg | Easy to pick up with handle |
+| Width | 380mm | Fits all doorways |
+| Height | 550mm | Below table height |
+
+### Motor Specs (8" hub motor, estimated)
+| Parameter | Value |
+|-----------|-------|
+| Nominal voltage | 36V |
+| Rated power | 250-350W per motor |
+| No-load RPM | ~250 RPM |
+| Wheel circumference | ~0.64m (Ø203mm) |
+| Max wheel speed | 160 m/min = 9.6 km/h |
+| Continuous torque | ~2-3 Nm |
+| Stall torque | ~8-10 Nm |
+
+---
+
+## 6. Safety Considerations
+
+| Hazard | Mitigation |
+|--------|-----------|
+| Falls over | TPU bumpers, max tilt cutoff (30°), low CoG |
+| Runs away | Software speed limit (5 km/h), E-stop button |
+| Pinches/crushes | No exposed gears, motor covers |
+| Battery fire | BMS on pack, fused main power, no charging unattended |
+| Hits furniture | LIDAR obstacle avoidance, bumper sensors (future) |
+| Scares the cat | Slow acceleration, no sudden movements |
+
+---
+
+## 7. Shopping List (Items NOT in Inventory)
+
+| Item | Price (CAD) | Source | Notes |
+|------|------------|--------|-------|
+| 2020 aluminum extrusion 500mm | ~$8 | Amazon/AliExpress | Spine |
+| T-slot nuts + M5 bolts (pack) | ~$12 | Amazon | For shelf mounting |
+| M6 bolts + nuts (axle clamps) | ~$5 | Hardware store | 4x sets |
+| NeoPixel ring (24 LED) | ~$8 | Amazon | Status indication |
+| Small speaker + amp (MAX98357A) | ~$10 | Amazon/Adafruit | I2S audio |
+| E-stop mushroom button | ~$5 | Amazon | Safety |
+| XT60 splitter/distribution | ~$8 | Amazon | Power wiring |
+| Misc: heat shrink, zip ties, wire | ~$10 | — | Always need more |
+| **TOTAL** | **~$66** | | Everything else: already owned |
+
+---
+
+*Last updated: 2026-02-27*
+*Project: SaltyRover / SaltyLab*

docs/SALTYLAB.md

@@ -0,0 +1,296 @@
+# SAUL-TEE — Self-Balancing Wagon Robot 🔬
+
+Four-wheel wagon (870×510×550 mm, 23 kg). Full spec: `docs/SAUL-TEE-SYSTEM-REFERENCE.md`
+
+## ⚠️ SAFETY — TOP PRIORITY
+
+**This robot can cause serious injury.** 8" hub motors with 36V power can crush toes, break fingers, and launch the frame if control is lost. Every design decision must prioritize safety.
+
+### Mandatory Safety Systems
+1. **Hardware kill switch** — physical big red button, wired inline with battery. Cuts ALL power instantly. Must be reachable without approaching the wheels.
+2. **Software tilt cutoff** — if pitch exceeds ±25° (not 30°), motors go to zero immediately. No retry, no recovery. Requires manual re-arm.
+3. **Startup arming sequence** — motors NEVER spin on power-on. Requires deliberate arming: hold button for 3 seconds while robot is upright and stable.
+4. **Watchdog timeout** — if FC firmware hangs or crashes, hardware watchdog resets to safe state (motors off) within 50ms.
+5. **Current limiting** — hoverboard ESC max current set conservatively. Start low, increase gradually.
+6. **Tether during development** — ceiling rope/strap during ALL balance testing. No free-standing tests until PID is proven stable for 5+ minutes tethered.
+7. **Speed limiting** — firmware hard cap on max speed. Start at 10% throttle, increase in 10% increments only after stable testing.
+8. **Remote kill** — Jetson can send emergency stop via UART. If Jetson disconnects (UART timeout >200ms), FC cuts motors automatically.
+9. **Bumpers** — TPU bumpers on all sides, mandatory before any untethered operation.
+10. **Test area** — clear 3m radius, no pets/kids/cables. Shoes mandatory.
+11. **RC kill channel** — ELRS receiver connected to FC UART. Dedicated switch on radio = instant disarm. Works independently of Jetson. Always have radio in hand during testing.
+
+### Safety Rules for Development
+- **Never reach near wheels while powered** — even "stopped" motors can spike
+- **Never test new firmware untethered** — tether FIRST, always
+- **Never increase speed and change PID in the same test** — one variable at a time
+- **Log everything** — FC sends telemetry (pitch, PID output, motor commands) to Jetson for post-crash analysis
+- **Two people for early tests** — one at the kill switch, one observing
+
+## Parts
+
+| Part | Status |
+|------|--------|
+| 2x 8" pneumatic hub motors (36 PSI) | ✅ Have |
+| 1x hoverboard ESC (FOC firmware) | ✅ Have |
+| 1x Drone FC (ESP32-S3 + QMI8658) | ✅ Have — balance brain |
+| 1x Jetson Orin Nano Super + Noctua fan | ✅ Have |
+| 1x RealSense D435i | ✅ Have |
+| 1x RPLIDAR A1M8 | ✅ Have |
+| 1x battery pack (36V) | ✅ Have |
+| 1x DC-DC 5V converter | ✅ Have |
+| 1x DC-DC 12V converter | ✅ Have |
+| 1x ESP32-C3 (LED controller) | ⬜ Need (~$3) |
+| WS2812B LED strip (60/m) | ⬜ Need |
+| BNO055 9-DOF IMU | ✅ Have (spare/backup) |
+| MPU6050 | ✅ Have (spare/backup) |
+| 1x Big red kill switch (NC, inline with battery) | ⬜ Need |
+| 1x Arming button (momentary, with LED) | ⬜ Need |
+| 1x Ceiling tether strap + carabiner | ⬜ Need |
+| 1x BetaFPV ELRS 2.4GHz 1W TX module | ✅ Have — RC control + kill switch |
+| 1x ELRS receiver (matching) | ✅ Have — mounts on FC UART |
+
+### ESP32-S3 BALANCE Board Details — Waveshare ESP32-S3 Touch LCD 1.28
+- **MCU:** ESP32-S3RET6 (Xtensa LX7 dual-core, 240MHz, 8MB Flash, 512KB SRAM)
+- **IMU:** QMI8658 (6-axis, 32kHz gyro, ultra-low noise, SPI) ← the good one!
+- **Display:** 1.28" round LCD (GC9A01 driver, 240x240)
+- **DFU mode:** Hold BOOT button while plugging USB
+- **Firmware:** Custom balance firmware (ESP-IDF / Arduino-ESP32)
+- **USB:** USB Serial via CH343 chip
+- **UART assignments:**
+  - UART0 → USB Serial (CH343) → debug/flash
+  - UART1 → Jetson Orin Nano Super
+  - UART2 → Hoverboard ESC
+  - UART3 → ELRS receiver
+  - UART4/5 → spare
+
+## Architecture
+
+```
+                    ┌──────────────┐
+                    │  RPLIDAR A1  │ ← 360° scan, top-mounted
+                    └──────┬───────┘
+                    ┌──────┴───────┐
+                    │ RealSense    │ ← Forward-facing depth+RGB
+                    │ D435i        │
+                    ├──────────────┤
+                    │ Jetson Orin Nano Super  │ ← AI brain: navigation, person tracking
+                    │              │   Sends velocity commands via UART
+                    ├──────────────┤
+                    │ Drone FC     │ ← Balance brain: IMU + PID @ 8kHz
+                    │ F745+MPU6000 │   Custom firmware, UART out to ESC
+                    ├──────────────┤
+                    │ Battery 36V  │
+                    │ + DC-DCs     │
+                    ├──────┬───────┤
+              ┌─────┤  ESC (FOC)   ├─────┐
+              │     │  Hoverboard  │     │
+              │     └──────────────┘     │
+           ┌──┴──┐                   ┌──┴──┐
+           │ 8"  │                   │ 8"  │
+           │ LEFT│                   │RIGHT│
+           └─────┘                   └─────┘
+```
+
+## Self-Balancing Control — ESP32-S3 BALANCE Board
+
+> For full system architecture, firmware details, and protocol specs, see
+> **docs/SAUL-TEE-SYSTEM-REFERENCE.md**
+
+The balance controller runs on the Waveshare ESP32-S3 Touch LCD 1.28 board
+(ESP32-S3 BALANCE). It reads the onboard QMI8658 IMU at 8kHz, runs a PID
+balance loop, and drives the hoverboard ESC via UART. Jetson Orin Nano Super
+sends velocity commands over UART1. ELRS receiver on UART3 provides RC
+override and kill-switch capability.
+
+The legacy STM32 firmware (Mamba F722S era) has been archived to
+=======
+The legacy STM32 firmware (STM32 era) has been archived to
+`legacy/stm32/` and is no longer built or deployed.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+
+## LED Subsystem (ESP32-C3)
+
+### Architecture
+The ESP32-C3 eavesdrops on the FC→Jetson telemetry UART line (listen-only, one wire).
+No extra UART needed on the FC — zero firmware change.
+
+```
+FC UART1 TX ──┬──→ Jetson RX
+              └──→ ESP32-C3 RX (listen-only, same wire)
+                   │
+                   └──→ WS2812B strip (via RMT peripheral)
+```
+
+### Telemetry Format (already sent by FC at 50Hz)
+```
+T:12.3,P:45,L:100,R:-80,S:3\n
+                          ^-- State byte: 0=disarmed, 1=arming, 2=armed, 3=fault
+```
+ESP32-C3 parses the `S:` field and `L:/R:` for turn detection.
+
+### LED Patterns
+| State | Pattern | Color |
+|-------|---------|-------|
+| Disarmed | Slow breathe | White |
+| Arming | Fast blink | Yellow |
+| Armed idle | Solid | Green |
+| Turning left | Sweep left | Orange |
+| Turning right | Sweep right | Orange |
+| Braking | Flash rear | Red |
+| Fault | Triple flash | Red |
+| RC signal lost | Alternating flash | Red/Blue |
+
+### Turn/Brake Detection (on ESP32-C3)
+```
+if (L - R > threshold)  → turning right
+if (R - L > threshold)  → turning left
+if (L < -threshold && R < -threshold) → braking
+```
+
+### Wiring
+```
+FC UART1 TX pin ──→ ESP32-C3 GPIO RX (e.g. GPIO20)
+ESP32-C3 GPIO8  ──→ WS2812B data in
+ESC 5V BEC      ──→ ESP32-C3 5V + WS2812B 5V
+GND             ──→ Common ground
+```
+
+### Dev Tools
+- **Flashing:** ESP32-S3CubeProgrammer via USB (DFU mode) or SWD
+- **IDE:** PlatformIO + ESP-IDF, or ESP32-S3CubeIDE
+- **Debug:** SWD via ST-Link (or use FC's USB as virtual COM for printf debug)
+
+## Physical Design
+
+### Frame: Vertical Tower
+```
+         SIDE VIEW                    FRONT VIEW
+    
+    ┌───────────┐                 ┌─────────────────┐
+    │  RPLIDAR  │ ~500mm          │     RPLIDAR     │
+    ├───────────┤                 ├─────────────────┤
+    │ RealSense │ ~400mm          │   [RealSense]   │
+    ├───────────┤                 ├─────────────────┤
+    │  Jetson   │ ~300mm          │    [Jetson]     │
+    ├───────────┤                 ├─────────────────┤
+    │ Drone FC  │ ~200mm          │   [Drone FC]    │
+    ├───────────┤                 ├─────────────────┤
+    │  Battery  │ ~100mm          │   [Battery]     │
+    │  + ESC    │  LOW!           │   [ESC+DCDC]    │
+    ├─────┬─────┤                 ├──┬──────────┬───┤
+    │     │     │                 │  │          │   │
+   ─┘     └─────┘─               ─┘ 8"      8" └──┘─
+   ═══════════════               ═══            ═══
+       GROUND                     L              R
+```
+
+### Key Dimensions
+- **Height:** ~500-550mm total (sensor tower top)
+- **Width:** ~350mm (axle to axle, constrained by motors)
+- **Depth:** ~150-200mm (thin profile for doorways)
+- **Weight target:** <10kg including battery
+- **Center of gravity:** AS LOW AS POSSIBLE — battery + ESC at bottom
+
+### Critical: Center of Mass
+- Battery is the heaviest component → mount at axle height or below
+- Jetson + sensors are light → can go higher
+- Lower CoG = easier to balance, less aggressive PID needed
+- If CoG is too high → oscillations, falls easily
+
+### Frame Material
+- **Main spine:** Aluminum extrusion 2020, vertical
+- **Motor mount plate:** 3D printed PETG, 6mm thick, reinforced
+- **Component shelves:** 3D printed PETG, bolt to spine
+- **Fender/bumper:** 3D printed TPU (flexible, absorbs falls)
+
+### 3D Printed Parts
+| Part | Size (mm) | Material | Qty |
+|------|-----------|----------|-----|
+| Motor mount plate | 350×150×6 | PETG 80% | 1 |
+| Battery shelf | 200×100×40 | PETG 60% | 1 |
+| ESC mount | 150×100×15 | PETG 40% | 1 |
+| Jetson shelf | 120×100×15 | PETG 40% | 1 |
+| Sensor tower top | 120×120×10 | ASA 80% | 1 |
+| LIDAR standoff | Ø80×80 | ASA 40% | 1 |
+| RealSense bracket | 100×50×40 | PETG 60% | 1 |
+| FC mount (vibration isolated) | 30×30×15 | TPU+PETG | 1 |
+| Bumper front | 350×50×30 | TPU 30% | 1 |
+| Bumper rear | 350×50×30 | TPU 30% | 1 |
+| Handle (for carrying) | 150×30×30 | PETG 80% | 1 |
+| Kill switch mount | 60×60×40 | PETG 80% | 1 |
+| Tether anchor point | 50×50×20 | PETG 100% | 1 |
+| LED diffuser ring | Ø120×15 | Clear PETG 30% | 1 |
+| ESP32-C3 mount | 30×25×10 | PETG 40% | 1 |
+
+## Software Stack
+
+### Jetson Orin Nano Super
+- **OS:** JetPack 4.6.1 (Ubuntu 18.04)
+- **ROS2 Humble** (or Foxy) for:
+  - `nav2` — navigation stack
+  - `slam_toolbox` — 2D SLAM from LIDAR
+  - `realsense-ros` — depth camera
+  - `rplidar_ros` — LIDAR driver
+- **Person following:** SSD-MobileNet-v2 via TensorRT (~20 FPS)
+- **Balance commands:** ROS topic → UART bridge to drone FC
+
+### Modes
+1. **Idle** — self-balancing in place, waiting for command
+2. **RC** — manual control via ELRS radio (primary testing mode)
+3. **Follow** — tracks person with RealSense, follows at set distance
+4. **Explore** — autonomous SLAM mapping, builds house map
+5. **Patrol** — follows waypoints on saved map
+6. **Dock** — returns to charging station (future)
+
+**Mode priority:** RC override always wins. If radio sends stick input, it overrides Jetson commands. Kill switch overrides everything.
+
+## Build Order
+
+### Phase 1: Balance (Week 1)
+**Safety first — no motor spins without kill switch + tether in place.**
+- [ ] Install hardware kill switch inline with 36V battery (NC — press to kill)
+- [ ] Set up ceiling tether point above test area (rated for >15kg)
+- [ ] Clear test area: 3m radius, no loose items, shoes on
+- [ ] Set up PlatformIO project for ESP32-S3 (ESP-IDF)
+- [ ] Write QMI8658 SPI driver (read gyro+accel, complementary filter)
+- [ ] Write PID balance loop with ALL safety checks:
+  - ±25° tilt cutoff → disarm, require manual re-arm
+  - Watchdog timer (50ms hardware WDT)
+  - Speed limit at 10% (max_speed_limit = 100)
+  - Arming sequence (3s hold while upright)
+- [ ] Write hoverboard ESC UART output (speed+steer protocol)
+- [ ] Flash firmware via USB DFU (boot0 jumper on FC)
+- [ ] Write ELRS CRSF receiver driver (UART3, parse channels + arm switch)
+- [ ] Bind ELRS TX ↔ RX, verify channel data on serial monitor
+- [ ] Map radio: CH1=steer, CH2=speed, CH5=arm/disarm switch
+- [ ] **Bench test first** — FC powered but ESC disconnected, verify IMU reads + PID output + RC channels on serial monitor
+- [ ] Wire FC UART2 → hoverboard ESC UART
+- [ ] Build minimal frame: motor plate + battery + ESC + FC
+- [ ] Power FC from ESC 5V BEC
+- [ ] **First balance test — TETHERED, kill switch in hand, 10% speed limit**
+- [ ] Tune PID at 10% speed until stable tethered for 5+ minutes
+- [ ] Gradually increase speed limit (10% increments, 5 min stable each)
+
+### Phase 2: Brain (Week 2)
+- [ ] Mount Jetson + power (DC-DC 5V)
+- [ ] Set up JetPack + ROS2
+- [ ] Add Jetson UART RX to FC firmware (receive speed+steer commands)
+- [ ] Wire Jetson UART1 → FC UART1
+- [ ] Python serial bridge: send speed+steer, read telemetry
+- [ ] Test: keyboard teleoperation while balancing
+
+### Phase 3: Senses (Week 3)
+- [ ] Mount RealSense + RPLIDAR
+- [ ] SLAM mapping of a room
+- [ ] Person detection + tracking (SSD-MobileNet-v2 via TensorRT)
+- [ ] Follow mode: maintain 1.5m distance from person
+
+### Phase 4: Polish (Week 4)
+- [ ] Print proper enclosures, bumpers, diffuser ring
+- [ ] Wire ESP32-C3 to FC telemetry TX line (listen-only tap)
+- [ ] Flash ESP32-C3: parse telemetry, drive WS2812B via RMT
+- [ ] Mount LED strip around frame with diffuser
+- [ ] Test all LED patterns: disarmed/arming/armed/turning/fault
+- [ ] Speaker for audio feedback
+- [ ] WiFi status dashboard (ESP32-C3 can serve this too)
+- [ ] Emergency stop button

docs/SAUL-TEE-SYSTEM-REFERENCE.md

@@ -0,0 +1,222 @@
+# SAUL-TEE System Reference — SaltyLab ESP32 Architecture
+*Authoritative source of truth for hardware, pins, protocols, and CAN assignments.*
+*Spec from hal@Orin, 2026-04-04.*
+
+---
+
+## Overview
+
+| Board | Role | MCU | USB chip |
+|-------|------|-----|----------|
+| **ESP32-S3 BALANCE** | PID balance loop, CAN→VESCs, LCD display | ESP32-S3 | CH343 USB-serial |
+| **ESP32-S3 IO** | RC input, motor drivers, sensors, LEDs, peripherals | ESP32-S3 | JTAG USB (native) |
+
+**Robot form factor:** 4-wheel wagon — 870 × 510 × 550 mm, ~23 kg
+**Power:** 36 V LiPo, DC-DC → 5 V and 12 V rails
+**Orin connection:** CANable2 USB → 500 kbps CAN (same bus as VESCs)
+
+---
+
+## ESP32-S3 BALANCE
+
+### Board
+Waveshare ESP32-S3 Touch LCD 1.28
+- GC9A01 round 240×240 LCD
+- CST816S capacitive touch
+- QMI8658 6-axis IMU (accel + gyro, SPI)
+- CH343 USB-to-serial chip
+
+### Pin Assignments
+
+| Function | GPIO | Notes |
+|----------|------|-------|
+| **QMI8658 IMU (SPI)** | | |
+| SCK | IO39 | |
+| MOSI | IO38 | |
+| MISO | IO40 | |
+| CS | IO41 | |
+| INT1 | IO42 | data-ready interrupt |
+| **GC9A01 LCD (shares SPI bus)** | | |
+| CS | IO12 | |
+| DC | IO11 | |
+| RST | IO10 | |
+| BL | IO9 | PWM backlight |
+| **CST816S Touch (I2C)** | | |
+| SDA | IO4 | |
+| SCL | IO5 | |
+| INT | IO6 | |
+| RST | IO7 | |
+| **CAN — SN65HVD230 transceiver** | | 500 kbps |
+| TX | IO43 | → SN65HVD230 TXD |
+| RX | IO44 | ← SN65HVD230 RXD |
+| **Inter-board UART (to IO board)** | | 460800 baud |
+| TX | IO17 | |
+| RX | IO18 | |
+
+### Responsibilities
+- Read QMI8658 @ 1 kHz (SPI, INT1-driven)
+- Complementary filter → pitch angle
+- PID balance loop (configurable Kp / Ki / Kd)
+- Send VESC speed commands via CAN (ID 68 = left, ID 56 = right)
+- Receive Orin velocity+mode commands via CAN (0x300–0x303)
+- Receive IO board status (arming, RC, faults) via UART protocol
+- Drive GC9A01 LCD: pitch, speed, battery %, error state
+- Enforce tilt cutoff at ±25°; IWDG 50 ms timeout
+- Publish telemetry on CAN 0x400–0x401 at 10 Hz
+
+---
+
+## ESP32-S3 IO
+
+### Board
+Bare ESP32-S3 devkit (JTAG USB)
+
+### Pin Assignments
+
+| Function | GPIO | Notes |
+|----------|------|-------|
+| **TBS Crossfire RC — UART0 (primary)** | | |
+| RX | IO44 | CRSF frames from Crossfire RX |
+| TX | IO43 | telemetry to Crossfire TX |
+| **ELRS failover — UART2** | | active if CRSF absent >100 ms |
+| RX | IO16 | |
+| TX | IO17 | |
+| **BTS7960 Motor Driver — Left** | | |
+| RPWM | IO1 | forward PWM |
+| LPWM | IO2 | reverse PWM |
+| R_EN | IO3 | right enable |
+| L_EN | IO4 | left enable |
+| **BTS7960 Motor Driver — Right** | | |
+| RPWM | IO5 | |
+| LPWM | IO6 | |
+| R_EN | IO7 | |
+| L_EN | IO8 | |
+| **I2C bus** | | |
+| SDA | IO11 | |
+| SCL | IO12 | |
+| NFC (PN532 or similar) | I2C | |
+| Barometer (BMP280/BMP388) | I2C | |
+| ToF (VL53L0X/VL53L1X) | I2C | |
+| **WS2812B LEDs** | | |
+| Data | IO13 | |
+| **Outputs** | | |
+| Horn / buzzer | IO14 | PWM tone |
+| Headlight | IO15 | PWM or digital |
+| Fan | IO16 | (if ELRS not fitted on UART2) |
+| **Inputs** | | |
+| Arming button | IO9 | active-low, hold 3 s to arm |
+| Kill switch sense | IO10 | hardware estop detect |
+| **Inter-board UART (to BALANCE board)** | | 460800 baud |
+| TX | IO18 | |
+| RX | IO21 | |
+
+### Responsibilities
+- Parse CRSF frames (TBS Crossfire, primary)
+- Parse ELRS frames (failover, activates if no CRSF for >100 ms)
+- Drive BTS7960 left/right PWM motor drivers
+- Read NFC, barometer, ToF via I2C
+- Drive WS2812B LEDs (armed/fault/idle patterns)
+- Control horn, headlight, fan, buzzer
+- Manage arming: hold button 3 s while upright → send ARM to BALANCE
+- Monitor kill switch input → immediate motor off + FAULT frame
+- Forward RC + sensor data to BALANCE via binary UART protocol
+- Report faults and RC-loss upstream
+
+---
+
+## Inter-Board Binary Protocol (UART @ 460800 baud)
+
+```
+[0xAA][LEN][TYPE][PAYLOAD × LEN bytes][CRC8]
+```
+- `0xAA` — start byte
+- `LEN` — payload length in bytes (uint8)
+- `TYPE` — message type (uint8)
+- `CRC8` — CRC-8/MAXIM over TYPE + PAYLOAD bytes
+
+### IO → BALANCE Messages
+
+| TYPE | Name | Payload | Description |
+|------|------|---------|-------------|
+| 0x01 | RC_CMD | int16 throttle, int16 steer, uint8 flags | flags: bit0=armed, bit1=kill |
+| 0x02 | SENSOR | uint16 tof_mm, int16 baro_delta_pa, uint8 nfc_present | |
+| 0x03 | FAULT | uint8 fault_flags | bit0=rc_loss, bit1=motor_fault, bit2=estop |
+
+### BALANCE → IO Messages
+
+| TYPE | Name | Payload | Description |
+|------|------|---------|-------------|
+| 0x10 | STATE | int16 pitch_x100, int16 pid_out, uint8 error_state | |
+| 0x11 | LED_CMD | uint8 pattern, uint8 r, uint8 g, uint8 b | |
+| 0x12 | BUZZER | uint8 tone_id, uint16 duration_ms | |
+
+---
+
+## CAN Bus — 500 kbps
+
+### Node Assignments
+
+| Node | CAN ID | Role |
+|------|--------|------|
+| VESC Left motor | **68** | Receives speed/duty via VESC CAN protocol |
+| VESC Right motor | **56** | Receives speed/duty via VESC CAN protocol |
+| ESP32-S3 BALANCE | — | Sends VESC commands; publishes telemetry |
+| Jetson Orin (CANable2) | — | Sends velocity commands; receives telemetry |
+
+### Frame Table
+
+| CAN ID | Direction | Description | Rate |
+|--------|-----------|-------------|------|
+| 0x300 | Orin → BALANCE | Velocity cmd: int16 speed_mmps, int16 steer_mrad | 20 Hz |
+| 0x301 | Orin → BALANCE | PID tuning: float Kp, float Ki, float Kd (3×4B IEEE-754) | on demand |
+| 0x302 | Orin → BALANCE | Mode: uint8 (0=off, 1=balance, 2=manual, 3=estop) | on demand |
+| 0x303 | Orin → BALANCE | Config: uint16 tilt_limit_x100, uint16 max_speed_mmps | on demand |
+| 0x400 | BALANCE → Orin | Telemetry A: int16 pitch_x100, int16 pid_out, int16 speed_mmps, uint8 state | 10 Hz |
+| 0x401 | BALANCE → Orin | Telemetry B: int16 vesc_l_rpm, int16 vesc_r_rpm, uint16 battery_mv, uint8 faults | 10 Hz |
+
+---
+
+## RC Channel Mapping (TBS Crossfire / ELRS CRSF)
+
+| CH | Function | Range (µs) | Notes |
+|----|----------|------------|-------|
+| 1 | Steer (Roll) | 988–2012 | ±100% → ±max steer |
+| 2 | Throttle (Pitch) | 988–2012 | forward / back speed |
+| 3 | Spare | 988–2012 | |
+| 4 | Spare | 988–2012 | |
+| 5 | ARM switch | <1500=disarm, >1500=arm | SB on TX |
+| 6 | **ESTOP** | <1500=normal, >1500=kill | SC on TX — checked first every loop |
+| 7 | Speed limit | 988–2012 | maps to 10–100% speed cap |
+| 8 | Spare | | |
+
+**RC loss:** No valid CRSF frame >100 ms → IO sends FAULT(rc_loss) → BALANCE cuts motors.
+
+---
+
+## Safety Invariants
+
+1. **Motors NEVER spin on power-on** — 3 s button hold required while upright
+2. **Tilt cutoff ±25°** — immediate motor zero, manual re-arm required
+3. **IWDG 50 ms** — firmware hang → motors cut
+4. **ESTOP RC channel** checked first in every loop iteration
+5. **Orin CAN timeout 500 ms** → revert to RC-only mode
+6. **Speed hard cap** — start at 10%, increase in 10% increments only after stable tethered testing
+7. **Never untethered** until stable for 5+ continuous minutes tethered
+
+---
+
+## USB Debug Commands (both boards, serial console)
+
+```
+help                     list commands
+status                   print pitch, PID state, CAN stats, UART stats
+pid <Kp> <Ki> <Kd>      set PID gains
+arm                      arm (if upright and safe)
+disarm                   disarm immediately
+estop                    emergency stop (requires re-arm)
+tilt_limit <deg>         set tilt cutoff angle (default 25)
+speed_limit <pct>        set speed cap percentage (default 10)
+can_stats                CAN bus counters (tx/rx/errors/busoff)
+uart_stats               inter-board UART frame counters
+reboot                   soft reboot
+```

docs/board-viz.html

@@ -0,0 +1,284 @@
+<!DOCTYPE html>
+<html>
+<head>
+<meta charset="utf-8">
+<title>GEPRC GEP-F722-45A AIO — Board Layout (Legacy / Archived)</title>
+<style>
+* { margin: 0; padding: 0; box-sizing: border-box; }
+body { background: #1a1a2e; color: #eee; font-family: 'Courier New', monospace; display: flex; flex-direction: column; align-items: center; padding: 20px; }
+h1 { color: #e94560; margin-bottom: 5px; font-size: 1.4em; }
+.subtitle { color: #888; margin-bottom: 20px; font-size: 0.85em; }
+.container { display: flex; gap: 30px; align-items: flex-start; flex-wrap: wrap; justify-content: center; }
+.board-wrap { position: relative; }
+.board { width: 400px; height: 340px; background: #1a472a; border: 3px solid #333; border-radius: 8px; position: relative; box-shadow: 0 0 20px rgba(0,0,0,0.5); }
+.board::before { content: 'GEPRC GEP-F722-45A AIO'; position: absolute; top: 8px; left: 50%; transform: translateX(-50%); color: #fff3; font-size: 10px; letter-spacing: 2px; }
+
+/* Mounting holes */
+.mount { width: 10px; height: 10px; background: #111; border: 2px solid #555; border-radius: 50%; position: absolute; }
+.mount.tl { top: 15px; left: 15px; }
+.mount.tr { top: 15px; right: 15px; }
+.mount.bl { bottom: 15px; left: 15px; }
+.mount.br { bottom: 15px; right: 15px; }
+
+/* MCU */
+.mcu { width: 80px; height: 80px; background: #222; border: 1px solid #555; position: absolute; top: 50%; left: 50%; transform: translate(-50%, -50%); display: flex; align-items: center; justify-content: center; font-size: 9px; color: #aaa; text-align: center; line-height: 1.3; }
+.mcu .dot { width: 5px; height: 5px; background: #666; border-radius: 50%; position: absolute; top: 4px; left: 4px; }
+
+/* IMU */
+.imu { width: 32px; height: 32px; background: #333; border: 1px solid #e94560; position: absolute; top: 85px; left: 60px; display: flex; align-items: center; justify-content: center; font-size: 7px; color: #e94560; }
+.imu::after { content: 'CW90°'; position: absolute; bottom: -14px; color: #e94560; font-size: 8px; white-space: nowrap; }
+
+/* Arrow showing CW90 rotation */
+.rotation-arrow { position: absolute; top: 72px; left: 55px; color: #e94560; font-size: 18px; }
+
+/* Pads */
+.pad { position: absolute; display: flex; align-items: center; gap: 4px; font-size: 10px; cursor: pointer; }
+.pad .dot { width: 12px; height: 12px; border-radius: 50%; border: 2px solid; display: flex; align-items: center; justify-content: center; font-size: 7px; font-weight: bold; }
+.pad:hover .label { color: #fff; }
+.pad .label { transition: color 0.2s; }
+.pad .sublabel { font-size: 8px; color: #888; }
+
+/* UART colors */
+.uart1 .dot { background: #2196F3; border-color: #64B5F6; }
+.uart2 .dot { background: #FF9800; border-color: #FFB74D; }
+.uart3 .dot { background: #9C27B0; border-color: #CE93D8; }
+.uart4 .dot { background: #4CAF50; border-color: #81C784; }
+.uart5 .dot { background: #F44336; border-color: #EF9A9A; }
+
+/* Component dots */
+.comp { position: absolute; font-size: 9px; display: flex; align-items: center; gap: 4px; }
+.comp .icon { width: 10px; height: 10px; border-radius: 2px; }
+
+/* LED */
+.led-blue { position: absolute; width: 8px; height: 8px; background: #2196F3; border-radius: 50%; box-shadow: 0 0 8px #2196F3; top: 45px; right: 50px; }
+.led-label { position: absolute; top: 36px; right: 30px; font-size: 8px; color: #64B5F6; }
+
+/* Boot button */
+.boot-btn { position: absolute; width: 16px; height: 10px; background: #b8860b; border: 1px solid #daa520; border-radius: 2px; bottom: 45px; right: 40px; }
+.boot-label { position: absolute; bottom: 32px; right: 30px; font-size: 8px; color: #daa520; }
+
+/* USB */
+.usb { position: absolute; width: 30px; height: 14px; background: #444; border: 2px solid #777; border-radius: 3px; bottom: -3px; left: 50%; transform: translateX(-50%); }
+.usb-label { position: absolute; bottom: 14px; left: 50%; transform: translateX(-50%); font-size: 8px; color: #999; }
+
+/* Connector pads along edges */
+/* Bottom row: T1 R1 T3 R3 */
+.pad-t1 { bottom: 20px; left: 40px; }
+.pad-r1 { bottom: 20px; left: 80px; }
+.pad-t3 { bottom: 20px; left: 140px; }
+.pad-r3 { bottom: 20px; left: 180px; }
+
+/* Right side: T2 R2 */
+.pad-t2 { right: 20px; top: 80px; flex-direction: row-reverse; }
+.pad-r2 { right: 20px; top: 110px; flex-direction: row-reverse; }
+
+/* Top row: T4 R4 T5 R5 */
+.pad-t4 { top: 30px; left: 40px; }
+.pad-r4 { top: 30px; left: 80px; }
+.pad-t5 { top: 30px; right: 100px; flex-direction: row-reverse; }
+.pad-r5 { top: 30px; right: 55px; flex-direction: row-reverse; }
+
+/* ESC pads (motor outputs - not used) */
+.esc-pads { position: absolute; left: 20px; top: 140px; }
+.esc-pads .esc-label { font-size: 8px; color: #555; }
+
+/* Legend */
+.legend { background: #16213e; padding: 15px 20px; border-radius: 8px; min-width: 280px; }
+.legend h2 { color: #e94560; font-size: 1.1em; margin-bottom: 10px; border-bottom: 1px solid #333; padding-bottom: 5px; }
+.legend-item { display: flex; align-items: center; gap: 8px; margin: 6px 0; font-size: 12px; }
+.legend-item .swatch { width: 14px; height: 14px; border-radius: 50%; flex-shrink: 0; }
+.legend-item .arrow { color: #888; font-size: 10px; }
+.legend-section { margin-top: 12px; padding-top: 8px; border-top: 1px solid #333; }
+.legend-section h3 { font-size: 0.9em; color: #888; margin-bottom: 6px; }
+
+/* Orientation guide */
+.orient { margin-top: 20px; background: #16213e; padding: 15px 20px; border-radius: 8px; width: 100%; max-width: 710px; }
+.orient h2 { color: #4CAF50; font-size: 1.1em; margin-bottom: 10px; }
+.orient-grid { display: grid; grid-template-columns: 1fr 1fr; gap: 10px; }
+.orient-item { font-size: 12px; padding: 6px 10px; background: #1a1a2e; border-radius: 4px; }
+.orient-item .dir { color: #4CAF50; font-weight: bold; }
+
+/* Axis overlay */
+.axis { position: absolute; }
+.axis-x { top: 50%; right: -60px; color: #F44336; font-size: 12px; font-weight: bold; }
+.axis-y { bottom: -30px; left: 50%; transform: translateX(-50%); color: #4CAF50; font-size: 12px; font-weight: bold; }
+.axis-arrow-x { position: absolute; top: 50%; right: -45px; transform: translateY(-50%); width: 30px; height: 2px; background: #F44336; }
+.axis-arrow-x::after { content: '▶'; position: absolute; right: -12px; top: -8px; color: #F44336; }
+.axis-arrow-y { position: absolute; bottom: -20px; left: 50%; transform: translateX(-50%); width: 2px; height: 20px; background: #4CAF50; }
+.axis-arrow-y::after { content: '▼'; position: absolute; bottom: -14px; left: -5px; color: #4CAF50; }
+
+.note { margin-top: 15px; color: #888; font-size: 11px; text-align: center; max-width: 710px; }
+.note em { color: #e94560; font-style: normal; }
+</style>
+</head>
+<body>
+<<<<<<< HEAD
+<h1>🤖 GEPRC GEP-F722-45A AIO — SaltyLab Pinout (Legacy / Archived)</h1>
+<p class="subtitle">ESP32RET6 + ICM-42688-P | Betaflight target: GEPR-GEPRC_F722_AIO</p>
+=======
+<h1>🤖 GEPRC GEP-F722-45A AIO — SaltyLab Pinout</h1>
+<p class="subtitle">ESP32-S3RET6 + ICM-42688-P | Betaflight target: GEPR-GEPRC_F722_AIO</p>
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+
+<div class="container">
+  <div class="board-wrap">
+    <div class="board">
+      <!-- Mounting holes -->
+      <div class="mount tl"></div>
+      <div class="mount tr"></div>
+      <div class="mount bl"></div>
+      <div class="mount br"></div>
+
+      <!-- MCU -->
+<<<<<<< HEAD
+      <div class="mcu"><div class="dot"></div>ESP32<br>(legacy:<br>F722RET6)</div>
+=======
+      <div class="mcu"><div class="dot"></div>ESP32-S3<br>F722RET6<br>216MHz</div>
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+
+      <!-- IMU -->
+      <div class="imu">ICM<br>42688</div>
+      <div class="rotation-arrow">↻</div>
+
+      <!-- LED -->
+      <div class="led-blue"></div>
+      <div class="led-label">LED PC4</div>
+
+      <!-- Boot button -->
+      <div class="boot-btn"></div>
+      <div class="boot-label">BOOT 🟡</div>
+
+      <!-- USB -->
+      <div class="usb"></div>
+      <div class="usb-label">USB-C (DFU)</div>
+
+      <!-- UART Pads - Bottom -->
+      <div class="pad pad-t1 uart1">
+        <div class="dot">T</div>
+        <span class="label">T1<br><span class="sublabel">PA9</span></span>
+      </div>
+      <div class="pad pad-r1 uart1">
+        <div class="dot">R</div>
+        <span class="label">R1<br><span class="sublabel">PA10</span></span>
+      </div>
+      <div class="pad pad-t3 uart3">
+        <div class="dot">T</div>
+        <span class="label">T3<br><span class="sublabel">PB10</span></span>
+      </div>
+      <div class="pad pad-r3 uart3">
+        <div class="dot">R</div>
+        <span class="label">R3<br><span class="sublabel">PB11</span></span>
+      </div>
+
+      <!-- UART Pads - Right -->
+      <div class="pad pad-t2 uart2">
+        <span class="label">T2<br><span class="sublabel">PA2</span></span>
+        <div class="dot">T</div>
+      </div>
+      <div class="pad pad-r2 uart2">
+        <span class="label">R2<br><span class="sublabel">PA3</span></span>
+        <div class="dot">R</div>
+      </div>
+
+      <!-- UART Pads - Top -->
+      <div class="pad pad-t4 uart4">
+        <div class="dot">T</div>
+        <span class="label">T4<br><span class="sublabel">PC10</span></span>
+      </div>
+      <div class="pad pad-r4 uart4">
+        <div class="dot">R</div>
+        <span class="label">R4<br><span class="sublabel">PC11</span></span>
+      </div>
+      <div class="pad pad-t5 uart5">
+        <span class="label">T5<br><span class="sublabel">PC12</span></span>
+        <div class="dot">T</div>
+      </div>
+      <div class="pad pad-r5 uart5">
+        <span class="label">R5<br><span class="sublabel">PD2</span></span>
+        <div class="dot">R</div>
+      </div>
+
+      <!-- ESC motor pads label -->
+      <div class="esc-pads">
+        <div class="esc-label">M1-M4 (unused)<br>PC6-PC9</div>
+      </div>
+
+      <!-- Board axes -->
+      <div class="axis-arrow-x"></div>
+      <div class="axis axis-x">X →<br><span style="font-size:9px;color:#888">board right</span></div>
+      <div class="axis-arrow-y"></div>
+      <div class="axis axis-y">Y ↓ (board forward = tilt axis)</div>
+    </div>
+  </div>
+
+  <div class="legend">
+    <h2>🔌 UART Assignments</h2>
+    <div class="legend-item">
+      <div class="swatch" style="background:#2196F3"></div>
+      <span><b>USART1</b> T1/R1 → Jetson Orin Nano Super</span>
+    </div>
+    <div class="legend-item">
+      <div class="swatch" style="background:#FF9800"></div>
+      <span><b>USART2</b> T2 → Hoverboard ESC (TX only)</span>
+    </div>
+    <div class="legend-item">
+      <div class="swatch" style="background:#9C27B0"></div>
+      <span><b>I2C2</b> T3/R3 → Baro/Mag (reserved)</span>
+    </div>
+    <div class="legend-item">
+      <div class="swatch" style="background:#4CAF50"></div>
+      <span><b>UART4</b> T4/R4 → ELRS RX (CRSF)</span>
+    </div>
+    <div class="legend-item">
+      <div class="swatch" style="background:#F44336"></div>
+      <span><b>UART5</b> T5/R5 → Debug/spare</span>
+    </div>
+
+    <div class="legend-section">
+      <h3>📡 SPI Bus</h3>
+      <div class="legend-item">
+        <span>SPI1: PA5/PA6/PA7 → IMU (CS: <em style="color:#e94560">PA15</em>)</span>
+      </div>
+      <div class="legend-item">
+        <span>SPI2: PB13-15 → OSD MAX7456</span>
+      </div>
+      <div class="legend-item">
+        <span>SPI3: PB3-5 → Flash W25Q128</span>
+      </div>
+    </div>
+
+    <div class="legend-section">
+      <h3>⚡ Other</h3>
+      <div class="legend-item">
+        <span>🔵 LED: PC4 | 📢 Beeper: PC15</span>
+      </div>
+      <div class="legend-item">
+        <span>🔋 VBAT: PC2 | ⚡ Current: PC1</span>
+      </div>
+      <div class="legend-item">
+        <span>💡 LED Strip: PA1 (WS2812)</span>
+      </div>
+      <div class="legend-item">
+        <span>📍 EXTI (IMU data-ready): PA8</span>
+      </div>
+    </div>
+  </div>
+</div>
+
+<div class="orient">
+  <h2>🧭 IMU Orientation (CW90° from chip to board)</h2>
+  <div class="orient-grid">
+    <div class="orient-item"><span class="dir">Board Forward</span> (tilt for balance) = Chip's +Y axis</div>
+    <div class="orient-item"><span class="dir">Board Right</span> = Chip's -X axis</div>
+    <div class="orient-item"><span class="dir">Board Pitch Rate</span> = -Gyro X (raw)</div>
+    <div class="orient-item"><span class="dir">Board Accel Forward</span> = Accel Y (raw)</div>
+  </div>
+</div>
+
+<p class="note">
+  ⚠️ Pad positions are <em>approximate</em> — check the physical board silkscreen for exact locations.
+  The CW90 rotation is handled in firmware (mpu6000.c). USB-C at bottom edge for DFU flashing.
+</p>
+
+</body>
+</html>

