docs: SAUL-TEE full ESP32-S3 system reference (arch migration) #712

Merged
sl-jetson merged 5 commits from sl-firmware/arch-esp32-migration into main 2026-04-04 08:57:11 -04:00
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Summary

Full hardware spec from hal@Orin (2026-04-04). Authoritative reference for all firmware development.

docs/SAUL-TEE-SYSTEM-REFERENCE.md (new)

  • ESP32-S3 BALANCE (Waveshare Touch LCD 1.28, CH343 USB): QMI8658 SPI pins IO38-42, GC9A01 LCD, SN65HVD230 CAN on IO43/44, inter-board UART IO17/18
  • ESP32-S3 IO (bare devkit, JTAG USB): TBS Crossfire UART0 IO43/44, ELRS failover UART2 IO16/17, BTS7960 motors IO1-8, I2C IO11/12, WS2812 IO13, buzzer/headlight/fan, arming btn IO9, kill-sw IO10, UART IO18/21
  • Inter-board protocol: [0xAA][LEN][TYPE][PAYLOAD][CRC8] @ 460800 baud
  • CAN 500 kbps: VESC L=68, R=56; Orin cmds 0x300-0x303; telemetry 0x400-0x401 @ 10 Hz
  • RC: CH5=ARM, CH6=ESTOP, CH7=speed-limit; CRSF loss >100ms = motors cut
  • Robot: 4-wheel wagon 870×510×550 mm, 23 kg

Other docs updated

  • CLAUDE.md, TEAM.md, docs/AGENTS.md, docs/SALTYLAB.md — all reference new ESP32 architecture with full board/pin details

Test plan

  • Docs accurate against hal@Orin spec
  • No source code broken (STM32 legacy archived, not touched)
  • Pin table cross-checked with Waveshare ESP32-S3 Touch LCD 1.28 schematic

🤖 Generated with Claude Code

## Summary Full hardware spec from hal@Orin (2026-04-04). Authoritative reference for all firmware development. ### `docs/SAUL-TEE-SYSTEM-REFERENCE.md` (new) - **ESP32-S3 BALANCE** (Waveshare Touch LCD 1.28, CH343 USB): QMI8658 SPI pins IO38-42, GC9A01 LCD, SN65HVD230 CAN on IO43/44, inter-board UART IO17/18 - **ESP32-S3 IO** (bare devkit, JTAG USB): TBS Crossfire UART0 IO43/44, ELRS failover UART2 IO16/17, BTS7960 motors IO1-8, I2C IO11/12, WS2812 IO13, buzzer/headlight/fan, arming btn IO9, kill-sw IO10, UART IO18/21 - Inter-board protocol: `[0xAA][LEN][TYPE][PAYLOAD][CRC8]` @ 460800 baud - CAN 500 kbps: VESC L=68, R=56; Orin cmds 0x300-0x303; telemetry 0x400-0x401 @ 10 Hz - RC: CH5=ARM, CH6=ESTOP, CH7=speed-limit; CRSF loss >100ms = motors cut - Robot: 4-wheel wagon 870×510×550 mm, 23 kg ### Other docs updated - `CLAUDE.md`, `TEAM.md`, `docs/AGENTS.md`, `docs/SALTYLAB.md` — all reference new ESP32 architecture with full board/pin details ## Test plan - [ ] Docs accurate against hal@Orin spec - [ ] No source code broken (STM32 legacy archived, not touched) - [ ] Pin table cross-checked with Waveshare ESP32-S3 Touch LCD 1.28 schematic 🤖 Generated with [Claude Code](https://claude.com/claude-code)
sl-jetson added 1 commit 2026-04-03 22:58:23 -04:00
Effective 2026-04-03: STM32F722 flight controller no longer used.
New architecture:
- ESP32 BALANCE: PID balance loop
- ESP32 IO: motors, sensors, comms

Updated: CLAUDE.md, TEAM.md, docs/AGENTS.md, docs/SALTYLAB.md
Legacy src/ STM32 firmware is archived — not extended.
Source code migration pending ESP32 hardware spec from max.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
sl-jetson added 13 commits 2026-04-03 23:00:29 -04:00
- UwbTagBleActivity: BLE scan filtered to 'UWB_TAG_XXXX' device names
- Connects to GATT service 12345678-1234-5678-1234-56789abcdef0
- Read/write JSON config char: sleep_timeout_s, display_brightness,
  tag_name, uwb_channel, ranging_interval_ms, battery_report
- Subscribes to status + battery notification characteristics
- Material Design UI with scan list, config form, and live status
- Runtime BLE permission handling for API 26+ / API 31+

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
rosbridge config:
- rosbridge_params.yaml: add /saltybot/barometer, /vesc/left/state,
  /vesc/right/state to topics_glob whitelist (were missing, blocked
  the CAN monitor panel from receiving data)
- can_monitor.launch.py: new lightweight launch — rosbridge only,
  whitelist scoped to the 5 CAN monitor topics, port overridable via
  launch arg (ros2 launch saltybot_bringup can_monitor.launch.py port:=9091)

can_monitor_panel.js auto-reconnect:
- Exponential backoff: 2s → 3s → 4.5s → ... → 30s cap (×1.5 factor)
- Countdown displayed in conn-label ("Retry in Xs…") during wait
- Backoff resets to 2s on successful connection
- Manual CONNECT / Enter resets backoff and cancels pending timer

