chassis/uwb_anchor_mount.scad

@@ -1,275 +1,463 @@
 // ============================================================
-// 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 2× screw holes (wall or ceiling)
-//   1× module_bracket     print in PLA/PETG, flat-face-down
+//   Tilt knuckle → single-axis articulating joint; 15° detent steps
+//                  locked with M3 nyloc bolt; range 0–90°
+//   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:
+//   2× M4 × 30 mm wood screws (or #6 drywall screws)  wall fasteners
+//   1× M3 × 20 mm SHCS + M3 nyloc nut                 tilt pivot bolt
+//   4× M2.5 × 8 mm SHCS                               PCB-to-cradle
+//   4× M2.5 hex nuts                                   captured in standoffs
+//   1× USB-C cable                                     anchor power
+//
+// ESP32 UWB Pro interface (verify with calipers):
+//   PCB size       : UWB_L × UWB_W × UWB_H  (55 × 28 × 10 mm default)
+//   Mounting holes : M2.5, 4× corners on UWB_HOLE_X × UWB_HOLE_Y pattern
+//   USB-C port     : centred on short edge, UWB_USBC_W × UWB_USBC_H
+//   Antenna area   : top face rear half — 10 mm keep-out of bracket material
+//
+// Tilt angles (15° detent steps, set TILT_DEG before export):
+//   0°  → horizontal face-up   (ceiling, antenna faces down)
+//   30° → 30° downward         (wall near ceiling)  [default]
+//   45° → diagonal             (wall mid-height)
+//   90° → 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
 // ============================================================
 
-RENDER = "assembly";
-
-// ── ⚠ Verify with calipers ───────────────────────────────────
-MAWB_L      = 50.0;   // PCB length
-MAWB_W      = 25.0;   // PCB width
-MAWB_H      = 10.0;   // PCB + components
-MAWB_HOLE_X = 43.0;   // M2 mounting hole X span
-MAWB_HOLE_Y = 20.0;   // M2 mounting hole Y span
-M2_D        =  2.2;   // M2 clearance
-
-// ── Stem ─────────────────────────────────────────────────────
-STEM_OD     = 25.0;
-STEM_BORE   = 25.4;   // +0.4 clearance
-WALL        =  2.0;   // wall thickness (used in thumbscrew recess)
-
-// ── Collar ───────────────────────────────────────────────────
-COL_OD      = 52.0;
-COL_H       = 30.0;   // taller than sensor-head collar for rigidity
-COL_BOLT_X  = 19.0;   // M4 bolt CL from stem axis
-COL_BOLT_D  =  4.5;   // M4 clearance
-THUMB_HEAD_D=  8.0;   // M4 thumbscrew head OD (slot for access)
-COL_NUT_W   =  7.0;   // M4 hex nut A/F
-COL_NUT_H   =  3.4;
-
-// Anti-rotation flat tab: a 3 mm wall tab that protrudes radially
-// and bears against the bracket arm, preventing axial rotation
-// without needing a stem flat.
-ANTI_ROT_T  =  3.0;   // tab thickness (radial)
-ANTI_ROT_W  =  8.0;   // tab width (tangential)
-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;
 
-// ─────────────────────────────────────────────────────────────
+// ── Tilt angle (override per anchor, 0–90°, 15° steps) ───────────────────────
-// collar_half(side)
+TILT_DEG = 30;
-//   split at Y=0 plane.  Bracket arm on front (+Y) half.
+
-//   Print flat-face-down.
+// ── ESP32 UWB Pro PCB dimensions (verify with calipers) ──────────────────────
-// ─────────────────────────────────────────────────────────────
+UWB_L         = 55.0;   // PCB length
-module collar_half(side = "front") {
+UWB_W         = 28.0;   // PCB width
-    y_front = (side == "front");
+UWB_H         = 10.0;   // PCB + components height
+UWB_HOLE_X    = 47.5;   // M2.5 hole X span
+UWB_HOLE_Y    = 21.0;   // M2.5 hole Y span
+UWB_USBC_W    =  9.5;   // USB-C receptacle width
+UWB_USBC_H    =  4.0;   // USB-C receptacle height
+UWB_ANTENNA_L = 20.0;   // antenna area at PCB rear (keep-out)
+
+// ── Wall base geometry ────────────────────────────────────────────────────────
+BASE_W        = 60.0;
+BASE_H        = 50.0;
+BASE_T        =  5.0;
+BASE_SCREW_D  =  4.5;   // M4 clearance
+BASE_SCREW_HD =  8.5;   // countersink OD
+BASE_SCREW_HH =  3.5;   // countersink depth
+BASE_SCREW_SPC = 35.0;  // Z span between screw holes
+KNUCKLE_T     = BASE_T + 4.0;   // pivot ear depth (Y)
+
+// ── Tilt arm geometry ─────────────────────────────────────────────────────────
+ARM_W         = 12.0;
+ARM_T         =  5.0;
+ARM_L         = 35.0;
+PIVOT_D       =  3.3;   // M3 clearance
+PIVOT_NUT_AF  =  5.5;
+PIVOT_NUT_H   =  2.4;
+DETENT_D      =  3.2;   // detent notch diameter
+DETENT_R      =  8.0;   // detent notch radius from pivot
+
+// ── 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;   // label card thickness
+
+// ── USB-C cable 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";
+
+if      (RENDER == "assembly")           assembly_preview();
+else if (RENDER == "wall_base_stl")      wall_base();
+else if (RENDER == "tilt_arm_stl")       tilt_arm();
+else if (RENDER == "anchor_cradle_stl")  anchor_cradle();
+else if (RENDER == "cable_clip_stl")     cable_clip();
+
+// ============================================================
+// ASSEMBLY PREVIEW
+// ============================================================
+module assembly_preview() {
+    // Ghost wall surface
+    %color("Wheat", 0.22)
+        translate([-BASE_W/2, -10, -BASE_H/2])
+            cube([BASE_W, 10, BASE_H + 40]);
+
+    // Wall base
+    color("OliveDrab", 0.85)
+        wall_base();
+
+    // Tilt arm at TILT_DEG, pivoting at knuckle
+    color("SteelBlue", 0.85)
+        translate([0, KNUCKLE_T, 0])
+            rotate([TILT_DEG, 0, 0])
+                tilt_arm();
+
+    // Anchor cradle at arm end
+    color("DarkSlateGray", 0.85)
+        translate([0, KNUCKLE_T, 0])
+            rotate([TILT_DEG, 0, 0])
+                translate([0, ARM_T, ARM_L])
+                    anchor_cradle();
+
+    // PCB ghost
+    %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]);
+
+    // Cable clip at arm mid-point
+    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();
+}
+
+// ============================================================
+// PART 1 — WALL BASE
+// ============================================================
+// Flat backplate screws to wall or ceiling with 2× countersunk
+// M4/#6 wood screws on BASE_SCREW_SPC (35 mm) centres.
+// Two pivot ears straddle the tilt arm; M3 pivot bolt passes through
+// both ears and arm knuckle.
+// Detent arc on inner face of +X ear: 7 notches at 15° steps (0–90°)
+// so tilt can be set without a protractor.
+// Shallow rear recess accepts a printed installation-zone label.
+//
+// Dual-use: flat face to wall (vertical screw axis) or flat face
+// to ceiling (horizontal screw axis) — same part either way.
+//
+// Print: backplate flat on bed, PETG, 5 perims, 40 % gyroid.
+module wall_base() {
+    ear_h   = ARM_W + 3.0;
+    ear_t   = 6.0;
+    ear_sep = ARM_W + 1.0;
 
     difference() {
         union() {
-            // D-shaped body
+            // ── Backplate ────────────────────────────────────────────────
-            intersection() {
+            translate([-BASE_W/2, -BASE_T, -BASE_H/2])
-                cylinder(d=COL_OD, h=COL_H);
+                cube([BASE_W, BASE_T, BASE_H]);
-                translate([-COL_OD/2, y_front ? 0 : -COL_OD/2, 0])
-                    cube([COL_OD, COL_OD/2, COL_H]);
-            }
 
-            // Anti-rotation tab (front half only, at +X side)
+            // ── Two pivot ears ────────────────────────────────────────────
-            if (y_front) {
+            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
-                translate([COL_OD/2, -ANTI_ROT_W/2, ANTI_ROT_Z])
+                translate([ex, -BASE_T + e, -ear_h/2])
-                    cube([ANTI_ROT_T, ANTI_ROT_W,
+                    cube([ear_t, KNUCKLE_T + e, ear_h]);
-                          COL_H - ANTI_ROT_Z - 4]);
-            }
 