docs/wiring-diagram.md

@@ -1,131 +1,155 @@
-# SaltyLab Wiring Diagram
+# SaltyLab / SAUL-TEE Wiring Reference
 
-## System Overview
+> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** Mamba F722S / STM32 retired.
+> New stack: **ESP32-S3 BALANCE** + **ESP32-S3 IO** + VESCs on 500 kbps CAN.
+> **Authoritative reference:** [`docs/SAUL-TEE-SYSTEM-REFERENCE.md`](SAUL-TEE-SYSTEM-REFERENCE.md)
+> Historical STM32/Mamba wiring below is **obsolete** — retained for reference only.
+
+---
+
+## ~~System Overview~~ (OBSOLETE — see SAUL-TEE-SYSTEM-REFERENCE.md)
 
 ```
 ┌─────────────────────────────────────────────────────────────────────┐
 │                        ORIN NANO SUPER                              │
 │                     (Top Plate — 25W)                               │
 │                                                                     │
-│  USB-C ──── STM32 CDC (/dev/stm32-bridge, 921600 baud)            │
+<<<<<<< HEAD
+│  USB-A ──── CANable2 USB-CAN adapter (slcan0, 500 kbps)           │
+│  USB-A ──── ESP32-S3 IO (/dev/esp32-io, 460800 baud)              │
+=======
+│  USB-C ──── ESP32-S3 CDC (/dev/esp32-bridge, 921600 baud)            │
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 │  USB-A1 ─── RealSense D435i (USB 3.1)                             │
 │  USB-A2 ─── RPLIDAR A1M8 (via CP2102 adapter, 115200)             │
 │  USB-C* ─── SIM7600A 4G/LTE modem (ttyUSB0-2, AT cmds + PPP)     │
 │  USB ─────── Leap Motion Controller (hand/gesture tracking)        │
-│  CSI-A ──── ArduCam adapter → 2× IMX219 (front + left)            │
+│  CSI-A ──── ArduCam adapter → 2x IMX219 (front + left)            │
-│  CSI-B ──── ArduCam adapter → 2× IMX219 (rear + right)            │
+│  CSI-B ──── ArduCam adapter → 2x IMX219 (rear + right)            │
 │  M.2 ───── 1TB NVMe SSD                                            │
 │  40-pin ─── ReSpeaker 2-Mic HAT (I2S + I2C, WM8960 codec)         │
 │  Pin 8 ──┐                                                         │
-│  Pin 10 ─┤ UART fallback to FC (ttyTHS0, 921600)                  │
+│  Pin 10 ─┤ UART fallback to ESP32-S3 BALANCE (ttyTHS0, 460800)    │
 │  Pin 6 ──┘ GND                                                     │
 │                                                                     │
 └─────────────────────────────────────────────────────────────────────┘
-         │ USB-C (data only)              │ UART fallback (3 wires)
+         │ USB-A (CANable2)               │ UART fallback (3 wires)
-         │ 921600 baud                    │ 921600 baud, 3.3V
+         │ SocketCAN slcan0               │ 460800 baud, 3.3V
+         │ 500 kbps                       │
          ▼                                ▼
 ┌─────────────────────────────────────────────────────────────────────┐
-│                     MAMBA F722S (FC)                                 │
+<<<<<<< HEAD
+│                  ESP32-S3 BALANCE                                    │
+│          (Waveshare Touch LCD 1.28, Middle Plate)                   │
+=======
+│                     ESP32-S3 BALANCE (FC)                                 │
 │                  (Middle Plate — foam mounted)                       │
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 │                                                                     │
-│  USB-C ──── Orin (CDC serial, primary link)                        │
+│  CAN bus ──── CANable2 → Orin (primary link, ISO 11898)            │
-│                                                                     │
+│  UART0 ──── Orin UART fallback (460800 baud, 3.3V)                │
-│  USART2 (PA2=TX, PA3=RX) ──── Hoverboard ESC (26400 baud)         │
+│  UART1 ──── VESC Left  (CAN ID 56) via UART/CAN bridge            │
-│  UART4  (PA0=TX, PA1=RX) ──── ELRS RX (CRSF, 420000 baud)        │
+│  UART2 ──── VESC Right (CAN ID 68) via UART/CAN bridge            │
-│  USART6 (PC6=TX, PC7=RX) ──── Orin UART fallback                  │
+│  I2C   ──── QMI8658 IMU (onboard, 6-DOF accel+gyro)               │
-│  UART5  (PC12=TX, PD2=RX) ─── Debug (optional)                    │
+│  SPI   ──── GC9A01 LCD (onboard, 240x240 round display)           │
-│                                                                     │
+│  GPIO  ──── WS2812B LED strip                                      │
-│  SPI1 ─── MPU6000 IMU (on-board, CW270)                           │
+│  GPIO  ──── Buzzer                                                  │
-│  I2C1 ─── BMP280 baro (on-board, disabled)                        │
+│  ADC   ──── Battery voltage divider                                │
-│  ADC ──── Battery voltage (PC1) + Current (PC3)                    │
-│  PB3 ──── WS2812B LED strip                                        │
-│  PB2 ──── Buzzer                                                    │
 │                                                                     │
 └─────────────────────────────────────────────────────────────────────┘
-         │ USART2                         │ UART4
+         │ CAN bus (ISO 11898)            │ UART (460800 baud)
-         │ PA2=TX → ESC RX               │ PA0=TX → ELRS TX
+         │ 500 kbps                       │
-         │ PA3=RX ← ESC TX               │ PA1=RX ← ELRS RX
-         │ GND ─── GND                   │ GND ─── GND
          ▼                                ▼
 ┌────────────────────────┐    ┌──────────────────────────┐
-│   HOVERBOARD ESC       │    │   ELRS 2.4GHz RX         │
+│   VESC Left (ID 56)    │    │   VESC Right (ID 68)     │
-│   (Bottom Plate)       │    │   (beside FC)             │
+│   (Bottom Plate)       │    │   (Bottom Plate)          │
+│                        │    │                            │
+│  BLDC hub motor        │    │  BLDC hub motor            │
+│  CAN 500 kbps          │    │  CAN 500 kbps             │
+│  FOC current control   │    │  FOC current control      │
+│  VESC Status 1 (0x900) │    │  VESC Status 1 (0x910)   │
 │                        │    │                            │
-│  2× BLDC hub motors    │    │  CRSF protocol            │
-│  26400 baud UART       │    │  420000 baud              │
-│  Frame: [0xABCD]       │    │  BetaFPV 1W TX → RX      │
-│  [steer][speed][csum]  │    │  CH3=speed CH4=steer      │
-│                        │    │  CH5=arm   CH6=mode       │
 └────────────────────────┘    └──────────────────────────┘
-         │                              
+         │                              │
-    ┌────┴────┐                         
+    LEFT MOTOR                    RIGHT MOTOR
-    ▼         ▼                         
+```
-  🛞 LEFT   RIGHT 🛞                    
-  MOTOR     MOTOR                       
 
 
 ## Wire-by-Wire Connections
 
-### 1. Orin ↔ FC (Primary: USB CDC)
+<<<<<<< HEAD
+### 1. Orin <-> ESP32-S3 BALANCE (Primary: CAN Bus via CANable2)
+=======
+### 1. Orin ↔ FC (Primary: USB Serial (CH343))
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
-| From | To | Wire Color | Notes |
+| From | To | Wire | Notes |
-|------|----|-----------|-------|
+|------|----|------|-------|
-| Orin USB-C port | FC USB-C port | USB cable | Data only, FC powered from 5V bus |
+| Orin USB-A | CANable2 USB | USB cable | SocketCAN slcan0 @ 500 kbps |
+| CANable2 CAN-H | ESP32-S3 BALANCE CAN-H | twisted pair | ISO 11898 differential |
+| CANable2 CAN-L | ESP32-S3 BALANCE CAN-L | twisted pair | ISO 11898 differential |
 
-- Device: `/dev/ttyACM0` → symlink `/dev/stm32-bridge`
+<<<<<<< HEAD
+- Interface: SocketCAN `slcan0`, 500 kbps
+- Device node: `/dev/canable2` (via udev, symlink to ttyUSBx)
+- Protocol: CAN frames --- ORIN_CMD_DRIVE (0x300), ORIN_CMD_MODE (0x301), ORIN_CMD_ESTOP (0x302)
+- Telemetry: BALANCE_STATUS (0x400), BALANCE_VESC (0x401), BALANCE_IMU (0x402), BALANCE_BATTERY (0x403)
+=======
+- Device: `/dev/ttyACM0` → symlink `/dev/esp32-bridge`
 - Baud: 921600, 8N1
 - Protocol: JSON telemetry (FC→Orin), ASCII commands (Orin→FC)
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
-### 2. Orin ↔ FC (Fallback: Hardware UART)
+### 2. Orin <-> ESP32-S3 BALANCE (Fallback: Hardware UART)
 
-| Orin Pin | Signal | FC Pin | FC Signal |
+| Orin Pin | Signal | ESP32-S3 Pin | Notes |
-|----------|--------|--------|-----------|
+|----------|--------|--------------|-------|
-| Pin 8 | TXD0 | PC7 | USART6 RX |
+| Pin 8 | TXD0 | GPIO17 (UART0 RX) | Orin TX -> BALANCE RX |
-| Pin 10 | RXD0 | PC6 | USART6 TX |
+| Pin 10 | RXD0 | GPIO18 (UART0 TX) | Orin RX <- BALANCE TX |
-| Pin 6 | GND | GND | GND |
+| Pin 6 | GND | GND | Common ground |
 
 - Jetson device: `/dev/ttyTHS0`
-- Baud: 921600, 8N1
+- Baud: 460800, 8N1
 - Voltage: 3.3V both sides (no level shifter needed)
-- **Cross-connect:** Orin TX → FC RX, Orin RX ← FC TX
+- Cross-connect: Orin TX -> BALANCE RX, Orin RX <- BALANCE TX
 
-### 3. FC ↔ Hoverboard ESC
+### 3. Orin <-> ESP32-S3 IO (USB Serial)
 
-| FC Pin | Signal | ESC Pin | Notes |
+| From | To | Notes |
-|--------|--------|---------|-------|
+|------|----|-------|
-| PA2 | USART2 TX | RX | FC sends speed/steer commands |
+| Orin USB-A | ESP32-S3 IO USB-C | USB cable, /dev/esp32-io |
-| PA3 | USART2 RX | TX | ESC sends feedback (optional) |
+
+- Device node: `/dev/esp32-io` (udev symlink)
+- Baud: 460800, 8N1
+- Protocol: Binary frames `[0xAA][LEN][TYPE][PAYLOAD][CRC8]`
+- Use: IO expansion, GPIO control, sensor polling
+
+### 4. ESP32-S3 BALANCE <-> VESC Motors (CAN Bus)
+
+| BALANCE Pin | Signal | VESC Pin | Notes |
+|-------------|--------|----------|-------|
+| GPIO21 | CAN-H | CAN-H | ISO 11898 differential pair |
+| GPIO22 | CAN-L | CAN-L | ISO 11898 differential pair |
 | GND | GND | GND | Common ground |
 
-- Baud: 26400, 8N1
+- Baud: 500 kbps CAN
-- Protocol: Binary frame — `[0xABCD][steer:int16][speed:int16][checksum:uint16]`
+- VESC Left: CAN ID 56, VESC Right: CAN ID 68
-- Speed range: -1000 to +1000
+- Commands: COMM_SET_RPM, COMM_SET_CURRENT, COMM_SET_DUTY
-- **Keep wires short and twisted** (EMI from ESC)
+- Telemetry: VESC Status 1 at 50 Hz (RPM, current, duty)
-
-### 4. FC ↔ ELRS Receiver
-
-| FC Pin | Signal | ELRS Pin | Notes |
-|--------|--------|----------|-------|
-| PA0 | UART4 TX | RX | Telemetry to TX (optional) |
-| PA1 | UART4 RX | TX | CRSF frames from RX |
-| GND | GND | GND | Common ground |
-| 5V | — | VCC | Power ELRS from 5V bus |
-
-- Baud: 420000 (CRSF protocol)
-- Failsafe: disarm after 300ms without frame
 
 ### 5. Power Distribution
 
 ```
-BATTERY (36V) ──┬── Hoverboard ESC (36V direct)
+BATTERY (36V) ──┬── VESC Left  (36V direct -> BLDC left motor)
+                ├── VESC Right (36V direct -> BLDC right motor)
                 │
                 ├── 5V BEC/regulator ──┬── Orin (USB-C PD or barrel jack)
-                │                      ├── FC (via USB or 5V pad)
+                │                      ├── ESP32-S3 BALANCE (5V via USB-C)
-                │                      ├── ELRS RX (5V)
+                │                      ├── ESP32-S3 IO (5V via USB-C)
                 │                      ├── WS2812B LEDs (5V)
                 │                      └── RPLIDAR (5V via USB)
                 │
-                └── Battery monitor ──── FC ADC (PC1=voltage, PC3=current)
+                └── Battery monitor ──── ESP32-S3 BALANCE ADC (voltage divider)
 ```
 
 ### 6. Sensors on Orin (USB/CSI)
@@ -136,10 +160,39 @@ BATTERY (36V) ──┬── Hoverboard ESC (36V direct)
 | RPLIDAR A1M8 | USB-UART | USB-A | `/dev/rplidar` |
 | IMX219 front+left | MIPI CSI-2 | CSI-A (J5) | `/dev/video0,2` |
 | IMX219 rear+right | MIPI CSI-2 | CSI-B (J8) | `/dev/video4,6` |
-| 1TB NVMe | PCIe Gen3 ×4 | M.2 Key M | `/dev/nvme0n1` |
+| 1TB NVMe | PCIe Gen3 x4 | M.2 Key M | `/dev/nvme0n1` |
+| CANable2 | USB-CAN | USB-A | `/dev/canable2` -> `slcan0` |
 
 
-## FC UART Summary (MAMBA F722S)
+<<<<<<< HEAD
+## FC UART Summary (MAMBA F722S — OBSOLETE)
+
+| Interface | Pins | Baud/Rate | Assignment | Notes |
+|-----------|------|-----------|------------|-------|
+| UART0 | GPIO17=RX, GPIO18=TX | 460800 | Orin UART fallback | 3.3V, cross-connect |
+| UART1 | GPIO19=RX, GPIO20=TX | 115200 | Debug serial | Optional |
+| CAN (TWAI) | GPIO21=H, GPIO22=L | 500 kbps | CAN bus (VESCs + Orin) | SN65HVD230 transceiver |
+| I2C | GPIO4=SDA, GPIO5=SCL | 400 kHz | QMI8658 IMU (addr 0x6B) | Onboard |
+| SPI | GPIO36=MOSI, GPIO37=SCLK, GPIO35=CS | 40 MHz | GC9A01 LCD (onboard) | 240x240 round |
+| USB CDC | USB-C | 460800 | Orin USB fallback | /dev/esp32-balance |
+
+## CAN Frame ID Map
+
+| CAN ID | Direction | Name | Contents |
+|--------|-----------|------|----------|
+| 0x300 | Orin -> BALANCE | ORIN_CMD_DRIVE | left_rpm_f32, right_rpm_f32 (8 bytes LE) |
+| 0x301 | Orin -> BALANCE | ORIN_CMD_MODE | mode byte (0=IDLE, 1=DRIVE, 2=ESTOP) |
+| 0x302 | Orin -> BALANCE | ORIN_CMD_ESTOP | flags byte (bit0=stop, bit1=clear) |
+| 0x400 | BALANCE -> Orin | BALANCE_STATUS | pitch x10:i16, motor_cmd:u16, vbat_mv:u16, state:u8, flags:u8 |
+| 0x401 | BALANCE -> Orin | BALANCE_VESC | l_rpm x10:i16, r_rpm x10:i16, l_cur x10:i16, r_cur x10:i16 |
+| 0x402 | BALANCE -> Orin | BALANCE_IMU | pitch x100:i16, roll x100:i16, yaw x100:i16, ax x100:i16, ay x100:i16, az x100:i16 |
+| 0x403 | BALANCE -> Orin | BALANCE_BATTERY | vbat_mv:u16, current_ma:i16, soc_pct:u8 |
+| 0x900+ID | VESC Left -> | VESC_STATUS_1 | erpm:i32, current x10:i16, duty x1000:i16 |
+| 0x910+ID | VESC Right -> | VESC_STATUS_1 | erpm:i32, current x10:i16, duty x1000:i16 |
+
+VESC Left CAN ID = 56 (0x38), VESC Right CAN ID = 68 (0x44).
+=======
+## FC UART Summary (ESP32-S3 BALANCE)
 
 | UART | Pins | Baud | Assignment | Notes |
 |------|------|------|------------|-------|
@@ -149,7 +202,8 @@ BATTERY (36V) ──┬── Hoverboard ESC (36V direct)
 | UART4 | PA0=TX, PA1=RX | 420000 | ELRS RX (CRSF) | RC control |
 | UART5 | PC12=TX, PD2=RX | 115200 | Debug serial | Optional |
 | USART6 | PC6=TX, PC7=RX | 921600 | Jetson UART | Fallback link |
-| USB CDC | USB-C | 921600 | Jetson primary | `/dev/stm32-bridge` |
+| USB Serial (CH343) | USB-C | 921600 | Jetson primary | `/dev/esp32-bridge` |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 
 ### 7. ReSpeaker 2-Mic HAT (on Orin 40-pin header)
@@ -167,57 +221,63 @@ BATTERY (36V) ──┬── Hoverboard ESC (36V direct)
 | Pin 2, 4 | 5V | Power |
 | Pin 6, 9 | GND | Ground |
 
-- **Codec:** Wolfson WM8960 (I2C addr 0x1A)
+- Codec: Wolfson WM8960 (I2C addr 0x1A)
-- **Mics:** 2× MEMS (left + right) — basic stereo / sound localization
+- Mics: 2x MEMS (left + right) --- basic stereo / sound localization
-- **Speaker:** 3W class-D amp output (JST connector)
+- Speaker: 3W class-D amp output (JST connector)
-- **Headset:** 3.5mm TRRS jack
+- Headset: 3.5mm TRRS jack
-- **Requires:** WM8960 device tree overlay for Jetson (community port)
+- Requires: WM8960 device tree overlay for Jetson (community port)
-- **Use:** Voice commands (faster-whisper), wake word (openWakeWord), audio feedback, status announcements
+- Use: Voice commands (faster-whisper), wake word (openWakeWord), audio feedback, status announcements
 
 ### 8. SIM7600A 4G/LTE HAT (via USB)
 
 | Connection | Detail |
 |-----------|--------|
-| Interface | USB (micro-B on HAT → USB-A/C on Orin) |
+| Interface | USB (micro-B on HAT -> USB-A/C on Orin) |
 | Device nodes | `/dev/ttyUSB0` (AT), `/dev/ttyUSB1` (PPP/data), `/dev/ttyUSB2` (GPS NMEA) |
 | Power | 5V from USB or separate 5V supply (peak 2A during TX) |
 | SIM | Nano-SIM slot on HAT |
-| Antenna | 4G LTE + GPS/GNSS (external SMA antennas — mount high on chassis) |
+| Antenna | 4G LTE + GPS/GNSS (external SMA antennas --- mount high on chassis) |
 
-- **Data:** PPP or QMI for internet connectivity
+- Data: PPP or QMI for internet connectivity
-- **GPS/GNSS:** Built-in receiver, NMEA sentences on ttyUSB2 — outdoor positioning
+- GPS/GNSS: Built-in receiver, NMEA sentences on ttyUSB2 --- outdoor positioning
-- **AT commands:** `AT+CGPS=1` (enable GPS), `AT+CGPSINFO` (get fix)
+- AT commands: `AT+CGPS=1` (enable GPS), `AT+CGPSINFO` (get fix)
-- **Connected via USB** (not 40-pin) — avoids UART conflict with FC fallback, flexible antenna placement
+- Connected via USB (not 40-pin) --- avoids UART conflict with BALANCE fallback, flexible antenna placement
-- **Use:** Remote telemetry, 4G connectivity outdoors, GPS positioning, remote SSH/control
+- Use: Remote telemetry, 4G connectivity outdoors, GPS positioning, remote SSH/control
 
-### 10. Leap Motion Controller (USB)
+### 9. Leap Motion Controller (USB)
 
 | Connection | Detail |
 |-----------|--------|
-| Interface | USB 3.0 (micro-B on controller → USB-A on Orin) |
+| Interface | USB 3.0 (micro-B on controller -> USB-A on Orin) |
 | Power | ~0.5W |
-| Range | ~80cm, 150° FOV |
+| Range | ~80cm, 150 deg FOV |
 | SDK | Ultraleap Gemini V5+ (Linux ARM64 support) |
 | ROS2 | `leap_motion_ros2` wrapper available |
 
-- **2× IR cameras + 3× IR LEDs** — tracks all 10 fingers in 3D, sub-mm precision
+- 2x IR cameras + 3x IR LEDs --- tracks all 10 fingers in 3D, sub-mm precision
-- **Mount:** Forward-facing on sensor tower or upward on Orin plate
+- Mount: Forward-facing on sensor tower or upward on Orin plate
-- **Use:** Gesture control (palm=stop, point=go, fist=arm), hand-following mode, demos
+- Use: Gesture control (palm=stop, point=go, fist=arm), hand-following mode, demos
-- **Combined with ReSpeaker:** Voice + gesture control with zero hardware in hand
+- Combined with ReSpeaker: Voice + gesture control with zero hardware in hand
 
-### 11. Power Budget (USB)
+### 10. Power Budget (USB)
 
 | Device | Interface | Power Draw |
 |--------|-----------|------------|
-| STM32 FC (CDC) | USB-C | ~0.5W (data only, FC on 5V bus) |
+<<<<<<< HEAD
+| CANable2 USB-CAN | USB-A | ~0.5W |
+| ESP32-S3 BALANCE | USB-C | ~0.8W (WiFi off) |
+| ESP32-S3 IO | USB-C | ~0.5W |
+=======
+| ESP32-S3 FC (CDC) | USB-C | ~0.5W (data only, FC on 5V bus) |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | RealSense D435i | USB-A | ~1.5W (3.5W peak) |
 | RPLIDAR A1M8 | USB-A | ~2.6W (motor on) |
 | SIM7600A | USB | ~1W idle, 3W TX peak |
-| Leap Motion | USB | ~0.5W |
+| Leap Motion | USB-A | ~0.5W |
 | ReSpeaker HAT | 40-pin | ~0.5W |
-| **Total USB** | | **~6.5W typical, ~10.5W peak** |
+| **Total USB** | | **~7.9W typical, ~11W peak** |
 
-Orin Nano Super delivers up to 25W — USB peripherals are well within budget.
+Orin Nano Super delivers up to 25W --- USB peripherals are well within budget.
 
 ---
 
@@ -225,38 +285,46 @@ Orin Nano Super delivers up to 25W — USB peripherals are well within budget.
 