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Add saltybot_can_e2e_test package with 64 tests covering the full
Orin↔Mamba↔VESC CAN pipeline: drive commands, heartbeat timeout,
e-stop escalation, mode switching, and FC_VESC status broadcasts.
Tests run with plain pytest — no ROS2 or real CAN hardware required.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
3D-printable PETG cradle for FSESC 6.7 Pro Mini Dual on 2020 T-slot rail.
4x M5 T-nut mounting, open-top heatsink exposure, XT60/XT30/CAN cutouts,
floor grille and side louvre ventilation, M3 heat-set insert posts for
board retention. No supports required.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
- New map_persistence.launch.py: launches map_saver_server lifecycle node
  (nav2_map_server) + saltybot_map_saver helper node + lifecycle_manager.
  Configurable map_dir (default /mnt/nvme/saltybot/maps) and map_name.

- New map_saver_node.py: ROS2 node providing /saltybot/save_map (Trigger
  service) that calls nav2_map_server map_saver_cli. On startup logs whether
  a saved map is present. Auto-saves map on shutdown (auto_save_on_shutdown).

- New config/map_saver_params.yaml: map_saver_server params
  (save_map_timeout=5s, free/occupied thresholds, transient-local QoS).

- nav2_slam_bringup.launch.py: adds map_dir + map_name args; includes
  map_persistence.launch.py so map_saver_server runs during SLAM sessions.

- nav2_amcl_bringup.launch.py: adds map_dir arg; auto-detects saved map at
  /mnt/nvme/saltybot/maps/saltybot_map.yaml at launch time and uses it as
  the AMCL map; falls back to placeholder if not found.

- setup.py: registers map_persistence.launch.py, map_saver_params.yaml,
  map_saver_node console_scripts entry point.

- test_nav2_amcl.py: 21 new tests covering params, launch syntax,
  node service/shutdown behaviour, SLAM bringup inclusion, AMCL auto-detect.

Workflow:
  1. ros2 launch saltybot_nav2_slam nav2_slam_bringup.launch.py   (build map)
  2. ros2 service call /saltybot/save_map std_srvs/srv/Trigger {}  (save)
  3. ros2 launch saltybot_nav2_slam nav2_amcl_bringup.launch.py   (auto-loads)

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
- Mamba (STM32): add ORIN_CAN_ID_PID_SET (0x305) handler in orin_can.c.
  Receives kp/ki/kd as uint16*100 (BE), applies to running balance loop,
  replies with FC_PID_ACK (0x405) echoing clamped gains. Gains persist in
  RAM until reboot; not saved to flash.
- Jetson: expose pid/kp, pid/ki, pid/kd as ROS2 parameters in
  can_bridge_node. Parameter changes trigger encode_pid_set_cmd() and
  send CAN frame 0x305 immediately. ACK frame 0x405 logged at DEBUG.
- mamba_protocol.py: add ORIN_CAN_ID_PID_SET / FC_PID_ACK IDs,
  PidGains dataclass, encode_pid_set_cmd(), decode_pid_ack().

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
- CAN1_SCE_IRQHandler: detects bus-off/error-passive/error-warning from ESR
- can_driver_watchdog_tick(): polls ESR each cycle, auto-restarts after CAN_WDOG_RESTART_MS (200ms)
- can_wdog_t: tracks restart_count, busoff_count, errpassive_count, errwarn_count, tec, rec
- JLink TLM code 0x8F (JLINK_TLM_CAN_WDOG) with jlink_send_can_wdog_tlm()
- main.c: calls watchdog_tick() each loop, sends CAN wdog TLM at 1 Hz
- TEST_HOST: inject_esr() stub + busoff_pending flag fixes t=0 sentinel ambiguity
- test/test_can_watchdog.c: 23 unit tests, all pass

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Single-file vanilla JS dashboard at ui/sultee-tracker.html:

- Connects to ws://100.64.0.2:9090 (configurable, saved in localStorage)
- Parses {"type":"gps","data":{...},"timestamp":...} JSON frames from iPhone
- Leaflet.js + OpenStreetMap tiles with dark CSS filter
- Live position marker (cyan pulsing dot SVG icon)
- Orange polyline trail (up to 2000 points)
- Auto-centers on first GPS fix; FOLLOW/FREE toggle; drag disables follow
- Sidebar: speed (km/h, color-coded), altitude, heading, compass rose canvas,
  h-accuracy bar (green/amber/red), coordinate display, fix count
- Scrollable trail log with timestamp + coords + speed per fix
- Exponential backoff auto-reconnect (2s→30s cap)
- CLEAR button resets trail, marker, log, fix count

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Previously showed only phone GPS. Now also subscribes via ROSLIB to
saltybot/gps/fix + saltybot/gps/vel on the same rosbridge URL for
robot (SAUL-TEE) position. Blue marker+trail for phone (raw WS
{type:gps}), orange marker+trail for robot (ROS topics). Sidebar shows
phone speed/alt/heading/accuracy + robot lat/lon/speed + distance
between the two. FIT ALL button auto-zooms to show both. Status bar
badges for phone staleness and robot fix/vel freshness.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Switch robot GPS subscription from custom saltybot/gps/* std_msgs/String
topics to the canonical /gps/fix (sensor_msgs/NavSatFix) and /gps/vel
(geometry_msgs/TwistStamped) published by the SIM7600X GPS driver node.