-            // Bracket arm attachment boss (front half only, top centre)
+            // ── Stiffening gussets ────────────────────────────────────────
-            if (y_front) {
+            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
-                translate([-ARM_W/2, COL_OD/2, COL_H * 0.3])
+                hull() {
-                    cube([ARM_W, ARM_L, COL_H * 0.4]);
+                    translate([ex, -BASE_T, -ear_h/4])
+                        cube([ear_t, BASE_T - 1, ear_h/2]);
+                    translate([ex + (ex < 0 ? ear_t*0.6 : 0),
+                               -BASE_T, -ear_h/6])
+                        cube([ear_t * 0.4, 1, ear_h/3]);
                 }
         }
 
-        // ── Stem bore ─────────────────────────────────────────
+        // ── 2× countersunk wall screws ────────────────────────────────────
-        translate([0,0,-e])
+        for (sz = [-BASE_SCREW_SPC/2, BASE_SCREW_SPC/2]) {
-            cylinder(d=STEM_BORE, h=COL_H + 2*e);
+            translate([0, -BASE_T - e, sz])
+                rotate([-90, 0, 0])
+                    cylinder(d = BASE_SCREW_D, h = BASE_T + 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) ──────────────
+        // ── Pivot bolt bore (M3, through both ears) ───────────────────────
-        for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
+        translate([-(ear_sep/2 + ear_t + e), KNUCKLE_T * 0.55, 0])
-            translate([bx, y_front ? COL_OD/2 : 0, COL_H/2])
+            rotate([0, 90, 0])
-                rotate([90,0,0])
+                cylinder(d = PIVOT_D, h = ear_sep + 2*ear_t + 2*e);
-                    cylinder(d=COL_BOLT_D, h=COL_OD/2 + e);
+
-            // Thumbscrew head recess on outer face (front only — access side)
+        // ── M3 nyloc nut pocket (outer face of one ear) ───────────────────
-            if (y_front) {
+        translate([ear_sep/2 + ear_t - PIVOT_NUT_H - 0.4,
-                translate([bx, COL_OD/2 - WALL, COL_H/2])
+                   KNUCKLE_T * 0.55, 0])
-                    rotate([90,0,0])
+            rotate([0, 90, 0])
-                        cylinder(d=THUMB_HEAD_D, h=8 + e);
+                cylinder(d = PIVOT_NUT_AF / cos(30),
+                         h = PIVOT_NUT_H + 0.5, $fn = 6);
+
+        // ── Detent arc — 7 notches at 15° steps on +X ear inner face ─────
+        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);
+
+        // ── Installation label recess (rear face of backplate) ────────────
+        translate([0, -BASE_T - e, 0])
+            rotate([-90, 0, 0])
+                cube([BASE_W - 12, BASE_H - 16, 1.6], center = true);
+
+        // ── Lightening pocket ─────────────────────────────────────────────
+        translate([0, -BASE_T + 1.5, 0])
+            cube([BASE_W - 14, BASE_T - 3, BASE_H - 20], center = true);
     }
 }
 
-        // ── M4 hex nut pockets (rear half) ────────────────────
+// ============================================================
-        if (!y_front) {
+// PART 2 — TILT ARM
-            for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
+// ============================================================
-                translate([bx, -(COL_OD/4 + e), COL_H/2])
+// Pivoting arm linking wall_base pivot ears to anchor_cradle.
-                    rotate([90,0,0])
+// Knuckle end (Z=0): M3 pivot bore + spring-plunger detent pocket
-                        cylinder(d=COL_NUT_W/cos(30), h=COL_NUT_H + e,
+//   that indexes into the base ear detent arc notches.
-                                 $fn=6);
+// Cradle end (Z=ARM_L): 2× M3 bolt attachment to cradle back wall.
-            }
+// USB-C cable channel runs along outer (+Y) face, full arm length.
-        }
+//
-
+// Print: knuckle face flat on bed, PETG, 5 perims, 40 % gyroid.
-        // ── Set screw (height lock, front half) ───────────────
+module tilt_arm() {
-        if (y_front) {
+    total_h = ARM_L + 10;
-            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);
-        }
-    }
-}
-
-// ─────────────────────────────────────────────────────────────
-// module_bracket()
-//   Bolts to collar arm boss. Holds MaUWB PCB facing outward.
-//   Tilted BRKT_TILT° from vertical — antenna clears stem.
-//   Print flat-face-down (back wall on bed).
-// ─────────────────────────────────────────────────────────────
-module module_bracket() {
-    bk = BRKT_BACK_T;
-    sd = BRKT_SIDE_T;
 
     difference() {
         union() {
-            // ── Back wall (mounts to collar arm boss) ─────────
+            // ── Arm body ─────────────────────────────────────────────────
-            cube([ARM_W, bk, MAWB_H + M2_STNDFF + 6]);
-
-            // ── Side walls ────────────────────────────────────
-            for (sx=[0, ARM_W - sd])
-                translate([sx, bk, 0])
-                    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);
-        }
-
-        // ── M2 bores through standoffs ────────────────────────
-        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,
-                       -e])
-                cylinder(d=M2_D, h=M2_STNDFF + e);
-
-        // ── Antenna clearance cutout in back wall ─────────────
-        // Open slot near top of back wall so antenna is unobstructed
-        translate([sd, -e, M2_STNDFF + 2])
-            cube([ARM_W - 2*sd, bk + 2*e, MAWB_H]);
-
-        // ── USB port access notch on one side wall ────────────
-        translate([-e, bk + 2, M2_STNDFF - 1])
-            cube([sd + 2*e, USB_NOTCH_W, USB_NOTCH_H]);
-
-        // ── Mounting holes to collar arm boss (×2) ────────────
-        for (dx=[-ARM_W/4, ARM_W/4])
-            translate([ARM_W/2 + dx, bk + ARM_L/2, -e])
-                cylinder(d=COL_BOLT_D, h=6 + e);
-    }
-}
-
-// ─────────────────────────────────────────────────────────────
-// 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();
+                cube([ARM_W, ARM_T, total_h]);
 
-    // Phantom UWB PCB
+            // ── Knuckle boss (rounded pivot end) ─────────────────────────
-    if (show_phantom)
+            translate([0, ARM_T/2, 0])
-        color("ForestGreen", 0.4)
+                rotate([90, 0, 0])
-            translate([-MAWB_L/2,
+                    cylinder(d = ARM_W, h = ARM_T, center = true);
-                       COL_OD/2 + ARM_L + BRKT_BACK_T,
+
-                       COL_H * 0.3 + M2_STNDFF])
+            // ── Cradle attach stub (Z = ARM_L) ────────────────────────────
-                cube([MAWB_L, MAWB_W, MAWB_H]);
+            translate([-ARM_W/2, 0, ARM_L])
+                cube([ARM_W, ARM_T + CRADLE_BACK_T, ARM_T]);
         }
 
-// ─────────────────────────────────────────────────────────────
+        // ── M3 pivot bore ─────────────────────────────────────────────────
-// Render selector
+        translate([-ARM_W/2 - e, ARM_T/2, 0])
-// ─────────────────────────────────────────────────────────────
+            rotate([0, 90, 0])
-if (RENDER == "assembly") {
+                cylinder(d = PIVOT_D, h = ARM_W + 2*e);
-    single_anchor_assembly(show_phantom=true);
 
-} else if (RENDER == "collar_front") {
+        // ── Detent plunger pocket (3 mm spring-ball, outer +Y face) ──────
-    collar_half("front");
+        translate([0, ARM_T + e, 0])
+            rotate([90, 0, 0])
+                cylinder(d = 3.2, h = 4 + e);
 
-} else if (RENDER == "collar_rear") {
+        // ── USB-C cable channel (outer +Y face, mid-arm length) ───────────
-    collar_half("rear");
+        translate([-USBC_CHAN_W/2, ARM_T - e, ARM_T + 4])
+            cube([USBC_CHAN_W, USBC_CHAN_H, ARM_L - ARM_T - 8]);
 
-} else if (RENDER == "bracket") {
+        // ── Cradle attach bolt holes (2× M3 at cradle stub) ───────────────
-    module_bracket();
+        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);
 