 ```
                     ┌──────────────┐
-                    │  ELRS TX     │ (in your hand)
+                    │  RC TX       │ (in your hand)
                     │  (2.4GHz)    │
                     └──────┬───────┘
                            │ radio
                     ┌──────▼───────┐
-                    │  ELRS RX     │ CRSF 420kbaud
+                    │  RC RX       │ CRSF 420kbaud (future)
                     └──────┬───────┘
-                           │ UART4
+                           │ UART
               ┌────────────▼────────────┐
-              │      MAMBA F722S        │
+<<<<<<< HEAD
+              │   ESP32-S3 BALANCE      │
+              │  (Waveshare LCD 1.28)   │
+=======
+              │      ESP32-S3 BALANCE        │
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
               │                         │
-              │  MPU6000 → Balance PID  │
+              │  QMI8658 -> Balance PID │
-              │  CRSF → Mode Manager   │
+              │  RC -> Mode Manager     │
               │  Safety Monitor         │
               │                         │
               └──┬──────────┬───────────┘
-    USART2 ─────┘          └───── USB CDC / USART6
+<<<<<<< HEAD
+    CAN 500kbps─┘          └───── CAN bus / UART fallback
+=======
+    USART2 ─────┘          └───── USB Serial (CH343) / USART6
     26400 baud                    921600 baud
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
          │                              │
-         ▼                              ▼
+    ┌────┴────────────┐                 ▼
-┌────────────────┐          ┌───────────────────┐
+    │ CAN bus (500k)  │        ┌───────────────────┐
-│ Hoverboard ESC │          │   Orin Nano Super  │
+    ├─ VESC Left  56  │        │   Orin Nano Super  │
-│                │          │                     │
+    └─ VESC Right 68  │        │                     │
-│ L motor  R motor│         │  SLAM / Nav2 / AI  │
+         │    │                │  SLAM / Nav2 / AI  │
-│    🛞      🛞   │         │  Person following   │
+         ▼    ▼                │  Person following   │
-└────────────────┘          │  Voice commands     │
+       LEFT  RIGHT             │  Voice commands     │
-                            │  4G telemetry       │
+       MOTOR MOTOR             │  4G telemetry       │
-                            └──┬──────────┬───────┘
+                               └──┬──────────┬───────┘
-                               │          │
+                                  │          │
-                    ┌──────────▼─┐   ┌────▼──────────┐
+                       ┌──────────▼─┐   ┌────▼──────────┐
-                    │ ReSpeaker  │   │  SIM7600A     │
+                       │ ReSpeaker  │   │  SIM7600A     │
-                    │ 2-Mic HAT  │   │  4G/LTE + GPS │
+                       │ 2-Mic HAT  │   │  4G/LTE + GPS │
-                    │ 🎤 🔊      │   │  📡 🛰️        │
+                       └────────────┘   └───────────────┘
-                    └────────────┘   └───────────────┘
 ```

esp32/uwb_anchor/platformio.ini

@@ -0,0 +1,30 @@
+; SaltyBot UWB Anchor Firmware — Issue #544
+; Target: Makerfabs ESP32 UWB Pro (DW3000 chip)
+;
+; Library: Makerfabs MaUWB_DW3000
+;   https://github.com/Makerfabs/MaUWB_DW3000
+;
+; Flash:
+;   pio run -e anchor0 --target upload   (port-side anchor)
+;   pio run -e anchor1 --target upload   (starboard anchor)
+; Monitor:
+;   pio device monitor -e anchor0 -b 115200
+
+[common]
+platform     = espressif32
+board        = esp32dev
+framework    = arduino
+monitor_speed = 115200
+upload_speed  = 921600
+lib_deps =
+    https://github.com/Makerfabs/MaUWB_DW3000.git
+build_flags =
+    -DCORE_DEBUG_LEVEL=0
+
+[env:anchor0]
+extends     = common
+build_flags = ${common.build_flags} -DANCHOR_ID=0
+
+[env:anchor1]
+extends     = common
+build_flags = ${common.build_flags} -DANCHOR_ID=1

esp32/uwb_anchor/src/main.cpp

@@ -0,0 +1,542 @@
+/*
+ * uwb_anchor — SaltyBot ESP32 UWB Pro anchor firmware (TWR responder)
+ * Issue #544
+ *
+ * Hardware: Makerfabs ESP32 UWB Pro (DW3000 chip)
+ *
+ * Role
+ * ────
+ *   Anchor sits on SaltyBot body, USB-connected to Jetson Orin.
+ *   Two anchors per robot (anchor-0 port side, anchor-1 starboard).
+ *   Person-worn tags initiate ranging; anchors respond.
+ *
+ * Protocol: Double-Sided TWR (DS-TWR)
+ * ────────────────────────────────────
+ *   Tag → Anchor   POLL   (msg_type 0x01)
+ *   Anchor → Tag   RESP   (msg_type 0x02, payload: T_poll_rx, T_resp_tx)
+ *   Tag → Anchor   FINAL  (msg_type 0x03, payload: Ra, Da, Db timestamps)
+ *   Anchor computes range via DS-TWR formula, emits +RANGE on Serial.
+ *
+ * Serial output (115200 8N1, USB-CDC to Jetson)
+ * ──────────────────────────────────────────────
+ *   +RANGE:<anchor_id>,<range_mm>,<rssi_dbm>\r\n   (on each successful range)
+ *
+ * AT commands (host → anchor)
+ * ───────────────────────────
+ *   AT+RANGE?                  → returns last buffered +RANGE line
+ *   AT+RANGE_ADDR=<hex_addr>   → pair with specific tag (filter others)
+ *   AT+RANGE_ADDR=             → clear pairing (accept all tags)
+ *   AT+ID?                     → returns +ID:<anchor_id>
+ *   AT+PEER_RANGE=<id>         → inter-anchor DS-TWR (for auto-calibration)
+ *                                → +PEER_RANGE:<my>,<peer>,<mm>,<rssi>
+ *
+ * Pin mapping — Makerfabs ESP32 UWB Pro
+ * ──────────────────────────────────────
+ *   SPI SCK   18    SPI MISO  19    SPI MOSI  23
+ *   DW CS     21    DW RST    27    DW IRQ    34
+ *
+ * Build
+ * ──────
+ *   pio run -e anchor0 --target upload   (port side)
+ *   pio run -e anchor1 --target upload   (starboard)
+ */
+
+#include <Arduino.h>
+#include <SPI.h>
+#include <math.h>
+#include "dw3000.h"   // Makerfabs MaUWB_DW3000 library
+
+/* ── Configurable ───────────────────────────────────────────────── */
+
+#ifndef ANCHOR_ID
+#  define ANCHOR_ID  0          /* 0 = port, 1 = starboard */
+#endif
+
+#define SERIAL_BAUD  115200
+
+/* ── Pin map (Makerfabs ESP32 UWB Pro) ─────────────────────────── */
+
+#define PIN_SCK   18
+#define PIN_MISO  19
+#define PIN_MOSI  23
+#define PIN_CS    21
+#define PIN_RST   27
+#define PIN_IRQ   34
+
+/* ── DW3000 channel / PHY config ───────────────────────────────── */
+
+static dwt_config_t dw_cfg = {
+    5,                 /* channel 5 (6.5 GHz, best penetration) */
+    DWT_PLEN_128,      /* preamble length                       */
+    DWT_PAC8,          /* PAC size                              */
+    9,                 /* TX preamble code                      */
+    9,                 /* RX preamble code                      */
+    1,                 /* SFD type (IEEE 802.15.4z)             */
+    DWT_BR_6M8,        /* data rate 6.8 Mbps                    */
+    DWT_PHR_MODE_STD,  /* standard PHR                          */
+    DWT_PHR_RATE_DATA,
+    (129 + 8 - 8),     /* SFD timeout                           */
+    DWT_STS_MODE_OFF,  /* STS off — standard TWR                */
+    DWT_STS_LEN_64,
+    DWT_PDOA_M0,       /* no PDoA                               */
+};
+
+/* ── Frame format ──────────────────────────────────────────────── */
+
+/* Byte layout for all frames:
+ *   [0]     frame_type  (FTYPE_*)
+ *   [1]     src_id      (tag 8-bit addr, or ANCHOR_ID)
+ *   [2]     dst_id
+ *   [3..]   payload
+ *   (FCS appended automatically by DW3000 — 2 bytes)
+ */
+
+#define FTYPE_POLL   0x01
+#define FTYPE_RESP   0x02
+#define FTYPE_FINAL  0x03
+
+#define FRAME_HDR   3
+#define FCS_LEN     2
+
+/* RESP payload: T_poll_rx(5 B) + T_resp_tx(5 B) */
+#define RESP_PAYLOAD   10
+#define RESP_FRAME_LEN (FRAME_HDR + RESP_PAYLOAD + FCS_LEN)
+
+/* FINAL payload: Ra(5 B) + Da(5 B) + Db(5 B) */
+#define FINAL_PAYLOAD   15
+#define FINAL_FRAME_LEN (FRAME_HDR + FINAL_PAYLOAD + FCS_LEN)
+
+/* ── Timing ────────────────────────────────────────────────────── */
+
+/* Turnaround delay: anchor waits 500 µs after poll_rx before tx_resp.
+ * DW3000 tick = 1/(128×499.2e6) ≈ 15.65 ps  →  500 µs = ~31.95M ticks.
+ * Stored as uint32 shifted right 8 bits for dwt_setdelayedtrxtime. */
+#define RESP_TX_DLY_US      500UL
+#define DWT_TICKS_PER_US    63898UL          /* 1µs in DW3000 ticks (×8 prescaler) */
+#define RESP_TX_DLY_TICKS   (RESP_TX_DLY_US * DWT_TICKS_PER_US)
+
+/* How long anchor listens for FINAL after sending RESP */
+#define FINAL_RX_TIMEOUT_US  3000
+
+/* Speed of light (m/s) */
+#define SPEED_OF_LIGHT  299702547.0
+
+/* DW3000 40-bit timestamp mask */
+#define DWT_TS_MASK  0xFFFFFFFFFFULL
+
+/* Antenna delay (factory default; calibrate per unit for best accuracy) */
+#define ANT_DELAY  16385
+
+/* ── Interrupt flags (set in ISR, polled in main) ──────────────── */
+
+static volatile bool g_rx_ok   = false;
+static volatile bool g_tx_done = false;
+static volatile bool g_rx_err  = false;
+static volatile bool g_rx_to   = false;
+
+static uint8_t  g_rx_buf[128];
+static uint32_t g_rx_len = 0;
+
+/* ── State ──────────────────────────────────────────────────────── */
+
+/* Last successful range (serves AT+RANGE? queries) */
+static int32_t g_last_range_mm = -1;
+static char    g_last_range_line[72] = {};
+
+/* Optional tag pairing: 0 = accept all tags */
+static uint8_t g_paired_tag_id = 0;
+
+/* ── DW3000 ISR callbacks ───────────────────────────────────────── */
+
+static void cb_tx_done(const dwt_cb_data_t *) { g_tx_done = true; }
+
+static void cb_rx_ok(const dwt_cb_data_t *d) {
+    g_rx_len = d->datalength;
+    if (g_rx_len > sizeof(g_rx_buf)) g_rx_len = sizeof(g_rx_buf);
+    dwt_readrxdata(g_rx_buf, g_rx_len, 0);
+    g_rx_ok = true;
+}
+
+static void cb_rx_err(const dwt_cb_data_t *) { g_rx_err = true; }
+static void cb_rx_to(const dwt_cb_data_t  *) { g_rx_to  = true; }
+
+/* ── Timestamp helpers ──────────────────────────────────────────── */
+
+static uint64_t ts_read(const uint8_t *p) {
+    uint64_t v = 0;
+    for (int i = 4; i >= 0; i--) v = (v << 8) | p[i];
+    return v;
+}
+
+static void ts_write(uint8_t *p, uint64_t v) {
+    for (int i = 0; i < 5; i++, v >>= 8) p[i] = (uint8_t)(v & 0xFF);
+}
+
+static inline uint64_t ts_diff(uint64_t later, uint64_t earlier) {
+    return (later - earlier) & DWT_TS_MASK;
+}
+
+static inline double ticks_to_s(uint64_t t) {
+    return (double)t / (128.0 * 499200000.0);
+}
+
+/* Estimate receive power from CIR diagnostics (dBm) */
+static float rx_power_dbm(void) {
+    dwt_rxdiag_t d;
+    dwt_readdiagnostics(&d);
+    if (d.maxGrowthCIR == 0 || d.rxPreamCount == 0) return 0.0f;
+    float f = (float)d.maxGrowthCIR;
+    float n = (float)d.rxPreamCount;
+    return 10.0f * log10f((f * f) / (n * n)) - 121.74f;
+}
+
+/* ── Peer-anchor ranging (initiator role, for auto-calibration) ─── */
+
+/* Timeout waiting for peer's RESP during inter-anchor ranging */
+#define PEER_RX_RESP_TIMEOUT_US   3500
+/* Block up to this many ms waiting for the interrupt flags */
+#define PEER_WAIT_MS              20
+
+/* Initiate a single DS-TWR exchange toward peer anchor `peer_id`.
+ * Returns range in mm (>=0) on success, or -1 on timeout/error.
+ * RSSI is stored in *rssi_out if non-null.
+ *
+ * Exchange:
+ *   This anchor  → peer  POLL
+ *   peer         → This  RESP  (carries T_poll_rx, T_resp_tx)
+ *   This anchor  → peer  FINAL (carries Ra, Da)
+ *   This side computes its own range estimate from Ra/Da.
+ */
+static int32_t peer_range_once(uint8_t peer_id, float *rssi_out) {
+    /* ── Reset interrupt flags ── */
+    g_tx_done = g_rx_ok = g_rx_err = g_rx_to = false;
+
+    /* ── Build POLL frame ── */
+    uint8_t poll_buf[FRAME_HDR + FCS_LEN] = {
+        FTYPE_POLL,
+        (uint8_t)ANCHOR_ID,
+        peer_id,
+    };
+
+    dwt_writetxdata(sizeof(poll_buf), poll_buf, 0);
+    dwt_writetxfctrl(sizeof(poll_buf), 0, 1);
+    dwt_setrxtimeout(PEER_RX_RESP_TIMEOUT_US);
+    dwt_rxenable(DWT_START_RX_IMMEDIATE);
+    if (dwt_starttx(DWT_START_TX_IMMEDIATE | DWT_RESPONSE_EXPECTED) != DWT_SUCCESS)
+        return -1;
+
+    /* Wait for TX done */
+    uint32_t t0 = millis();
+    while (!g_tx_done && !g_rx_err && !g_rx_to) {
+        if (millis() - t0 > (uint32_t)PEER_WAIT_MS) return -1;
+    }
+    if (g_rx_err || g_rx_to) return -1;
+    g_tx_done = false;
+
+    /* Capture T_poll_tx */
+    uint64_t T_poll_tx;
+    dwt_readtxtimestamp((uint8_t *)&T_poll_tx);
+    T_poll_tx &= DWT_TS_MASK;
+
+    /* Wait for RESP */
+    t0 = millis();
+    while (!g_rx_ok && !g_rx_err && !g_rx_to) {
+        if (millis() - t0 > (uint32_t)PEER_WAIT_MS) return -1;
+    }
+    if (!g_rx_ok) return -1;
+
+    /* Validate RESP */
+    if (g_rx_len < (uint32_t)(FRAME_HDR + RESP_PAYLOAD + FCS_LEN)) return -1;
+    if (g_rx_buf[0] != FTYPE_RESP)              return -1;
+    if (g_rx_buf[1] != peer_id)                  return -1;
+    if (g_rx_buf[2] != (uint8_t)ANCHOR_ID)       return -1;
+
+    uint64_t T_resp_rx;
+    dwt_readrxtimestamp((uint8_t *)&T_resp_rx);
+    T_resp_rx &= DWT_TS_MASK;
+
+    /* Extract peer timestamps from RESP payload */
+    const uint8_t *pl = g_rx_buf + FRAME_HDR;
+    uint64_t T_poll_rx_peer = ts_read(pl);
+    uint64_t T_resp_tx_peer = ts_read(pl + 5);
+
+    /* DS-TWR Ra, Da */
+    uint64_t Ra = ts_diff(T_resp_rx, T_poll_tx);
+    uint64_t Da = ts_diff(T_resp_tx_peer, T_poll_rx_peer);
+
+    g_rx_ok = g_rx_err = g_rx_to = false;
+
+    /* ── Build FINAL frame ── */
+    uint8_t final_buf[FRAME_HDR + FINAL_PAYLOAD + FCS_LEN];
+    final_buf[0] = FTYPE_FINAL;
+    final_buf[1] = (uint8_t)ANCHOR_ID;
+    final_buf[2] = peer_id;
+    ts_write(final_buf + FRAME_HDR,      Ra);
+    ts_write(final_buf + FRAME_HDR + 5,  Da);
+    ts_write(final_buf + FRAME_HDR + 10, (uint64_t)0);  /* Db placeholder */
+
+    dwt_setrxtimeout(0);
+    dwt_writetxdata(sizeof(final_buf), final_buf, 0);
+    dwt_writetxfctrl(sizeof(final_buf), 0, 1);
+    if (dwt_starttx(DWT_START_TX_IMMEDIATE) != DWT_SUCCESS) return -1;
+
+    t0 = millis();
+    while (!g_tx_done && !g_rx_err) {
+        if (millis() - t0 > (uint32_t)PEER_WAIT_MS) return -1;
+    }
+    g_tx_done = false;
+
+    /* Simplified one-sided range estimate: tof = Ra - Da/2 */
+    double tof_s = ticks_to_s(Ra) - ticks_to_s(Da) / 2.0;
+    if (tof_s < 0.0) tof_s = 0.0;
+    int32_t range_mm = (int32_t)(tof_s * SPEED_OF_LIGHT * 1000.0);
+
+    if (rssi_out) *rssi_out = rx_power_dbm();
+
+    /* Re-enable normal RX for tag ranging */
+    dwt_setrxtimeout(0);
+    dwt_rxenable(DWT_START_RX_IMMEDIATE);
+
+    return range_mm;
+}
+
+/* ── AT command handler ─────────────────────────────────────────── */
+
+static char g_at_buf[64];
+static int  g_at_idx = 0;
+
+static void at_dispatch(const char *cmd) {
+    if (strcmp(cmd, "AT+RANGE?") == 0) {
+        if (g_last_range_mm >= 0)
+            Serial.println(g_last_range_line);
+        else
+            Serial.println("+RANGE:NO_DATA");
+
+    } else if (strcmp(cmd, "AT+ID?") == 0) {
+        Serial.printf("+ID:%d\r\n", ANCHOR_ID);
+
+    } else if (strncmp(cmd, "AT+RANGE_ADDR=", 14) == 0) {
+        const char *v = cmd + 14;
+        if (*v == '\0') {
+            g_paired_tag_id = 0;
+            Serial.println("+OK:UNPAIRED");
+        } else {
+            g_paired_tag_id = (uint8_t)strtoul(v, nullptr, 0);
+            Serial.printf("+OK:PAIRED=0x%02X\r\n", g_paired_tag_id);
+        }
+
+    } else if (strncmp(cmd, "AT+PEER_RANGE=", 14) == 0) {
+        /* Inter-anchor ranging for calibration.
+         * Usage: AT+PEER_RANGE=<peer_anchor_id>
+         * Response: +PEER_RANGE:<my_id>,<peer_id>,<range_mm>,<rssi_dbm>
+         *       or: +PEER_RANGE:ERR,<peer_id>,TIMEOUT
+         */
+        uint8_t peer_id = (uint8_t)strtoul(cmd + 14, nullptr, 0);
+        float rssi = 0.0f;
+        int32_t mm = peer_range_once(peer_id, &rssi);
+        if (mm >= 0) {
+            Serial.printf("+PEER_RANGE:%d,%d,%ld,%.1f\r\n",
+                          ANCHOR_ID, peer_id, mm, (double)rssi);
+        } else {
+            Serial.printf("+PEER_RANGE:ERR,%d,TIMEOUT\r\n", peer_id);
+        }
+
+    } else {
+        Serial.println("+ERR:UNKNOWN_CMD");
+    }
+}
+
+static void serial_poll(void) {
+    while (Serial.available()) {
+        char c = (char)Serial.read();
+        if (c == '\r') continue;
+        if (c == '\n') {
+            g_at_buf[g_at_idx] = '\0';
+            if (g_at_idx > 0) at_dispatch(g_at_buf);
+            g_at_idx = 0;
+        } else if (g_at_idx < (int)(sizeof(g_at_buf) - 1)) {
+            g_at_buf[g_at_idx++] = c;
+        }
+    }
+}
+
+/* ── DS-TWR anchor state machine ────────────────────────────────── */
+
+/*
+ * DS-TWR responder (one shot):
+ *   1. Wait for POLL from tag
+ *   2. Delayed-TX RESP (carry T_poll_rx + scheduled T_resp_tx)
+ *   3. Wait for FINAL from tag  (tag embeds Ra, Da, Db)
+ *   4. Compute: Rb = T_final_rx − T_resp_tx
+ *               tof = (Ra·Rb − Da·Db) / (Ra+Rb+Da+Db)
+ *               range_m = tof × c
+ *   5. Print +RANGE line
+ */
+static void twr_cycle(void) {
+
+    /* --- 1. Listen for POLL --- */
+    dwt_setrxtimeout(0);
+    dwt_rxenable(DWT_START_RX_IMMEDIATE);
+
+    g_rx_ok = g_rx_err = false;
+    uint32_t deadline = millis() + 2000;
+    while (!g_rx_ok && !g_rx_err) {
+        serial_poll();
+        if (millis() > deadline) {
+            /* restart RX if we've been stuck */
+            dwt_rxenable(DWT_START_RX_IMMEDIATE);
+            deadline = millis() + 2000;
+        }
+        yield();
+    }
+    if (!g_rx_ok || g_rx_len < FRAME_HDR) return;
+
+    /* validate POLL */
+    if (g_rx_buf[0] != FTYPE_POLL) return;
+    uint8_t tag_id = g_rx_buf[1];
+    if (g_paired_tag_id != 0 && tag_id != g_paired_tag_id) return;
+
+    /* --- 2. Record T_poll_rx --- */
+    uint8_t  poll_rx_raw[5];
+    dwt_readrxtimestamp(poll_rx_raw);
+    uint64_t T_poll_rx = ts_read(poll_rx_raw);
+
+    /* Compute delayed TX time: poll_rx + turnaround, aligned to 512-tick grid */
+    uint64_t resp_tx_sched = (T_poll_rx + RESP_TX_DLY_TICKS) & ~0x1FFULL;
+
+    /* Build RESP frame */
+    uint8_t resp[RESP_FRAME_LEN];
+    resp[0] = FTYPE_RESP;
+    resp[1] = ANCHOR_ID;
+    resp[2] = tag_id;
+    ts_write(&resp[3], T_poll_rx);      /* T_poll_rx  (tag uses this) */
+    ts_write(&resp[8], resp_tx_sched);  /* scheduled T_resp_tx */
+
+    dwt_writetxdata(RESP_FRAME_LEN - FCS_LEN, resp, 0);
+    dwt_writetxfctrl(RESP_FRAME_LEN, 0, 1 /*ranging*/);
+    dwt_setdelayedtrxtime((uint32_t)(resp_tx_sched >> 8));
+
+    /* Enable RX after TX to receive FINAL */
+    dwt_setrxaftertxdelay(300);
+    dwt_setrxtimeout(FINAL_RX_TIMEOUT_US);
+
+    /* Fire delayed TX */
+    g_tx_done = g_rx_ok = g_rx_err = g_rx_to = false;
+    if (dwt_starttx(DWT_START_TX_DELAYED | DWT_RESPONSE_EXPECTED) != DWT_SUCCESS) {
+        dwt_forcetrxoff();
+        return; /* TX window missed — try next cycle */
+    }
+
+    /* Wait for TX done (short wait, ISR fires fast) */
+    uint32_t t0 = millis();
+    while (!g_tx_done && millis() - t0 < 15) { yield(); }
+
+    /* Read actual T_resp_tx */
+    uint8_t resp_tx_raw[5];
+    dwt_readtxtimestamp(resp_tx_raw);
+    uint64_t T_resp_tx = ts_read(resp_tx_raw);
+
+    /* --- 3. Wait for FINAL --- */
+    t0 = millis();
+    while (!g_rx_ok && !g_rx_err && !g_rx_to && millis() - t0 < 60) {
+        serial_poll();
+        yield();
+    }
+    if (!g_rx_ok || g_rx_len < FRAME_HDR + FINAL_PAYLOAD) return;
+    if (g_rx_buf[0] != FTYPE_FINAL) return;
+    if (g_rx_buf[1] != tag_id)      return;
+
+    /* Extract DS-TWR timestamps from FINAL payload */
+    uint64_t Ra = ts_read(&g_rx_buf[3]);   /* tag: T_resp_rx − T_poll_tx */
+    uint64_t Da = ts_read(&g_rx_buf[8]);   /* tag: T_final_tx − T_resp_rx */
+    /* g_rx_buf[13..17] = Db from tag (cross-check, unused here) */
+
+    /* T_final_rx */
+    uint8_t final_rx_raw[5];
+    dwt_readrxtimestamp(final_rx_raw);
+    uint64_t T_final_rx = ts_read(final_rx_raw);
+
+    /* --- 4. DS-TWR formula --- */
+    uint64_t Rb = ts_diff(T_final_rx, T_resp_tx);  /* anchor round-trip */
+    uint64_t Db = ts_diff(T_resp_tx,  T_poll_rx);  /* anchor turnaround */
+
+    double ra = ticks_to_s(Ra), rb = ticks_to_s(Rb);
+    double da = ticks_to_s(Da), db = ticks_to_s(Db);
+
+    double denom = ra + rb + da + db;
+    if (denom < 1e-15) return;
+
+    double tof    = (ra * rb - da * db) / denom;
+    double range_m = tof * SPEED_OF_LIGHT;
+
+    /* Validity window: 0.1 m – 130 m */
+    if (range_m < 0.1 || range_m > 130.0) return;
+
+    int32_t range_mm = (int32_t)(range_m * 1000.0 + 0.5);
+    float   rssi     = rx_power_dbm();
+
+    /* --- 5. Emit +RANGE --- */
+    snprintf(g_last_range_line, sizeof(g_last_range_line),
+             "+RANGE:%d,%ld,%.1f", ANCHOR_ID, (long)range_mm, rssi);
+    g_last_range_mm = range_mm;
+    Serial.println(g_last_range_line);
+}
+
+/* ── Arduino setup ──────────────────────────────────────────────── */
+
+void setup(void) {
+    Serial.begin(SERIAL_BAUD);
+    delay(300);
+
+    Serial.printf("\r\n[uwb_anchor] anchor_id=%d  starting\r\n", ANCHOR_ID);
+
+    SPI.begin(PIN_SCK, PIN_MISO, PIN_MOSI, PIN_CS);
+
+    /* Hardware reset */
+    pinMode(PIN_RST, OUTPUT);
+    digitalWrite(PIN_RST, LOW);
+    delay(2);
+    pinMode(PIN_RST, INPUT_PULLUP);
+    delay(5);
+
+    /* DW3000 probe + init (Makerfabs MaUWB_DW3000 library) */
+    if (dwt_probe((struct dwt_probe_s *)&dw3000_probe_interf)) {
+        Serial.println("[uwb_anchor] FATAL: DW3000 probe failed — check SPI wiring");
+        for (;;) delay(1000);
+    }
+
+    if (dwt_initialise(DWT_DW_INIT) != DWT_SUCCESS) {
+        Serial.println("[uwb_anchor] FATAL: dwt_initialise failed");
+        for (;;) delay(1000);
+    }
+
+    if (dwt_configure(&dw_cfg) != DWT_SUCCESS) {
+        Serial.println("[uwb_anchor] FATAL: dwt_configure failed");
+        for (;;) delay(1000);
+    }
+
+    dwt_setrxantennadelay(ANT_DELAY);
+    dwt_settxantennadelay(ANT_DELAY);
+    dwt_settxpower(0x0E080222UL);  /* max TX power for 120 m range */
+
+    dwt_setcallbacks(cb_tx_done, cb_rx_ok, cb_rx_to, cb_rx_err,
+                     nullptr, nullptr, nullptr);
+    dwt_setinterrupt(
+        DWT_INT_TXFRS | DWT_INT_RFCG | DWT_INT_RFTO |
+        DWT_INT_RFSL  | DWT_INT_SFDT | DWT_INT_ARFE | DWT_INT_CPERR,
+        0, DWT_ENABLE_INT_ONLY);
+
+    attachInterrupt(digitalPinToInterrupt(PIN_IRQ),
+                    []() { dwt_isr(); }, RISING);
+
+    Serial.printf("[uwb_anchor] DW3000 ready  ch=%d  6.8Mbps  id=%d\r\n",
+                  dw_cfg.chan, ANCHOR_ID);
+    Serial.println("[uwb_anchor] Listening for tags...");
+}
+
+/* ── Arduino loop ───────────────────────────────────────────────── */
+
+void loop(void) {
+    serial_poll();
+    twr_cycle();
+}

esp32/uwb_anchor/udev/99-uwb-anchors.rules

@@ -0,0 +1,19 @@
+# SaltyBot UWB anchor USB-serial persistent symlinks
+# Install:
+#   sudo cp 99-uwb-anchors.rules /etc/udev/rules.d/
+#   sudo udevadm control --reload && sudo udevadm trigger
+#
+# Find serial numbers:
+#   udevadm info -a /dev/ttyUSB0 | grep ATTRS{serial}
+#
+# Fill ANCHOR0_SERIAL and ANCHOR1_SERIAL with the values found above.
+# Anchor 0 = port  side → /dev/uwb-anchor0
+# Anchor 1 = starboard  → /dev/uwb-anchor1
+
+SUBSYSTEM=="tty", ATTRS{idVendor}=="10c4", ATTRS{idProduct}=="ea60", \
+    ATTRS{serial}=="ANCHOR0_SERIAL", \
+    SYMLINK+="uwb-anchor0", MODE="0666"
+
+SUBSYSTEM=="tty", ATTRS{idVendor}=="10c4", ATTRS{idProduct}=="ea60", \
+    ATTRS{serial}=="ANCHOR1_SERIAL", \
+    SYMLINK+="uwb-anchor1", MODE="0666"

esp32/uwb_tag/platformio.ini

@@ -0,0 +1,30 @@
+; SaltyBot UWB Tag Firmware — Issue #545
+; Target: Makerfabs ESP32 UWB Pro with Display (DW3000 + SSD1306 OLED)
+;
+; The tag is battery-powered, worn by the person being tracked.
+; It initiates DS-TWR ranging with each anchor in round-robin,
+; shows status on OLED display, and sends data via ESP-NOW.
+;
+; Library: Makerfabs MaUWB_DW3000
+;   https://github.com/Makerfabs/MaUWB_DW3000
+;
+; Flash:
+;   pio run -e tag --target upload
+; Monitor (USB debug):
+;   pio device monitor -b 115200
+
+[env:tag]
+platform      = espressif32
+board         = esp32dev
+framework     = arduino
+monitor_speed = 115200
+upload_speed  = 921600
+lib_deps =
+    https://github.com/Makerfabs/MaUWB_DW3000.git
+    adafruit/Adafruit SSD1306@^2.5.7
+    adafruit/Adafruit GFX Library@^1.11.5
+build_flags =
+    -DCORE_DEBUG_LEVEL=0
+    -DTAG_ID=0x01        ; unique per tag (0x01–0xFE)
+    -DNUM_ANCHORS=2      ; number of anchors to range with
+    -DRANGE_INTERVAL_MS=50  ; 20 Hz round-robin across anchors

esp32/uwb_tag/src/main.cpp

@@ -0,0 +1,615 @@
+/*
+ * uwb_tag — SaltyBot ESP32 UWB Pro tag firmware (DS-TWR initiator)
+ * Issue #545 + display/ESP-NOW/e-stop extensions
+ *
+ * Hardware: Makerfabs ESP32 UWB Pro with Display (DW3000 + SSD1306 OLED)
+ *
+ * Role
+ * ────
+ *   Tag is worn by a person riding an EUC while SaltyBot follows.
+ *   Initiates DS-TWR ranging with 2 anchors on the robot at 20 Hz.
+ *   Shows distance/status on OLED.  Sends range data via ESP-NOW
+ *   (no WiFi AP needed — peer-to-peer, ~1ms latency, works outdoors).
+ *   GPIO 0 = emergency stop button (active low).
+ *
+ * Serial output (USB, 115200) — debug
+ * ────────────────────────────────────
+ *   +RANGE:<anchor_id>,<range_mm>,<rssi_dbm>\r\n
+ *
+ * ESP-NOW packet (broadcast, 20 bytes)
+ * ─────────────────────────────────────
+ *   [0-1]  magic  0x5B 0x01
+ *   [2]    tag_id
+ *   [3]    msg_type   0x10=range, 0x20=estop, 0x30=heartbeat
+ *   [4]    anchor_id
+ *   [5-8]  range_mm   (int32_t LE)
+ *   [9-12] rssi_dbm   (float LE)
+ *   [13-16] timestamp  (uint32_t millis)
+ *   [17]   battery_pct (0-100 or 0xFF)
+ *   [18]   flags       bit0=estop_active
+ *   [19]   seq_num_lo  (uint8_t, rolling)
+ *
+ * Pin mapping — Makerfabs ESP32 UWB Pro with Display
+ * ──────────────────────────────────────────────────
+ *   SPI SCK  18   SPI MISO 19   SPI MOSI 23
+ *   DW CS    21   DW RST   27   DW IRQ   34
+ *   I2C SDA   4   I2C SCL   5   OLED addr 0x3C
+ *   LED       2   E-STOP    0 (BOOT, active LOW)
+ */
+
+#include <Arduino.h>
+#include <SPI.h>
+#include <Wire.h>
+#include <math.h>
+#include <WiFi.h>
+#include <esp_now.h>
+#include <esp_wifi.h>
+
+#include "dw3000.h"
+
+#include <Adafruit_GFX.h>
+#include <Adafruit_SSD1306.h>
+
+/* ── Configurable ───────────────────────────────────────────────── */
+
+#ifndef TAG_ID
+#  define TAG_ID          0x01
+#endif
+
+#ifndef NUM_ANCHORS
+#  define NUM_ANCHORS     2
+#endif
+
+#ifndef RANGE_INTERVAL_MS
+#  define RANGE_INTERVAL_MS  50   /* 20 Hz round-robin */
+#endif
+
+#define SERIAL_BAUD       115200
+
+/* ── Pins ───────────────────────────────────────────────────────── */
+
+#define PIN_SCK   18
+#define PIN_MISO  19
+#define PIN_MOSI  23
+#define PIN_CS    21
+#define PIN_RST   27
+#define PIN_IRQ   34
+
+#define PIN_SDA    4
+#define PIN_SCL    5
+
+#define PIN_LED    2
+#define PIN_ESTOP  0   /* BOOT button, active LOW */
+
+/* ── OLED ───────────────────────────────────────────────────────── */
+
+#define SCREEN_W  128
+#define SCREEN_H   64
+Adafruit_SSD1306 display(SCREEN_W, SCREEN_H, &Wire, -1);
+
+/* ── ESP-NOW ────────────────────────────────────────────────────── */
+
+#define ESPNOW_MAGIC_0   0x5B   /* "SB" */
+#define ESPNOW_MAGIC_1   0x01   /* v1   */
+
+#define MSG_RANGE         0x10
+#define MSG_ESTOP         0x20
+#define MSG_HEARTBEAT     0x30
+
+static uint8_t broadcast_mac[6] = {0xFF, 0xFF, 0xFF, 0xFF, 0xFF, 0xFF};
+static uint8_t g_seq = 0;
+
+#pragma pack(push, 1)
+struct EspNowPacket {
+    uint8_t  magic[2];
+    uint8_t  tag_id;
+    uint8_t  msg_type;
+    uint8_t  anchor_id;
+    int32_t  range_mm;
+    float    rssi_dbm;
+    uint32_t timestamp_ms;
+    uint8_t  battery_pct;
+    uint8_t  flags;
+    uint8_t  seq_num;
+    uint8_t  _pad;          /* pad to 20 bytes */
+};
+#pragma pack(pop)
+
+static_assert(sizeof(EspNowPacket) == 20, "packet must be 20 bytes");
+
+/* ── DW3000 PHY config (must match anchor) ──────────────────────── */
+
+static dwt_config_t dw_cfg = {
+    5,                 /* channel 5 */
+    DWT_PLEN_128,
+    DWT_PAC8,
+    9, 9,              /* TX/RX preamble code */
+    1,                 /* SFD type */
+    DWT_BR_6M8,
+    DWT_PHR_MODE_STD,
+    DWT_PHR_RATE_DATA,
+    (129 + 8 - 8),
+    DWT_STS_MODE_OFF,
+    DWT_STS_LEN_64,
+    DWT_PDOA_M0,
+};
+
+/* ── Frame format ──────────────────────────────────────────────── */
+
+#define FTYPE_POLL   0x01
+#define FTYPE_RESP   0x02
+#define FTYPE_FINAL  0x03
+
+#define FRAME_HDR   3
+#define FCS_LEN     2
+
+#define POLL_FRAME_LEN   (FRAME_HDR + FCS_LEN)
+#define RESP_PAYLOAD     10
+#define RESP_FRAME_LEN   (FRAME_HDR + RESP_PAYLOAD + FCS_LEN)
+#define FINAL_PAYLOAD    15
+#define FINAL_FRAME_LEN  (FRAME_HDR + FINAL_PAYLOAD + FCS_LEN)
+
+/* ── Timing ────────────────────────────────────────────────────── */
+
+#define FINAL_TX_DLY_US     500UL
+#define DWT_TICKS_PER_US    63898UL
+#define FINAL_TX_DLY_TICKS  (FINAL_TX_DLY_US * DWT_TICKS_PER_US)
+#define RESP_RX_TIMEOUT_US  3000
+
+#define SPEED_OF_LIGHT  299702547.0
+#define DWT_TS_MASK     0xFFFFFFFFFFULL
+#define ANT_DELAY       16385
+
+/* ── ISR state ──────────────────────────────────────────────────── */
+
+static volatile bool g_rx_ok   = false;
+static volatile bool g_tx_done = false;
+static volatile bool g_rx_err  = false;
+static volatile bool g_rx_to   = false;
+
+static uint8_t  g_rx_buf[128];
+static uint32_t g_rx_len = 0;
+
+static void cb_tx_done(const dwt_cb_data_t *) { g_tx_done = true; }
+static void cb_rx_ok(const dwt_cb_data_t *d) {
+    g_rx_len = d->datalength;
+    if (g_rx_len > sizeof(g_rx_buf)) g_rx_len = sizeof(g_rx_buf);
+    dwt_readrxdata(g_rx_buf, g_rx_len, 0);
+    g_rx_ok = true;
+}
+static void cb_rx_err(const dwt_cb_data_t *) { g_rx_err = true; }
+static void cb_rx_to(const dwt_cb_data_t  *) { g_rx_to  = true; }
+
+/* ── Timestamp helpers ──────────────────────────────────────────── */
+
+static uint64_t ts_read(const uint8_t *p) {
+    uint64_t v = 0;
+    for (int i = 4; i >= 0; i--) v = (v << 8) | p[i];
+    return v;
+}
+
+static void ts_write(uint8_t *p, uint64_t v) {
+    for (int i = 0; i < 5; i++, v >>= 8) p[i] = (uint8_t)(v & 0xFF);
+}
+
+static inline uint64_t ts_diff(uint64_t later, uint64_t earlier) {
+    return (later - earlier) & DWT_TS_MASK;
+}
+
+static inline double ticks_to_s(uint64_t t) {
+    return (double)t / (128.0 * 499200000.0);
+}
+
+static float rx_power_dbm(void) {
+    dwt_rxdiag_t d;
+    dwt_readdiagnostics(&d);
+    if (d.maxGrowthCIR == 0 || d.rxPreamCount == 0) return 0.0f;
+    float f = (float)d.maxGrowthCIR;
+    float n = (float)d.rxPreamCount;
+    return 10.0f * log10f((f * f) / (n * n)) - 121.74f;
+}
+
+/* ── Shared state for display ───────────────────────────────────── */
+
+static int32_t g_anchor_range_mm[NUM_ANCHORS];   /* last range per anchor */
+static float   g_anchor_rssi[NUM_ANCHORS];        /* last RSSI per anchor */
+static uint32_t g_anchor_last_ok[NUM_ANCHORS];    /* millis() of last good range */
+static bool    g_estop_active = false;
+
+/* ── ESP-NOW send helper ────────────────────────────────────────── */
+
+static void espnow_send(uint8_t msg_type, uint8_t anchor_id,
+                         int32_t range_mm, float rssi) {
+    EspNowPacket pkt = {};
+    pkt.magic[0]     = ESPNOW_MAGIC_0;
+    pkt.magic[1]     = ESPNOW_MAGIC_1;
+    pkt.tag_id       = TAG_ID;
+    pkt.msg_type     = msg_type;
+    pkt.anchor_id    = anchor_id;
+    pkt.range_mm     = range_mm;
+    pkt.rssi_dbm     = rssi;
+    pkt.timestamp_ms = millis();
+    pkt.battery_pct  = 0xFF;   /* TODO: read ADC battery voltage */
+    pkt.flags        = g_estop_active ? 0x01 : 0x00;
+    pkt.seq_num      = g_seq++;
+
+    esp_now_send(broadcast_mac, (uint8_t *)&pkt, sizeof(pkt));
+}
+
+/* ── E-Stop handling ────────────────────────────────────────────── */
+
+static uint32_t g_estop_last_tx = 0;
+