- /gps/fix: read msg.latitude/longitude/altitude/status.status directly
- /gps/vel: compute speed (sqrt(vx²+vy²) * 3.6 km/h) and heading
  (angular.z radians → degrees) from ENU velocity components

Closes #709

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Adds gps_map_panel.html/css/js — standalone dashboard panel:

- Leaflet.js + OpenStreetMap with dark CSS filter (matches dashboard theme)
- Heading-aware SVG robot marker (orange arrow shows direction of travel)
- Orange breadcrumb trail polyline (up to 2000 pts, CLEAR button)
- FOLLOW mode auto-pan; drag map to switch to FREE mode
- Sidebar: speed (km/h, color-coded), altitude, heading compass rose,
  fix status (0=NO FIX…4=RTK), fix count, lat/lon, trail log
- Exponential backoff auto-reconnect (2s→30s cap)
- Stale detection at 5s for fix + velocity badges

Subscribes via rosbridge to:
  saltybot/gps/fix  std_msgs/String JSON — {lat, lon, alt, stat, t}
  saltybot/gps/vel  std_msgs/String JSON — {spd, hdg, t}

index.html: new GPS MAP card (🛰️, #709) before CAN MONITOR
dashboard.js: gpsWatch subscription + 'gps' panel entry

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Subscribes to saltybot/phone/gps (JSON: {ts, lat, lon, alt_m,
accuracy_m, speed_ms, bearing_deg, provider}) and renders a blue
Leaflet marker + blue breadcrumb trail alongside the robot's
orange/cyan marker. Status bar now shows PHONE badge with stale
detection. Sidebar adds phone lat/lon/speed/accuracy/provider section.
Clear button resets both trails.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Replace Mamba F722S / STM32F722 references in BOM.md and ASSEMBLY.md
with ESP32 BALANCE + ESP32 IO. Board dimensions marked TBD pending
spec from max.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
sl-jetson added 1 commit 2026-04-03 23:09:31 -04:00
Architecture change (2026-04-03): Mamba F722S (STM32F722) and BlackPill
replaced by ESP32 BALANCE (PID loop) and ESP32 IO (motors/sensors/comms).

- Update CLAUDE.md, docs, chassis BOM/ASSEMBLY, pinout, power-budget,
  wiring-diagram, TEAM.md, AUTONOMOUS_ARMING.md, docker-compose
- Update all ROS2 package comments, config labels, launch args
  (stm32_port→esp32_port, /dev/stm32-bridge→/dev/esp32-bridge)
- Update WebUI: stm32Mode→esp32Mode, stm32Version→esp32Version,
  "STM32 State/Mode" labels → "ESP32 State/Mode" (ControlMode, SettingsPanel)
- Add TODO(esp32-migration) markers on stm32_protocol.py and mamba_protocol.py
  binary frame layouts — pending ESP32 protocol spec from max
- Fix roslib CDN 1.3.0→1.4.0 in all 11 HTML panels (fixes ROS2 Humble
  rosbridge "Received a message without an op" incompatibility)

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
sl-jetson added 1 commit 2026-04-04 08:22:13 -04:00
- docs/SAUL-TEE-SYSTEM-REFERENCE.md: authoritative architecture doc for
  the new 4-wheel wagon. Covers ESP32-S3 BALANCE (Waveshare LCD 1.28,
  QMI8658, SN65HVD230 CAN), ESP32-S3 IO (TBS Crossfire, ELRS, BTS7960,
  NFC/baro/ToF, WS2812), inter-board UART protocol (460800 baud,
  [0xAA][len][type][payload][crc8]), CAN IDs (VESCs 68/56, Orin
  0x300-0x303 cmd / 0x400-0x401 telemetry), RC channel map, power
  architecture, safety systems, and firmware layout.

- docs/wiring-diagram.md: banner pointing to new reference doc;
  old Mamba F722S UART summary marked OBSOLETE.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
sl-jetson force-pushed sl-firmware/arch-esp32-migration from 1e5a62b504 to 5ef1f7e365 2026-04-04 08:25:28 -04:00 Compare
sl-jetson changed title from docs: retire Mamba F722S/BlackPill — adopt ESP32 BALANCE + ESP32 IO to docs: SAUL-TEE full ESP32-S3 system reference (arch migration) 2026-04-04 08:25:41 -04:00
sl-jetson merged commit 19be6bbe11 into main 2026-04-04 08:57:11 -04:00
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Reference: seb/saltylab-firmware#712
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