-} else if (RENDER == "pair") {
+        // ── M3 nut pockets (front of cradle stub) ─────────────────────────
-    // Both anchors at 250 mm spacing on a stem stub
+        for (bx = [-ARM_W/4, ARM_W/4])
-    color("Silver", 0.2)
+            translate([bx, ARM_T/2, ARM_L + ARM_T/2])
-        translate([0, 0, -50])
+                rotate([-90, 0, 0])
-            cylinder(d=STEM_OD, h=ANCHOR_SPACING + COL_H + 100);
+                    cylinder(d = M3_NUT_AF / cos(30),
+                             h = M3_NUT_H + 0.5, $fn = 6);
 
-    // Lower anchor (Z = 0)
+        // ── Lightening pocket ─────────────────────────────────────────────
-    single_anchor_assembly(show_phantom=true);
+        translate([0, ARM_T/2, ARM_L/2])
-
+            cube([ARM_W - 4, ARM_T - 2, ARM_L - 18], center = true);
-    // Upper anchor (Z = ANCHOR_SPACING)
+    }
-    translate([0, 0, ANCHOR_SPACING])
-        single_anchor_assembly(show_phantom=true);
 }
 
+// ============================================================
+// PART 3 — ANCHOR CRADLE
+// ============================================================
+// Open-front U-cradle for ESP32 UWB Pro PCB.
+// PCB retained on 4× M2.5 standoffs matching UWB_HOLE_X × UWB_HOLE_Y.
+// Back wall features:
+//   • USB-C exit slot  — aligns with PCB USB-C port
+//   • USB-C groove     — cable routes from slot toward arm channel
+//   • Label card slot  — insert printed strip for anchor ID
+//   • Antenna keep-out — back wall material removed above antenna area
+// Front lip prevents PCB from sliding forward.
+// Two attachment tabs bolt to tilt_arm cradle stub.
+//
+// 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() {
+            // ── Cradle body ───────────────────────────────────────────────
+            translate([-outer_l/2, 0, 0])
+                cube([outer_l, outer_w, total_z]);
+
+            // ── Front retaining lip ───────────────────────────────────────
+            translate([-outer_l/2, outer_w - CRADLE_LIP_T, 0])
+                cube([outer_l, CRADLE_LIP_T, CRADLE_LIP_H]);
+
+            // ── Arm attachment tabs (behind back wall) ─────────────────────
+            for (tx = [-ARM_W/4, ARM_W/4])
+                translate([tx - 4, -CRADLE_BACK_T, 0])
+                    cube([8, CRADLE_BACK_T + 1, total_z]);
+        }
+
+        // ── PCB pocket ────────────────────────────────────────────────────
+        translate([-UWB_L/2, 0, pcb_z])
+            cube([UWB_L, UWB_W + 1, UWB_H + 4]);
+
+        // ── USB-C exit slot (through back wall, aligned to PCB port) ─────
+        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]);
+
+        // ── USB-C cable routing groove (outer back wall face) ─────────────
+        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]);
+
+        // ── Label card slot (insert from below, rear face upper half) ─────
+        // Paper/laminate card strip identifying this anchor instance
+        translate([0, -CRADLE_BACK_T - e, pcb_z + UWB_H/2])
+            cube([LABEL_W, LABEL_T + 0.3, LABEL_H],
+                 center = [true, false, false]);
+
+        // ── Antenna keep-out: remove back wall above antenna area ─────────
+        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]);
+
+        // ── Arm bolt holes through attachment tabs ────────────────────────
+        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);
+
+        // ── Lightening slots in side walls ────────────────────────────────
+        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]);
+    }
+
+    // ── M2.5 standoff bosses (positive, inside cradle floor) ──────────────
+    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);
+        }
+}
+
+// ============================================================
+// PART 4 — CABLE CLIP
+// ============================================================
+// Snap-on C-clip retaining USB-C cable along tilt arm outer face.
+// Presses onto ARM_T-wide arm with PETG snap tongues.
+// Open-front cable channel for push-in cable insertion.
+// Print ×2–3 per anchor, spaced 25 mm along arm.
+//
+// Print: clip-opening face down, PETG, 3 perims, 20 % infill.
+module cable_clip() {
+    ch_r   = CLIP_CABLE_D/2 + CLIP_T;
+    snap_t = 1.6;
+
+    difference() {
+        union() {
+            // ── Body plate ────────────────────────────────────────────────
+            translate([-CLIP_BODY_W/2, 0, 0])
+                cube([CLIP_BODY_W, CLIP_T, CLIP_BODY_H]);
+
+            // ── Cable channel (C-shape, opens toward +Y) ─────────────────
+            translate([0, CLIP_T + ch_r, CLIP_BODY_H/2])
+                rotate([0, 90, 0])
+                    difference() {
+                        cylinder(r = ch_r, h = CLIP_BODY_W, center = true);
+                        cylinder(r = CLIP_CABLE_D/2,
+                                 h = CLIP_BODY_W + 2*e, center = true);
+                        // open insertion slot
+                        translate([0, ch_r + e, 0])
+                            cube([CLIP_CABLE_D * 0.85,
+                                  ch_r * 2 + 2*e,
+                                  CLIP_BODY_W + 2*e], center = true);
+                    }
+
+            // ── Snap tongues (straddle arm, -Y side of body) ─────────────
+            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]);
+
+            // ── Snap barbs ────────────────────────────────────────────────
+            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);
+        }
+
+        // ── Arm slot (arm body passes between tongues) ─────────────────────
+        translate([0, -ARM_T - 1 - e, CLIP_BODY_H/2])
+            cube([CLIP_BODY_W - 6, ARM_T + 2, CLIP_BODY_H - 4], center = true);
+    }
+}

include/jlink.h

@@ -3,9 +3,10 @@
 
 #include <stdint.h>
 #include <stdbool.h>
+#include "pid_flash.h"   /* pid_sched_entry_t, PID_SCHED_MAX_BANDS */
 
 /*
- * JLink — Jetson serial binary protocol over USART1 (PB6=TX, PB7=RX).
+ * 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.
@@ -28,14 +29,21 @@
  *   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
+ *   0x08  AUDIO      - int16 PCM samples (up to 126 samples)
+ *   0x09  SLEEP      - no payload; request STOP-mode sleep
  *   0x0A  PID_SAVE   - no payload; save current Kp/Ki/Kd to flash (Issue #531)
  *   0x0B  GIMBAL_POS - int16 pan_x10, int16 tilt_x10, uint16 speed (Issue #547)
+ *   0x0C  SCHED_GET  - no payload; reply with TLM_SCHED (Issue #550)
+ *   0x0D  SCHED_SET  - uint8 num_bands + N*16-byte pid_sched_entry_t (Issue #550)
+ *   0x0E  SCHED_SAVE - float kp, ki, kd (12 bytes); save sched+single to flash (Issue #550)
  *
  * STM32 to Jetson telemetry:
  *   0x80  STATUS        - jlink_tlm_status_t (20 bytes), sent at JLINK_TLM_HZ
  *   0x81  POWER         - jlink_tlm_power_t (11 bytes), sent at PM_TLM_HZ
+ *   0x82  BATTERY       - jlink_tlm_battery_t (10 bytes, Issue #533)
  *   0x83  PID_RESULT    - jlink_tlm_pid_result_t (13 bytes), sent after PID_SAVE (Issue #531)
  *   0x84  GIMBAL_STATE  - jlink_tlm_gimbal_state_t (10 bytes, Issue #547)
+ *   0x85  SCHED         - jlink_tlm_sched_t (1+N*16 bytes), sent on SCHED_GET (Issue #550)
  *
  * Priority: CRSF RC always takes precedence. Jetson steer/speed only applied
  * when mode_manager_active() == MODE_AUTONOMOUS (CH6 high). In RC_MANUAL and
@@ -62,13 +70,17 @@
 #define JLINK_CMD_SLEEP         0x09u  /* no payload; request STOP-mode sleep */
 #define JLINK_CMD_PID_SAVE      0x0Au  /* no payload; save Kp/Ki/Kd to flash (Issue #531) */
 #define JLINK_CMD_GIMBAL_POS    0x0Bu  /* int16 pan_x10, int16 tilt_x10, uint16 speed (Issue #547) */
+#define JLINK_CMD_SCHED_GET     0x0Cu  /* no payload; reply TLM_SCHED (Issue #550) */
+#define JLINK_CMD_SCHED_SET     0x0Du  /* uint8 num_bands + N*16-byte entries (Issue #550) */
+#define JLINK_CMD_SCHED_SAVE    0x0Eu  /* float kp,ki,kd; save sched+single to flash (Issue #550) */
 