+static void estop_check(void) {
+    bool pressed = (digitalRead(PIN_ESTOP) == LOW);
+
+    if (pressed && !g_estop_active) {
+        /* Just pressed — enter e-stop */
+        g_estop_active = true;
+        Serial.println("+ESTOP:ACTIVE");
+    }
+
+    if (g_estop_active && pressed) {
+        /* While held: send e-stop at 10 Hz */
+        if (millis() - g_estop_last_tx >= 100) {
+            espnow_send(MSG_ESTOP, 0xFF, 0, 0.0f);
+            g_estop_last_tx = millis();
+        }
+    }
+
+    if (!pressed && g_estop_active) {
+        /* Released: send 3x clear packets, resume */
+        for (int i = 0; i < 3; i++) {
+            g_estop_active = false;  /* clear flag before sending so flags=0 */
+            espnow_send(MSG_ESTOP, 0xFF, 0, 0.0f);
+            delay(10);
+        }
+        g_estop_active = false;
+        Serial.println("+ESTOP:CLEAR");
+    }
+}
+
+/* ── OLED display update (5 Hz) ─────────────────────────────────── */
+
+static uint32_t g_display_last = 0;
+
+static void display_update(void) {
+    if (millis() - g_display_last < 200) return;
+    g_display_last = millis();
+
+    display.clearDisplay();
+
+    if (g_estop_active) {
+        /* Big E-STOP warning */
+        display.setTextSize(3);
+        display.setTextColor(SSD1306_WHITE);
+        display.setCursor(10, 4);
+        display.println(F("E-STOP"));
+        display.setTextSize(1);
+        display.setCursor(20, 48);
+        display.println(F("RELEASE TO CLEAR"));
+        display.display();
+        return;
+    }
+
+    uint32_t now = millis();
+
+    /* Find closest anchor */
+    int32_t min_range = INT32_MAX;
+    for (int i = 0; i < NUM_ANCHORS; i++) {
+        if (g_anchor_range_mm[i] > 0 && g_anchor_range_mm[i] < min_range)
+            min_range = g_anchor_range_mm[i];
+    }
+
+    /* Line 1: Big distance to nearest anchor */
+    display.setTextSize(3);
+    display.setTextColor(SSD1306_WHITE);
+    display.setCursor(0, 0);
+    if (min_range < INT32_MAX && min_range > 0) {
+        float m = min_range / 1000.0f;
+        if (m < 10.0f)
+            display.printf("%.1fm", m);
+        else
+            display.printf("%.0fm", m);
+    } else {
+        display.println(F("---"));
+    }
+
+    /* Line 2: Both anchor ranges */
+    display.setTextSize(1);
+    display.setCursor(0, 30);
+    for (int i = 0; i < NUM_ANCHORS && i < 2; i++) {
+        if (g_anchor_range_mm[i] > 0) {
+            float m = g_anchor_range_mm[i] / 1000.0f;
+            display.printf("A%d:%.1fm ", i, m);
+        } else {
+            display.printf("A%d:--- ", i);
+        }
+    }
+
+    /* Line 3: Connection status */
+    display.setCursor(0, 42);
+    bool any_linked = false;
+    for (int i = 0; i < NUM_ANCHORS; i++) {
+        if (g_anchor_last_ok[i] > 0 && (now - g_anchor_last_ok[i]) < 2000) {
+            any_linked = true;
+            break;
+        }
+    }
+
+    if (any_linked) {
+        /* RSSI bar: map -90..-30 dBm to 0-5 bars */
+        float best_rssi = -100.0f;
+        for (int i = 0; i < NUM_ANCHORS; i++) {
+            if (g_anchor_rssi[i] > best_rssi) best_rssi = g_anchor_rssi[i];
+        }
+        int bars = constrain((int)((best_rssi + 90.0f) / 12.0f), 0, 5);
+
+        display.print(F("LINKED "));
+        /* Draw signal bars */
+        for (int b = 0; b < 5; b++) {
+            int x = 50 + b * 6;
+            int h = 2 + b * 2;
+            int y = 50 - h;
+            if (b < bars)
+                display.fillRect(x, y, 4, h, SSD1306_WHITE);
+            else
+                display.drawRect(x, y, 4, h, SSD1306_WHITE);
+        }
+        display.printf(" %.0fdB", best_rssi);
+    } else {
+        display.println(F("LOST  -- searching --"));
+    }
+
+    /* Line 4: Uptime */
+    display.setCursor(0, 54);
+    uint32_t secs = now / 1000;
+    display.printf("UP %02d:%02d  seq:%d", secs / 60, secs % 60, g_seq);
+
+    display.display();
+}
+
+/* ── DS-TWR initiator (one anchor, one cycle) ───────────────────── */
+
+static int32_t twr_range_once(uint8_t anchor_id) {
+
+    /* --- 1. TX POLL --- */
+    uint8_t poll[POLL_FRAME_LEN];
+    poll[0] = FTYPE_POLL;
+    poll[1] = TAG_ID;
+    poll[2] = anchor_id;
+
+    dwt_writetxdata(POLL_FRAME_LEN - FCS_LEN, poll, 0);
+    dwt_writetxfctrl(POLL_FRAME_LEN, 0, 1);
+
+    dwt_setrxaftertxdelay(300);
+    dwt_setrxtimeout(RESP_RX_TIMEOUT_US);
+
+    g_tx_done = g_rx_ok = g_rx_err = g_rx_to = false;
+    if (dwt_starttx(DWT_START_TX_IMMEDIATE | DWT_RESPONSE_EXPECTED) != DWT_SUCCESS)
+        return -1;
+
+    uint32_t t0 = millis();
+    while (!g_tx_done && millis() - t0 < 15) yield();
+
+    uint8_t poll_tx_raw[5];
+    dwt_readtxtimestamp(poll_tx_raw);
+    uint64_t T_poll_tx = ts_read(poll_tx_raw);
+
+    /* --- 2. Wait for RESP --- */
+    t0 = millis();
+    while (!g_rx_ok && !g_rx_err && !g_rx_to && millis() - t0 < 60) yield();
+    if (!g_rx_ok || g_rx_len < FRAME_HDR + RESP_PAYLOAD) return -1;
+    if (g_rx_buf[0] != FTYPE_RESP)   return -1;
+    if (g_rx_buf[2] != TAG_ID)       return -1;
+    if (g_rx_buf[1] != anchor_id)    return -1;
+
+    uint8_t resp_rx_raw[5];
+    dwt_readrxtimestamp(resp_rx_raw);
+    uint64_t T_resp_rx = ts_read(resp_rx_raw);
+
+    uint64_t T_poll_rx_a = ts_read(&g_rx_buf[3]);
+    uint64_t T_resp_tx_a = ts_read(&g_rx_buf[8]);
+
+    /* --- 3. Compute DS-TWR values for FINAL --- */
+    uint64_t Ra = ts_diff(T_resp_rx, T_poll_tx);
+    uint64_t Db = ts_diff(T_resp_tx_a, T_poll_rx_a);
+
+    uint64_t final_tx_sched = (T_resp_rx + FINAL_TX_DLY_TICKS) & ~0x1FFULL;
+    uint64_t Da = ts_diff(final_tx_sched, T_resp_rx);
+
+    /* --- 4. TX FINAL --- */
+    uint8_t final_buf[FINAL_FRAME_LEN];
+    final_buf[0] = FTYPE_FINAL;
+    final_buf[1] = TAG_ID;
+    final_buf[2] = anchor_id;
+    ts_write(&final_buf[3],  Ra);
+    ts_write(&final_buf[8],  Da);
+    ts_write(&final_buf[13], Db);
+
+    dwt_writetxdata(FINAL_FRAME_LEN - FCS_LEN, final_buf, 0);
+    dwt_writetxfctrl(FINAL_FRAME_LEN, 0, 1);
+    dwt_setdelayedtrxtime((uint32_t)(final_tx_sched >> 8));
+
+    g_tx_done = false;
+    if (dwt_starttx(DWT_START_TX_DELAYED) != DWT_SUCCESS) {
+        dwt_forcetrxoff();
+        return -1;
+    }
+    t0 = millis();
+    while (!g_tx_done && millis() - t0 < 15) yield();
+
+    /* --- 5. Local range estimate (debug) --- */
+    uint8_t final_tx_raw[5];
+    dwt_readtxtimestamp(final_tx_raw);
+    /* uint64_t T_final_tx = ts_read(final_tx_raw); -- unused, tag uses SS estimate */
+
+    double ra = ticks_to_s(Ra);
+    double db = ticks_to_s(Db);
+    double tof    = (ra - db) / 2.0;
+    double range_m = tof * SPEED_OF_LIGHT;
+
+    if (range_m < 0.1 || range_m > 130.0) return -1;
+    return (int32_t)(range_m * 1000.0 + 0.5);
+}
+
+/* ── Setup ──────────────────────────────────────────────────────── */
+
+void setup(void) {
+    Serial.begin(SERIAL_BAUD);
+    delay(300);
+
+    /* E-Stop button */
+    pinMode(PIN_ESTOP, INPUT_PULLUP);
+    pinMode(PIN_LED, OUTPUT);
+    digitalWrite(PIN_LED, LOW);
+
+    Serial.printf("\r\n[uwb_tag] tag_id=0x%02X  num_anchors=%d  starting\r\n",
+                  TAG_ID, NUM_ANCHORS);
+
+    /* --- OLED init --- */
+    Wire.begin(PIN_SDA, PIN_SCL);
+    if (!display.begin(SSD1306_SWITCHCAPVCC, 0x3C)) {
+        Serial.println("[uwb_tag] WARN: SSD1306 not found — running headless");
+    } else {
+        display.clearDisplay();
+        display.setTextSize(2);
+        display.setTextColor(SSD1306_WHITE);
+        display.setCursor(0, 0);
+        display.println(F("SaltyBot"));
+        display.setTextSize(1);
+        display.setCursor(0, 20);
+        display.printf("Tag 0x%02X  v2.0", TAG_ID);
+        display.setCursor(0, 35);
+        display.println(F("DW3000 DS-TWR + ESP-NOW"));
+        display.setCursor(0, 50);
+        display.println(F("Initializing..."));
+        display.display();
+        Serial.println("[uwb_tag] OLED ok");
+    }
+
+    /* --- ESP-NOW init --- */
+    WiFi.mode(WIFI_STA);
+    WiFi.disconnect();
+    /* Set WiFi channel to match anchors (default ch 1) */
+    esp_wifi_set_channel(1, WIFI_SECOND_CHAN_NONE);
+
+    if (esp_now_init() != ESP_OK) {
+        Serial.println("[uwb_tag] FATAL: esp_now_init failed");
+        for (;;) delay(1000);
+    }
+
+    /* Add broadcast peer */
+    esp_now_peer_info_t peer = {};
+    memcpy(peer.peer_addr, broadcast_mac, 6);
+    peer.channel = 0;  /* use current channel */
+    peer.encrypt = false;
+    esp_now_add_peer(&peer);
+    Serial.println("[uwb_tag] ESP-NOW ok");
+
+    /* --- DW3000 init --- */
+    SPI.begin(PIN_SCK, PIN_MISO, PIN_MOSI, PIN_CS);
+
+    pinMode(PIN_RST, OUTPUT);
+    digitalWrite(PIN_RST, LOW);
+    delay(2);
+    pinMode(PIN_RST, INPUT_PULLUP);
+    delay(5);
+
+    if (dwt_probe((struct dwt_probe_s *)&dw3000_probe_interf)) {
+        Serial.println("[uwb_tag] FATAL: DW3000 probe failed");
+        for (;;) delay(1000);
+    }
+
+    if (dwt_initialise(DWT_DW_INIT) != DWT_SUCCESS) {
+        Serial.println("[uwb_tag] FATAL: dwt_initialise failed");
+        for (;;) delay(1000);
+    }
+
+    if (dwt_configure(&dw_cfg) != DWT_SUCCESS) {
+        Serial.println("[uwb_tag] FATAL: dwt_configure failed");
+        for (;;) delay(1000);
+    }
+
+    dwt_setrxantennadelay(ANT_DELAY);
+    dwt_settxantennadelay(ANT_DELAY);
+    dwt_settxpower(0x0E080222UL);
+
+    dwt_setcallbacks(cb_tx_done, cb_rx_ok, cb_rx_to, cb_rx_err,
+                     nullptr, nullptr, nullptr);
+    dwt_setinterrupt(
+        DWT_INT_TXFRS | DWT_INT_RFCG | DWT_INT_RFTO |
+        DWT_INT_RFSL  | DWT_INT_SFDT | DWT_INT_ARFE | DWT_INT_CPERR,
+        0, DWT_ENABLE_INT_ONLY);
+
+    attachInterrupt(digitalPinToInterrupt(PIN_IRQ),
+                    []() { dwt_isr(); }, RISING);
+
+    /* Init range state */
+    for (int i = 0; i < NUM_ANCHORS; i++) {
+        g_anchor_range_mm[i] = -1;
+        g_anchor_rssi[i] = -100.0f;
+        g_anchor_last_ok[i] = 0;
+    }
+
+    Serial.printf("[uwb_tag] DW3000 ready  ch=%d  6.8Mbps  tag=0x%02X\r\n",
+                  dw_cfg.chan, TAG_ID);
+    Serial.println("[uwb_tag] Ranging + ESP-NOW + display active");
+}
+
+/* ── Main loop ──────────────────────────────────────────────────── */
+
+void loop(void) {
+    static uint8_t  anchor_idx    = 0;
+    static uint32_t last_range_ms = 0;
+    static uint32_t last_hb_ms    = 0;
+
+    /* E-Stop always has priority */
+    estop_check();
+    if (g_estop_active) {
+        display_update();
+        return;   /* skip ranging while e-stop active */
+    }
+
+    /* Heartbeat every 1 second */
+    uint32_t now = millis();
+    if (now - last_hb_ms >= 1000) {
+        espnow_send(MSG_HEARTBEAT, 0xFF, 0, 0.0f);
+        last_hb_ms = now;
+    }
+
+    /* Ranging at configured interval */
+    if (now - last_range_ms >= RANGE_INTERVAL_MS) {
+        last_range_ms = now;
+
+        uint8_t anchor_id = anchor_idx % NUM_ANCHORS;
+        int32_t range_mm  = twr_range_once(anchor_id);
+
+        if (range_mm > 0) {
+            float rssi = rx_power_dbm();
+
+            /* Update shared state for display */
+            g_anchor_range_mm[anchor_id] = range_mm;
+            g_anchor_rssi[anchor_id]     = rssi;
+            g_anchor_last_ok[anchor_id]  = now;
+
+            /* Serial debug */
+            Serial.printf("+RANGE:%d,%ld,%.1f\r\n",
+                          anchor_id, (long)range_mm, rssi);
+
+            /* ESP-NOW broadcast */
+            espnow_send(MSG_RANGE, anchor_id, range_mm, rssi);
+
+            /* LED blink */
+            digitalWrite(PIN_LED, HIGH);
+            delay(2);
+            digitalWrite(PIN_LED, LOW);
+        }
+
+        anchor_idx++;
+        if (anchor_idx >= NUM_ANCHORS) anchor_idx = 0;
+    }
+
+    /* Display at 5 Hz (non-blocking) */
+    display_update();
+}

esp32s3/balance/CMakeLists.txt

@@ -0,0 +1,3 @@
+cmake_minimum_required(VERSION 3.16)
+include($ENV{IDF_PATH}/tools/cmake/project.cmake)
+project(esp32s3_balance)

esp32s3/balance/main/CMakeLists.txt

@@ -0,0 +1,22 @@
+idf_component_register(
+    SRCS
+        "main.c"
+        "orin_serial.c"
+        "vesc_can.c"
+        "gitea_ota.c"
+        "ota_self.c"
+        "uart_ota.c"
+        "ota_display.c"
+    INCLUDE_DIRS "."
+    REQUIRES
+        esp_wifi
+        esp_http_client
+        esp_https_ota
+        nvs_flash
+        app_update
+        mbedtls
+        cJSON
+        driver
+        freertos
+        esp_timer
+)

esp32s3/balance/main/config.h

@@ -0,0 +1,42 @@
+#pragma once
+
+/* ── ESP32-S3 BALANCE board — bd-66hx pin/config definitions ───────────────
+ *
+ * Hardware change from pre-bd-66hx design:
+ *   Previously: IO43/IO44 = CAN SN65HVD230 (shared Orin+VESC bus via CANable2)
+ *   After bd-66hx: IO43/IO44 = CH343 UART0 (Orin serial comms)
+ *                  IO2/IO1   = CAN SN65HVD230 rewired (VESC-only bus)
+ *
+ * The SN65HVD230 transceiver physical wiring must be updated from IO43/44
+ * to IO2/IO1 when deploying this firmware.  See docs/SAUL-TEE-SYSTEM-REFERENCE.md.
+ */
+
+/* ── Orin serial (CH343 USB-to-UART, 1a86:55d3 on Orin side) ── */
+#define ORIN_UART_PORT          UART_NUM_0
+#define ORIN_UART_BAUD          460800
+#define ORIN_UART_TX_GPIO       43      /* ESP32→CH343 RXD */
+#define ORIN_UART_RX_GPIO       44      /* CH343 TXD→ESP32 */
+#define ORIN_UART_RX_BUF        1024
+#define ORIN_TX_QUEUE_DEPTH     16
+
+/* ── VESC CAN TWAI (SN65HVD230 transceiver, rewired for bd-66hx) ── */
+#define VESC_CAN_TX_GPIO        2       /* ESP32 TWAI TX → SN65HVD230 TXD */
+#define VESC_CAN_RX_GPIO        1       /* SN65HVD230 RXD → ESP32 TWAI RX */
+#define VESC_CAN_RX_QUEUE       32
+
+/* VESC node IDs — matched to bd-wim1 TELEM_VESC_LEFT/RIGHT mapping */
+#define VESC_ID_A               56u     /* TELEM_VESC_LEFT  (0x81) */
+#define VESC_ID_B               68u     /* TELEM_VESC_RIGHT (0x82) */
+
+/* ── Safety / timing ── */
+#define HB_TIMEOUT_MS           500u    /* heartbeat watchdog: disarm if exceeded */
+#define DRIVE_TIMEOUT_MS        500u    /* drive command staleness timeout */
+#define TELEM_STATUS_PERIOD_MS  100u    /* 10 Hz status telemetry to Orin */
+#define TELEM_VESC_PERIOD_MS    100u    /* 10 Hz VESC telemetry to Orin */
+
+/* ── Drive → VESC RPM scaling ── */
+#define RPM_PER_SPEED_UNIT      5       /* speed_units=1000 → 5000 ERPM */
+#define RPM_PER_STEER_UNIT      3       /* steer differential scale */
+
+/* ── Tilt cutoff ── */
+#define TILT_CUTOFF_DEG         25.0f

esp32s3/balance/main/gitea_ota.c

@@ -0,0 +1,285 @@
+/* gitea_ota.c — Gitea version checker (bd-3hte)
+ *
+ * Uses esp_http_client + cJSON to query:
+ *   GET /api/v1/repos/{repo}/releases?limit=10
+ * Filters releases by tag prefix, extracts version and download URLs.
+ */
+
+#include "gitea_ota.h"
+#include "version.h"
+#include "esp_log.h"
+#include "esp_wifi.h"
+#include "esp_event.h"
+#include "esp_netif.h"
+#include "esp_http_client.h"
+#include "nvs_flash.h"
+#include "nvs.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include "freertos/event_groups.h"
+#include "cJSON.h"
+#include <string.h>
+#include <stdio.h>
+
+static const char *TAG = "gitea_ota";
+
+ota_update_info_t g_balance_update = {0};
+ota_update_info_t g_io_update      = {0};
+
+/* ── WiFi connection ── */
+#define WIFI_CONNECTED_BIT  BIT0
+#define WIFI_FAIL_BIT       BIT1
+#define WIFI_MAX_RETRIES    5
+
+/* Compile-time WiFi fallback (override in NVS "wifi"/"ssid","pass") */
+#define DEFAULT_WIFI_SSID   "saltylab"
+#define DEFAULT_WIFI_PASS   ""
+
+static EventGroupHandle_t s_wifi_eg;
+static int s_wifi_retries = 0;
+
+static void wifi_event_handler(void *arg, esp_event_base_t base,
+                                int32_t id, void *data)
+{
+    if (base == WIFI_EVENT && id == WIFI_EVENT_STA_START) {
+        esp_wifi_connect();
+    } else if (base == WIFI_EVENT && id == WIFI_EVENT_STA_DISCONNECTED) {
+        if (s_wifi_retries < WIFI_MAX_RETRIES) {
+            esp_wifi_connect();
+            s_wifi_retries++;
+        } else {
+            xEventGroupSetBits(s_wifi_eg, WIFI_FAIL_BIT);
+        }
+    } else if (base == IP_EVENT && id == IP_EVENT_STA_GOT_IP) {
+        s_wifi_retries = 0;
+        xEventGroupSetBits(s_wifi_eg, WIFI_CONNECTED_BIT);
+    }
+}
+
+static bool wifi_connect(void)
+{
+    char ssid[64] = DEFAULT_WIFI_SSID;
+    char pass[64] = DEFAULT_WIFI_PASS;
+
+    /* Try to read credentials from NVS */
+    nvs_handle_t nvs;
+    if (nvs_open("wifi", NVS_READONLY, &nvs) == ESP_OK) {
+        size_t sz = sizeof(ssid);
+        nvs_get_str(nvs, "ssid", ssid, &sz);
+        sz = sizeof(pass);
+        nvs_get_str(nvs, "pass", pass, &sz);
+        nvs_close(nvs);
+    }
+
+    s_wifi_eg = xEventGroupCreate();
+    s_wifi_retries = 0;
+
+    ESP_ERROR_CHECK(esp_netif_init());
+    ESP_ERROR_CHECK(esp_event_loop_create_default());
+    esp_netif_create_default_wifi_sta();
+
+    wifi_init_config_t cfg = WIFI_INIT_CONFIG_DEFAULT();
+    ESP_ERROR_CHECK(esp_wifi_init(&cfg));
+
+    esp_event_handler_instance_t h1, h2;
+    ESP_ERROR_CHECK(esp_event_handler_instance_register(
+        WIFI_EVENT, ESP_EVENT_ANY_ID, wifi_event_handler, NULL, &h1));
+    ESP_ERROR_CHECK(esp_event_handler_instance_register(
+        IP_EVENT, IP_EVENT_STA_GOT_IP, wifi_event_handler, NULL, &h2));
+
+    wifi_config_t wcfg = {0};
+    strlcpy((char *)wcfg.sta.ssid,     ssid, sizeof(wcfg.sta.ssid));
+    strlcpy((char *)wcfg.sta.password, pass, sizeof(wcfg.sta.password));
+
+    ESP_ERROR_CHECK(esp_wifi_set_mode(WIFI_MODE_STA));
+    ESP_ERROR_CHECK(esp_wifi_set_config(WIFI_IF_STA, &wcfg));
+    ESP_ERROR_CHECK(esp_wifi_start());
+
+    EventBits_t bits = xEventGroupWaitBits(s_wifi_eg,
+        WIFI_CONNECTED_BIT | WIFI_FAIL_BIT, pdFALSE, pdFALSE,
+        pdMS_TO_TICKS(15000));
+
+    esp_event_handler_instance_unregister(IP_EVENT, IP_EVENT_STA_GOT_IP, h2);
+    esp_event_handler_instance_unregister(WIFI_EVENT, ESP_EVENT_ANY_ID, h1);
+    vEventGroupDelete(s_wifi_eg);
+
+    if (bits & WIFI_CONNECTED_BIT) {
+        ESP_LOGI(TAG, "WiFi connected SSID=%s", ssid);
+        return true;
+    }
+    ESP_LOGW(TAG, "WiFi connect failed SSID=%s", ssid);
+    return false;
+}
+
+/* ── HTTP fetch into a heap buffer ── */
+#define HTTP_RESP_MAX   (8 * 1024)
+
+typedef struct { char *buf; int len; int cap; } http_buf_t;
+
+static esp_err_t http_event_cb(esp_http_client_event_t *evt)
+{
+    http_buf_t *b = (http_buf_t *)evt->user_data;
+    if (evt->event_id == HTTP_EVENT_ON_DATA && b) {
+        if (b->len + evt->data_len < b->cap) {
+            memcpy(b->buf + b->len, evt->data, evt->data_len);
+            b->len += evt->data_len;
+        }
+    }
+    return ESP_OK;
+}
+
+static char *http_get(const char *url)
+{
+    char *buf = malloc(HTTP_RESP_MAX);
+    if (!buf) return NULL;
+    http_buf_t b = {.buf = buf, .len = 0, .cap = HTTP_RESP_MAX};
+    buf[0] = '\0';
+
+    esp_http_client_config_t cfg = {
+        .url            = url,
+        .event_handler  = http_event_cb,
+        .user_data      = &b,
+        .timeout_ms     = GITEA_API_TIMEOUT_MS,
+        .skip_cert_common_name_check = true,
+    };
+    esp_http_client_handle_t client = esp_http_client_init(&cfg);
+    esp_err_t err = esp_http_client_perform(client);
+    int status = esp_http_client_get_status_code(client);
+    esp_http_client_cleanup(client);
+
+    if (err != ESP_OK || status != 200) {
+        ESP_LOGW(TAG, "HTTP GET %s → err=%d status=%d", url, err, status);
+        free(buf);
+        return NULL;
+    }
+    buf[b.len] = '\0';
+    return buf;
+}
+
+/* ── Version comparison: returns true if remote > local ── */
+static bool version_newer(const char *local, const char *remote)
+{
+    int la=0,lb=0,lc=0, ra=0,rb=0,rc=0;
+    sscanf(local,  "%d.%d.%d", &la, &lb, &lc);
+    sscanf(remote, "%d.%d.%d", &ra, &rb, &rc);
+    if (ra != la) return ra > la;
+    if (rb != lb) return rb > lb;
+    return rc > lc;
+}
+
+/* ── Parse releases JSON array, fill ota_update_info_t ── */
+static void parse_releases(const char *json, const char *tag_prefix,
+                             const char *bin_asset, const char *sha_asset,
+                             const char *local_version,
+                             ota_update_info_t *out)
+{
+    cJSON *arr = cJSON_Parse(json);
+    if (!arr || !cJSON_IsArray(arr)) {
+        ESP_LOGW(TAG, "JSON parse failed");
+        cJSON_Delete(arr);
+        return;
+    }
+
+    cJSON *rel;
+    cJSON_ArrayForEach(rel, arr) {
+        cJSON *tag_j = cJSON_GetObjectItem(rel, "tag_name");
+        if (!cJSON_IsString(tag_j)) continue;
+
+        const char *tag = tag_j->valuestring;
+        if (strncmp(tag, tag_prefix, strlen(tag_prefix)) != 0) continue;
+
+        /* Extract version after prefix */
+        const char *ver = tag + strlen(tag_prefix);
+        if (*ver == 'v') ver++;  /* strip leading 'v' */
+
+        if (!version_newer(local_version, ver)) continue;
+
+        /* Found a newer release — extract asset URLs */
+        cJSON *assets = cJSON_GetObjectItem(rel, "assets");
+        if (!cJSON_IsArray(assets)) continue;
+
+        out->available = false;
+        out->download_url[0] = '\0';
+        out->sha256[0] = '\0';
+        strlcpy(out->version, ver, sizeof(out->version));
+
+        cJSON *asset;
+        cJSON_ArrayForEach(asset, assets) {
+            cJSON *name_j = cJSON_GetObjectItem(asset, "name");
+            cJSON *url_j  = cJSON_GetObjectItem(asset, "browser_download_url");
+            if (!cJSON_IsString(name_j) || !cJSON_IsString(url_j)) continue;
+
+            if (strcmp(name_j->valuestring, bin_asset) == 0) {
+                strlcpy(out->download_url, url_j->valuestring,
+                        sizeof(out->download_url));
+                out->available = true;
+            } else if (strcmp(name_j->valuestring, sha_asset) == 0) {
+                /* Download the SHA256 asset inline */
+                char *sha = http_get(url_j->valuestring);
+                if (sha) {
+                    /* sha file is just hex+newline */
+                    size_t n = strspn(sha, "0123456789abcdefABCDEF");
+                    if (n == 64) {
+                        memcpy(out->sha256, sha, 64);
+                        out->sha256[64] = '\0';
+                    }
+                    free(sha);
+                }
+            }
+        }
+
+        if (out->available) {
+            ESP_LOGI(TAG, "update: tag=%s ver=%s", tag, out->version);
+        }
+        break;  /* use first matching release */
+    }
+
+    cJSON_Delete(arr);
+}
+
+/* ── Main check ── */
+void gitea_ota_check_now(void)
+{
+    char url[512];
+    snprintf(url, sizeof(url),
+             "%s/api/v1/repos/%s/releases?limit=10",
+             GITEA_BASE_URL, GITEA_REPO);
+
+    char *json = http_get(url);
+    if (!json) {
+        ESP_LOGW(TAG, "releases fetch failed");
+        return;
+    }
+
+    parse_releases(json, BALANCE_TAG_PREFIX, BALANCE_BIN_ASSET,
+                   BALANCE_SHA256_ASSET, BALANCE_FW_VERSION, &g_balance_update);
+    parse_releases(json, IO_TAG_PREFIX, IO_BIN_ASSET,
+                   IO_SHA256_ASSET, IO_FW_VERSION, &g_io_update);
+    free(json);
+}
+
+/* ── Background task ── */
+static void version_check_task(void *arg)
+{
+    /* Initial check immediately after WiFi up */
+    vTaskDelay(pdMS_TO_TICKS(2000));
+    gitea_ota_check_now();
+
+    for (;;) {
+        vTaskDelay(pdMS_TO_TICKS(VERSION_CHECK_PERIOD_MS));
+        gitea_ota_check_now();
+    }
+}
+
+void gitea_ota_init(void)
+{
+    ESP_ERROR_CHECK(nvs_flash_init());
+
+    if (!wifi_connect()) {
+        ESP_LOGW(TAG, "WiFi unavailable — version checks disabled");
+        return;
+    }
+
+    xTaskCreate(version_check_task, "ver_check", 6144, NULL, 3, NULL);
+    ESP_LOGI(TAG, "version check task started");
+}

esp32s3/balance/main/gitea_ota.h

@@ -0,0 +1,42 @@
+#pragma once
+/* gitea_ota.h — Gitea release version checker (bd-3hte)
+ *
+ * WiFi task: on boot and every 30 min, queries Gitea releases API,
+ * compares tag version against embedded FW_VERSION, stores update info.
+ *
+ * WiFi credentials read from NVS namespace "wifi" keys "ssid"/"pass".
+ * Fall back to compile-time defaults if NVS is empty.
+ */
+
+#include <stdint.h>
+#include <stdbool.h>
+
+/* Gitea instance */
+#define GITEA_BASE_URL      "http://gitea.vayrette.com"
+#define GITEA_REPO          "seb/saltylab-firmware"
+#define GITEA_API_TIMEOUT_MS 10000
+
+/* Version check interval */
+#define VERSION_CHECK_PERIOD_MS  (30u * 60u * 1000u)  /* 30 minutes */
+
+/* Max URL/version string lengths */
+#define OTA_URL_MAX     384
+#define OTA_VER_MAX     32
+#define OTA_SHA256_MAX  65
+
+typedef struct {
+    bool    available;
+    char    version[OTA_VER_MAX];      /* remote version string, e.g. "1.2.3" */
+    char    download_url[OTA_URL_MAX]; /* direct download URL for .bin */
+    char    sha256[OTA_SHA256_MAX];    /* hex SHA256 (from .sha256 asset), or "" */
+} ota_update_info_t;
+
+/* Shared state — written by gitea_ota_check_task, read by display/OTA tasks */
+extern ota_update_info_t g_balance_update;
+extern ota_update_info_t g_io_update;
+
+/* Initialize WiFi and start version check task */
+void gitea_ota_init(void);
+
+/* One-shot sync check (can be called from any task) */
+void gitea_ota_check_now(void);

esp32s3/balance/main/main.c

@@ -0,0 +1,114 @@
+/* main.c — ESP32-S3 BALANCE app_main (bd-66hx + OTA beads) */
+
+#include "orin_serial.h"
+#include "vesc_can.h"
+#include "gitea_ota.h"
+#include "ota_self.h"
+#include "uart_ota.h"
+#include "ota_display.h"
+#include "config.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include "freertos/queue.h"
+#include "esp_log.h"
+#include "esp_timer.h"
+#include <string.h>
+
+static const char *TAG = "main";
+
+static QueueHandle_t s_orin_tx_q;
+
+/* ── Telemetry task: sends TELEM_STATUS to Orin at 10 Hz ── */
+static void telem_task(void *arg)
+{
+    for (;;) {
+        vTaskDelay(pdMS_TO_TICKS(TELEM_STATUS_PERIOD_MS));
+
+        uint32_t now_ms = (uint32_t)(esp_timer_get_time() / 1000LL);
+        bool hb_timeout = (now_ms - g_orin_ctrl.hb_last_ms) > HB_TIMEOUT_MS;
+
+        /* Determine balance state for telemetry */
+        bal_state_t state;
+        if (g_orin_ctrl.estop) {
+            state = BAL_ESTOP;
+        } else if (!g_orin_ctrl.armed) {
+            state = BAL_DISARMED;
+        } else {
+            state = BAL_ARMED;
+        }
+
+        /* flags: bit0=estop_active, bit1=heartbeat_timeout */
+        uint8_t flags = (g_orin_ctrl.estop ? 0x01u : 0x00u) |
+                        (hb_timeout         ? 0x02u : 0x00u);
+
+        /* Battery voltage from VESC_ID_A STATUS_5 (V×10 → mV) */
+        uint16_t vbat_mv = (uint16_t)((int32_t)g_vesc[0].voltage_x10 * 100);
+
+        orin_send_status(s_orin_tx_q,
+                         0,      /* pitch_x10: stub — full IMU in future bead */
+                         0,      /* motor_cmd: stub */
+                         vbat_mv,
+                         state,
+                         flags);
+    }
+}
+
+/* ── Drive task: applies Orin drive commands to VESCs @ 50 Hz ── */
+static void drive_task(void *arg)
+{
+    for (;;) {
+        vTaskDelay(pdMS_TO_TICKS(20));  /* 50 Hz */
+
+        uint32_t now_ms   = (uint32_t)(esp_timer_get_time() / 1000LL);
+        bool hb_timeout   = (now_ms - g_orin_ctrl.hb_last_ms) > HB_TIMEOUT_MS;
+        bool drive_stale  = (now_ms - g_orin_drive.updated_ms) > DRIVE_TIMEOUT_MS;
+
+        int32_t left_erpm  = 0;
+        int32_t right_erpm = 0;
+
+        if (g_orin_ctrl.armed && !g_orin_ctrl.estop &&
+            !hb_timeout && !drive_stale) {
+            int32_t spd = (int32_t)g_orin_drive.speed * RPM_PER_SPEED_UNIT;
+            int32_t str = (int32_t)g_orin_drive.steer * RPM_PER_STEER_UNIT;
+            left_erpm  = spd + str;
+            right_erpm = spd - str;
+        }
+
+        /* VESC_ID_A (56) = LEFT, VESC_ID_B (68) = RIGHT per bd-wim1 protocol */
+        vesc_can_send_rpm(VESC_ID_A, left_erpm);
+        vesc_can_send_rpm(VESC_ID_B, right_erpm);
+    }
+}
+
+void app_main(void)
+{
+    ESP_LOGI(TAG, "ESP32-S3 BALANCE starting");
+
+    /* OTA rollback health check — must be called within OTA_ROLLBACK_WINDOW_S */
+    ota_self_health_check();
+
+    /* Init peripherals */
+    orin_serial_init();
+    vesc_can_init();
+
+    /* TX queue for outbound serial frames */
+    s_orin_tx_q = xQueueCreate(ORIN_TX_QUEUE_DEPTH, sizeof(orin_tx_frame_t));
+    configASSERT(s_orin_tx_q);
+
+    /* Seed heartbeat timer so we don't immediately timeout */
+    g_orin_ctrl.hb_last_ms = (uint32_t)(esp_timer_get_time() / 1000LL);
+
+    /* Create tasks */
+    xTaskCreate(orin_serial_rx_task, "orin_rx",  4096, s_orin_tx_q, 10, NULL);
+    xTaskCreate(orin_serial_tx_task, "orin_tx",  2048, s_orin_tx_q,  9, NULL);
+    xTaskCreate(vesc_can_rx_task,    "vesc_rx",  4096, s_orin_tx_q, 10, NULL);
+    xTaskCreate(telem_task,          "telem",    2048, NULL,          5, NULL);
+    xTaskCreate(drive_task,          "drive",    2048, NULL,          8, NULL);
+
+    /* OTA subsystem — WiFi version checker + display overlay */
+    gitea_ota_init();
+    ota_display_init();
+
+    ESP_LOGI(TAG, "all tasks started");
+    /* app_main returns — FreeRTOS scheduler continues */
+}

esp32s3/balance/main/orin_serial.c

@@ -0,0 +1,354 @@
+/* orin_serial.c — Orin↔ESP32-S3 serial protocol (bd-66hx + bd-1s1s OTA cmds) */
+
+#include "orin_serial.h"
+#include "config.h"
+#include "gitea_ota.h"
+#include "ota_self.h"
+#include "uart_ota.h"
+#include "version.h"
+#include "driver/uart.h"
+#include "esp_log.h"
+#include "esp_timer.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/queue.h"
+#include <string.h>
+#include <stdio.h>
+
+static const char *TAG = "orin";
+
+/* ── Shared state ── */
+orin_drive_t   g_orin_drive   = {0};
+orin_pid_t     g_orin_pid     = {0};
+orin_control_t g_orin_ctrl    = {.armed = false, .estop = false, .hb_last_ms = 0};
+
+/* ── CRC8-SMBUS (poly=0x07, init=0x00) ── */
+static uint8_t crc8(const uint8_t *data, uint8_t len)
+{
+    uint8_t crc = 0x00u;
+    for (uint8_t i = 0; i < len; i++) {
+        crc ^= data[i];
+        for (uint8_t b = 0; b < 8u; b++) {
+            crc = (crc & 0x80u) ? (uint8_t)((crc << 1u) ^ 0x07u) : (uint8_t)(crc << 1u);
+        }
+    }
+    return crc;
+}
+
+/* ── Frame builder ── */
+static void build_frame(orin_tx_frame_t *f, uint8_t out[/* ORIN_MAX_PAYLOAD + 4 */], uint8_t *out_len)
+{
+    /* [SYNC][LEN][TYPE][PAYLOAD...][CRC] */
+    uint8_t crc_buf[2u + ORIN_MAX_PAYLOAD];
+    crc_buf[0] = f->len;
+    crc_buf[1] = f->type;
+    memcpy(&crc_buf[2], f->payload, f->len);
+    uint8_t crc = crc8(crc_buf, (uint8_t)(2u + f->len));
+
+    out[0] = ORIN_SYNC;
+    out[1] = f->len;
+    out[2] = f->type;
+    memcpy(&out[3], f->payload, f->len);
+    out[3u + f->len] = crc;
+    *out_len = (uint8_t)(4u + f->len);
+}
+
+/* ── Enqueue helpers ── */
+static void enqueue(QueueHandle_t q, uint8_t type, const uint8_t *payload, uint8_t len)
+{
+    orin_tx_frame_t f = {.type = type, .len = len};
+    if (len > 0u && payload) {
+        memcpy(f.payload, payload, len);
+    }
+    if (xQueueSend(q, &f, 0) != pdTRUE) {
+        ESP_LOGW(TAG, "tx queue full, dropped type=0x%02x", type);
+    }
+}
+
+void orin_send_ack(QueueHandle_t q, uint8_t cmd_type)
+{
+    enqueue(q, RESP_ACK, &cmd_type, 1u);
+}
+
+void orin_send_nack(QueueHandle_t q, uint8_t cmd_type, uint8_t err)
+{
+    uint8_t p[2] = {cmd_type, err};
+    enqueue(q, RESP_NACK, p, 2u);
+}
+
+void orin_send_status(QueueHandle_t q,
+                      int16_t pitch_x10, int16_t motor_cmd,
+                      uint16_t vbat_mv, bal_state_t state, uint8_t flags)
+{
+    /* int16 pitch_x10, int16 motor_cmd, uint16 vbat_mv, uint8 state, uint8 flags — BE */
+    uint8_t p[8];
+    p[0] = (uint8_t)((uint16_t)pitch_x10 >> 8u);
+    p[1] = (uint8_t)((uint16_t)pitch_x10);