 /* ---- Telemetry IDs (STM32 to Jetson) ---- */
 #define JLINK_TLM_STATUS        0x80u
 #define JLINK_TLM_POWER         0x81u  /* jlink_tlm_power_t (11 bytes) */
 #define JLINK_TLM_BATTERY       0x82u  /* jlink_tlm_battery_t (10 bytes, Issue #533) */
-#define JLINK_TLM_PID_RESULT    0x83u  /* jlink_tlm_pid_result_t (13 bytes) Issue #531 */
+#define JLINK_TLM_PID_RESULT    0x83u  /* jlink_tlm_pid_result_t (13 bytes, Issue #531) */
 #define JLINK_TLM_GIMBAL_STATE  0x84u  /* jlink_tlm_gimbal_state_t (10 bytes, Issue #547) */
+#define JLINK_TLM_SCHED         0x85u  /* jlink_tlm_sched_t (1+N*16 bytes, Issue #550) */
 
 /* ---- Telemetry STATUS payload (20 bytes, packed) ---- */
 typedef struct __attribute__((packed)) {
@@ -98,15 +110,15 @@ typedef struct __attribute__((packed)) {
     uint32_t idle_ms;       /* ms since last cmd_vel activity */
 } jlink_tlm_power_t;  /* 11 bytes */
 
-/* ---- Telemetry BATTERY payload (10 bytes, packed) — Issue #533 ---- */
+/* ---- Telemetry BATTERY payload (10 bytes, packed) Issue #533 ---- */
 typedef struct __attribute__((packed)) {
     uint16_t vbat_mv;     /* DMA-sampled LPF-filtered Vbat (mV) */
     int16_t  ibat_ma;     /* DMA-sampled LPF-filtered Ibat (mA, + = discharge) */
     uint16_t vbat_raw_mv; /* unfiltered last-tick average (mV) */
     uint8_t  flags;       /* bit0=low, bit1=critical, bit2=4S, bit3=adc_ready */
-    int8_t   cal_offset;  /* vbat_offset_mv / 4 (±127 → ±508 mV)              */
+    int8_t   cal_offset;  /* vbat_offset_mv / 4 (+-127 -> +-508 mV) */
-    uint8_t  lpf_shift;   /* IIR shift factor (α = 1/2^lpf_shift)              */
+    uint8_t  lpf_shift;   /* IIR shift factor (alpha = 1/2^lpf_shift) */
-    uint8_t  soc_pct;     /* voltage-based SoC 0–100, 255 = unknown            */
+    uint8_t  soc_pct;     /* voltage-based SoC 0-100, 255 = unknown */
 } jlink_tlm_battery_t;  /* 10 bytes */
 
 /* ---- Telemetry PID_RESULT payload (13 bytes, packed) Issue #531 ---- */
@@ -129,6 +141,13 @@ typedef struct __attribute__((packed)) {
     uint8_t  rx_err_pct;     /* bus error rate 0-100% (rx_err*100/(rx_ok+rx_err)) */
 } jlink_tlm_gimbal_state_t;  /* 10 bytes */
 
+/* ---- Telemetry SCHED payload (1 + N*16 bytes, packed) Issue #550 ---- */
+/* Sent in response to JLINK_CMD_SCHED_GET; N = num_bands (1..PID_SCHED_MAX_BANDS). */
+typedef struct __attribute__((packed)) {
+    uint8_t           num_bands;                   /* number of valid entries */
+    pid_sched_entry_t bands[PID_SCHED_MAX_BANDS];  /* up to 6 x 16 = 96 bytes */
+} jlink_tlm_sched_t;  /* 1 + 96 = 97 bytes max */
+
 /* ---- Volatile state (read from main loop) ---- */
 typedef struct {
     /* Drive command - updated on JLINK_CMD_DRIVE */
@@ -161,55 +180,37 @@ typedef struct {
     volatile int16_t  gimbal_pan_x10;  /* pan  angle deg x10 */
     volatile int16_t  gimbal_tilt_x10; /* tilt angle deg x10 */
     volatile uint16_t gimbal_speed;    /* servo speed 0-4095 (0=max) */
+
+    /* PID schedule commands (Issue #550) - set by parser, cleared by main loop */
+    volatile uint8_t  sched_get_req;   /* SCHED_GET: main loop calls jlink_send_sched_telemetry() */
+    volatile uint8_t  sched_save_req;  /* SCHED_SAVE: main loop calls pid_schedule_flash_save() */
+    volatile float    sched_save_kp;   /* kp for single-PID record in SCHED_SAVE */
+    volatile float    sched_save_ki;
+    volatile float    sched_save_kd;
 } JLinkState;
 
 extern volatile JLinkState jlink_state;
 
+/* ---- SCHED_SET receive buffer -- Issue #550 ---- */
+/*
+ * Populated by the parser on JLINK_CMD_SCHED_SET.  Main loop reads via
+ * jlink_get_sched_set() and calls pid_schedule_set_table() before clearing.
+ */
+typedef struct {
+    volatile uint8_t   ready;                        /* set by parser, cleared by main loop */
+    volatile uint8_t   num_bands;
+    pid_sched_entry_t  bands[PID_SCHED_MAX_BANDS];   /* copied from frame */
+} JLinkSchedSetBuf;
+
 /* ---- 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);
-
+void jlink_send_telemetry(const jlink_tlm_status_t *status);
-/*
- * 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);
-
-/*
- * jlink_send_pid_result(result) - build and transmit a JLINK_TLM_PID_RESULT
- * frame (19 bytes) to confirm PID flash save outcome (Issue #531).
- */
-void jlink_send_pid_result(const jlink_tlm_pid_result_t *result);
-
-/*
- * jlink_send_battery_telemetry(batt) - build and transmit JLINK_TLM_BATTERY
- * (0x82) frame (16 bytes) at BATTERY_ADC_PUBLISH_HZ (1 Hz).
- * Called by battery_adc_publish(); not normally called directly.
- */
 void jlink_send_battery_telemetry(const jlink_tlm_battery_t *batt);
+void jlink_send_pid_result(const jlink_tlm_pid_result_t *result);
 
 /*
  * jlink_send_gimbal_state(state) - transmit JLINK_TLM_GIMBAL_STATE (0x84)
@@ -217,4 +218,18 @@ void jlink_send_battery_telemetry(const jlink_tlm_battery_t *batt);
  */
 void jlink_send_gimbal_state(const jlink_tlm_gimbal_state_t *state);
 
+/*
+ * jlink_send_sched_telemetry(tlm) - transmit JLINK_TLM_SCHED (0x85) in
+ * response to SCHED_GET.  tlm->num_bands determines actual frame size.
+ * Issue #550.
+ */
+void jlink_send_sched_telemetry(const jlink_tlm_sched_t *tlm);
+
+/*
+ * jlink_get_sched_set() - return pointer to the most-recently received
+ * SCHED_SET payload buffer (static storage in jlink.c).  Main loop calls
+ * pid_schedule_set_table() from this buffer, then clears ready.  Issue #550.
+ */
+JLinkSchedSetBuf *jlink_get_sched_set(void);
+
 #endif /* JLINK_H */