+    p[2] = (uint8_t)((uint16_t)motor_cmd >> 8u);
+    p[3] = (uint8_t)((uint16_t)motor_cmd);
+    p[4] = (uint8_t)(vbat_mv >> 8u);
+    p[5] = (uint8_t)(vbat_mv);
+    p[6] = (uint8_t)state;
+    p[7] = flags;
+    enqueue(q, TELEM_STATUS, p, 8u);
+}
+
+void orin_send_vesc(QueueHandle_t q, uint8_t telem_type,
+                    int32_t erpm, uint16_t voltage_mv,
+                    int16_t current_ma, uint16_t temp_c_x10)
+{
+    /* int32 erpm, uint16 voltage_mv, int16 current_ma, uint16 temp_c_x10 — BE */
+    uint8_t p[10];
+    uint32_t u = (uint32_t)erpm;
+    p[0] = (uint8_t)(u >> 24u);
+    p[1] = (uint8_t)(u >> 16u);
+    p[2] = (uint8_t)(u >>  8u);
+    p[3] = (uint8_t)(u);
+    p[4] = (uint8_t)(voltage_mv >> 8u);
+    p[5] = (uint8_t)(voltage_mv);
+    p[6] = (uint8_t)((uint16_t)current_ma >> 8u);
+    p[7] = (uint8_t)((uint16_t)current_ma);
+    p[8] = (uint8_t)(temp_c_x10 >> 8u);
+    p[9] = (uint8_t)(temp_c_x10);
+    enqueue(q, telem_type, p, 10u);
+}
+
+/* ── UART init ── */
+void orin_serial_init(void)
+{
+    uart_config_t cfg = {
+        .baud_rate  = ORIN_UART_BAUD,
+        .data_bits  = UART_DATA_8_BITS,
+        .parity     = UART_PARITY_DISABLE,
+        .stop_bits  = UART_STOP_BITS_1,
+        .flow_ctrl  = UART_HW_FLOWCTRL_DISABLE,
+    };
+    ESP_ERROR_CHECK(uart_param_config(ORIN_UART_PORT, &cfg));
+    ESP_ERROR_CHECK(uart_set_pin(ORIN_UART_PORT,
+                                  ORIN_UART_TX_GPIO, ORIN_UART_RX_GPIO,
+                                  UART_PIN_NO_CHANGE, UART_PIN_NO_CHANGE));
+    ESP_ERROR_CHECK(uart_driver_install(ORIN_UART_PORT, ORIN_UART_RX_BUF, 0,
+                                        0, NULL, 0));
+    ESP_LOGI(TAG, "UART%d init OK: tx=%d rx=%d baud=%d",
+             ORIN_UART_PORT, ORIN_UART_TX_GPIO, ORIN_UART_RX_GPIO, ORIN_UART_BAUD);
+}
+
+/* ── RX parser state machine ── */
+typedef enum {
+    WAIT_SYNC,
+    WAIT_LEN,
+    WAIT_TYPE,
+    WAIT_PAYLOAD,
+    WAIT_CRC,
+} rx_state_t;
+
+static void dispatch_cmd(uint8_t type, const uint8_t *payload, uint8_t len,
+                          QueueHandle_t tx_q)
+{
+    uint32_t now_ms = (uint32_t)(esp_timer_get_time() / 1000LL);
+
+    switch (type) {
+    case CMD_HEARTBEAT:
+        g_orin_ctrl.hb_last_ms = now_ms;
+        orin_send_ack(tx_q, type);
+        break;
+
+    case CMD_DRIVE:
+        if (len < 4u) { orin_send_nack(tx_q, type, ERR_BAD_LEN); break; }
+        if (g_orin_ctrl.estop) { orin_send_nack(tx_q, type, ERR_ESTOP_ACTIVE); break; }
+        if (!g_orin_ctrl.armed) { orin_send_nack(tx_q, type, ERR_DISARMED); break; }
+        g_orin_drive.speed      = (int16_t)(((uint16_t)payload[0] << 8u) | payload[1]);
+        g_orin_drive.steer      = (int16_t)(((uint16_t)payload[2] << 8u) | payload[3]);
+        g_orin_drive.updated_ms = now_ms;
+        g_orin_ctrl.hb_last_ms  = now_ms;  /* drive counts as heartbeat */
+        orin_send_ack(tx_q, type);
+        break;
+
+    case CMD_ESTOP:
+        if (len < 1u) { orin_send_nack(tx_q, type, ERR_BAD_LEN); break; }
+        g_orin_ctrl.estop = (payload[0] != 0u);
+        if (g_orin_ctrl.estop) {
+            g_orin_drive.speed = 0;
+            g_orin_drive.steer = 0;
+        }
+        orin_send_ack(tx_q, type);
+        break;
+
+    case CMD_ARM:
+        if (len < 1u) { orin_send_nack(tx_q, type, ERR_BAD_LEN); break; }
+        if (g_orin_ctrl.estop && payload[0] != 0u) {
+            /* cannot arm while estop is active */
+            orin_send_nack(tx_q, type, ERR_ESTOP_ACTIVE);
+            break;
+        }
+        g_orin_ctrl.armed = (payload[0] != 0u);
+        if (!g_orin_ctrl.armed) {
+            g_orin_drive.speed = 0;
+            g_orin_drive.steer = 0;
+        }
+        orin_send_ack(tx_q, type);
+        break;
+
+    case CMD_PID:
+        if (len < 12u) { orin_send_nack(tx_q, type, ERR_BAD_LEN); break; }
+        /* float32 big-endian: copy and swap bytes */
+        {
+            uint32_t raw;
+            raw = ((uint32_t)payload[0] << 24u) | ((uint32_t)payload[1] << 16u) |
+                  ((uint32_t)payload[2] <<  8u) |  (uint32_t)payload[3];
+            memcpy((void*)&g_orin_pid.kp, &raw, 4u);
+            raw = ((uint32_t)payload[4] << 24u) | ((uint32_t)payload[5] << 16u) |
+                  ((uint32_t)payload[6] <<  8u) |  (uint32_t)payload[7];
+            memcpy((void*)&g_orin_pid.ki, &raw, 4u);
+            raw = ((uint32_t)payload[8] << 24u) | ((uint32_t)payload[9] << 16u) |
+                  ((uint32_t)payload[10] << 8u) |  (uint32_t)payload[11];
+            memcpy((void*)&g_orin_pid.kd, &raw, 4u);
+            g_orin_pid.updated = true;
+        }
+        orin_send_ack(tx_q, type);
+        break;
+
+    case CMD_OTA_CHECK:
+        /* Trigger an immediate Gitea version check */
+        gitea_ota_check_now();
+        orin_send_version_info(tx_q, OTA_TARGET_BALANCE,
+                                BALANCE_FW_VERSION,
+                                g_balance_update.available
+                                    ? g_balance_update.version : "");
+        orin_send_version_info(tx_q, OTA_TARGET_IO,
+                                IO_FW_VERSION,
+                                g_io_update.available
+                                    ? g_io_update.version : "");
+        orin_send_ack(tx_q, type);
+        break;
+
+    case CMD_OTA_UPDATE:
+        if (len < 1u) { orin_send_nack(tx_q, type, ERR_BAD_LEN); break; }
+        {
+            uint8_t target = payload[0];
+            bool triggered = false;
+            if (target == OTA_TARGET_IO || target == OTA_TARGET_BOTH) {
+                if (!uart_ota_trigger()) {
+                    orin_send_nack(tx_q, type,
+                        g_io_update.available ? ERR_OTA_BUSY : ERR_OTA_NO_UPDATE);
+                    break;
+                }
+                triggered = true;
+            }
+            if (target == OTA_TARGET_BALANCE || target == OTA_TARGET_BOTH) {
+                if (!ota_self_trigger()) {
+                    if (!triggered) {
+                        orin_send_nack(tx_q, type,
+                            g_balance_update.available ? ERR_OTA_BUSY : ERR_OTA_NO_UPDATE);
+                        break;
+                    }
+                }
+            }
+            orin_send_ack(tx_q, type);
+        }
+        break;
+
+    default:
+        ESP_LOGW(TAG, "unknown cmd type=0x%02x", type);
+        break;
+    }
+}
+
+void orin_serial_rx_task(void *arg)
+{
+    QueueHandle_t tx_q = (QueueHandle_t)arg;
+    rx_state_t state   = WAIT_SYNC;
+    uint8_t    rx_len  = 0;
+    uint8_t    rx_type = 0;
+    uint8_t    payload[ORIN_MAX_PAYLOAD];
+    uint8_t    pay_idx = 0;
+
+    uint8_t byte;
+    for (;;) {
+        int r = uart_read_bytes(ORIN_UART_PORT, &byte, 1, pdMS_TO_TICKS(10));
+        if (r <= 0) {
+            continue;
+        }
+
+        switch (state) {
+        case WAIT_SYNC:
+            if (byte == ORIN_SYNC) { state = WAIT_LEN; }
+            break;
+
+        case WAIT_LEN:
+            if (byte > ORIN_MAX_PAYLOAD) {
+                /* oversize — send NACK and reset */
+                orin_send_nack(tx_q, 0x00u, ERR_BAD_LEN);
+                state = WAIT_SYNC;
+            } else {
+                rx_len = byte;
+                state  = WAIT_TYPE;
+            }
+            break;
+
+        case WAIT_TYPE:
+            rx_type = byte;
+            pay_idx = 0u;
+            state   = (rx_len == 0u) ? WAIT_CRC : WAIT_PAYLOAD;
+            break;
+
+        case WAIT_PAYLOAD:
+            payload[pay_idx++] = byte;
+            if (pay_idx == rx_len) { state = WAIT_CRC; }
+            break;
+
+        case WAIT_CRC: {
+            /* Verify CRC over [LEN, TYPE, PAYLOAD] */
+            uint8_t crc_buf[2u + ORIN_MAX_PAYLOAD];
+            crc_buf[0] = rx_len;
+            crc_buf[1] = rx_type;
+            memcpy(&crc_buf[2], payload, rx_len);
+            uint8_t expected = crc8(crc_buf, (uint8_t)(2u + rx_len));
+            if (byte != expected) {
+                ESP_LOGW(TAG, "CRC fail type=0x%02x got=0x%02x exp=0x%02x",
+                         rx_type, byte, expected);
+                orin_send_nack(tx_q, rx_type, ERR_BAD_CRC);
+            } else {
+                dispatch_cmd(rx_type, payload, rx_len, tx_q);
+            }
+            state = WAIT_SYNC;
+            break;
+        }
+        }
+    }
+}
+
+void orin_serial_tx_task(void *arg)
+{
+    QueueHandle_t tx_q = (QueueHandle_t)arg;
+    orin_tx_frame_t f;
+    uint8_t wire[4u + ORIN_MAX_PAYLOAD];
+    uint8_t wire_len;
+
+    for (;;) {
+        if (xQueueReceive(tx_q, &f, portMAX_DELAY) == pdTRUE) {
+            build_frame(&f, wire, &wire_len);
+            uart_write_bytes(ORIN_UART_PORT, (const char *)wire, wire_len);
+        }
+    }
+}
+
+/* ── OTA telemetry helpers (bd-1s1s) ── */
+
+void orin_send_ota_status(QueueHandle_t q, uint8_t target,
+                           uint8_t state, uint8_t progress, uint8_t err)
+{
+    /* TELEM_OTA_STATUS: uint8 target, uint8 state, uint8 progress, uint8 err */
+    uint8_t p[4] = {target, state, progress, err};
+    enqueue(q, TELEM_OTA_STATUS, p, 4u);
+}
+
+void orin_send_version_info(QueueHandle_t q, uint8_t target,
+                             const char *current, const char *available)
+{
+    /* TELEM_VERSION_INFO: uint8 target, char current[16], char available[16] */
+    uint8_t p[33];
+    p[0] = target;
+    strncpy((char *)&p[1],  current,   16); p[16] = '\0';
+    strncpy((char *)&p[17], available ? available : "", 16); p[32] = '\0';
+    enqueue(q, TELEM_VERSION_INFO, p, 33u);
+}

esp32s3/balance/main/orin_serial.h

@@ -0,0 +1,113 @@
+#pragma once
+/* orin_serial.h — Orin↔ESP32-S3 BALANCE USB/UART serial protocol (bd-66hx)
+ *
+ * Frame layout (matches bd-wim1 esp32_balance_protocol.py exactly):
+ *   [0xAA][LEN][TYPE][PAYLOAD × LEN bytes][CRC8-SMBUS]
+ *   CRC covers LEN + TYPE + PAYLOAD bytes.
+ *   All multi-byte payload fields are big-endian.
+ *
+ * Physical: UART0 → CH343 USB-serial → Orin /dev/esp32-balance  @ 460800 baud
+ */
+
+#include <stdint.h>
+#include <stdbool.h>
+#include "freertos/FreeRTOS.h"
+#include "freertos/queue.h"
+
+/* ── Frame constants ── */
+#define ORIN_SYNC           0xAAu
+#define ORIN_MAX_PAYLOAD    62u
+
+/* ── Command types: Orin → ESP32 ── */
+#define CMD_HEARTBEAT       0x01u
+#define CMD_DRIVE           0x02u   /* int16 speed + int16 steer, BE */
+#define CMD_ESTOP           0x03u   /* uint8: 1=assert, 0=clear */
+#define CMD_ARM             0x04u   /* uint8: 1=arm, 0=disarm */
+#define CMD_PID             0x05u   /* float32 kp, ki, kd, BE */
+
+/* ── Telemetry types: ESP32 → Orin ── */
+#define TELEM_STATUS        0x80u   /* status @ 10 Hz */
+#define TELEM_VESC_LEFT     0x81u   /* VESC ID 56 telemetry @ 10 Hz */
+#define TELEM_VESC_RIGHT    0x82u   /* VESC ID 68 telemetry @ 10 Hz */
+#define TELEM_OTA_STATUS    0x83u   /* OTA state + progress (bd-1s1s) */
+#define TELEM_VERSION_INFO  0x84u   /* firmware version report (bd-1s1s) */
+#define RESP_ACK            0xA0u
+#define RESP_NACK           0xA1u
+
+/* ── OTA commands (Orin → ESP32, bd-1s1s) ── */
+#define CMD_OTA_CHECK       0x10u   /* no payload: trigger Gitea version check */
+#define CMD_OTA_UPDATE      0x11u   /* uint8 target: 0=balance, 1=io, 2=both */
+
+/* ── OTA target constants ── */
+#define OTA_TARGET_BALANCE  0x00u
+#define OTA_TARGET_IO       0x01u
+#define OTA_TARGET_BOTH     0x02u
+
+/* ── NACK error codes ── */
+#define ERR_BAD_CRC         0x01u
+#define ERR_BAD_LEN         0x02u
+#define ERR_ESTOP_ACTIVE    0x03u
+#define ERR_DISARMED        0x04u
+#define ERR_OTA_BUSY        0x05u
+#define ERR_OTA_NO_UPDATE   0x06u
+
+/* ── Balance state (mirrored from TELEM_STATUS.balance_state) ── */
+typedef enum {
+    BAL_DISARMED   = 0,
+    BAL_ARMED      = 1,
+    BAL_TILT_FAULT = 2,
+    BAL_ESTOP      = 3,
+} bal_state_t;
+
+/* ── Shared state written by RX task, consumed by main/vesc tasks ── */
+typedef struct {
+    volatile int16_t  speed;        /* -1000..+1000 */
+    volatile int16_t  steer;        /* -1000..+1000 */
+    volatile uint32_t updated_ms;   /* esp_timer tick at last CMD_DRIVE */
+} orin_drive_t;
+
+typedef struct {
+    volatile float    kp, ki, kd;
+    volatile bool     updated;
+} orin_pid_t;
+
+typedef struct {
+    volatile bool     armed;
+    volatile bool     estop;
+    volatile uint32_t hb_last_ms;   /* esp_timer tick at last CMD_HEARTBEAT/CMD_DRIVE */
+} orin_control_t;
+
+/* ── TX frame queue item ── */
+typedef struct {
+    uint8_t type;
+    uint8_t len;
+    uint8_t payload[ORIN_MAX_PAYLOAD];
+} orin_tx_frame_t;
+
+/* ── Globals (defined in orin_serial.c, extern here) ── */
+extern orin_drive_t   g_orin_drive;
+extern orin_pid_t     g_orin_pid;
+extern orin_control_t g_orin_ctrl;
+
+/* ── API ── */
+void orin_serial_init(void);
+
+/* Tasks — pass tx_queue as arg to both */
+void orin_serial_rx_task(void *arg);   /* arg = QueueHandle_t tx_queue */
+void orin_serial_tx_task(void *arg);   /* arg = QueueHandle_t tx_queue */
+
+/* Enqueue outbound frames */
+void orin_send_status(QueueHandle_t q,
+                      int16_t pitch_x10, int16_t motor_cmd,
+                      uint16_t vbat_mv, bal_state_t state, uint8_t flags);
+void orin_send_vesc(QueueHandle_t q, uint8_t telem_type,
+                    int32_t erpm, uint16_t voltage_mv,
+                    int16_t current_ma, uint16_t temp_c_x10);
+void orin_send_ack(QueueHandle_t q, uint8_t cmd_type);
+void orin_send_nack(QueueHandle_t q, uint8_t cmd_type, uint8_t err);
+
+/* OTA telemetry helpers (bd-1s1s) */
+void orin_send_ota_status(QueueHandle_t q, uint8_t target,
+                           uint8_t state, uint8_t progress, uint8_t err);
+void orin_send_version_info(QueueHandle_t q, uint8_t target,
+                             const char *current, const char *available);

esp32s3/balance/main/ota_display.c

@@ -0,0 +1,150 @@
+/* ota_display.c — OTA notification/progress UI on GC9A01 (bd-1yr8)
+ *
+ * Renders OTA state overlaid on the 240×240 round HUD display:
+ *   - BADGE: small dot on top-right when update available (idle state)
+ *   - UPDATE SCREEN: version compare, Update Balance / Update IO / Update All
+ *   - PROGRESS: arc around display perimeter + % + status text
+ *   - ERROR: red banner + "RETRY" prompt
+ *
+ * The display_draw_* primitives must be provided by the GC9A01 driver.
+ * Actual SPI driver implementation is in a separate driver bead.
+ */
+
+#include "ota_display.h"
+#include "gitea_ota.h"
+#include "version.h"
+#include "esp_log.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include <stdio.h>
+#include <string.h>
+
+static const char *TAG = "ota_disp";
+
+/* Display centre and radius for the 240×240 GC9A01 */
+#define CX   120
+#define CY   120
+#define RAD  110
+
+/* ── Availability badge: 8×8 dot at top-right of display ── */
+static void draw_badge(bool balance_avail, bool io_avail)
+{
+    uint16_t col = (balance_avail || io_avail) ? COL_ORANGE : COL_BG;
+    display_fill_rect(200, 15, 12, 12, col);
+}
+
+/* ── Progress arc: sweeps 0→360° proportional to progress% ── */
+static void draw_progress_arc(uint8_t pct, uint16_t color)
+{
+    int end_deg = (int)(360 * pct / 100);
+    display_draw_arc(CX, CY, RAD, 0, end_deg, 6, color);
+}
+
+/* ── Status banner: 2 lines of text centred on display ── */
+static void draw_status(const char *line1, const char *line2,
+                         uint16_t fg, uint16_t bg)
+{
+    display_fill_rect(20, 90, 200, 60, bg);
+    if (line1 && line1[0])
+        display_draw_string(CX - (int)(strlen(line1) * 6 / 2), 96,
+                             line1, fg, bg);
+    if (line2 && line2[0])
+        display_draw_string(CX - (int)(strlen(line2) * 6 / 2), 116,
+                             line2, fg, bg);
+}
+
+/* ── Main render logic ── */
+void ota_display_update(void)
+{
+    /* Determine dominant OTA state */
+    ota_self_state_t  self  = g_ota_self_state;
+    uart_ota_send_state_t io_s = g_uart_ota_state;
+
+    switch (self) {
+    case OTA_SELF_DOWNLOADING:
+    case OTA_SELF_VERIFYING:
+    case OTA_SELF_APPLYING: {
+        /* Balance self-update in progress */
+        char pct_str[16];
+        snprintf(pct_str, sizeof(pct_str), "%d%%", g_ota_self_progress);
+        const char *phase = (self == OTA_SELF_VERIFYING) ? "Verifying..." :
+                            (self == OTA_SELF_APPLYING)  ? "Applying..." :
+                                                            "Downloading...";
+        draw_progress_arc(g_ota_self_progress, COL_BLUE);
+        draw_status("Updating Balance", pct_str, COL_WHITE, COL_BG);
+        ESP_LOGD(TAG, "balance OTA %s %d%%", phase, g_ota_self_progress);
+        return;
+    }
+    case OTA_SELF_REBOOTING:
+        draw_status("Update complete", "Rebooting...", COL_GREEN, COL_BG);
+        return;
+    case OTA_SELF_FAILED:
+        draw_progress_arc(0, COL_RED);
+        draw_status("Balance update", "FAILED  RETRY?", COL_RED, COL_BG);
+        return;
+    default:
+        break;
+    }
+
+    switch (io_s) {
+    case UART_OTA_S_DOWNLOADING:
+        draw_progress_arc(g_uart_ota_progress, COL_YELLOW);
+        draw_status("Downloading IO", "firmware...", COL_WHITE, COL_BG);
+        return;
+    case UART_OTA_S_SENDING: {
+        char pct_str[16];
+        snprintf(pct_str, sizeof(pct_str), "%d%%", g_uart_ota_progress);
+        draw_progress_arc(g_uart_ota_progress, COL_YELLOW);
+        draw_status("Updating IO", pct_str, COL_WHITE, COL_BG);
+        return;
+    }
+    case UART_OTA_S_DONE:
+        draw_status("IO update done", "", COL_GREEN, COL_BG);
+        return;
+    case UART_OTA_S_FAILED:
+        draw_progress_arc(0, COL_RED);
+        draw_status("IO update", "FAILED  RETRY?", COL_RED, COL_BG);
+        return;
+    default:
+        break;
+    }
+
+    /* Idle — show badge if update available */
+    bool bal_avail = g_balance_update.available;
+    bool io_avail  = g_io_update.available;
+    draw_badge(bal_avail, io_avail);
+
+    if (bal_avail || io_avail) {
+        /* Show available versions on display when idle */
+        char verline[32];
+        if (bal_avail) {
+            snprintf(verline, sizeof(verline), "Bal v%s rdy",
+                     g_balance_update.version);
+            draw_status(verline, io_avail ? "IO update rdy" : "",
+                         COL_ORANGE, COL_BG);
+        } else if (io_avail) {
+            snprintf(verline, sizeof(verline), "IO v%s rdy",
+                     g_io_update.version);
+            draw_status(verline, "", COL_ORANGE, COL_BG);
+        }
+    } else {
+        /* Clear OTA overlay area */
+        display_fill_rect(20, 90, 200, 60, COL_BG);
+        draw_badge(false, false);
+    }
+}
+
+/* ── Background display task (5 Hz) ── */
+static void ota_display_task(void *arg)
+{
+    for (;;) {
+        vTaskDelay(pdMS_TO_TICKS(200));
+        ota_display_update();
+    }
+}
+
+void ota_display_init(void)
+{
+    xTaskCreate(ota_display_task, "ota_disp", 2048, NULL, 3, NULL);
+    ESP_LOGI(TAG, "OTA display task started");
+}

esp32s3/balance/main/ota_display.h

@@ -0,0 +1,33 @@
+#pragma once
+/* ota_display.h — OTA notification UI on GC9A01 round LCD (bd-1yr8)
+ *
+ * GC9A01 240×240 round display via SPI (IO12 CS, IO11 DC, IO10 RST, IO9 BL).
+ * Calls into display_draw_* primitives (provided by display driver layer).
+ * This module owns the "OTA notification overlay" rendered over the HUD.
+ */
+
+#include <stdint.h>
+#include <stdbool.h>
+#include "ota_self.h"
+#include "uart_ota.h"
+
+/* ── Display primitives API (must be provided by display driver) ── */
+void display_fill_rect(int x, int y, int w, int h, uint16_t rgb565);
+void display_draw_string(int x, int y, const char *str, uint16_t fg, uint16_t bg);
+void display_draw_arc(int cx, int cy, int r, int start_deg, int end_deg,
+                       int thickness, uint16_t color);
+
+/* ── Colour palette (RGB565) ── */
+#define COL_BG       0x0000u  /* black */
+#define COL_WHITE    0xFFFFu
+#define COL_GREEN    0x07E0u
+#define COL_YELLOW   0xFFE0u
+#define COL_RED      0xF800u
+#define COL_BLUE     0x001Fu
+#define COL_ORANGE   0xFD20u
+
+/* ── OTA display task: runs at 5 Hz, overlays OTA state on HUD ── */
+void ota_display_init(void);
+
+/* Called from main loop or display task to render the OTA overlay */
+void ota_display_update(void);

esp32s3/balance/main/ota_self.c

@@ -0,0 +1,183 @@
+/* ota_self.c — Balance self-OTA (bd-18nb)
+ *
+ * Uses esp_https_ota / esp_ota_ops to download from Gitea release URL,
+ * stream-verify SHA256 with mbedTLS, set new boot partition, and reboot.
+ * CONFIG_BOOTLOADER_APP_ROLLBACK_ENABLE in sdkconfig allows auto-rollback
+ * if the new image doesn't call esp_ota_mark_app_valid_cancel_rollback()
+ * within OTA_ROLLBACK_WINDOW_S seconds.
+ */
+
+#include "ota_self.h"
+#include "gitea_ota.h"
+#include "esp_log.h"
+#include "esp_ota_ops.h"
+#include "esp_http_client.h"
+#include "esp_timer.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include "mbedtls/sha256.h"
+#include <string.h>
+#include <stdio.h>
+
+static const char *TAG = "ota_self";
+
+volatile ota_self_state_t g_ota_self_state   = OTA_SELF_IDLE;
+volatile uint8_t          g_ota_self_progress = 0;
+
+#define OTA_CHUNK_SIZE  4096
+
+/* ── SHA256 verify helper ── */
+static bool sha256_matches(const uint8_t *digest, const char *expected_hex)
+{
+    if (!expected_hex || expected_hex[0] == '\0') {
+        ESP_LOGW(TAG, "no SHA256 to verify — skipping");
+        return true;
+    }
+    char got[65] = {0};
+    for (int i = 0; i < 32; i++) {
+        snprintf(&got[i*2], 3, "%02x", digest[i]);
+    }
+    bool ok = (strncasecmp(got, expected_hex, 64) == 0);
+    if (!ok) {
+        ESP_LOGE(TAG, "SHA256 mismatch: got=%s exp=%s", got, expected_hex);
+    }
+    return ok;
+}
+
+/* ── OTA download + flash task ── */
+static void ota_self_task(void *arg)
+{
+    const char *url    = g_balance_update.download_url;
+    const char *sha256 = g_balance_update.sha256;
+
+    g_ota_self_state    = OTA_SELF_DOWNLOADING;
+    g_ota_self_progress = 0;
+
+    ESP_LOGI(TAG, "OTA start: %s", url);
+
+    esp_ota_handle_t       handle     = 0;
+    const esp_partition_t *ota_part   = esp_ota_get_next_update_partition(NULL);
+    if (!ota_part) {
+        ESP_LOGE(TAG, "no OTA partition");
+        g_ota_self_state = OTA_SELF_FAILED;
+        vTaskDelete(NULL);
+        return;
+    }
+
+    esp_err_t err = esp_ota_begin(ota_part, OTA_WITH_SEQUENTIAL_WRITES, &handle);
+    if (err != ESP_OK) {
+        ESP_LOGE(TAG, "ota_begin: %s", esp_err_to_name(err));
+        g_ota_self_state = OTA_SELF_FAILED;
+        vTaskDelete(NULL);
+        return;
+    }
+
+    /* Setup HTTP client */
+    esp_http_client_config_t hcfg = {
+        .url        = url,
+        .timeout_ms = 30000,
+        .buffer_size = OTA_CHUNK_SIZE,
+        .skip_cert_common_name_check = true,
+    };
+    esp_http_client_handle_t client = esp_http_client_init(&hcfg);
+    err = esp_http_client_open(client, 0);
+    if (err != ESP_OK) {
+        ESP_LOGE(TAG, "http_open: %s", esp_err_to_name(err));
+        esp_ota_abort(handle);
+        esp_http_client_cleanup(client);
+        g_ota_self_state = OTA_SELF_FAILED;
+        vTaskDelete(NULL);
+        return;
+    }
+
+    int content_len = esp_http_client_fetch_headers(client);
+    ESP_LOGI(TAG, "content-length: %d", content_len);
+
+    mbedtls_sha256_context sha_ctx;
+    mbedtls_sha256_init(&sha_ctx);
+    mbedtls_sha256_starts(&sha_ctx, 0);  /* 0 = SHA-256 */
+
+    static uint8_t buf[OTA_CHUNK_SIZE];
+    int total = 0;
+    int rd;
+    while ((rd = esp_http_client_read(client, (char *)buf, sizeof(buf))) > 0) {
+        mbedtls_sha256_update(&sha_ctx, buf, rd);
+        err = esp_ota_write(handle, buf, rd);
+        if (err != ESP_OK) {
+            ESP_LOGE(TAG, "ota_write: %s", esp_err_to_name(err));
+            esp_ota_abort(handle);
+            goto cleanup;
+        }
+        total += rd;
+        if (content_len > 0) {
+            g_ota_self_progress = (uint8_t)((total * 100) / content_len);
+        }
+    }
+    esp_http_client_close(client);
+
+    /* Verify SHA256 */
+    g_ota_self_state = OTA_SELF_VERIFYING;
+    uint8_t digest[32];
+    mbedtls_sha256_finish(&sha_ctx, digest);
+    if (!sha256_matches(digest, sha256)) {
+        ESP_LOGE(TAG, "SHA256 verification failed");
+        esp_ota_abort(handle);
+        g_ota_self_state = OTA_SELF_FAILED;
+        goto cleanup;
+    }
+
+    /* Finalize + set boot partition */
+    g_ota_self_state = OTA_SELF_APPLYING;
+    err = esp_ota_end(handle);
+    if (err != ESP_OK) {
+        ESP_LOGE(TAG, "ota_end: %s", esp_err_to_name(err));
+        g_ota_self_state = OTA_SELF_FAILED;
+        goto cleanup;
+    }
+
+    err = esp_ota_set_boot_partition(ota_part);
+    if (err != ESP_OK) {
+        ESP_LOGE(TAG, "set_boot_partition: %s", esp_err_to_name(err));
+        g_ota_self_state = OTA_SELF_FAILED;
+        goto cleanup;
+    }
+
+    g_ota_self_state    = OTA_SELF_REBOOTING;
+    g_ota_self_progress = 100;
+    ESP_LOGI(TAG, "OTA success — rebooting");
+    vTaskDelay(pdMS_TO_TICKS(500));
+    esp_restart();
+
+cleanup:
+    mbedtls_sha256_free(&sha_ctx);
+    esp_http_client_cleanup(client);
+    handle = 0;
+    vTaskDelete(NULL);
+}
+
+bool ota_self_trigger(void)
+{
+    if (!g_balance_update.available) {
+        ESP_LOGW(TAG, "no update available");
+        return false;
+    }
+    if (g_ota_self_state != OTA_SELF_IDLE) {
+        ESP_LOGW(TAG, "OTA already in progress (state=%d)", g_ota_self_state);
+        return false;
+    }
+    xTaskCreate(ota_self_task, "ota_self", 8192, NULL, 5, NULL);
+    return true;
+}
+
+void ota_self_health_check(void)
+{
+    /* Mark running image as valid — prevents rollback */
+    esp_err_t err = esp_ota_mark_app_valid_cancel_rollback();
+    if (err == ESP_OK) {
+        ESP_LOGI(TAG, "image marked valid");
+    } else if (err == ESP_ERR_NOT_SUPPORTED) {
+        /* Not an OTA image (e.g., flashed via JTAG) — ignore */
+    } else {
+        ESP_LOGW(TAG, "mark_valid: %s", esp_err_to_name(err));
+    }
+}

esp32s3/balance/main/ota_self.h

@@ -0,0 +1,34 @@
+#pragma once
+/* ota_self.h — Balance self-OTA (bd-18nb)
+ *
+ * Downloads balance-firmware.bin from Gitea release URL to the inactive
+ * OTA partition, verifies SHA256, sets boot partition, reboots.
+ * Auto-rollback if health check not called within ROLLBACK_WINDOW_S seconds.
+ */
+
+#include <stdint.h>
+#include <stdbool.h>
+
+#define OTA_ROLLBACK_WINDOW_S  30
+
+typedef enum {
+    OTA_SELF_IDLE      = 0,
+    OTA_SELF_CHECKING,    /* (unused — gitea_ota handles this) */
+    OTA_SELF_DOWNLOADING,
+    OTA_SELF_VERIFYING,
+    OTA_SELF_APPLYING,
+    OTA_SELF_REBOOTING,
+    OTA_SELF_FAILED,
+} ota_self_state_t;
+
+extern volatile ota_self_state_t g_ota_self_state;
+extern volatile uint8_t          g_ota_self_progress; /* 0-100 % */
+
+/* Trigger a Balance self-update.
+ * Uses g_balance_update (from gitea_ota). Non-blocking: starts in a task.
+ * Returns false if no update available or OTA already in progress. */
+bool ota_self_trigger(void);
+
+/* Called from app_main after boot to mark the running image as valid.
+ * Must be called within OTA_ROLLBACK_WINDOW_S after boot or rollback fires. */
+void ota_self_health_check(void);

esp32s3/balance/main/uart_ota.c

@@ -0,0 +1,241 @@
+/* uart_ota.c — UART OTA sender: Balance→IO board (bd-21hv)
+ *
+ * Downloads io-firmware.bin from Gitea, then sends to IO board via UART1.
+ * IO board must update itself BEFORE Balance self-update (per spec).
+ */
+
+#include "uart_ota.h"
+#include "gitea_ota.h"
+#include "esp_log.h"
+#include "esp_http_client.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include "mbedtls/sha256.h"
+#include <string.h>
+#include <stdio.h>
+
+static const char *TAG = "uart_ota";
+
+volatile uart_ota_send_state_t g_uart_ota_state    = UART_OTA_S_IDLE;
+volatile uint8_t               g_uart_ota_progress  = 0;
+
+/* ── CRC8-SMBUS ── */
+static uint8_t crc8(const uint8_t *d, uint16_t len)
+{
+    uint8_t crc = 0;
+    for (uint16_t i = 0; i < len; i++) {
+        crc ^= d[i];
+        for (uint8_t b = 0; b < 8; b++)
+            crc = (crc & 0x80u) ? (uint8_t)((crc << 1u) ^ 0x07u) : (uint8_t)(crc << 1u);
+    }
+    return crc;
+}
+
+/* ── Build and send one UART OTA frame ── */
+static void send_frame(uint8_t type, uint16_t seq,
+                        const uint8_t *payload, uint16_t plen)
+{
+    /* [TYPE:1][SEQ:2 BE][LEN:2 BE][PAYLOAD][CRC8:1] */
+    uint8_t hdr[5];
+    hdr[0] = type;
+    hdr[1] = (uint8_t)(seq >> 8u);
+    hdr[2] = (uint8_t)(seq);
+    hdr[3] = (uint8_t)(plen >> 8u);
+    hdr[4] = (uint8_t)(plen);
+
+    /* CRC over hdr + payload */
+    uint8_t crc_buf[5 + OTA_UART_CHUNK_SIZE];
+    memcpy(crc_buf, hdr, 5);
+    if (plen > 0 && payload) memcpy(crc_buf + 5, payload, plen);
+    uint8_t crc = crc8(crc_buf, (uint16_t)(5 + plen));
+
+    uart_write_bytes(UART_OTA_PORT, (char *)hdr, 5);
+    if (plen > 0 && payload)
+        uart_write_bytes(UART_OTA_PORT, (char *)payload, plen);
+    uart_write_bytes(UART_OTA_PORT, (char *)&crc, 1);
+}
+
+/* ── Wait for ACK/NACK from IO board ── */
+static bool wait_ack(uint16_t expected_seq)
+{
+    /* Response frame: [TYPE:1][SEQ:2][LEN:2][PAYLOAD][CRC:1] */
+    uint8_t buf[16];
+    int timeout = OTA_UART_ACK_TIMEOUT_MS;
+    int got = 0;
+
+    while (timeout > 0 && got < 6) {
+        int r = uart_read_bytes(UART_OTA_PORT, buf + got, 1, pdMS_TO_TICKS(50));
+        if (r > 0) got++;
+        else timeout -= 50;
+    }
+
+    if (got < 3) return false;
+
+    uint8_t type = buf[0];
+    uint16_t seq = (uint16_t)((buf[1] << 8u) | buf[2]);
+
+    if (type == UART_OTA_ACK && seq == expected_seq) return true;
+    if (type == UART_OTA_NACK) {
+        uint8_t err = (got >= 6) ? buf[5] : 0;
+        ESP_LOGW(TAG, "NACK seq=%u err=%u", seq, err);
+    }
+    return false;
+}
+
+/* ── Download firmware to RAM buffer (max 1.75 MB) ── */
+static uint8_t *download_io_firmware(uint32_t *out_size)
+{
+    const char *url = g_io_update.download_url;
+    ESP_LOGI(TAG, "downloading IO fw: %s", url);
+
+    esp_http_client_config_t cfg = {
+        .url = url, .timeout_ms = 30000,
+        .skip_cert_common_name_check = true,
+    };
+    esp_http_client_handle_t client = esp_http_client_init(&cfg);
+    if (esp_http_client_open(client, 0) != ESP_OK) {
+        esp_http_client_cleanup(client);
+        return NULL;
+    }
+
+    int content_len = esp_http_client_fetch_headers(client);
+    if (content_len <= 0 || content_len > (int)(0x1B0000)) {
+        ESP_LOGE(TAG, "bad content-length: %d", content_len);
+        esp_http_client_cleanup(client);
+        return NULL;
+    }
+
+    uint8_t *buf = malloc(content_len);
+    if (!buf) {
+        ESP_LOGE(TAG, "malloc %d failed", content_len);
+        esp_http_client_cleanup(client);
+        return NULL;
+    }
+
+    int total = 0, rd;
+    while ((rd = esp_http_client_read(client, (char *)buf + total,
+                                       content_len - total)) > 0) {
+        total += rd;
+        g_uart_ota_progress = (uint8_t)((total * 50) / content_len); /* 0-50% for download */
+    }
+    esp_http_client_cleanup(client);
+
+    if (total != content_len) {
+        free(buf);
+        return NULL;
+    }
+    *out_size = (uint32_t)total;
+    return buf;
+}
+
+/* ── UART OTA send task ── */
+static void uart_ota_task(void *arg)
+{
+    g_uart_ota_state    = UART_OTA_S_DOWNLOADING;
+    g_uart_ota_progress = 0;
+
+    uint32_t fw_size = 0;
+    uint8_t *fw = download_io_firmware(&fw_size);
+    if (!fw) {
+        ESP_LOGE(TAG, "download failed");
+        g_uart_ota_state = UART_OTA_S_FAILED;
+        vTaskDelete(NULL);
+        return;
+    }
+