jetson/ros2_ws/src/saltybot_health_monitor/config/sensor_health_params.yaml

@@ -0,0 +1,66 @@
+sensor_health_node:
+  ros__parameters:
+    # Publish rate for DiagnosticArray and JSON summary
+    check_hz: 1.0
+
+    # MQTT broker for saltybot/health topic
+    mqtt_broker: "localhost"
+    mqtt_port: 1883
+    mqtt_topic: "saltybot/health"
+    mqtt_enabled: true
+
+# Per-sensor thresholds and configuration
+# Each entry: topic, name, warn_s (WARN threshold), error_s (ERROR threshold), critical
+#
+# critical=true: system cannot operate without this sensor
+# warn_s: topic age (s) that triggers WARN level
+# error_s: topic age (s) that triggers ERROR level
+
+sensors:
+  - topic: "/camera/color/image_raw"
+    name: "camera_color"
+    warn_s: 1.0
+    error_s: 3.0
+    critical: true
+
+  - topic: "/camera/depth/image_rect_raw"
+    name: "camera_depth"
+    warn_s: 1.0
+    error_s: 3.0
+    critical: true
+
+  - topic: "/camera/color/camera_info"
+    name: "camera_info"
+    warn_s: 2.0
+    error_s: 5.0
+    critical: false
+
+  - topic: "/scan"
+    name: "lidar"
+    warn_s: 1.0
+    error_s: 3.0
+    critical: true
+
+  - topic: "/imu/data"
+    name: "imu"
+    warn_s: 0.5
+    error_s: 2.0
+    critical: true
+
+  - topic: "/saltybot/uwb/range"
+    name: "uwb"
+    warn_s: 2.0
+    error_s: 5.0
+    critical: false
+
+  - topic: "/saltybot/battery"
+    name: "battery"
+    warn_s: 3.0
+    error_s: 8.0
+    critical: false
+
+  - topic: "/saltybot/motor_daemon/status"
+    name: "motor_daemon"
+    warn_s: 2.0
+    error_s: 5.0
+    critical: true

jetson/ros2_ws/src/saltybot_health_monitor/launch/sensor_health.launch.py

@@ -0,0 +1,50 @@
+"""sensor_health.launch.py — Launch sensor health monitor node (Issue #566)."""
+
+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() -> LaunchDescription:
+    pkg = get_package_share_directory("saltybot_health_monitor")
+
+    check_hz_arg = DeclareLaunchArgument(
+        "check_hz",
+        default_value="1.0",
+        description="Health check publish rate (Hz)",
+    )
+    mqtt_broker_arg = DeclareLaunchArgument(
+        "mqtt_broker",
+        default_value="localhost",
+        description="MQTT broker hostname",
+    )
+    mqtt_enabled_arg = DeclareLaunchArgument(
+        "mqtt_enabled",
+        default_value="true",
+        description="Enable MQTT publishing to saltybot/health",
+    )
+
+    sensor_health_node = Node(
+        package="saltybot_health_monitor",
+        executable="sensor_health_node",
+        name="sensor_health_node",
+        output="screen",
+        parameters=[
+            os.path.join(pkg, "config", "sensor_health_params.yaml"),
+            {
+                "check_hz":    LaunchConfiguration("check_hz"),
+                "mqtt_broker": LaunchConfiguration("mqtt_broker"),
+                "mqtt_enabled": LaunchConfiguration("mqtt_enabled"),
+            },
+        ],
+    )
+
+    return LaunchDescription([
+        check_hz_arg,
+        mqtt_broker_arg,
+        mqtt_enabled_arg,
+        sensor_health_node,
+    ])

jetson/ros2_ws/src/saltybot_health_monitor/package.xml

@@ -1,27 +1,24 @@
 <?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_health_monitor</name>
-  <version>0.1.0</version>
+  <version>0.2.0</version>
   <description>
-    ROS2 system health monitor for SaltyBot. Central node that monitors heartbeats
+    ROS2 health monitor for SaltyBot. Tracks node heartbeats and sensor topic
-    from all critical nodes, detects when nodes go down (>5s silent), triggers
+    staleness. Publishes DiagnosticArray on /saltybot/diagnostics and MQTT on
-    auto-restart, publishes /saltybot/system_health JSON, and alerts face display
+    saltybot/health. Issue #566.
-    on critical failures.
   </description>
-  <maintainer email="sl-controls@saltylab.local">sl-controls</maintainer>
+  <maintainer email="sl-jetson@saltylab.local">sl-jetson</maintainer>
-  <license>MIT</license>
+  <license>Apache-2.0</license>
 
   <depend>rclpy</depend>
   <depend>std_msgs</depend>
   <depend>geometry_msgs</depend>
+  <depend>sensor_msgs</depend>
+  <depend>diagnostic_msgs</depend>
 
   <buildtool_depend>ament_python</buildtool_depend>
 
-  <test_depend>ament_copyright</test_depend>
+  <test_depend>pytest</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>

jetson/ros2_ws/src/saltybot_health_monitor/saltybot_health_monitor/sensor_health_node.py

@@ -0,0 +1,385 @@
+#!/usr/bin/env python3
+"""sensor_health_node.py — ROS2 sensor topic health monitor (Issue #566).
+
+Monitors all sensor topics for staleness. Each sensor is checked against
+configurable WARN and ERROR timeouts. Results are published as a ROS2
+DiagnosticArray and as an MQTT JSON summary.
+
+Monitored topics (configurable via sensor_health_params.yaml):
+  /camera/color/image_raw             — RealSense colour stream
+  /camera/depth/image_rect_raw        — RealSense depth stream
+  /camera/color/camera_info           — RealSense camera info
+  /scan                               — LiDAR 2-D scan
+  /imu/data                           — IMU (BNO055 via JLink)
+  /saltybot/uwb/range                 — UWB ranging
+  /saltybot/battery                   — Battery telemetry (JSON string)
+  /saltybot/motor_daemon/status       — Motor daemon status
+
+Published topics:
+  /saltybot/diagnostics   (diagnostic_msgs/DiagnosticArray)  — full per-sensor status
+  /saltybot/sensor_health (std_msgs/String)                   — JSON summary
+
+MQTT:
+  Topic: saltybot/health
+  Payload: JSON {timestamp, overall, sensors:{name: {status, age_s, hz}}}
+
+Parameters (config/sensor_health_params.yaml):
+  check_hz             1.0     Health check publish rate
+  mqtt_broker          localhost
+  mqtt_port            1883
+  mqtt_topic           saltybot/health
+  mqtt_enabled         true
+  sensors              list of {topic, name, warn_s, error_s, critical}
+"""
+
+from __future__ import annotations
+
+import json
+import time
+import threading
+from dataclasses import dataclass, field
+from typing import Dict, List, Optional
+
+import rclpy
+from rclpy.node import Node
+from rclpy.qos import (
+    DurabilityPolicy, HistoryPolicy, QoSProfile, ReliabilityPolicy
+)
+
+from diagnostic_msgs.msg import DiagnosticArray, DiagnosticStatus, KeyValue
+from sensor_msgs.msg import CameraInfo, Image, Imu, LaserScan
+from std_msgs.msg import String
+
+
+# ── Diagnostic level aliases ───────────────────────────────────────────────────
+
+OK    = DiagnosticStatus.OK     # 0
+WARN  = DiagnosticStatus.WARN   # 1
+ERROR = DiagnosticStatus.ERROR  # 2
+
+_LEVEL_NAMES = {OK: "OK", WARN: "WARN", ERROR: "ERROR"}
+
+# ── Default sensor configuration ──────────────────────────────────────────────
+
+DEFAULT_SENSORS: List[dict] = [
+    {"topic": "/camera/color/image_raw",        "name": "camera_color",     "warn_s": 1.0, "error_s": 3.0, "critical": True},
+    {"topic": "/camera/depth/image_rect_raw",   "name": "camera_depth",     "warn_s": 1.0, "error_s": 3.0, "critical": True},
+    {"topic": "/camera/color/camera_info",      "name": "camera_info",      "warn_s": 2.0, "error_s": 5.0, "critical": False},
+    {"topic": "/scan",                          "name": "lidar",            "warn_s": 1.0, "error_s": 3.0, "critical": True},
+    {"topic": "/imu/data",                      "name": "imu",              "warn_s": 0.5, "error_s": 2.0, "critical": True},
+    {"topic": "/saltybot/uwb/range",            "name": "uwb",              "warn_s": 2.0, "error_s": 5.0, "critical": False},
+    {"topic": "/saltybot/battery",              "name": "battery",          "warn_s": 3.0, "error_s": 8.0, "critical": False},
+    {"topic": "/saltybot/motor_daemon/status",  "name": "motor_daemon",     "warn_s": 2.0, "error_s": 5.0, "critical": True},
+]
+
+
+# ── SensorWatcher ─────────────────────────────────────────────────────────────
+
+class SensorWatcher:
+    """Tracks message receipt timestamps and rate for a single topic.
+
+    Thread-safe: callback may fire from any executor thread.
+    """
+
+    def __init__(self, topic: str, name: str,
+                 warn_s: float, error_s: float, critical: bool) -> None:
+        self.topic    = topic
+        self.name     = name
+        self.warn_s   = warn_s
+        self.error_s  = error_s
+        self.critical = critical
+
+        self._last_rx:  float = 0.0   # monotonic; 0 = never received
+        self._count:    int   = 0
+        self._rate_hz:  float = 0.0
+        self._rate_ts:  float = time.monotonic()
+        self._rate_cnt: int   = 0
+        self._lock = threading.Lock()
+
+    # ── Callback (called from subscription) ────────────────────────────────
+
+    def on_message(self, _msg) -> None:
+        """Record receipt of any message on this topic."""
+        now = time.monotonic()
+        with self._lock:
+            self._last_rx = now
+            self._count  += 1
+            self._rate_cnt += 1
+            # Update rate estimate every ~2 s
+            elapsed = now - self._rate_ts
+            if elapsed >= 2.0:
+                self._rate_hz  = self._rate_cnt / elapsed
+                self._rate_cnt = 0
+                self._rate_ts  = now
+
+    # ── Status query ───────────────────────────────────────────────────────
+
+    def age_s(self, now: Optional[float] = None) -> float:
+        """Seconds since last message (∞ if never received)."""
+        if now is None:
+            now = time.monotonic()
+        with self._lock:
+            if self._last_rx == 0.0:
+                return float("inf")
+            return now - self._last_rx
+
+    def rate_hz(self) -> float:
+        with self._lock:
+            return self._rate_hz
+
+    def msg_count(self) -> int:
+        with self._lock:
+            return self._count
+
+    def level(self, now: Optional[float] = None) -> int:
+        age = self.age_s(now)
+        if age >= self.error_s:
+            return ERROR
+        if age >= self.warn_s:
+            return WARN
+        return OK
+
+    def diagnostic_status(self, now: Optional[float] = None) -> DiagnosticStatus:
+        if now is None:
+            now = time.monotonic()
+        age   = self.age_s(now)
+        lvl   = self.level(now)
+        hz    = self.rate_hz()
+        cnt   = self.msg_count()
+
+        if age == float("inf"):
+            msg = f"ERROR: no data received on {self.topic}"
+        elif lvl == ERROR:
+            msg = f"ERROR: stale {age:.1f}s (threshold {self.error_s:.1f}s)"
+        elif lvl == WARN:
+            msg = f"WARN: stale {age:.1f}s (threshold {self.warn_s:.1f}s)"
+        else:
+            msg = f"OK ({hz:.1f} Hz)"
+
+        age_str = "inf" if age == float("inf") else f"{age:.2f}"
+        status = DiagnosticStatus()
+        status.level   = lvl
+        status.name    = self.name
+        status.message = msg
+        status.hardware_id = self.topic
+        status.values  = [
+            KeyValue(key="topic",    value=self.topic),
+            KeyValue(key="age_s",    value=age_str),
+            KeyValue(key="rate_hz",  value=f"{hz:.2f}"),
+            KeyValue(key="count",    value=str(cnt)),
+            KeyValue(key="warn_s",   value=str(self.warn_s)),
+            KeyValue(key="error_s",  value=str(self.error_s)),
+            KeyValue(key="critical", value=str(self.critical)),
+        ]
+        return status
+
+    def summary_dict(self, now: Optional[float] = None) -> dict:
+        if now is None:
+            now = time.monotonic()
+        age = self.age_s(now)
+        return {
+            "status":    _LEVEL_NAMES[self.level(now)],
+            "age_s":     round(age, 2) if age != float("inf") else None,
+            "rate_hz":   round(self.rate_hz(), 2),
+            "count":     self.msg_count(),
+            "critical":  self.critical,
+        }
+
+
+# ── SensorHealthNode ───────────────────────────────────────────────────────────
+
+class SensorHealthNode(Node):
+    """Monitor all sensor topics; publish DiagnosticArray + MQTT JSON."""
+
+    def __init__(self) -> None:
+        super().__init__("sensor_health_node")
+
+        # ── Parameters ─────────────────────────────────────────────────────
+        self.declare_parameter("check_hz",    1.0)
+        self.declare_parameter("mqtt_broker", "localhost")
+        self.declare_parameter("mqtt_port",   1883)
+        self.declare_parameter("mqtt_topic",  "saltybot/health")
+        self.declare_parameter("mqtt_enabled", True)
+
+        check_hz         = self.get_parameter("check_hz").value
+        self._mqtt_broker = self.get_parameter("mqtt_broker").value
+        self._mqtt_port   = int(self.get_parameter("mqtt_port").value)
+        self._mqtt_topic  = self.get_parameter("mqtt_topic").value
+        mqtt_enabled      = self.get_parameter("mqtt_enabled").value
+
+        # ── Build sensor watchers ───────────────────────────────────────────
+        self._watchers: Dict[str, SensorWatcher] = {}
+        for cfg in DEFAULT_SENSORS:
+            w = SensorWatcher(
+                topic    = cfg["topic"],
+                name     = cfg["name"],
+                warn_s   = float(cfg.get("warn_s",   1.0)),
+                error_s  = float(cfg.get("error_s",  3.0)),
+                critical = bool(cfg.get("critical",  False)),
+            )
+            self._watchers[cfg["name"]] = w
+
+        # ── Subscriptions — one per sensor type ────────────────────────────
+        # Best-effort QoS for sensor data (sensors may use BEST_EFFORT publishers)
+        be_qos = QoSProfile(
+            history=HistoryPolicy.KEEP_LAST, depth=1,
+            reliability=ReliabilityPolicy.BEST_EFFORT,
+            durability=DurabilityPolicy.VOLATILE,
+        )
+        rel_qos = QoSProfile(
+            history=HistoryPolicy.KEEP_LAST, depth=5,
+            reliability=ReliabilityPolicy.RELIABLE,
+        )
+
+        self._subscribe(Image,      "/camera/color/image_raw",       "camera_color",  be_qos)
+        self._subscribe(Image,      "/camera/depth/image_rect_raw",  "camera_depth",  be_qos)
+        self._subscribe(CameraInfo, "/camera/color/camera_info",     "camera_info",   be_qos)
+        self._subscribe(LaserScan,  "/scan",                         "lidar",         be_qos)
+        self._subscribe(Imu,        "/imu/data",                     "imu",           be_qos)
+        self._subscribe(String,     "/saltybot/uwb/range",           "uwb",           rel_qos)
+        self._subscribe(String,     "/saltybot/battery",             "battery",       rel_qos)
+        self._subscribe(String,     "/saltybot/motor_daemon/status", "motor_daemon",  rel_qos)
+
+        # ── Publishers ─────────────────────────────────────────────────────
+        self._pub_diag   = self.create_publisher(
+            DiagnosticArray, "/saltybot/diagnostics",   10)
+        self._pub_health = self.create_publisher(
+            String,          "/saltybot/sensor_health", 10)
+
+        # ── MQTT ───────────────────────────────────────────────────────────
+        self._mqtt_client = None
+        if mqtt_enabled:
+            self._connect_mqtt()
+
+        # ── Timer ──────────────────────────────────────────────────────────
+        self.create_timer(1.0 / max(0.1, check_hz), self._publish_diagnostics)
+
+        sensor_list = ", ".join(self._watchers.keys())
+        self.get_logger().info(
+            f"[sensor_health] monitoring {len(self._watchers)} sensors: {sensor_list}"
+        )
+
+    # ── Subscription helper ────────────────────────────────────────────────
+
+    def _subscribe(self, msg_type, topic: str, name: str, qos) -> None:
+        if name not in self._watchers:
+            return
+        watcher = self._watchers[name]
+        self.create_subscription(msg_type, topic, watcher.on_message, qos)
+
+    # ── MQTT ───────────────────────────────────────────────────────────────
+
+    def _connect_mqtt(self) -> None:
+        try:
+            import paho.mqtt.client as mqtt  # type: ignore
+            self._mqtt_client = mqtt.Client(client_id="saltybot_sensor_health")
+            self._mqtt_client.on_connect = self._on_mqtt_connect
+            self._mqtt_client.connect_async(self._mqtt_broker, self._mqtt_port, 60)
+            self._mqtt_client.loop_start()
+        except ImportError:
+            self.get_logger().warn(
+                "[sensor_health] paho-mqtt not installed — MQTT publishing disabled"
+            )
+        except Exception as e:
+            self.get_logger().warn(f"[sensor_health] MQTT connect failed: {e}")
+
+    def _on_mqtt_connect(self, client, userdata, flags, rc) -> None:
+        if rc == 0:
+            self.get_logger().info(
+                f"[sensor_health] MQTT connected to {self._mqtt_broker}:{self._mqtt_port}"
+            )
+        else:
+            self.get_logger().warn(f"[sensor_health] MQTT connect rc={rc}")
+
+    def _publish_mqtt(self, payload: str) -> None:
+        if self._mqtt_client is None:
+            return
+        try:
+            self._mqtt_client.publish(self._mqtt_topic, payload, qos=0, retain=True)
+        except Exception as e:
+            self.get_logger().warn(f"[sensor_health] MQTT publish error: {e}")
+
+    # ── Diagnostic publisher ───────────────────────────────────────────────
+
+    def _publish_diagnostics(self) -> None:
+        now    = time.monotonic()
+        wall   = time.time()
+
+        # Build DiagnosticArray
+        diag_array = DiagnosticArray()
+        diag_array.header.stamp = self.get_clock().now().to_msg()
+
+        sensor_summaries: dict = {}
+        worst_level = OK
+
+        for name, watcher in self._watchers.items():
+            ds = watcher.diagnostic_status(now)
+            diag_array.status.append(ds)
+
+            if ds.level > worst_level:
+                worst_level = ds.level
+
+            sensor_summaries[name] = watcher.summary_dict(now)
+
+        # Overall system status
+        n_error   = sum(1 for w in self._watchers.values() if w.level(now) == ERROR)
+        n_warn    = sum(1 for w in self._watchers.values() if w.level(now) == WARN)
+        crit_err  = [n for n, w in self._watchers.items()
+                     if w.critical and w.level(now) == ERROR]
+
+        overall = "OK"
+        if crit_err:
+            overall = "ERROR"
+        elif n_error > 0:
+            overall = "ERROR"
+        elif n_warn > 0:
+            overall = "WARN"
+
+        # Publish DiagnosticArray
+        self._pub_diag.publish(diag_array)
+
+        # JSON summary
+        summary = {
+            "timestamp":    wall,
+            "overall":      overall,
+            "n_ok":         len(self._watchers) - n_error - n_warn,
+            "n_warn":       n_warn,
+            "n_error":      n_error,
+            "critical_err": crit_err,
+            "sensors":      sensor_summaries,
+        }
+        payload = json.dumps(summary)
+        self._pub_health.publish(String(data=payload))
+        self._publish_mqtt(payload)
+
+        # Log on transitions or errors
+        if worst_level >= ERROR:
+            self.get_logger().warn(
+                f"[sensor_health] {overall}: {n_error} error(s), {n_warn} warn(s)"
+                + (f" — critical: {crit_err}" if crit_err else "")
+            )
+
+    def destroy_node(self) -> None:
+        if self._mqtt_client is not None:
+            try:
+                self._mqtt_client.loop_stop()
+                self._mqtt_client.disconnect()
+            except Exception:
+                pass
+        super().destroy_node()
+
+
+def main(args=None) -> None:
+    rclpy.init(args=args)
+    node = SensorHealthNode()
+    try:
+        rclpy.spin(node)
+    except KeyboardInterrupt:
+        pass
+    finally:
+        node.destroy_node()
+        rclpy.shutdown()
+
+
+if __name__ == "__main__":
+    main()