+    /* Compute SHA256 of downloaded firmware */
+    uint8_t digest[32];
+    mbedtls_sha256_context sha;
+    mbedtls_sha256_init(&sha);
+    mbedtls_sha256_starts(&sha, 0);
+    mbedtls_sha256_update(&sha, fw, fw_size);
+    mbedtls_sha256_finish(&sha, digest);
+    mbedtls_sha256_free(&sha);
+
+    g_uart_ota_state = UART_OTA_S_SENDING;
+
+    /* Send OTA_BEGIN: uint32 size + uint8[32] sha256 */
+    uint8_t begin_payload[36];
+    begin_payload[0] = (uint8_t)(fw_size >> 24u);
+    begin_payload[1] = (uint8_t)(fw_size >> 16u);
+    begin_payload[2] = (uint8_t)(fw_size >>  8u);
+    begin_payload[3] = (uint8_t)(fw_size);
+    memcpy(&begin_payload[4], digest, 32);
+
+    for (int retry = 0; retry < OTA_UART_MAX_RETRIES; retry++) {
+        send_frame(UART_OTA_BEGIN, 0, begin_payload, 36);
+        if (wait_ack(0)) goto send_data;
+        ESP_LOGW(TAG, "BEGIN retry %d", retry);
+    }
+    ESP_LOGE(TAG, "BEGIN failed");
+    free(fw);
+    g_uart_ota_state = UART_OTA_S_FAILED;
+    vTaskDelete(NULL);
+    return;
+
+send_data: {
+    uint32_t offset = 0;
+    uint16_t seq    = 1;
+    while (offset < fw_size) {
+        uint16_t chunk = (uint16_t)((fw_size - offset) < OTA_UART_CHUNK_SIZE
+                          ? (fw_size - offset) : OTA_UART_CHUNK_SIZE);
+        bool acked = false;
+        for (int retry = 0; retry < OTA_UART_MAX_RETRIES; retry++) {
+            send_frame(UART_OTA_DATA, seq, fw + offset, chunk);
+            if (wait_ack(seq)) { acked = true; break; }
+            ESP_LOGW(TAG, "DATA seq=%u retry=%d", seq, retry);
+        }
+        if (!acked) {
+            ESP_LOGE(TAG, "DATA seq=%u failed", seq);
+            send_frame(UART_OTA_ABORT, seq, NULL, 0);
+            free(fw);
+            g_uart_ota_state = UART_OTA_S_FAILED;
+            vTaskDelete(NULL);
+            return;
+        }
+        offset += chunk;
+        seq++;
+        /* 50-100% for sending phase */
+        g_uart_ota_progress = (uint8_t)(50u + (offset * 50u) / fw_size);
+    }
+
+    /* Send OTA_END */
+    for (int retry = 0; retry < OTA_UART_MAX_RETRIES; retry++) {
+        send_frame(UART_OTA_END, seq, NULL, 0);
+        if (wait_ack(seq)) break;
+    }
+    }
+
+    free(fw);
+    g_uart_ota_progress = 100;
+    g_uart_ota_state    = UART_OTA_S_DONE;
+    ESP_LOGI(TAG, "IO OTA complete — %lu bytes sent", (unsigned long)fw_size);
+    vTaskDelete(NULL);
+}
+
+bool uart_ota_trigger(void)
+{
+    if (!g_io_update.available) {
+        ESP_LOGW(TAG, "no IO update available");
+        return false;
+    }
+    if (g_uart_ota_state != UART_OTA_S_IDLE) {
+        ESP_LOGW(TAG, "UART OTA busy (state=%d)", g_uart_ota_state);
+        return false;
+    }
+    /* Init UART1 for OTA */
+    uart_config_t ucfg = {
+        .baud_rate  = UART_OTA_BAUD,
+        .data_bits  = UART_DATA_8_BITS,
+        .parity     = UART_PARITY_DISABLE,
+        .stop_bits  = UART_STOP_BITS_1,
+        .flow_ctrl  = UART_HW_FLOWCTRL_DISABLE,
+    };
+    uart_param_config(UART_OTA_PORT, &ucfg);
+    uart_set_pin(UART_OTA_PORT, UART_OTA_TX_GPIO, UART_OTA_RX_GPIO,
+                  UART_PIN_NO_CHANGE, UART_PIN_NO_CHANGE);
+    uart_driver_install(UART_OTA_PORT, 2048, 0, 0, NULL, 0);
+
+    xTaskCreate(uart_ota_task, "uart_ota", 16384, NULL, 4, NULL);
+    return true;
+}

esp32s3/balance/main/uart_ota.h

@@ -0,0 +1,64 @@
+#pragma once
+/* uart_ota.h — UART OTA protocol for Balance→IO firmware update (bd-21hv)
+ *
+ * Balance downloads io-firmware.bin from Gitea, then streams it to the IO
+ * board over UART1 (GPIO17/18, 460800 baud) in 1 KB chunks with ACK.
+ *
+ * Protocol frame format (both directions):
+ *   [TYPE:1][SEQ:2 BE][LEN:2 BE][PAYLOAD:LEN][CRC8:1]
+ *   CRC8-SMBUS over TYPE+SEQ+LEN+PAYLOAD.
+ *
+ * Balance→IO:
+ *   OTA_BEGIN  (0xC0) payload: uint32 total_size BE + uint8[32] sha256
+ *   OTA_DATA   (0xC1) payload: uint8[] chunk (up to 1024 bytes)
+ *   OTA_END    (0xC2) no payload
+ *   OTA_ABORT  (0xC3) no payload
+ *
+ * IO→Balance:
+ *   OTA_ACK    (0xC4) payload: uint16 acked_seq BE
+ *   OTA_NACK   (0xC5) payload: uint16 failed_seq BE + uint8 err_code
+ *   OTA_STATUS (0xC6) payload: uint8 state + uint8 progress%
+ */
+
+#include <stdint.h>
+#include <stdbool.h>
+
+/* UART for Balance→IO OTA */
+#include "driver/uart.h"
+#define UART_OTA_PORT       UART_NUM_1
+#define UART_OTA_BAUD       460800
+#define UART_OTA_TX_GPIO    17
+#define UART_OTA_RX_GPIO    18
+
+#define OTA_UART_CHUNK_SIZE  1024
+#define OTA_UART_ACK_TIMEOUT_MS  3000
+#define OTA_UART_MAX_RETRIES     3
+
+/* Frame type bytes */
+#define UART_OTA_BEGIN   0xC0u
+#define UART_OTA_DATA    0xC1u
+#define UART_OTA_END     0xC2u
+#define UART_OTA_ABORT   0xC3u
+#define UART_OTA_ACK     0xC4u
+#define UART_OTA_NACK    0xC5u
+#define UART_OTA_STATUS  0xC6u
+
+/* NACK error codes */
+#define OTA_ERR_BAD_CRC  0x01u
+#define OTA_ERR_WRITE    0x02u
+#define OTA_ERR_SIZE     0x03u
+
+typedef enum {
+    UART_OTA_S_IDLE        = 0,
+    UART_OTA_S_DOWNLOADING,  /* downloading from Gitea */
+    UART_OTA_S_SENDING,      /* sending to IO board */
+    UART_OTA_S_DONE,
+    UART_OTA_S_FAILED,
+} uart_ota_send_state_t;
+
+extern volatile uart_ota_send_state_t g_uart_ota_state;
+extern volatile uint8_t               g_uart_ota_progress;
+
+/* Trigger IO firmware update. Uses g_io_update (from gitea_ota).
+ * Downloads bin, then streams via UART. Returns false if busy or no update. */
+bool uart_ota_trigger(void);

esp32s3/balance/main/version.h

@@ -0,0 +1,14 @@
+#pragma once
+/* Embedded firmware version — bump on each release */
+#define BALANCE_FW_VERSION      "1.0.0"
+#define IO_FW_VERSION           "1.0.0"
+
+/* Gitea release tag prefixes */
+#define BALANCE_TAG_PREFIX      "esp32-balance/"
+#define IO_TAG_PREFIX           "esp32-io/"
+
+/* Gitea release asset filenames */
+#define BALANCE_BIN_ASSET       "balance-firmware.bin"
+#define IO_BIN_ASSET            "io-firmware.bin"
+#define BALANCE_SHA256_ASSET    "balance-firmware.sha256"
+#define IO_SHA256_ASSET         "io-firmware.sha256"

esp32s3/balance/main/vesc_can.c

@@ -0,0 +1,119 @@
+/* vesc_can.c — VESC CAN TWAI driver (bd-66hx)
+ *
+ * Receives VESC STATUS/4/5 frames via TWAI, proxies to Orin over serial.
+ * Transmits SET_RPM commands from Orin drive requests.
+ */
+
+#include "vesc_can.h"
+#include "orin_serial.h"
+#include "config.h"
+#include "driver/twai.h"
+#include "esp_log.h"
+#include "esp_timer.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include <string.h>
+
+static const char *TAG = "vesc_can";
+
+vesc_state_t g_vesc[2] = {0};
+
+/* Index for a given VESC node ID: 0=VESC_ID_A, 1=VESC_ID_B */
+static int vesc_idx(uint8_t id)
+{
+    if (id == VESC_ID_A) return 0;
+    if (id == VESC_ID_B) return 1;
+    return -1;
+}
+
+void vesc_can_init(void)
+{
+    twai_general_config_t gcfg = TWAI_GENERAL_CONFIG_DEFAULT(
+        (gpio_num_t)VESC_CAN_TX_GPIO,
+        (gpio_num_t)VESC_CAN_RX_GPIO,
+        TWAI_MODE_NORMAL);
+    gcfg.rx_queue_len = VESC_CAN_RX_QUEUE;
+
+    twai_timing_config_t  tcfg = TWAI_TIMING_CONFIG_500KBITS();
+    twai_filter_config_t  fcfg = TWAI_FILTER_CONFIG_ACCEPT_ALL();
+
+    ESP_ERROR_CHECK(twai_driver_install(&gcfg, &tcfg, &fcfg));
+    ESP_ERROR_CHECK(twai_start());
+    ESP_LOGI(TAG, "TWAI init OK: tx=%d rx=%d 500kbps", VESC_CAN_TX_GPIO, VESC_CAN_RX_GPIO);
+}
+
+void vesc_can_send_rpm(uint8_t vesc_id, int32_t erpm)
+{
+    uint32_t ext_id = ((uint32_t)VESC_PKT_SET_RPM << 8u) | vesc_id;
+    twai_message_t msg = {
+        .extd            = 1,
+        .identifier      = ext_id,
+        .data_length_code = 4,
+    };
+    uint32_t u = (uint32_t)erpm;
+    msg.data[0] = (uint8_t)(u >> 24u);
+    msg.data[1] = (uint8_t)(u >> 16u);
+    msg.data[2] = (uint8_t)(u >>  8u);
+    msg.data[3] = (uint8_t)(u);
+    twai_transmit(&msg, pdMS_TO_TICKS(5));
+}
+
+void vesc_can_rx_task(void *arg)
+{
+    QueueHandle_t tx_q = (QueueHandle_t)arg;
+    twai_message_t msg;
+
+    for (;;) {
+        if (twai_receive(&msg, pdMS_TO_TICKS(50)) != ESP_OK) {
+            continue;
+        }
+        if (!msg.extd) {
+            continue;  /* ignore standard frames */
+        }
+
+        uint8_t pkt_type = (uint8_t)(msg.identifier >> 8u);
+        uint8_t vesc_id  = (uint8_t)(msg.identifier & 0xFFu);
+        int idx = vesc_idx(vesc_id);
+        if (idx < 0) {
+            continue;  /* not our VESC */
+        }
+
+        uint32_t now_ms = (uint32_t)(esp_timer_get_time() / 1000LL);
+        vesc_state_t *s = &g_vesc[idx];
+
+        switch (pkt_type) {
+        case VESC_PKT_STATUS:
+            if (msg.data_length_code < 8u) { break; }
+            s->erpm = (int32_t)(
+                ((uint32_t)msg.data[0] << 24u) | ((uint32_t)msg.data[1] << 16u) |
+                ((uint32_t)msg.data[2] <<  8u) |  (uint32_t)msg.data[3]);
+            s->current_x10 = (int16_t)(((uint16_t)msg.data[4] << 8u) | msg.data[5]);
+            s->last_rx_ms  = now_ms;
+            /* Proxy to Orin: voltage from STATUS_5 (may be zero until received) */
+            {
+                uint8_t ttype = (vesc_id == VESC_ID_A) ? TELEM_VESC_LEFT : TELEM_VESC_RIGHT;
+                /* voltage_mv: V×10 → mV (/10 * 1000 = *100); current_ma: A×10 → mA (*100) */
+                uint16_t vmv = (uint16_t)((int32_t)s->voltage_x10 * 100);
+                int16_t  ima = (int16_t)((int32_t)s->current_x10 * 100);
+                orin_send_vesc(tx_q, ttype, s->erpm, vmv, ima,
+                               (uint16_t)s->temp_mot_x10);
+            }
+            break;
+
+        case VESC_PKT_STATUS_4:
+            if (msg.data_length_code < 6u) { break; }
+            /* T_fet×10, T_mot×10, I_in×10 */
+            s->temp_mot_x10 = (int16_t)(((uint16_t)msg.data[2] << 8u) | msg.data[3]);
+            break;
+
+        case VESC_PKT_STATUS_5:
+            if (msg.data_length_code < 6u) { break; }
+            /* int32 tacho (ignored), int16 V_in×10 */
+            s->voltage_x10 = (int16_t)(((uint16_t)msg.data[4] << 8u) | msg.data[5]);
+            break;
+
+        default:
+            break;
+        }
+    }
+}

esp32s3/balance/main/vesc_can.h

@@ -0,0 +1,36 @@
+#pragma once
+/* vesc_can.h — VESC CAN TWAI driver for ESP32-S3 BALANCE (bd-66hx)
+ *
+ * VESC extended CAN ID: (packet_type << 8) | vesc_node_id
+ * Physical layer: TWAI peripheral → SN65HVD230 → 500 kbps shared bus
+ */
+
+#include <stdint.h>
+#include <stdbool.h>
+#include "freertos/FreeRTOS.h"
+#include "freertos/queue.h"
+
+/* ── VESC packet types ── */
+#define VESC_PKT_SET_RPM    3u
+#define VESC_PKT_STATUS     9u    /* int32 erpm, int16 I×10, int16 duty×1000 */
+#define VESC_PKT_STATUS_4   16u   /* int16 T_fet×10, T_mot×10, I_in×10 */
+#define VESC_PKT_STATUS_5   27u   /* int32 tacho, int16 V_in×10 */
+
+/* ── VESC telemetry snapshot ── */
+typedef struct {
+    int32_t  erpm;          /* electrical RPM (STATUS) */
+    int16_t  current_x10;   /* phase current A×10 (STATUS) */
+    int16_t  voltage_x10;   /* bus voltage V×10 (STATUS_5) */
+    int16_t  temp_mot_x10;  /* motor temp °C×10 (STATUS_4) */
+    uint32_t last_rx_ms;    /* esp_timer ms of last STATUS frame */
+} vesc_state_t;
+
+/* ── Globals (two VESC nodes: index 0 = VESC_ID_A=56, 1 = VESC_ID_B=68) ── */
+extern vesc_state_t g_vesc[2];
+
+/* ── API ── */
+void vesc_can_init(void);
+void vesc_can_send_rpm(uint8_t vesc_id, int32_t erpm);
+
+/* RX task — pass tx_queue as arg; forwards STATUS frames to Orin over serial */
+void vesc_can_rx_task(void *arg);   /* arg = QueueHandle_t orin_tx_queue */

esp32s3/balance/partitions.csv

@@ -0,0 +1,7 @@
+# ESP32-S3 BALANCE — 4 MB flash, dual OTA partitions
+# Name,     Type,  SubType,  Offset,    Size
+nvs,        data,  nvs,      0x9000,    0x5000,
+otadata,    data,  ota,      0xe000,    0x2000,
+app0,       app,   ota_0,    0x10000,   0x1B0000,
+app1,       app,   ota_1,    0x1C0000,  0x1B0000,
+nvs_user,   data,  nvs,      0x370000,  0x50000,

esp32s3/balance/sdkconfig.defaults

@@ -0,0 +1,19 @@
+CONFIG_IDF_TARGET="esp32s3"
+CONFIG_ESPTOOLPY_FLASHSIZE_4MB=y
+CONFIG_FREERTOS_HZ=1000
+CONFIG_ESP_TASK_WDT_EN=y
+CONFIG_ESP_TASK_WDT_TIMEOUT_S=5
+CONFIG_TWAI_ISR_IN_IRAM=y
+CONFIG_UART_ISR_IN_IRAM=y
+CONFIG_ESP_CONSOLE_UART_DEFAULT=y
+CONFIG_ESP_CONSOLE_UART_NUM=0
+CONFIG_ESP_CONSOLE_UART_BAUDRATE=115200
+CONFIG_LOG_DEFAULT_LEVEL_INFO=y
+
+# OTA — bd-3gwo: dual OTA partitions + rollback
+CONFIG_PARTITION_TABLE_CUSTOM=y
+CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions.csv"
+CONFIG_BOOTLOADER_APP_ROLLBACK_ENABLE=y
+CONFIG_OTA_ALLOW_HTTP=y
+CONFIG_ESP_HTTPS_OTA_ALLOW_HTTP=y
+CONFIG_MBEDTLS_CERTIFICATE_BUNDLE=y

esp32s3/io/CMakeLists.txt

@@ -0,0 +1,3 @@
+cmake_minimum_required(VERSION 3.16)
+include($ENV{IDF_PATH}/tools/cmake/project.cmake)
+project(esp32s3_io)

esp32s3/io/main/CMakeLists.txt

@@ -0,0 +1,10 @@
+idf_component_register(
+    SRCS "main.c" "uart_ota_recv.c"
+    INCLUDE_DIRS "."
+    REQUIRES
+        app_update
+        mbedtls
+        driver
+        freertos
+        esp_timer
+)

esp32s3/io/main/config.h

@@ -0,0 +1,35 @@
+#pragma once
+/* ESP32-S3 IO board — pin assignments (SAUL-TEE-SYSTEM-REFERENCE.md) */
+
+/* ── Inter-board UART (to/from BALANCE board) ── */
+#define IO_UART_PORT        UART_NUM_0
+#define IO_UART_BAUD        460800
+#define IO_UART_TX_GPIO     43   /* IO board UART0_TXD → BALANCE RX */
+#define IO_UART_RX_GPIO     44   /* IO board UART0_RXD ← BALANCE TX */
+/* Note: SAUL-TEE spec says IO TX=IO18, RX=IO21; BALANCE TX=IO17, RX=IO18.
+ * This is UART0 on the IO devkit (GPIO43/44). Adjust to match actual wiring. */
+
+/* ── BTS7960 Left motor driver ── */
+#define MOTOR_L_RPWM    1
+#define MOTOR_L_LPWM    2
+#define MOTOR_L_EN_R    3
+#define MOTOR_L_EN_L    4
+
+/* ── BTS7960 Right motor driver ── */
+#define MOTOR_R_RPWM    5
+#define MOTOR_R_LPWM    6
+#define MOTOR_R_EN_R    7
+#define MOTOR_R_EN_L    8
+
+/* ── Arming button / kill switch ── */
+#define ARM_BTN_GPIO    9
+#define KILL_GPIO       10
+
+/* ── WS2812B LED strip ── */
+#define LED_DATA_GPIO   13
+
+/* ── OTA UART — receives firmware from BALANCE (bd-21hv) ── */
+/* Uses same IO_UART_PORT since Balance drives OTA over the inter-board link */
+
+/* ── Firmware version ── */
+#define IO_FW_VERSION   "1.0.0"

esp32s3/io/main/main.c

@@ -0,0 +1,42 @@
+/* main.c — ESP32-S3 IO board app_main */
+
+#include "uart_ota_recv.h"
+#include "config.h"
+#include "esp_log.h"
+#include "esp_ota_ops.h"
+#include "driver/uart.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+
+static const char *TAG = "io_main";
+
+static void uart_init(void)
+{
+    uart_config_t cfg = {
+        .baud_rate  = IO_UART_BAUD,
+        .data_bits  = UART_DATA_8_BITS,
+        .parity     = UART_PARITY_DISABLE,
+        .stop_bits  = UART_STOP_BITS_1,
+        .flow_ctrl  = UART_HW_FLOWCTRL_DISABLE,
+    };
+    uart_param_config(IO_UART_PORT, &cfg);
+    uart_set_pin(IO_UART_PORT, IO_UART_TX_GPIO, IO_UART_RX_GPIO,
+                  UART_PIN_NO_CHANGE, UART_PIN_NO_CHANGE);
+    uart_driver_install(IO_UART_PORT, 4096, 0, 0, NULL, 0);
+}
+
+void app_main(void)
+{
+    ESP_LOGI(TAG, "ESP32-S3 IO v%s starting", IO_FW_VERSION);
+
+    /* Mark running image valid (OTA rollback support) */
+    esp_ota_mark_app_valid_cancel_rollback();
+
+    uart_init();
+    uart_ota_recv_init();
+
+    /* IO board main loop placeholder — RC/motor/sensor tasks added in later beads */
+    while (1) {
+        vTaskDelay(pdMS_TO_TICKS(1000));
+    }
+}

esp32s3/io/main/uart_ota_recv.c

@@ -0,0 +1,210 @@
+/* uart_ota_recv.c — IO board OTA receiver (bd-21hv)
+ *
+ * Listens on UART0 for OTA frames from Balance board.
+ * Writes incoming chunks to the inactive OTA partition, verifies SHA256,
+ * then reboots into new firmware.
+ */
+
+#include "uart_ota_recv.h"
+#include "config.h"
+#include "esp_log.h"
+#include "esp_ota_ops.h"
+#include "driver/uart.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include "mbedtls/sha256.h"
+#include <string.h>
+
+static const char *TAG = "io_ota";
+
+volatile io_ota_state_t g_io_ota_state    = IO_OTA_IDLE;
+volatile uint8_t        g_io_ota_progress = 0;
+
+/* Frame type bytes (same as uart_ota.h sender side) */
+#define OTA_BEGIN   0xC0u
+#define OTA_DATA    0xC1u
+#define OTA_END     0xC2u
+#define OTA_ABORT   0xC3u
+#define OTA_ACK     0xC4u
+#define OTA_NACK    0xC5u
+
+#define CHUNK_MAX   1024
+
+static uint8_t crc8(const uint8_t *d, uint16_t len)
+{
+    uint8_t crc = 0;
+    for (uint16_t i = 0; i < len; i++) {
+        crc ^= d[i];
+        for (uint8_t b = 0; b < 8; b++)
+            crc = (crc & 0x80u) ? (uint8_t)((crc << 1u) ^ 0x07u) : (uint8_t)(crc << 1u);
+    }
+    return crc;
+}
+
+static void send_ack(uint16_t seq)
+{
+    uint8_t frame[6];
+    frame[0] = OTA_ACK;
+    frame[1] = (uint8_t)(seq >> 8u);
+    frame[2] = (uint8_t)(seq);
+    frame[3] = 0; frame[4] = 0;  /* LEN=0 */
+    uint8_t crc = crc8(frame, 5);
+    frame[5] = crc;
+    uart_write_bytes(IO_UART_PORT, (char *)frame, 6);
+}
+
+static void send_nack(uint16_t seq, uint8_t err)
+{
+    uint8_t frame[8];
+    frame[0] = OTA_NACK;
+    frame[1] = (uint8_t)(seq >> 8u);
+    frame[2] = (uint8_t)(seq);
+    frame[3] = 0; frame[4] = 1;  /* LEN=1 */
+    frame[5] = err;
+    uint8_t crc = crc8(frame, 6);
+    frame[6] = crc;
+    uart_write_bytes(IO_UART_PORT, (char *)frame, 7);
+}
+
+/* Read exact n bytes with timeout */
+static bool uart_read_exact(uint8_t *buf, int n, int timeout_ms)
+{
+    int got = 0;
+    while (got < n && timeout_ms > 0) {
+        int r = uart_read_bytes(IO_UART_PORT, buf + got, n - got,
+                                pdMS_TO_TICKS(50));
+        if (r > 0) got += r;
+        else timeout_ms -= 50;
+    }
+    return got == n;
+}
+
+static void ota_recv_task(void *arg)
+{
+    esp_ota_handle_t       handle    = 0;
+    const esp_partition_t *ota_part  = esp_ota_get_next_update_partition(NULL);
+    mbedtls_sha256_context sha;
+    mbedtls_sha256_init(&sha);
+    uint32_t expected_size = 0;
+    uint8_t  expected_digest[32] = {0};
+    uint32_t received = 0;
+    bool     ota_started = false;
+    static uint8_t payload[CHUNK_MAX];
+
+    for (;;) {
+        /* Read frame header: TYPE(1) + SEQ(2) + LEN(2) = 5 bytes */
+        uint8_t hdr[5];
+        if (!uart_read_exact(hdr, 5, 5000)) continue;
+
+        uint8_t  type = hdr[0];
+        uint16_t seq  = (uint16_t)((hdr[1] << 8u) | hdr[2]);
+        uint16_t plen = (uint16_t)((hdr[3] << 8u) | hdr[4]);
+
+        if (plen > CHUNK_MAX + 36) {
+            ESP_LOGW(TAG, "oversized frame plen=%u", plen);
+            continue;
+        }
+
+        /* Read payload + CRC */
+        if (plen > 0 && !uart_read_exact(payload, plen, 2000)) continue;
+        uint8_t crc_rx;
+        if (!uart_read_exact(&crc_rx, 1, 500)) continue;
+
+        /* Verify CRC over hdr+payload */
+        uint8_t crc_buf[5 + CHUNK_MAX + 36];
+        memcpy(crc_buf, hdr, 5);
+        if (plen > 0) memcpy(crc_buf + 5, payload, plen);
+        uint8_t expected_crc = crc8(crc_buf, (uint16_t)(5 + plen));
+        if (crc_rx != expected_crc) {
+            ESP_LOGW(TAG, "CRC fail seq=%u", seq);
+            send_nack(seq, 0x01u);  /* OTA_ERR_BAD_CRC */
+            continue;
+        }
+
+        switch (type) {
+        case OTA_BEGIN:
+            if (plen < 36) { send_nack(seq, 0x03u); break; }
+            expected_size = ((uint32_t)payload[0] << 24u) |
+                            ((uint32_t)payload[1] << 16u) |
+                            ((uint32_t)payload[2] <<  8u) |
+                             (uint32_t)payload[3];
+            memcpy(expected_digest, &payload[4], 32);
+
+            if (!ota_part || esp_ota_begin(ota_part, OTA_WITH_SEQUENTIAL_WRITES,
+                                            &handle) != ESP_OK) {
+                send_nack(seq, 0x02u);
+                break;
+            }
+            mbedtls_sha256_starts(&sha, 0);
+            received   = 0;
+            ota_started = true;
+            g_io_ota_state    = IO_OTA_RECEIVING;
+            g_io_ota_progress = 0;
+            ESP_LOGI(TAG, "OTA begin: %lu bytes", (unsigned long)expected_size);
+            send_ack(seq);
+            break;
+
+        case OTA_DATA:
+            if (!ota_started) { send_nack(seq, 0x02u); break; }
+            if (esp_ota_write(handle, payload, plen) != ESP_OK) {
+                send_nack(seq, 0x02u);
+                esp_ota_abort(handle);
+                ota_started = false;
+                g_io_ota_state = IO_OTA_FAILED;
+                break;
+            }
+            mbedtls_sha256_update(&sha, payload, plen);
+            received += plen;
+            if (expected_size > 0)
+                g_io_ota_progress = (uint8_t)((received * 100u) / expected_size);
+            send_ack(seq);
+            break;
+
+        case OTA_END: {
+            if (!ota_started) { send_nack(seq, 0x02u); break; }
+            g_io_ota_state = IO_OTA_VERIFYING;
+
+            uint8_t digest[32];
+            mbedtls_sha256_finish(&sha, digest);
+            if (memcmp(digest, expected_digest, 32) != 0) {
+                ESP_LOGE(TAG, "SHA256 mismatch");
+                esp_ota_abort(handle);
+                send_nack(seq, 0x01u);
+                g_io_ota_state = IO_OTA_FAILED;
+                break;
+            }
+
+            if (esp_ota_end(handle) != ESP_OK ||
+                esp_ota_set_boot_partition(ota_part) != ESP_OK) {
+                send_nack(seq, 0x02u);
+                g_io_ota_state = IO_OTA_FAILED;
+                break;
+            }
+
+            g_io_ota_state    = IO_OTA_REBOOTING;
+            g_io_ota_progress = 100;
+            ESP_LOGI(TAG, "OTA done — rebooting");
+            send_ack(seq);
+            vTaskDelay(pdMS_TO_TICKS(500));
+            esp_restart();
+            break;
+        }
+
+        case OTA_ABORT:
+            if (ota_started) { esp_ota_abort(handle); ota_started = false; }
+            g_io_ota_state = IO_OTA_IDLE;
+            ESP_LOGW(TAG, "OTA aborted");
+            break;
+
+        default:
+            break;
+        }
+    }
+}
+
+void uart_ota_recv_init(void)
+{
+    /* UART0 already initialized for inter-board comms; just create the task */
+    xTaskCreate(ota_recv_task, "io_ota_recv", 8192, NULL, 6, NULL);
+    ESP_LOGI(TAG, "OTA receiver task started");
+}

esp32s3/io/main/uart_ota_recv.h

@@ -0,0 +1,20 @@
+#pragma once
+/* uart_ota_recv.h — IO board: receives OTA firmware from Balance (bd-21hv) */
+
+#include <stdint.h>
+#include <stdbool.h>
+
+typedef enum {
+    IO_OTA_IDLE       = 0,
+    IO_OTA_RECEIVING,
+    IO_OTA_VERIFYING,
+    IO_OTA_APPLYING,
+    IO_OTA_REBOOTING,
+    IO_OTA_FAILED,
+} io_ota_state_t;
+
+extern volatile io_ota_state_t g_io_ota_state;
+extern volatile uint8_t        g_io_ota_progress;
+
+/* Start listening for OTA frames on UART0 */
+void uart_ota_recv_init(void);

esp32s3/io/partitions.csv

@@ -0,0 +1,7 @@
+# ESP32-S3 IO — 4 MB flash, dual OTA partitions
+# Name,     Type,  SubType,  Offset,    Size
+nvs,        data,  nvs,      0x9000,    0x5000,
+otadata,    data,  ota,      0xe000,    0x2000,
+app0,       app,   ota_0,    0x10000,   0x1B0000,
+app1,       app,   ota_1,    0x1C0000,  0x1B0000,
+nvs_user,   data,  nvs,      0x370000,  0x50000,

esp32s3/io/sdkconfig.defaults

@@ -0,0 +1,13 @@
+CONFIG_IDF_TARGET="esp32s3"
+CONFIG_ESPTOOLPY_FLASHSIZE_4MB=y
+CONFIG_FREERTOS_HZ=1000
+CONFIG_ESP_TASK_WDT_EN=y
+CONFIG_ESP_TASK_WDT_TIMEOUT_S=5
+CONFIG_UART_ISR_IN_IRAM=y
+CONFIG_ESP_CONSOLE_UART_DEFAULT=y
+CONFIG_LOG_DEFAULT_LEVEL_INFO=y
+
+# OTA — bd-3gwo: dual OTA partitions + rollback
+CONFIG_PARTITION_TABLE_CUSTOM=y
+CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions.csv"
+CONFIG_BOOTLOADER_APP_ROLLBACK_ENABLE=y

include/jlink.h

@@ -1,152 +0,0 @@
-#ifndef JLINK_H
-#define JLINK_H
-
-#include <stdint.h>
-#include <stdbool.h>
-
-/*
- * JLink — Jetson serial binary protocol over USART1 (PB6=TX, PB7=RX).
- *
- * Issue #120: replaces jetson_cmd ASCII-over-USB-CDC with a dedicated
- * hardware UART at 921600 baud using DMA circular RX and IDLE interrupt.
- *
- * Frame format (both directions):
- *   [STX=0x02][LEN][CMD][PAYLOAD...][CRC16_hi][CRC16_lo][ETX=0x03]
- *
- *   STX   : frame start sentinel (0x02)
- *   LEN   : count of CMD + PAYLOAD bytes (1 + payload_len)
- *   CMD   : command/telemetry type byte
- *   PAYLOAD: 0..N bytes depending on CMD
- *   CRC16 : CRC16-XModem over CMD+PAYLOAD (poly 0x1021, init 0), big-endian
- *   ETX   : frame end sentinel (0x03)
- *
- * Jetson → STM32 commands:
- *   0x01  HEARTBEAT  — no payload; refreshes heartbeat timer
- *   0x02  DRIVE      — int16 speed (-1000..+1000), int16 steer (-1000..+1000)
- *   0x03  ARM        — no payload; request arm (same interlock as CDC 'A')
- *   0x04  DISARM     — no payload; disarm immediately
- *   0x05  PID_SET    — float kp, float ki, float kd (12 bytes, IEEE-754 LE)
- *   0x06  DFU_ENTER  — no payload; request OTA DFU reboot (denied while armed)
- *   0x07  ESTOP      — no payload; engage emergency stop
- *
- * STM32 → Jetson telemetry:
- *   0x80  STATUS     — jlink_tlm_status_t (20 bytes), sent at JLINK_TLM_HZ
- *
- * Priority: CRSF RC always takes precedence. Jetson steer/speed only applied
- * when mode_manager_active() == MODE_AUTONOMOUS (CH6 high). In RC_MANUAL and
- * RC_ASSISTED modes the Jetson speed offset and steer are injected via
- * mode_manager_set_auto_cmd() and blended per the existing blend ramp.
- *
- * Heartbeat: if no valid frame arrives within JLINK_HB_TIMEOUT_MS (1000ms),
- * jlink_is_active() returns false and the main loop clears the auto command.
- */
-
-/* ---- Frame constants ---- */
-#define JLINK_STX               0x02u
-#define JLINK_ETX               0x03u
-
-/* ---- Command IDs (Jetson → STM32) ---- */
-#define JLINK_CMD_HEARTBEAT     0x01u
-#define JLINK_CMD_DRIVE         0x02u
-#define JLINK_CMD_ARM           0x03u
-#define JLINK_CMD_DISARM        0x04u
-#define JLINK_CMD_PID_SET       0x05u
-#define JLINK_CMD_DFU_ENTER     0x06u
-#define JLINK_CMD_ESTOP         0x07u
-#define JLINK_CMD_AUDIO         0x08u  /* PCM audio chunk: int16 samples, up to 126 */
-#define JLINK_CMD_SLEEP         0x09u  /* no payload; request STOP-mode sleep */
-
-/* ---- Telemetry IDs (STM32 → Jetson) ---- */
-#define JLINK_TLM_STATUS        0x80u
-#define JLINK_TLM_POWER         0x81u  /* jlink_tlm_power_t (11 bytes) */
-
-/* ---- Telemetry STATUS payload (20 bytes, packed) ---- */
-typedef struct __attribute__((packed)) {
-    int16_t  pitch_x10;     /* pitch degrees ×10 */
-    int16_t  roll_x10;      /* roll  degrees ×10 */
-    int16_t  yaw_x10;       /* yaw   degrees ×10 (gyro-integrated) */
-    int16_t  motor_cmd;     /* ESC output -1000..+1000 */
-    uint16_t vbat_mv;       /* battery millivolts */
-    int8_t   rssi_dbm;      /* CRSF RSSI (dBm, negative) */
-    uint8_t  link_quality;  /* CRSF LQ 0-100 */
-    uint8_t  balance_state; /* 0=DISARMED, 1=ARMED, 2=TILT_FAULT */
-    uint8_t  rc_armed;      /* crsf_state.armed (1=armed) */
-    uint8_t  mode;          /* robot_mode_t: 0=RC_MANUAL,1=ASSISTED,2=AUTONOMOUS */
-    uint8_t  estop;         /* EstopSource value */
-    uint8_t  soc_pct;       /* state-of-charge 0-100, 255=unknown */
-    uint8_t  fw_major;
-    uint8_t  fw_minor;
-    uint8_t  fw_patch;
-} jlink_tlm_status_t;  /* 20 bytes */
-
-/* ---- Telemetry POWER payload (11 bytes, packed) ---- */
-typedef struct __attribute__((packed)) {
-    uint8_t  power_state;   /* PowerState: 0=ACTIVE,1=SLEEP_PENDING,2=SLEEPING,3=WAKING */
-    uint16_t est_total_ma;  /* estimated total current draw (mA) */
-    uint16_t est_audio_ma;  /* estimated I2S3+amp current (mA); 0 if gated */
-    uint16_t est_osd_ma;    /* estimated OSD SPI2 current (mA); 0 if gated */
-    uint32_t idle_ms;       /* ms since last cmd_vel activity */
-} jlink_tlm_power_t;  /* 11 bytes */
-
-/* ---- Volatile state (read from main loop) ---- */
-typedef struct {
-    /* Drive command — updated on JLINK_CMD_DRIVE */
-    volatile int16_t  speed;        /* -1000..+1000 */
-    volatile int16_t  steer;        /* -1000..+1000 */
-
-    /* Heartbeat timer — updated on any valid frame */
-    volatile uint32_t last_rx_ms;   /* HAL_GetTick() of last valid frame; 0=none */
-
-    /* One-shot request flags — set by parser, cleared by main loop */
-    volatile uint8_t  arm_req;
-    volatile uint8_t  disarm_req;
-    volatile uint8_t  estop_req;
-
-    /* PID update — set by parser, cleared by main loop */
-    volatile uint8_t  pid_updated;
-    volatile float    pid_kp;
-    volatile float    pid_ki;
-    volatile float    pid_kd;
-
-    /* DFU reboot request — set by parser, cleared by main loop */
-    volatile uint8_t  dfu_req;
-    /* Sleep request — set by JLINK_CMD_SLEEP, cleared by main loop */
-    volatile uint8_t  sleep_req;
-} JLinkState;
-
-extern volatile JLinkState jlink_state;
-
-/* ---- API ---- */
-
-/*
- * jlink_init() — configure USART1 (PB6=TX, PB7=RX) at 921600 baud with
- * DMA2_Stream2_Channel4 circular RX (128-byte buffer) and IDLE interrupt.
- * Call once before safety_init().
- */
-void jlink_init(void);
-
-/*
- * jlink_is_active(now_ms) — returns true if a valid frame arrived within
- * JLINK_HB_TIMEOUT_MS. Returns false if no frame ever received.
- */
-bool jlink_is_active(uint32_t now_ms);
-
-/*
- * jlink_send_telemetry(status) — build and transmit a JLINK_TLM_STATUS frame
- * over USART1 TX (blocking, ~0.2ms at 921600). Call at JLINK_TLM_HZ.
- */
-void jlink_send_telemetry(const jlink_tlm_status_t *status);
-
-/*
- * jlink_process() — drain DMA circular buffer and parse frames.
- * Call from main loop every iteration (not ISR). Lightweight: O(bytes_pending).
- */
-void jlink_process(void);
-
-/*
- * jlink_send_power_telemetry(power) — build and transmit a JLINK_TLM_POWER
- * frame (17 bytes) at PM_TLM_HZ. Call from main loop when not in STOP mode.
- */
-void jlink_send_power_telemetry(const jlink_tlm_power_t *power);
-
-#endif /* JLINK_H */

jetson/Dockerfile

@@ -2,7 +2,7 @@
 # Base: JetPack 6 (L4T R36.2.0) + CUDA 12.x / Ubuntu 22.04
 #
 # Hardware: Jetson Orin Nano Super 8GB (67 TOPS, 1024-core Ampere)
-# Previous: Jetson Nano 4GB (JetPack 4.6 / L4T R32.6.1) — see git history
+# Previous: Jetson Orin Nano Super 4GB (JetPack 4.6 / L4T R32.6.1) — see git history
 
 FROM nvcr.io/nvidia/l4t-jetpack:r36.2.0
 

jetson/README.md

@@ -1,12 +1,12 @@
-# Jetson Nano — AI/SLAM Platform Setup
+# Jetson Orin Nano Super — AI/SLAM Platform Setup
 
-Self-balancing robot: Jetson Nano dev environment for ROS2 Humble + SLAM stack.
+Self-balancing robot: Jetson Orin Nano Super dev environment for ROS2 Humble + SLAM stack.
 
 ## Stack
 
 | Component | Version / Part |
 |-----------|---------------|
-| Platform | Jetson Nano 4GB |
+| Platform | Jetson Orin Nano Super 4GB |
 | JetPack | 4.6 (L4T R32.6.1, CUDA 10.2) |
 | ROS2 | Humble Hawksbill |
 | DDS | CycloneDDS |
@@ -14,7 +14,11 @@ Self-balancing robot: Jetson Nano dev environment for ROS2 Humble + SLAM stack.
 | Nav | Nav2 |
 | Depth camera | Intel RealSense D435i |
 | LiDAR | RPLIDAR A1M8 |
-| MCU bridge | STM32F722 (USB CDC @ 921600) |
+<<<<<<< HEAD
+| MCU bridge | ESP32 (USB CDC @ 921600) |
+=======
+| MCU bridge | ESP32-S3 (USB Serial (CH343) @ 921600) |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Quick Start
 
@@ -42,7 +46,11 @@ bash scripts/build-and-run.sh shell
 ```
 jetson/
 ├── Dockerfile              # L4T base + ROS2 Humble + SLAM packages
-├── docker-compose.yml      # Multi-service stack (ROS2, RPLIDAR, D435i, STM32)
+<<<<<<< HEAD
+├── docker-compose.yml      # Multi-service stack (ROS2, RPLIDAR, D435i, ESP32 BALANCE)
+=======
+├── docker-compose.yml      # Multi-service stack (ROS2, RPLIDAR, D435i, ESP32-S3)
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 ├── README.md               # This file
 ├── docs/
 │   ├── pinout.md           # GPIO/I2C/UART pinout reference