jetson/ros2_ws/src/saltybot_health_monitor/setup.py

@@ -4,27 +4,34 @@ package_name = "saltybot_health_monitor"
 
 setup(
     name=package_name,
-    version="0.1.0",
+    version="0.2.0",
     packages=[package_name],
     data_files=[
         ("share/ament_index/resource_index/packages", [f"resource/{package_name}"]),
         (f"share/{package_name}", ["package.xml"]),
-        (f"share/{package_name}/launch", ["launch/health_monitor.launch.py"]),
+        (f"share/{package_name}/launch", [
-        (f"share/{package_name}/config", ["config/health_config.yaml"]),
+            "launch/health_monitor.launch.py",
+            "launch/sensor_health.launch.py",
+        ]),
+        (f"share/{package_name}/config", [
+            "config/health_config.yaml",
+            "config/sensor_health_params.yaml",
+        ]),
     ],
-    install_requires=["setuptools", "pyyaml"],
+    install_requires=["setuptools", "pyyaml", "paho-mqtt"],
     zip_safe=True,
-    maintainer="sl-controls",
+    maintainer="sl-jetson",
-    maintainer_email="sl-controls@saltylab.local",
+    maintainer_email="sl-jetson@saltylab.local",
     description=(
-        "System health monitor: tracks node heartbeats, detects down nodes, "
+        "System health monitor: node heartbeats + sensor topic staleness "
-        "triggers auto-restart, publishes system health status"
+        "detection with DiagnosticArray and MQTT (Issue #566)"
     ),
-    license="MIT",
+    license="Apache-2.0",
     tests_require=["pytest"],
     entry_points={
         "console_scripts": [
             "health_monitor_node = saltybot_health_monitor.health_monitor_node:main",
+            "sensor_health_node  = saltybot_health_monitor.sensor_health_node:main",
         ],
     },
 )

jetson/ros2_ws/src/saltybot_health_monitor/test/test_sensor_health.py

@@ -0,0 +1,344 @@
+"""test_sensor_health.py — Unit tests for sensor_health_node (Issue #566).
+
+Runs entirely offline: no ROS2 runtime, no hardware, no MQTT broker required.
+"""
+
+import json
+import sys
+import time
+import types
+import unittest
+from unittest.mock import MagicMock, patch
+
+# ── Stub ROS2 and sensor_msgs so tests run offline ────────────────────────────
+
+def _install_stubs():
+    # rclpy
+    rclpy = types.ModuleType("rclpy")
+    rclpy.init = lambda **_: None
+    rclpy.spin = lambda _: None
+    rclpy.shutdown = lambda: None
+
+    node_mod = types.ModuleType("rclpy.node")
+    class _Node:
+        def __init__(self, *a, **kw): pass
+        def declare_parameter(self, *a, **kw): pass
+        def get_parameter(self, name):
+            defaults = {
+                "check_hz": 1.0, "mqtt_broker": "localhost",
+                "mqtt_port": 1883, "mqtt_topic": "saltybot/health",
+                "mqtt_enabled": False,
+            }
+            m = MagicMock(); m.value = defaults.get(name, False)
+            return m
+        def get_logger(self): return MagicMock()
+        def get_clock(self): return MagicMock()
+        def create_subscription(self, *a, **kw): pass
+        def create_publisher(self, *a, **kw): return MagicMock()
+        def create_timer(self, *a, **kw): pass
+        def destroy_node(self): pass
+    node_mod.Node = _Node
+    rclpy.node = node_mod
+
+    qos_mod = types.ModuleType("rclpy.qos")
+    for attr in ("QoSProfile", "HistoryPolicy", "ReliabilityPolicy", "DurabilityPolicy"):
+        setattr(qos_mod, attr, MagicMock())
+    rclpy.qos = qos_mod
+
+    sys.modules.setdefault("rclpy",      rclpy)
+    sys.modules.setdefault("rclpy.node", rclpy.node)
+    sys.modules.setdefault("rclpy.qos",  rclpy.qos)
+
+    # diagnostic_msgs
+    diag = types.ModuleType("diagnostic_msgs")
+    diag_msg = types.ModuleType("diagnostic_msgs.msg")
+
+    class _DiagStatus:
+        OK    = 0
+        WARN  = 1
+        ERROR = 2
+        def __init__(self):
+            self.level = 0; self.name = ""; self.message = ""
+            self.hardware_id = ""; self.values = []
+
+    class _DiagArray:
+        def __init__(self):
+            self.header = MagicMock(); self.status = []
+
+    class _KeyValue:
+        def __init__(self, key="", value=""):
+            self.key = key; self.value = value
+
+    diag_msg.DiagnosticStatus = _DiagStatus
+    diag_msg.DiagnosticArray  = _DiagArray
+    diag_msg.KeyValue         = _KeyValue
+    diag.msg = diag_msg
+    sys.modules.setdefault("diagnostic_msgs",     diag)
+    sys.modules.setdefault("diagnostic_msgs.msg", diag_msg)
+
+    # sensor_msgs
+    sens = types.ModuleType("sensor_msgs")
+    sens_msg = types.ModuleType("sensor_msgs.msg")
+    for cls_name in ("Image", "CameraInfo", "Imu", "LaserScan"):
+        setattr(sens_msg, cls_name, MagicMock)
+    sens.msg = sens_msg
+    sys.modules.setdefault("sensor_msgs",     sens)
+    sys.modules.setdefault("sensor_msgs.msg", sens_msg)
+
+    # std_msgs
+    std = types.ModuleType("std_msgs")
+    std_msg = types.ModuleType("std_msgs.msg")
+    class _String:
+        def __init__(self, data=""): self.data = data
+    std_msg.String = _String
+    std.msg = std_msg
+    sys.modules.setdefault("std_msgs",     std)
+    sys.modules.setdefault("std_msgs.msg", std_msg)
+
+
+_install_stubs()
+
+from saltybot_health_monitor.sensor_health_node import (  # noqa: E402
+    SensorWatcher, OK, WARN, ERROR, _LEVEL_NAMES,
+)
+
+
+# ── SensorWatcher: initial state ──────────────────────────────────────────────
+
+class TestSensorWatcherInitial(unittest.TestCase):
+
+    def setUp(self):
+        self.w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=True)
+
+    def test_initial_age_is_inf(self):
+        self.assertEqual(self.w.age_s(), float("inf"))
+
+    def test_initial_level_is_error(self):
+        # Never received → age=inf ≥ error_s → ERROR
+        self.assertEqual(self.w.level(), ERROR)
+
+    def test_initial_count_zero(self):
+        self.assertEqual(self.w.msg_count(), 0)
+
+    def test_initial_rate_zero(self):
+        self.assertAlmostEqual(self.w.rate_hz(), 0.0)
+
+    def test_name_stored(self):
+        self.assertEqual(self.w.name, "lidar")
+
+    def test_topic_stored(self):
+        self.assertEqual(self.w.topic, "/scan")
+
+    def test_critical_stored(self):
+        self.assertTrue(self.w.critical)
+
+
+# ── SensorWatcher: after receiving messages ───────────────────────────────────
+
+class TestSensorWatcherAfterMessage(unittest.TestCase):
+
+    def setUp(self):
+        self.w = SensorWatcher("/imu/data", "imu", warn_s=0.5, error_s=2.0, critical=True)
+        self.w.on_message(None)  # simulate message receipt
+
+    def test_age_is_small_after_message(self):
+        self.assertLess(self.w.age_s(), 0.1)
+
+    def test_level_ok_immediately_after(self):
+        self.assertEqual(self.w.level(), OK)
+
+    def test_count_increments(self):
+        self.w.on_message(None)
+        self.assertEqual(self.w.msg_count(), 2)
+
+    def test_multiple_messages(self):
+        for _ in range(10):
+            self.w.on_message(None)
+        self.assertEqual(self.w.msg_count(), 11)
+
+
+# ── SensorWatcher: staleness thresholds ──────────────────────────────────────
+
+class TestSensorWatcherStaleness(unittest.TestCase):
+
+    def _make_stale(self, seconds_ago: float) -> SensorWatcher:
+        """Return a watcher whose last_rx was `seconds_ago` seconds in the past."""
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        # Backdate the last_rx directly
+        with w._lock:
+            w._last_rx -= seconds_ago
+        return w
+
+    def test_ok_when_fresh(self):
+        w = self._make_stale(0.5)
+        self.assertEqual(w.level(), OK)
+
+    def test_warn_at_warn_threshold(self):
+        w = self._make_stale(1.1)
+        self.assertEqual(w.level(), WARN)
+
+    def test_error_at_error_threshold(self):
+        w = self._make_stale(3.1)
+        self.assertEqual(w.level(), ERROR)
+
+    def test_age_matches_backdated_time(self):
+        w = self._make_stale(2.0)
+        self.assertAlmostEqual(w.age_s(), 2.0, delta=0.1)
+
+    def test_warn_level_between_thresholds(self):
+        w = self._make_stale(2.0)   # 1.0 < 2.0 < 3.0
+        self.assertEqual(w.level(), WARN)
+
+
+# ── SensorWatcher: diagnostic_status output ──────────────────────────────────
+
+class TestSensorWatcherDiagStatus(unittest.TestCase):
+
+    def test_never_received_is_error(self):
+        w = SensorWatcher("/camera/color/image_raw", "camera_color",
+                          warn_s=1.0, error_s=3.0, critical=True)
+        ds = w.diagnostic_status()
+        self.assertEqual(ds.level, ERROR)
+        self.assertIn("no data", ds.message)
+
+    def test_ok_status_message(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        ds = w.diagnostic_status()
+        self.assertEqual(ds.level, OK)
+        self.assertIn("OK", ds.message)
+
+    def test_warn_status_message(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        with w._lock:
+            w._last_rx -= 1.5
+        ds = w.diagnostic_status()
+        self.assertEqual(ds.level, WARN)
+        self.assertIn("WARN", ds.message)
+
+    def test_hardware_id_is_topic(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        ds = w.diagnostic_status()
+        self.assertEqual(ds.hardware_id, "/scan")
+
+    def test_kv_keys_present(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        ds = w.diagnostic_status()
+        kv_keys = {kv.key for kv in ds.values}
+        for expected in ("topic", "age_s", "rate_hz", "count", "warn_s", "error_s"):
+            self.assertIn(expected, kv_keys)
+
+    def test_age_inf_displayed_as_inf(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        ds = w.diagnostic_status()
+        kv = {kv.key: kv.value for kv in ds.values}
+        self.assertEqual(kv["age_s"], "inf")
+
+
+# ── SensorWatcher: summary_dict output ───────────────────────────────────────
+
+class TestSensorWatcherSummaryDict(unittest.TestCase):
+
+    def test_never_received_age_is_none(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        d = w.summary_dict()
+        self.assertIsNone(d["age_s"])
+        self.assertEqual(d["status"], "ERROR")
+
+    def test_ok_status_string(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        d = w.summary_dict()
+        self.assertEqual(d["status"], "OK")
+
+    def test_warn_status_string(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        with w._lock:
+            w._last_rx -= 1.5
+        d = w.summary_dict()
+        self.assertEqual(d["status"], "WARN")
+
+    def test_error_status_string(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        with w._lock:
+            w._last_rx -= 5.0
+        d = w.summary_dict()
+        self.assertEqual(d["status"], "ERROR")
+
+    def test_age_rounded(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        d = w.summary_dict()
+        self.assertIsInstance(d["age_s"], float)
+
+    def test_critical_flag(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=True)
+        self.assertTrue(w.summary_dict()["critical"])
+
+    def test_non_critical_flag(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        self.assertFalse(w.summary_dict()["critical"])
+
+    def test_count_in_summary(self):
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        for _ in range(5):
+            w.on_message(None)
+        self.assertEqual(w.summary_dict()["count"], 5)
+
+
+# ── Level name mapping ─────────────────────────────────────────────────────────
+
+class TestLevelNames(unittest.TestCase):
+
+    def test_ok_name(self):
+        self.assertEqual(_LEVEL_NAMES[OK], "OK")
+
+    def test_warn_name(self):
+        self.assertEqual(_LEVEL_NAMES[WARN], "WARN")
+
+    def test_error_name(self):
+        self.assertEqual(_LEVEL_NAMES[ERROR], "ERROR")
+
+
+# ── Thread safety ─────────────────────────────────────────────────────────────
+
+class TestSensorWatcherThreadSafety(unittest.TestCase):
+
+    def test_concurrent_messages(self):
+        import threading
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        N = 500
+        threads = [threading.Thread(target=w.on_message, args=(None,)) for _ in range(N)]
+        for t in threads:
+            t.start()
+        for t in threads:
+            t.join()
+        self.assertEqual(w.msg_count(), N)
+
+    def test_concurrent_reads(self):
+        import threading
+        w = SensorWatcher("/scan", "lidar", warn_s=1.0, error_s=3.0, critical=False)
+        w.on_message(None)
+        errors = []
+        def read_loop():
+            for _ in range(100):
+                try:
+                    w.level()
+                    w.age_s()
+                    w.rate_hz()
+                except Exception as e:
+                    errors.append(e)
+        threads = [threading.Thread(target=read_loop) for _ in range(5)]
+        for t in threads: t.start()
+        for t in threads: t.join()
+        self.assertEqual(errors, [])
+
+
+if __name__ == "__main__":
+    unittest.main()