jetson/config/RECOVERY_BEHAVIORS.md

@@ -34,7 +34,11 @@ Recovery behaviors are triggered when Nav2 encounters navigation failures (path
 
 The emergency stop system (Issue #459, `saltybot_emergency` package) runs independently of Nav2 and takes absolute priority.
 
-Recovery behaviors cannot interfere with E-stop because the emergency system operates at the motor driver level on the STM32 firmware.
+<<<<<<< HEAD
+Recovery behaviors cannot interfere with E-stop because the emergency system operates at the motor driver level on the ESP32 BALANCE firmware.
+=======
+Recovery behaviors cannot interfere with E-stop because the emergency system operates at the motor driver level on the ESP32-S3 firmware.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ## Behavior Tree Sequence
 

jetson/config/nav2_params.yaml

@@ -12,7 +12,11 @@
 #   /scan                    — RPLIDAR A1M8  (obstacle layer)
 #   /camera/depth/color/points — RealSense D435i (voxel layer)
 #
-# Output: /cmd_vel (Twist) — STM32 bridge consumes this topic.
+<<<<<<< HEAD
+# Output: /cmd_vel (Twist) — ESP32 bridge consumes this topic.
+=======
+# Output: /cmd_vel (Twist) — ESP32-S3 bridge consumes this topic.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 bt_navigator:
   ros__parameters:

jetson/docker-compose.yml

@@ -31,7 +31,7 @@ services:
       - ./config:/config:ro
     devices:
       - /dev/rplidar:/dev/rplidar
-      - /dev/stm32-bridge:/dev/stm32-bridge
+      - /dev/esp32-bridge:/dev/esp32-bridge
       - /dev/bus/usb:/dev/bus/usb
       - /dev/i2c-7:/dev/i2c-7
       - /dev/video0:/dev/video0
@@ -97,13 +97,17 @@ services:
           rgb_camera.profile:=640x480x30
       "
 
-  # ── STM32 bridge node (bidirectional serial<->ROS2) ────────────────────────
+<<<<<<< HEAD
-  stm32-bridge:
+  # ── ESP32 bridge node (bidirectional serial<->ROS2) ────────────────────────
+=======
+  # ── ESP32-S3 bridge node (bidirectional serial<->ROS2) ────────────────────────
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+  esp32-bridge:
     image: saltybot/ros2-humble:jetson-orin
     build:
       context: .
       dockerfile: Dockerfile
-    container_name: saltybot-stm32-bridge
+    container_name: saltybot-esp32-bridge
     restart: unless-stopped
     runtime: nvidia
     network_mode: host
@@ -111,13 +115,13 @@ services:
       - ROS_DOMAIN_ID=42
       - RMW_IMPLEMENTATION=rmw_cyclonedds_cpp
     devices:
-      - /dev/stm32-bridge:/dev/stm32-bridge
+      - /dev/esp32-bridge:/dev/esp32-bridge
     command: >
       bash -c "
         source /opt/ros/humble/setup.bash &&
         ros2 launch saltybot_bridge bridge.launch.py
           mode:=bidirectional
-          serial_port:=/dev/stm32-bridge
+          serial_port:=/dev/esp32-bridge
       "
 
   # ── 4x IMX219 CSI cameras ──────────────────────────────────────────────────
@@ -192,7 +196,7 @@ services:
     network_mode: host
     depends_on:
       - saltybot-ros2
-      - stm32-bridge
+      - esp32-bridge
       - csi-cameras
     environment:
       - ROS_DOMAIN_ID=42
@@ -208,8 +212,13 @@ services:
       "
 
 
-  # -- Remote e-stop bridge (MQTT over 4G -> STM32 CDC) ----------------------
+<<<<<<< HEAD
-  # Subscribes to saltybot/estop MQTT topic. {"kill":true} -> 'E\r\n' to STM32.
+  # -- Remote e-stop bridge (MQTT over 4G -> ESP32 CDC) ----------------------
+  # Subscribes to saltybot/estop MQTT topic. {"kill":true} -> 'E\r\n' to ESP32 BALANCE.
+=======
+  # -- Remote e-stop bridge (MQTT over 4G -> ESP32-S3 CDC) ----------------------
+  # Subscribes to saltybot/estop MQTT topic. {"kill":true} -> 'E\r\n' to ESP32-S3.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
   # Cellular watchdog: 5s MQTT drop in AUTO mode -> 'F\r\n' (ESTOP_CELLULAR_TIMEOUT).
   remote-estop:
     image: saltybot/ros2-humble:jetson-orin
@@ -221,12 +230,12 @@ services:
     runtime: nvidia
     network_mode: host
     depends_on:
-      - stm32-bridge
+      - esp32-bridge
     environment:
       - ROS_DOMAIN_ID=42
       - RMW_IMPLEMENTATION=rmw_cyclonedds_cpp
     devices:
-      - /dev/stm32-bridge:/dev/stm32-bridge
+      - /dev/esp32-bridge:/dev/esp32-bridge
     volumes:
       - ./ros2_ws/src:/ros2_ws/src:rw
       - ./config:/config:ro
@@ -316,7 +325,7 @@ services:
     runtime: nvidia
     network_mode: host
     depends_on:
-      - stm32-bridge
+      - esp32-bridge
     environment:
       - NVIDIA_VISIBLE_DEVICES=all
       - NVIDIA_DRIVER_CAPABILITIES=all,audio

jetson/docs/pinout.md

@@ -1,5 +1,9 @@
 # Jetson Orin Nano Super — GPIO / I2C / UART / CSI Pinout Reference
-## Self-Balancing Robot: STM32F722 Bridge + RealSense D435i + RPLIDAR A1M8 + 4× IMX219
+<<<<<<< HEAD
+## Self-Balancing Robot: ESP32 Bridge + RealSense D435i + RPLIDAR A1M8 + 4× IMX219
+=======
+## Self-Balancing Robot: ESP32-S3 Bridge + RealSense D435i + RPLIDAR A1M8 + 4× IMX219
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 Last updated: 2026-02-28
 JetPack version: 6.x (L4T R36.x / Ubuntu 22.04)
@@ -43,21 +47,37 @@ i2cdetect -l
 
 ---
 
-## 1. STM32F722 Bridge (USB CDC — Primary)
+<<<<<<< HEAD
+## 1. ESP32 Bridge (USB CDC — Primary)
 
-The STM32 acts as a real-time motor + IMU controller. Communication is via **USB CDC serial**.
+The ESP32 BALANCE acts as a real-time motor + IMU controller. Communication is via **USB CDC serial**.
+=======
+## 1. ESP32-S3 Bridge (USB Serial (CH343) — Primary)
 
-### USB CDC Connection
+The ESP32-S3 acts as a real-time motor + IMU controller. Communication is via **USB Serial (CH343) serial**.
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
+
+### USB Serial (CH343) Connection
 | Connection | Detail |
 |-----------|--------|
-| Interface | USB Micro-B on STM32 dev board → USB-A on Jetson |
+<<<<<<< HEAD
-| Device node | `/dev/ttyACM0` → symlink `/dev/stm32-bridge` (via udev) |
+| Interface | USB on ESP32 BALANCE board → USB-A on Jetson |
-| Baud rate | 921600 (configured in STM32 firmware) |
+| Device node | `/dev/ttyACM0` → symlink `/dev/esp32-bridge` (via udev) |
+| Baud rate | 921600 (configured in ESP32 BALANCE firmware) |
+=======
+| Interface | USB Micro-B on ESP32-S3 dev board → USB-A on Jetson |
+| Device node | `/dev/ttyACM0` → symlink `/dev/esp32-bridge` (via udev) |
+| Baud rate | 921600 (configured in ESP32-S3 firmware) |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | Protocol | JSON telemetry RX + ASCII command TX (see bridge docs) |
 | Power | Powered via robot 5V bus (data-only via USB) |
 
 ### Hardware UART (Fallback — 40-pin header)
-| Jetson Pin | Signal | STM32 Pin | Notes |
+<<<<<<< HEAD
+| Jetson Pin | Signal | ESP32 Pin | Notes |
+=======
+| Jetson Pin | Signal | ESP32-S3 Pin | Notes |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 |-----------|--------|-----------|-------|
 | Pin 8 (TXD0) | TX → | PA10 (UART1 RX) | Cross-connect TX→RX |
 | Pin 10 (RXD0) | RX ← | PA9 (UART1 TX) | Cross-connect RX→TX |
@@ -65,7 +85,11 @@ The STM32 acts as a real-time motor + IMU controller. Communication is via **USB
 
 **Jetson device node:** `/dev/ttyTHS0`
 **Baud rate:** 921600, 8N1
-**Voltage level:** 3.3V — both Jetson Orin and STM32F722 are 3.3V GPIO
+<<<<<<< HEAD
+**Voltage level:** 3.3V — both Jetson Orin and ESP32 are 3.3V GPIO
+=======
+**Voltage level:** 3.3V — both Jetson Orin and ESP32-S3 are 3.3V GPIO
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ```bash
 # Verify UART
@@ -75,13 +99,23 @@ sudo usermod -aG dialout $USER
 picocom -b 921600 /dev/ttyTHS0
 ```
 
-**ROS2 topics (STM32 bridge node):**
+<<<<<<< HEAD
+**ROS2 topics (ESP32 bridge node):**
 | ROS2 Topic | Direction | Content |
 |-----------|-----------|---------
-| `/saltybot/imu` | STM32→Jetson | IMU data (accel, gyro) at 50Hz |
+| `/saltybot/imu` | ESP32 BALANCE→Jetson | IMU data (accel, gyro) at 50Hz |
-| `/saltybot/balance_state` | STM32→Jetson | Motor cmd, pitch, state |
+| `/saltybot/balance_state` | ESP32 BALANCE→Jetson | Motor cmd, pitch, state |
-| `/cmd_vel` | Jetson→STM32 | Velocity commands → `C<spd>,<str>\n` |
+| `/cmd_vel` | Jetson→ESP32 BALANCE | Velocity commands → `C<spd>,<str>\n` |
-| `/saltybot/estop` | Jetson→STM32 | Emergency stop |
+| `/saltybot/estop` | Jetson→ESP32 BALANCE | Emergency stop |
+=======
+**ROS2 topics (ESP32-S3 bridge node):**
+| ROS2 Topic | Direction | Content |
+|-----------|-----------|---------
+| `/saltybot/imu` | ESP32-S3→Jetson | IMU data (accel, gyro) at 50Hz |
+| `/saltybot/balance_state` | ESP32-S3→Jetson | Motor cmd, pitch, state |
+| `/cmd_vel` | Jetson→ESP32-S3 | Velocity commands → `C<spd>,<str>\n` |
+| `/saltybot/estop` | Jetson→ESP32-S3 | Emergency stop |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 
 ---
 
@@ -266,7 +300,11 @@ sudo mkdir -p /mnt/nvme
 |------|------|----------|
 | USB-A (top, blue) | USB 3.1 Gen 1 | RealSense D435i |
 | USB-A (bottom) | USB 2.0 | RPLIDAR (via USB-UART adapter) |
-| USB-C | USB 3.1 Gen 1 (+ DP) | STM32 CDC or host flash |
+<<<<<<< HEAD
+| USB-C | USB 3.1 Gen 1 (+ DP) | ESP32 CDC or host flash |
+=======
+| USB-C | USB 3.1 Gen 1 (+ DP) | ESP32-S3 CDC or host flash |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | Micro-USB | Debug/flash | JetPack flash only |
 
 ---
@@ -277,10 +315,17 @@ sudo mkdir -p /mnt/nvme
 |-------------|----------|---------|----------|
 | 3 | SDA1 | 3.3V | I2C data (i2c-7) |
 | 5 | SCL1 | 3.3V | I2C clock (i2c-7) |
-| 8 | TXD0 | 3.3V | UART TX → STM32 (fallback) |
+<<<<<<< HEAD
-| 10 | RXD0 | 3.3V | UART RX ← STM32 (fallback) |
+| 8 | TXD0 | 3.3V | UART TX → ESP32 BALANCE (fallback) |
+| 10 | RXD0 | 3.3V | UART RX ← ESP32 BALANCE (fallback) |
 | USB-A ×2 | — | 5V | D435i, RPLIDAR |
-| USB-C | — | 5V | STM32 CDC |
+| USB-C | — | 5V | ESP32 CDC |
+=======
+| 8 | TXD0 | 3.3V | UART TX → ESP32-S3 (fallback) |
+| 10 | RXD0 | 3.3V | UART RX ← ESP32-S3 (fallback) |
+| USB-A ×2 | — | 5V | D435i, RPLIDAR |
+| USB-C | — | 5V | ESP32-S3 CDC |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | CSI-A (J5) | MIPI CSI-2 | — | Cameras front + left |
 | CSI-B (J8) | MIPI CSI-2 | — | Cameras rear + right |
 | M.2 Key M | PCIe Gen3 ×4 | — | NVMe SSD |
@@ -298,9 +343,13 @@ Apply stable device names:
 KERNEL=="ttyUSB*", ATTRS{idVendor}=="10c4", ATTRS{idProduct}=="ea60", \
   SYMLINK+="rplidar", MODE="0666"
 
-# STM32 USB CDC (STMicroelectronics)
+<<<<<<< HEAD
+# ESP32 USB CDC (STMicroelectronics)
+=======
+# ESP32-S3 USB Serial (CH343) (STMicroelectronics)
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 KERNEL=="ttyACM*", ATTRS{idVendor}=="0483", ATTRS{idProduct}=="5740", \
-  SYMLINK+="stm32-bridge", MODE="0666"
+  SYMLINK+="esp32-bridge", MODE="0666"
 
 # Intel RealSense D435i
 SUBSYSTEM=="usb", ATTRS{idVendor}=="8086", ATTRS{idProduct}=="0b3a", \

jetson/docs/power-budget.md

@@ -56,7 +56,11 @@ sudo jtop
 |-----------|----------|------------|----------|-----------|-------|
 | RealSense D435i | 0.3 | 1.5 | 3.5 | USB 3.1 | Peak during boot/init |
 | RPLIDAR A1M8 | 0.4 | 2.6 | 3.0 | USB (UART adapter) | Motor spinning |
-| STM32F722 bridge | 0.0 | 0.0 | 0.0 | USB CDC | Self-powered from robot 5V |
+<<<<<<< HEAD
+| ESP32 bridge | 0.0 | 0.0 | 0.0 | USB CDC | Self-powered from robot 5V |
+=======
+| ESP32-S3 bridge | 0.0 | 0.0 | 0.0 | USB Serial (CH343) | Self-powered from robot 5V |
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
 | 4× IMX219 cameras | 0.2 | 2.0 | 2.4 | MIPI CSI-2 | ~0.5W per camera active |
 | **Peripheral Subtotal** | **0.9** | **6.1** | **8.9** | | |
 
@@ -72,7 +76,7 @@ sudo jtop
 
 ## Budget Analysis vs Previous Platform
 
-| Metric | Jetson Nano | Jetson Orin Nano Super |
+| Metric | Jetson Orin Nano Super | Jetson Orin Nano Super |
 |--------|------------|------------------------|
 | TDP | 10W | 25W |
 | CPU | 4× Cortex-A57 @ 1.43GHz | 6× A78AE @ 1.5GHz |
@@ -151,7 +155,11 @@ LiPo 4S (16.8V max)
        ├─► DC-DC Buck → 5V 6A ──► Jetson Orin barrel jack (30W)
        │   (e.g., XL4016E1)
        │
-       ├─► DC-DC Buck → 5V 3A ──► STM32 + logic 5V rail
+<<<<<<< HEAD
+       ├─► DC-DC Buck → 5V 3A ──► ESP32 + logic 5V rail
+=======
+       ├─► DC-DC Buck → 5V 3A ──► ESP32-S3 + logic 5V rail
+>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
        │
        └─► Hoverboard ESC ──► Hub motors (48V loop)
 ```

jetson/ros2_ws/src/saltybot_aruco_detect/config/aruco_detect_params.yaml

@@ -0,0 +1,34 @@
+aruco_detect:
+  ros__parameters:
+    # ── Marker specification ─────────────────────────────────────────────────
+    marker_size_m:      0.10      # physical side length of printed ArUco markers (m)
+                                  # measure the black border edge-to-edge
+
+    # ── Dock target filter ───────────────────────────────────────────────────
+    # dock_marker_ids: IDs that may serve as dock target.
+    #   - Empty list [] → any detected marker is a dock candidate (closest wins)
+    #   - Non-empty     → only listed IDs are candidates; others still appear in
+    #                     /saltybot/aruco/markers but not in dock_target
+    # The saltybot dock uses marker ID 42 on the charging face by convention.
+    dock_marker_ids:    [42]
+
+    # Maximum distance to consider a marker as dock target (m)
+    max_dock_range_m:   3.0
+
+    # ── ArUco dictionary ─────────────────────────────────────────────────────
+    aruco_dict:         DICT_4X4_50          # cv2.aruco constant name
+
+    # Corner sub-pixel refinement (improves pose accuracy at close range)
+    #   CORNER_REFINE_NONE     — fastest, no refinement
+    #   CORNER_REFINE_SUBPIX   — best for high-contrast markers (recommended)
+    #   CORNER_REFINE_CONTOUR  — good for blurry or low-res images
+    corner_refinement:  CORNER_REFINE_SUBPIX
+
+    # ── Frame / topic config ─────────────────────────────────────────────────
+    camera_frame:       camera_color_optical_frame
+
+    # ── Debug image output (disabled by default) ─────────────────────────────
+    # When true, publishes annotated BGR image with markers + axes drawn.
+    # Useful for tuning but costs ~10 ms/frame encoding overhead.
+    draw_debug_image:   false
+    debug_image_topic:  /saltybot/aruco/debug_image

jetson/ros2_ws/src/saltybot_aruco_detect/launch/aruco_detect.launch.py

@@ -0,0 +1,29 @@
+"""aruco_detect.launch.py — ArUco marker detection for docking (Issue #627)."""
+
+import os
+from ament_index_python.packages import get_package_share_directory
+from launch import LaunchDescription
+from launch.actions import DeclareLaunchArgument
+from launch.substitutions import LaunchConfiguration
+from launch_ros.actions import Node
+
+
+def generate_launch_description():
+    pkg_share = get_package_share_directory('saltybot_aruco_detect')
+    default_params = os.path.join(pkg_share, 'config', 'aruco_detect_params.yaml')
+
+    params_arg = DeclareLaunchArgument(
+        'params_file',
+        default_value=default_params,
+        description='Path to aruco_detect_params.yaml',
+    )
+
+    aruco_node = Node(
+        package='saltybot_aruco_detect',
+        executable='aruco_detect',
+        name='aruco_detect',
+        output='screen',
+        parameters=[LaunchConfiguration('params_file')],
+    )
+
+    return LaunchDescription([params_arg, aruco_node])

jetson/ros2_ws/src/saltybot_aruco_detect/package.xml

@@ -0,0 +1,37 @@
+<?xml version="1.0"?>
+<?xml-model href="http://download.ros.org/schema/package_format3.xsd" schematypens="http://www.w3.org/2001/XMLSchema"?>
+<package format="3">
+  <name>saltybot_aruco_detect</name>
+  <version>0.1.0</version>
+  <description>
+    ArUco marker detection for docking alignment (Issue #627).
+    Detects all DICT_4X4_50 markers from RealSense D435i RGB, estimates 6-DOF
+    pose with estimatePoseSingleMarkers, publishes PoseArray on
+    /saltybot/aruco/markers and closest dock-candidate marker on
+    /saltybot/aruco/dock_target (PoseStamped) with RViz MarkerArray and
+    JSON status.
+  </description>
+  <maintainer email="sl-perception@saltylab.local">sl-perception</maintainer>
+  <license>MIT</license>
+
+  <buildtool_depend>ament_python</buildtool_depend>
+
+  <depend>rclpy</depend>
+  <depend>std_msgs</depend>
+  <depend>sensor_msgs</depend>
+  <depend>geometry_msgs</depend>
+  <depend>visualization_msgs</depend>
+  <depend>cv_bridge</depend>
+
+  <exec_depend>python3-numpy</exec_depend>
+  <exec_depend>python3-opencv</exec_depend>
+
+  <test_depend>ament_copyright</test_depend>
+  <test_depend>ament_flake8</test_depend>
+  <test_depend>ament_pep257</test_depend>
+  <test_depend>python3-pytest</test_depend>
+
+  <export>
+    <build_type>ament_python</build_type>
+  </export>
+</package>

jetson/ros2_ws/src/saltybot_aruco_detect/saltybot_aruco_detect/aruco_detect_node.py

@@ -0,0 +1,518 @@
+"""
+aruco_detect_node.py — ArUco marker detection for docking alignment (Issue #627).
+
+Detects all DICT_4X4_50 ArUco markers visible in the RealSense D435i RGB stream,
+estimates their 6-DOF poses relative to the camera using estimatePoseSingleMarkers,
+and publishes:
+
+  /saltybot/aruco/markers      geometry_msgs/PoseArray        — all detected markers
+  /saltybot/aruco/dock_target  geometry_msgs/PoseStamped      — closest dock marker
+  /saltybot/aruco/viz          visualization_msgs/MarkerArray — RViz axes overlays
+  /saltybot/aruco/status       std_msgs/String                — JSON summary (10 Hz)
+
+Coordinate frame
+────────────────
+All poses are expressed in camera_color_optical_frame (ROS optical convention):
+  +X = right, +Y = down, +Z = forward (into scene)
+
+The dock_target pose gives the docking controller everything it needs:
+  position.z  — forward distance to dock (m)      → throttle target
+  position.x  — lateral offset (m)                → steer target
+  orientation — marker orientation for final align → yaw servo
+
+Dock target selection
+─────────────────────
+  dock_marker_ids   list[int]  []   — empty = accept any detected marker
+                                       non-empty = only these IDs are candidates
+  closest_wins      bool       true — among candidates, prefer the nearest
+  max_dock_range_m  float      3.0  — ignore markers beyond this distance
+
+estimatePoseSingleMarkers API
+──────────────────────────────
+  Uses cv2.aruco.estimatePoseSingleMarkers (legacy OpenCV API still present in
+  4.x with a deprecation notice).  Falls back to per-marker cv2.solvePnP with
+  SOLVEPNP_IPPE_SQUARE if the legacy function is unavailable.
+  Both paths use the same camera_matrix / dist_coeffs from CameraInfo.
+
+Subscribes
+──────────
+  /camera/color/image_raw       sensor_msgs/Image      30 Hz (BGR8)
+  /camera/color/camera_info     sensor_msgs/CameraInfo (latched, once)
+
+Publishes
+─────────
+  /saltybot/aruco/markers       geometry_msgs/PoseArray
+  /saltybot/aruco/dock_target   geometry_msgs/PoseStamped
+  /saltybot/aruco/viz           visualization_msgs/MarkerArray
+  /saltybot/aruco/status        std_msgs/String   (JSON, 10 Hz)
+
+Parameters (see config/aruco_detect_params.yaml)
+────────────────────────────────────────────────
+  marker_size_m      float   0.10     physical side length of printed markers (m)
+  dock_marker_ids    int[]   []       IDs to accept as dock targets (empty = all)
+  max_dock_range_m   float   3.0      ignore candidates beyond this (m)
+  aruco_dict         str     DICT_4X4_50
+  corner_refinement  str     CORNER_REFINE_SUBPIX
+  camera_frame       str     camera_color_optical_frame
+  draw_debug_image   bool    false    publish annotated image for debugging
+  debug_image_topic  str     /saltybot/aruco/debug_image
+"""
+
+from __future__ import annotations
+
+import json
+import math
+
+import rclpy
+from rclpy.node import Node
+from rclpy.qos import (
+    QoSProfile, ReliabilityPolicy, HistoryPolicy, DurabilityPolicy
+)
+
+import numpy as np
+import cv2
+from cv_bridge import CvBridge
+
+from geometry_msgs.msg import (
+    Pose, PoseArray, PoseStamped, Point, Quaternion, Vector3, TransformStamped
+)
+from sensor_msgs.msg import Image, CameraInfo
+from std_msgs.msg import Header, String, ColorRGBA
+from visualization_msgs.msg import Marker, MarkerArray
+
+from .aruco_math import MarkerPose, rvec_to_quat, tvec_distance
+
+
+# ── QoS ───────────────────────────────────────────────────────────────────────
+_SENSOR_QOS = QoSProfile(
+    reliability=ReliabilityPolicy.BEST_EFFORT,
+    history=HistoryPolicy.KEEP_LAST,
+    depth=5,
+)
+_LATCHED_QOS = QoSProfile(
+    reliability=ReliabilityPolicy.RELIABLE,
+    history=HistoryPolicy.KEEP_LAST,
+    depth=1,
+    durability=DurabilityPolicy.TRANSIENT_LOCAL,
+)
+
+# ArUco axis length for viz (fraction of marker size)
+_AXIS_LEN_FRAC = 0.5
+
+
+class ArucoDetectNode(Node):
+    """ArUco marker detection + pose estimation node — see module docstring."""
+
+    def __init__(self) -> None:
+        super().__init__('aruco_detect')
+
+        # ── Parameters ────────────────────────────────────────────────────────
+        self.declare_parameter('marker_size_m',     0.10)
+        self.declare_parameter('dock_marker_ids',   [])       # empty list = all
+        self.declare_parameter('max_dock_range_m',  3.0)
+        self.declare_parameter('aruco_dict',        'DICT_4X4_50')
+        self.declare_parameter('corner_refinement', 'CORNER_REFINE_SUBPIX')
+        self.declare_parameter('camera_frame',      'camera_color_optical_frame')
+        self.declare_parameter('draw_debug_image',  False)
+        self.declare_parameter('debug_image_topic', '/saltybot/aruco/debug_image')
+
+        self._marker_size  = self.get_parameter('marker_size_m').value
+        self._dock_ids     = set(self.get_parameter('dock_marker_ids').value)
+        self._max_range    = self.get_parameter('max_dock_range_m').value
+        self._cam_frame    = self.get_parameter('camera_frame').value
+        self._draw_debug   = self.get_parameter('draw_debug_image').value
+        self._debug_topic  = self.get_parameter('debug_image_topic').value
+
+        aruco_dict_name    = self.get_parameter('aruco_dict').value
+        refine_name        = self.get_parameter('corner_refinement').value
+
+        # ── ArUco detector setup ──────────────────────────────────────────────
+        dict_id    = getattr(cv2.aruco, aruco_dict_name, cv2.aruco.DICT_4X4_50)
+        params     = cv2.aruco.DetectorParameters()
+        # Apply corner refinement
+        refine_id  = getattr(cv2.aruco, refine_name, cv2.aruco.CORNER_REFINE_SUBPIX)
+        params.cornerRefinementMethod = refine_id
+
+        aruco_dict     = cv2.aruco.getPredefinedDictionary(dict_id)
+        self._detector = cv2.aruco.ArucoDetector(aruco_dict, params)
+
+        # Object points for solvePnP fallback (counter-clockwise from top-left)
+        half = self._marker_size / 2.0
+        self._obj_pts = np.array([
+            [-half,  half, 0.0],
+            [ half,  half, 0.0],
+            [ half, -half, 0.0],
+            [-half, -half, 0.0],
+        ], dtype=np.float64)
+
+        # ── Camera intrinsics (set on first CameraInfo) ───────────────────────
+        self._K:    np.ndarray | None = None
+        self._dist: np.ndarray | None = None
+        self._bridge = CvBridge()
+
+        # ── Publishers ─────────────────────────────────────────────────────────
+        self._pose_array_pub = self.create_publisher(
+            PoseArray, '/saltybot/aruco/markers', 10
+        )
+        self._dock_pub = self.create_publisher(
+            PoseStamped, '/saltybot/aruco/dock_target', 10
+        )
+        self._viz_pub = self.create_publisher(
+            MarkerArray, '/saltybot/aruco/viz', 10
+        )
+        self._status_pub = self.create_publisher(
+            String, '/saltybot/aruco/status', 10
+        )
+        if self._draw_debug:
+            self._debug_pub = self.create_publisher(
+                Image, self._debug_topic, 5
+            )
+        else:
+            self._debug_pub = None
+
+        # ── Subscriptions ──────────────────────────────────────────────────────
+        self.create_subscription(
+            CameraInfo,
+            '/camera/color/camera_info',
+            self._on_camera_info,
+            _LATCHED_QOS,
+        )
+        self.create_subscription(
+            Image,
+            '/camera/color/image_raw',
+            self._on_image,
+            _SENSOR_QOS,
+        )
+
+        # ── Status timer (10 Hz) ────────────────────────────────────────────────
+        self._last_detections: list[MarkerPose] = []
+        self.create_timer(0.1, self._on_status_timer)
+
+        self.get_logger().info(
+            f'aruco_detect ready — '
+            f'dict={aruco_dict_name} '
+            f'marker_size={self._marker_size * 100:.0f}cm '
+            f'dock_ids={list(self._dock_ids) if self._dock_ids else "any"} '
+            f'max_range={self._max_range}m'
+        )
+
+    # ── Camera info ───────────────────────────────────────────────────────────
+
+    def _on_camera_info(self, msg: CameraInfo) -> None:
+        if self._K is not None:
+            return
+        self._K    = np.array(msg.k, dtype=np.float64).reshape(3, 3)
+        self._dist = np.array(msg.d, dtype=np.float64).reshape(1, -1)
+        self.get_logger().info(
+            f'camera_info received — '
+            f'fx={self._K[0,0]:.1f} fy={self._K[1,1]:.1f}'
+        )
+
+    # ── Image callback ────────────────────────────────────────────────────────
+
+    def _on_image(self, msg: Image) -> None:
+        if self._K is None:
+            return
+
+        # ── Decode ────────────────────────────────────────────────────────────
+        try:
+            bgr = self._bridge.imgmsg_to_cv2(msg, desired_encoding='bgr8')
+        except Exception as exc:
+            self.get_logger().warning(f'image decode error: {exc}',
+                                      throttle_duration_sec=5.0)
+            return
+
+        # Convert to greyscale for detection (faster, same accuracy)
+        gray = cv2.cvtColor(bgr, cv2.COLOR_BGR2GRAY)
+
+        stamp  = msg.header.stamp
+
+        # ── Detect markers ────────────────────────────────────────────────────
+        corners, ids, _ = self._detector.detectMarkers(gray)
+
+        if ids is None or len(ids) == 0:
+            self._last_detections = []
+            self._publish_empty(stamp)
+            return
+
+        ids_flat = ids.flatten().tolist()
+
+        # ── Pose estimation ───────────────────────────────────────────────────
+        detections = self._estimate_poses(corners, ids_flat)
+
+        # Filter by range
+        detections = [d for d in detections if d.distance_m <= self._max_range]
+
+        self._last_detections = detections
+
+        # ── Publish ───────────────────────────────────────────────────────────
+        self._publish_pose_array(detections, stamp)
+        self._publish_dock_target(detections, stamp)
+        self._publish_viz(detections, stamp)
+
+        # Debug image
+        if self._debug_pub is not None:
+            self._publish_debug(bgr, corners, ids, detections, stamp)
+
+    # ── Pose estimation ───────────────────────────────────────────────────────
+
+    def _estimate_poses(
+        self,
+        corners: list,
+        ids:     list[int],
+    ) -> list[MarkerPose]:
+        """
+        Estimate 6-DOF pose for each detected marker.
+
+        Uses estimatePoseSingleMarkers (legacy API, still present in cv2 4.x).
+        Falls back to per-marker solvePnP(IPPE_SQUARE) if unavailable.
+        """
+        results: list[MarkerPose] = []
+
+        # ── Try legacy estimatePoseSingleMarkers ──────────────────────────────
+        if hasattr(cv2.aruco, 'estimatePoseSingleMarkers'):
+            try:
+                rvecs, tvecs, _ = cv2.aruco.estimatePoseSingleMarkers(
+                    corners, self._marker_size, self._K, self._dist
+                )
+                for i, mid in enumerate(ids):
+                    rvec = rvecs[i].ravel().astype(np.float64)
+                    tvec = tvecs[i].ravel().astype(np.float64)
+                    results.append(MarkerPose(
+                        marker_id = int(mid),
+                        tvec      = tvec,
+                        rvec      = rvec,
+                        corners   = corners[i].reshape(4, 2).astype(np.float64),
+                    ))
+                return results
+            except Exception as exc:
+                self.get_logger().debug(
+                    f'estimatePoseSingleMarkers failed ({exc}), '
+                    'falling back to solvePnP'
+                )
+
+        # ── Fallback: per-marker solvePnP ─────────────────────────────────────
+        for i, mid in enumerate(ids):
+            img_pts = corners[i].reshape(4, 2).astype(np.float64)
+            ok, rvec, tvec = cv2.solvePnP(
+                self._obj_pts, img_pts,
+                self._K, self._dist,
+                flags=cv2.SOLVEPNP_IPPE_SQUARE,
+            )
+            if not ok:
+                continue
+            results.append(MarkerPose(
+                marker_id = int(mid),
+                tvec      = tvec.ravel().astype(np.float64),
+                rvec      = rvec.ravel().astype(np.float64),
+                corners   = img_pts,
+            ))
+        return results
+
+    # ── Dock target selection ─────────────────────────────────────────────────
+
+    def _select_dock_target(
+        self,
+        detections: list[MarkerPose],
+    ) -> MarkerPose | None:
+        """Select the closest marker that matches dock_marker_ids filter."""
+        candidates = [
+            d for d in detections
+            if not self._dock_ids or d.marker_id in self._dock_ids
+        ]
+        if not candidates:
+            return None
+        return min(candidates, key=lambda d: d.distance_m)
+
+    # ── Publishers ────────────────────────────────────────────────────────────
+
+    def _publish_pose_array(
+        self,
+        detections: list[MarkerPose],
+        stamp,
+    ) -> None:
+        pa              = PoseArray()
+        pa.header.stamp    = stamp
+        pa.header.frame_id = self._cam_frame
+
+        for d in detections:
+            qx, qy, qz, qw = d.quat
+            pose               = Pose()
+            pose.position      = Point(x=float(d.tvec[0]),
+                                       y=float(d.tvec[1]),
+                                       z=float(d.tvec[2]))
+            pose.orientation   = Quaternion(x=qx, y=qy, z=qz, w=qw)
+            pa.poses.append(pose)
+
+        self._pose_array_pub.publish(pa)
+
+    def _publish_dock_target(
+        self,
+        detections: list[MarkerPose],
+        stamp,
+    ) -> None:
+        target = self._select_dock_target(detections)
+        if target is None:
+            return
+
+        qx, qy, qz, qw = target.quat
+        ps                  = PoseStamped()
+        ps.header.stamp     = stamp
+        ps.header.frame_id  = self._cam_frame
+        ps.pose.position    = Point(x=float(target.tvec[0]),
+                                    y=float(target.tvec[1]),
+                                    z=float(target.tvec[2]))
+        ps.pose.orientation = Quaternion(x=qx, y=qy, z=qz, w=qw)
+        self._dock_pub.publish(ps)
+
+    def _publish_viz(
+        self,
+        detections: list[MarkerPose],
+        stamp,
+    ) -> None:
+        """Publish coordinate-axes MarkerArray for each detected marker."""
+        ma      = MarkerArray()
+        lifetime = _ros_duration(0.2)
+
+        # Delete-all
+        dm              = Marker()
+        dm.action       = Marker.DELETEALL
+        dm.header.stamp    = stamp
+        dm.header.frame_id = self._cam_frame
+        ma.markers.append(dm)
+
+        target = self._select_dock_target(detections)
+        axis_len = self._marker_size * _AXIS_LEN_FRAC
+
+        for idx, d in enumerate(detections):
+            is_target = (target is not None and d.marker_id == target.marker_id)
+            cx, cy, cz = float(d.tvec[0]), float(d.tvec[1]), float(d.tvec[2])
+            qx, qy, qz, qw = d.quat
+            base_id = idx * 10
+
+            # Sphere at marker centre
+            sph                       = Marker()
+            sph.header.stamp          = stamp
+            sph.header.frame_id       = self._cam_frame
+            sph.ns                    = 'aruco_centers'
+            sph.id                    = base_id
+            sph.type                  = Marker.SPHERE
+            sph.action                = Marker.ADD
+            sph.pose.position         = Point(x=cx, y=cy, z=cz)
+            sph.pose.orientation      = Quaternion(x=qx, y=qy, z=qz, w=qw)
+            r_s = 0.015 if not is_target else 0.025
+            sph.scale                 = Vector3(x=r_s * 2, y=r_s * 2, z=r_s * 2)
+            sph.color = (
+                ColorRGBA(r=1.0, g=0.2, b=0.2, a=1.0) if is_target else
+                ColorRGBA(r=0.2, g=0.8, b=1.0, a=0.9)
+            )
+            sph.lifetime              = lifetime
+            ma.markers.append(sph)
+
+            # Text label: ID + distance
+            txt                       = Marker()
+            txt.header.stamp          = stamp
+            txt.header.frame_id       = self._cam_frame
+            txt.ns                    = 'aruco_labels'
+            txt.id                    = base_id + 1
+            txt.type                  = Marker.TEXT_VIEW_FACING
+            txt.action                = Marker.ADD
+            txt.pose.position         = Point(x=cx, y=cy - 0.08, z=cz)
+            txt.pose.orientation.w    = 1.0
+            txt.scale.z               = 0.06
+            txt.color                 = ColorRGBA(r=1.0, g=1.0, b=0.0, a=1.0)
+            txt.text = f'ID={d.marker_id}\n{d.distance_m:.2f}m'
+            if is_target:
+                txt.text += '\n[DOCK]'
+            txt.lifetime              = lifetime
+            ma.markers.append(txt)
+
+        self._viz_pub.publish(ma)
+
+    def _publish_empty(self, stamp) -> None:
+        pa              = PoseArray()
+        pa.header.stamp    = stamp
+        pa.header.frame_id = self._cam_frame
+        self._pose_array_pub.publish(pa)
+        self._publish_viz([], stamp)
+
+    def _publish_debug(self, bgr, corners, ids, detections, stamp) -> None:
+        """Annotate and publish debug image with detected markers drawn."""
+        debug = bgr.copy()
+        if ids is not None and len(ids) > 0:
+            cv2.aruco.drawDetectedMarkers(debug, corners, ids)
+
+        # Draw axes for each detection using the estimated poses
+        for d in detections:
+            try:
+                cv2.drawFrameAxes(
+                    debug, self._K, self._dist,
+                    d.rvec.reshape(3, 1),
+                    d.tvec.reshape(3, 1),
+                    self._marker_size * _AXIS_LEN_FRAC,
+                )
+            except Exception:
+                pass
+
+        try:
+            img_msg = self._bridge.cv2_to_imgmsg(debug, encoding='bgr8')
+            img_msg.header.stamp    = stamp
+            img_msg.header.frame_id = self._cam_frame
+            self._debug_pub.publish(img_msg)
+        except Exception:
+            pass
+
+    # ── Status timer ─────────────────────────────────────────────────────────
+
+    def _on_status_timer(self) -> None:
+        detections = self._last_detections
+        target     = self._select_dock_target(detections)
+
+        markers_info = [
+            {
+                'id':         d.marker_id,
+                'distance_m': round(d.distance_m,  3),
+                'yaw_deg':    round(math.degrees(d.yaw_rad), 2),
+                'lateral_m':  round(d.lateral_m,   3),
+                'forward_m':  round(d.forward_m,   3),
+                'is_target':  target is not None and d.marker_id == target.marker_id,
+            }
+            for d in detections
+        ]
+
+        status = {
+            'detected_count':  len(detections),
+            'dock_target_id':  target.marker_id  if target else None,
+            'dock_distance_m': round(target.distance_m, 3) if target else None,
+            'dock_yaw_deg':    round(math.degrees(target.yaw_rad), 2) if target else None,
+            'dock_lateral_m':  round(target.lateral_m, 3) if target else None,
+            'markers':         markers_info,
+        }
+        msg      = String()
+        msg.data = json.dumps(status)
+        self._status_pub.publish(msg)
+
+
+# ── Helpers ───────────────────────────────────────────────────────────────────
+
+def _ros_duration(seconds: float):
+    from rclpy.duration import Duration
+    sec  = int(seconds)
+    nsec = int((seconds - sec) * 1e9)
+    return Duration(seconds=sec, nanoseconds=nsec).to_msg()
+
+
+def main(args=None) -> None:
+    rclpy.init(args=args)
+    node = ArucoDetectNode()
+    try:
+        rclpy.spin(node)
+    except KeyboardInterrupt:
+        pass
+    finally:
+        node.destroy_node()
+        rclpy.try_shutdown()
+
+
+if __name__ == '__main__':
+    main()

jetson/ros2_ws/src/saltybot_aruco_detect/saltybot_aruco_detect/aruco_math.py

@@ -0,0 +1,156 @@
+"""
+aruco_math.py — Pure-math helpers for ArUco detection (Issue #627).
+
+No ROS2 dependencies — importable in unit tests without a ROS2 install.
+
+Provides:
+  rot_mat_to_quat(R)         → (qx, qy, qz, qw)
+  rvec_to_quat(rvec)         → (qx, qy, qz, qw)   [via cv2.Rodrigues]
+  tvec_distance(tvec)        → float   (Euclidean norm)
+  tvec_yaw_rad(tvec)         → float   (atan2(tx, tz) — lateral bearing error)
+  MarkerPose dataclass       — per-marker detection result
+"""
+
+from __future__ import annotations
+
+import math
+from dataclasses import dataclass, field
+from typing import List, Optional, Tuple
+
+import numpy as np
+
+
+# ── Rotation helpers ──────────────────────────────────────────────────────────
+
+def rot_mat_to_quat(R: np.ndarray) -> Tuple[float, float, float, float]:
+    """
+    Convert a 3×3 rotation matrix to quaternion (qx, qy, qz, qw).
+
+    Uses Shepperd's method for numerical stability.
+    R must be a valid rotation matrix (‖R‖₂ = 1, det R = +1).
+    """
+    R = np.asarray(R, dtype=np.float64)
+    trace = R[0, 0] + R[1, 1] + R[2, 2]
+
+    if trace > 0.0:
+        s = 0.5 / math.sqrt(trace + 1.0)
+        w = 0.25 / s
+        x = (R[2, 1] - R[1, 2]) * s
+        y = (R[0, 2] - R[2, 0]) * s
+        z = (R[1, 0] - R[0, 1]) * s
+    elif R[0, 0] > R[1, 1] and R[0, 0] > R[2, 2]:
+        s = 2.0 * math.sqrt(1.0 + R[0, 0] - R[1, 1] - R[2, 2])
+        w = (R[2, 1] - R[1, 2]) / s
+        x = 0.25 * s
+        y = (R[0, 1] + R[1, 0]) / s
+        z = (R[0, 2] + R[2, 0]) / s
+    elif R[1, 1] > R[2, 2]:
+        s = 2.0 * math.sqrt(1.0 + R[1, 1] - R[0, 0] - R[2, 2])
+        w = (R[0, 2] - R[2, 0]) / s
+        x = (R[0, 1] + R[1, 0]) / s
+        y = 0.25 * s
+        z = (R[1, 2] + R[2, 1]) / s
+    else:
+        s = 2.0 * math.sqrt(1.0 + R[2, 2] - R[0, 0] - R[1, 1])
+        w = (R[1, 0] - R[0, 1]) / s
+        x = (R[0, 2] + R[2, 0]) / s
+        y = (R[1, 2] + R[2, 1]) / s
+        z = 0.25 * s
+
+    # Normalise
+    norm = math.sqrt(x * x + y * y + z * z + w * w)
+    if norm < 1e-10:
+        return 0.0, 0.0, 0.0, 1.0
+    inv = 1.0 / norm
+    return x * inv, y * inv, z * inv, w * inv
+
+
+def rvec_to_quat(rvec: np.ndarray) -> Tuple[float, float, float, float]:
+    """
+    Convert a Rodrigues rotation vector (3,) or (1,3) to quaternion.
+
+    Requires cv2 for cv2.Rodrigues(); falls back to manual exponential map
+    if cv2 is unavailable.
+    """
+    vec = np.asarray(rvec, dtype=np.float64).ravel()
+    try:
+        import cv2
+        R, _ = cv2.Rodrigues(vec)
+    except ImportError:
+        # Manual Rodrigues exponential map
+        angle = float(np.linalg.norm(vec))
+        if angle < 1e-12:
+            return 0.0, 0.0, 0.0, 1.0
+        axis = vec / angle
+        K = np.array([
+            [     0.0, -axis[2],  axis[1]],
+            [ axis[2],      0.0, -axis[0]],
+            [-axis[1],  axis[0],      0.0],
+        ])
+        R = np.eye(3) + math.sin(angle) * K + (1.0 - math.cos(angle)) * K @ K
+
+    return rot_mat_to_quat(R)
+
+
+# ── Metric helpers ────────────────────────────────────────────────────────────
+
+def tvec_distance(tvec: np.ndarray) -> float:
+    """Euclidean distance from camera to marker (m)."""
+    t = np.asarray(tvec, dtype=np.float64).ravel()
+    return float(math.sqrt(t[0] ** 2 + t[1] ** 2 + t[2] ** 2))
+
+
+def tvec_yaw_rad(tvec: np.ndarray) -> float:
+    """
+    Horizontal bearing error to marker (rad).
+
+    atan2(tx, tz): +ve when marker is to the right of the camera optical axis.
+    Zero when the marker is directly in front.
+    """
+    t = np.asarray(tvec, dtype=np.float64).ravel()
+    return float(math.atan2(t[0], t[2]))
+
+
+# ── Per-marker result ─────────────────────────────────────────────────────────
+
+@dataclass
+class MarkerPose:
+    """Pose result for a single detected ArUco marker."""
+    marker_id:  int
+    tvec:       np.ndarray    # (3,) translation in camera optical frame (m)
+    rvec:       np.ndarray    # (3,) Rodrigues rotation vector
+    corners:    np.ndarray    # (4, 2) image-plane corner coordinates (px)
+
+    # Derived (computed lazily)
+    _distance_m: Optional[float] = field(default=None, repr=False)
+    _yaw_rad:    Optional[float] = field(default=None, repr=False)
+    _quat:       Optional[Tuple[float, float, float, float]] = field(default=None, repr=False)
+
+    @property
+    def distance_m(self) -> float:
+        if self._distance_m is None:
+            self._distance_m = tvec_distance(self.tvec)
+        return self._distance_m
+
+    @property
+    def yaw_rad(self) -> float:
+        if self._yaw_rad is None:
+            self._yaw_rad = tvec_yaw_rad(self.tvec)
+        return self._yaw_rad
+
+    @property
+    def lateral_m(self) -> float:
+        """Lateral offset (m); +ve = marker is to the right."""
+        return float(self.tvec[0])
+
+    @property
+    def forward_m(self) -> float:
+        """Forward distance (Z component in camera frame, m)."""
+        return float(self.tvec[2])
+
+    @property
+    def quat(self) -> Tuple[float, float, float, float]:
+        """Quaternion (qx, qy, qz, qw) from rvec."""
+        if self._quat is None:
+            self._quat = rvec_to_quat(self.rvec)
+        return self._quat

jetson/ros2_ws/src/saltybot_aruco_detect/setup.cfg

@@ -0,0 +1,5 @@
+[develop]
+script_dir=$base/lib/saltybot_aruco_detect
+
+[install]
+install_scripts=$base/lib/saltybot_aruco_detect

jetson/ros2_ws/src/saltybot_aruco_detect/setup.py

@@ -0,0 +1,30 @@
+import os
+from glob import glob
+from setuptools import setup
+
+package_name = 'saltybot_aruco_detect'
+
+setup(
+    name=package_name,
+    version='0.1.0',
+    packages=[package_name],
+    data_files=[
+        ('share/ament_index/resource_index/packages',
+            ['resource/' + package_name]),
+        ('share/' + package_name, ['package.xml']),
+        (os.path.join('share', package_name, 'launch'), glob('launch/*.py')),
+        (os.path.join('share', package_name, 'config'), glob('config/*.yaml')),
+    ],
+    install_requires=['setuptools'],
+    zip_safe=True,
+    maintainer='sl-perception',
+    maintainer_email='sl-perception@saltylab.local',
+    description='ArUco marker detection for docking alignment (Issue #627)',
+    license='MIT',
+    tests_require=['pytest'],
+    entry_points={
+        'console_scripts': [
+            'aruco_detect = saltybot_aruco_detect.aruco_detect_node:main',
+        ],
+    },
+)

jetson/ros2_ws/src/saltybot_aruco_detect/test/test_aruco_math.py

@@ -0,0 +1,206 @@
+"""Unit tests for aruco_math.py — no ROS2, no live camera required."""
+
+import math
+import numpy as np
+import pytest
+
+from saltybot_aruco_detect.aruco_math import (
+    rot_mat_to_quat,
+    rvec_to_quat,
+    tvec_distance,
+    tvec_yaw_rad,
+    MarkerPose,
+)
+
+
+# ── Helpers ───────────────────────────────────────────────────────────────────
+
+def _quat_norm(q):
+    return math.sqrt(sum(x * x for x in q))
+
+
+def _quat_rotate(q, v):
+    """Rotate vector v by quaternion q (qx, qy, qz, qw)."""
+    qx, qy, qz, qw = q
+    # Quaternion product: q * (0,v) * q^-1
+    # Using formula: v' = v + 2qw(q × v) + 2(q × (q × v))
+    qvec = np.array([qx, qy, qz])
+    t    = 2.0 * np.cross(qvec, v)
+    return v + qw * t + np.cross(qvec, t)
+
+
+# ── rot_mat_to_quat ───────────────────────────────────────────────────────────
+
+def test_identity_rotation():
+    R = np.eye(3)
+    q = rot_mat_to_quat(R)
+    assert abs(q[3] - 1.0) < 1e-9   # w = 1 for identity
+    assert abs(q[0]) < 1e-9
+    assert abs(q[1]) < 1e-9
+    assert abs(q[2]) < 1e-9
+
+
+def test_90deg_yaw():
+    """90° rotation about Z axis."""
+    angle = math.pi / 2
+    R = np.array([
+        [math.cos(angle), -math.sin(angle), 0],
+        [math.sin(angle),  math.cos(angle), 0],
+        [0,                0,               1],
+    ])
+    qx, qy, qz, qw = rot_mat_to_quat(R)
+    # For 90° Z rotation: q = (0, 0, sin45°, cos45°)
+    assert abs(qx) < 1e-6
+    assert abs(qy) < 1e-6
+    assert abs(qz - math.sin(angle / 2)) < 1e-6
+    assert abs(qw - math.cos(angle / 2)) < 1e-6
+
+
+def test_unit_norm():
+    for yaw in [0, 0.5, 1.0, 2.0, math.pi]:
+        R = np.array([
+            [math.cos(yaw), -math.sin(yaw), 0],
+            [math.sin(yaw),  math.cos(yaw), 0],
+            [0, 0, 1],
+        ])
+        q = rot_mat_to_quat(R)
+        assert abs(_quat_norm(q) - 1.0) < 1e-9, f"yaw={yaw}: norm={_quat_norm(q)}"
+
+
+def test_roundtrip_rotation_matrix():
+    """Rotating a vector with the matrix and quaternion should give same result."""
+    angle = 1.23
+    R = np.array([
+        [math.cos(angle), -math.sin(angle), 0],
+        [math.sin(angle),  math.cos(angle), 0],
+        [0, 0, 1],
+    ])
+    q = rot_mat_to_quat(R)
+    v = np.array([1.0, 0.0, 0.0])
+    v_R = R @ v
+    v_q = _quat_rotate(q, v)
+    np.testing.assert_allclose(v_R, v_q, atol=1e-9)
+
+
+def test_180deg_pitch():
+    """180° rotation about Y axis."""
+    R = np.array([[-1, 0, 0], [0, 1, 0], [0, 0, -1]], dtype=float)
+    q = rot_mat_to_quat(R)
+    assert abs(_quat_norm(q) - 1.0) < 1e-9
+    # For 180° Y: q = (0, 1, 0, 0) or (0, -1, 0, 0)
+    assert abs(abs(q[1]) - 1.0) < 1e-6
+
+
+# ── rvec_to_quat ──────────────────────────────────────────────────────────────
+
+def test_rvec_zero_is_identity():
+    q = rvec_to_quat(np.array([0.0, 0.0, 0.0]))
+    assert abs(_quat_norm(q) - 1.0) < 1e-6
+    assert abs(q[3] - 1.0) < 1e-6   # w = 1
+
+
+def test_rvec_unit_norm():
+    for rvec in [
+        [0.1, 0.0, 0.0],
+        [0.0, 0.5, 0.0],
+        [0.0, 0.0, 1.57],
+        [0.3, 0.4, 0.5],
+    ]:
+        q = rvec_to_quat(np.array(rvec))
+        assert abs(_quat_norm(q) - 1.0) < 1e-9, f"rvec={rvec}: norm={_quat_norm(q)}"
+
+
+def test_rvec_z_rotation_matches_rot_mat():
+    """rvec=[0,0,π/3] should match 60° Z rotation matrix quaternion."""
+    angle = math.pi / 3
+    rvec  = np.array([0.0, 0.0, angle])
+    R     = np.array([
+        [math.cos(angle), -math.sin(angle), 0],
+        [math.sin(angle),  math.cos(angle), 0],
+        [0, 0, 1],
+    ])
+    q_rvec = rvec_to_quat(rvec)
+    q_R    = rot_mat_to_quat(R)
+    # Allow sign flip (q and -q represent the same rotation)
+    diff = min(
+        abs(_quat_norm(np.array(q_rvec) - np.array(q_R))),
+        abs(_quat_norm(np.array(q_rvec) + np.array(q_R))),
+    )
+    assert diff < 1e-6, f"rvec q={q_rvec}, mat q={q_R}"
+
+
+# ── tvec_distance ─────────────────────────────────────────────────────────────
+
+def test_tvec_distance_basic():
+    assert abs(tvec_distance(np.array([3.0, 4.0, 0.0])) - 5.0) < 1e-9
+
+
+def test_tvec_distance_zero():
+    assert tvec_distance(np.array([0.0, 0.0, 0.0])) == 0.0
+
+
+def test_tvec_distance_forward():
+    assert abs(tvec_distance(np.array([0.0, 0.0, 2.5])) - 2.5) < 1e-9
+
+
+def test_tvec_distance_3d():
+    t = np.array([1.0, 2.0, 3.0])
+    expected = math.sqrt(14.0)
+    assert abs(tvec_distance(t) - expected) < 1e-9
+
+
+# ── tvec_yaw_rad ──────────────────────────────────────────────────────────────
+
+def test_yaw_zero_when_centred():
+    """Marker directly in front: tx=0 → yaw=0."""
+    assert abs(tvec_yaw_rad(np.array([0.0, 0.0, 2.0]))) < 1e-9
+
+
+def test_yaw_positive_right():
+    """Marker to the right (tx>0) → positive yaw."""
+    assert tvec_yaw_rad(np.array([1.0, 0.0, 2.0])) > 0.0
+
+
+def test_yaw_negative_left():
+    """Marker to the left (tx<0) → negative yaw."""
+    assert tvec_yaw_rad(np.array([-1.0, 0.0, 2.0])) < 0.0
+
+
+def test_yaw_45deg():
+    """tx=tz → 45°."""
+    assert abs(tvec_yaw_rad(np.array([1.0, 0.0, 1.0])) - math.pi / 4) < 1e-9
+
+
+# ── MarkerPose ────────────────────────────────────────────────────────────────
+
+def _make_marker(mid=42, tx=0.0, ty=0.0, tz=2.0):
+    rvec = np.array([0.0, 0.0, 0.1])
+    tvec = np.array([tx, ty, tz])
+    corners = np.zeros((4, 2))
+    return MarkerPose(marker_id=mid, tvec=tvec, rvec=rvec, corners=corners)
+
+
+def test_marker_distance_cached():
+    m = _make_marker(tz=3.0)
+    d1 = m.distance_m
+    d2 = m.distance_m
+    assert d1 == d2
+
+
+def test_marker_lateral_and_forward():
+    m = _make_marker(tx=0.5, tz=2.0)
+    assert abs(m.lateral_m  - 0.5) < 1e-9
+    assert abs(m.forward_m  - 2.0) < 1e-9
+
+
+def test_marker_quat_unit_norm():
+    m = _make_marker()
+    q = m.quat
+    assert abs(_quat_norm(q) - 1.0) < 1e-9
+
+
+def test_marker_yaw_sign():
+    m_right = _make_marker(tx=+0.3, tz=1.0)
+    m_left  = _make_marker(tx=-0.3, tz=1.0)
+    assert m_right.yaw_rad > 0
+    assert m_left.yaw_rad  < 0