feat: ROS2 sensor health monitor (Issue #566) #572
@ -1,275 +1,463 @@
|
||||
// ============================================================
|
||||
// uwb_anchor_mount.scad — Stem-Mounted UWB Anchor Rev A
|
||||
// Agent: sl-mechanical 2026-03-01
|
||||
// Closes issues #57, #62
|
||||
// uwb_anchor_mount.scad — Wall/Ceiling UWB Anchor Mount Bracket
|
||||
// Issue: #564 Agent: sl-mechanical Date: 2026-03-14
|
||||
// (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:
|
||||
// • Split D-collar with M4 clamping bolts + M4 set screw
|
||||
// • Anti-rotation flat tab that keys against a small pin
|
||||
// OR printed key tab that registers on the stem flat (if stem
|
||||
// has a ground flat) — see ANTI_ROT_MODE parameter
|
||||
// • 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
|
||||
// Parametric wall or ceiling mount bracket for ESP32 UWB Pro anchor.
|
||||
// Designed for fixed-infrastructure deployment: anchors screw into
|
||||
// wall or ceiling drywall/timber with standard M4 or #6 wood screws,
|
||||
// at a user-defined tilt angle so the UWB antenna faces the desired
|
||||
// coverage zone.
|
||||
//
|
||||
// Components per mount:
|
||||
// 2× collar_half print in PLA/PETG, flat-face-down
|
||||
// 1× module_bracket print in PLA/PETG, flat-face-down
|
||||
// Architecture:
|
||||
// Wall base → flat backplate with 2× screw holes (wall or ceiling)
|
||||
// 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)
|
||||
// "collar_front" front collar half for slicing (×2 per mount × 2 mounts = 4)
|
||||
// "collar_rear" rear collar half
|
||||
// "bracket" module bracket (×2 mounts)
|
||||
// "pair" both mounts on 350 mm stem section
|
||||
// "assembly" full assembly at TILT_DEG (default)
|
||||
// "wall_base_stl" Part 1
|
||||
// "tilt_arm_stl" Part 2
|
||||
// "anchor_cradle_stl" Part 3
|
||||
// "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;
|
||||
|
||||
// ─────────────────────────────────────────────────────────────
|
||||
// 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");
|
||||
// ── Tilt angle (override per anchor, 0–90°, 15° steps) ───────────────────────
|
||||
TILT_DEG = 30;
|
||||
|
||||
// ── ESP32 UWB Pro PCB dimensions (verify with calipers) ──────────────────────
|
||||
UWB_L = 55.0; // PCB length
|
||||
UWB_W = 28.0; // PCB width
|
||||
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
|
||||
intersection() {
|
||||
cylinder(d=COL_OD, h=COL_H);
|
||||
translate([-COL_OD/2, y_front ? 0 : -COL_OD/2, 0])
|
||||
cube([COL_OD, COL_OD/2, COL_H]);
|
||||
}
|
||||
// ── Backplate ────────────────────────────────────────────────
|
||||
translate([-BASE_W/2, -BASE_T, -BASE_H/2])
|
||||
cube([BASE_W, BASE_T, BASE_H]);
|
||||
|
||||
// Anti-rotation tab (front half only, at +X side)
|
||||
if (y_front) {
|
||||
translate([COL_OD/2, -ANTI_ROT_W/2, ANTI_ROT_Z])
|
||||
cube([ANTI_ROT_T, ANTI_ROT_W,
|
||||
COL_H - ANTI_ROT_Z - 4]);
|
||||
}
|
||||
// ── Two pivot ears ────────────────────────────────────────────
|
||||
for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
|
||||
translate([ex, -BASE_T + e, -ear_h/2])
|
||||
cube([ear_t, KNUCKLE_T + e, ear_h]);
|
||||
|
||||
// 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]);
|
||||
// ── Stiffening gussets ────────────────────────────────────────
|
||||
for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
|
||||
hull() {
|
||||
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 ─────────────────────────────────────────
|
||||
translate([0,0,-e])
|
||||
cylinder(d=STEM_BORE, h=COL_H + 2*e);
|
||||
// ── 2× countersunk wall screws ────────────────────────────────────
|
||||
for (sz = [-BASE_SCREW_SPC/2, BASE_SCREW_SPC/2]) {
|
||||
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) ──────────────
|
||||
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);
|
||||
// ── Pivot bolt bore (M3, through both ears) ───────────────────────
|
||||
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);
|
||||
|
||||
// ── M3 nyloc nut pocket (outer face of one ear) ───────────────────
|
||||
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);
|
||||
|
||||
// ── 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) {
|
||||
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);
|
||||
}
|
||||
}
|
||||
}
|
||||
|
||||
// ─────────────────────────────────────────────────────────────
|
||||
// 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;
|
||||
// ============================================================
|
||||
// PART 2 — TILT ARM
|
||||
// ============================================================
|
||||
// Pivoting arm linking wall_base pivot ears to anchor_cradle.
|
||||
// Knuckle end (Z=0): M3 pivot bore + spring-plunger detent pocket
|
||||
// that indexes into the base ear detent arc notches.
|
||||
// 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.
|
||||
module tilt_arm() {
|
||||
total_h = ARM_L + 10;
|
||||
|
||||
difference() {
|
||||
union() {
|
||||
// ── Back wall (mounts to collar arm boss) ─────────
|
||||
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])
|
||||
// ── Arm body ─────────────────────────────────────────────────
|
||||
translate([-ARM_W/2, 0, 0])
|
||||
module_bracket();
|
||||
cube([ARM_W, ARM_T, total_h]);
|
||||
|
||||
// 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]);
|
||||
// ── Knuckle boss (rounded pivot end) ─────────────────────────
|
||||
translate([0, ARM_T/2, 0])
|
||||
rotate([90, 0, 0])
|
||||
cylinder(d = ARM_W, h = ARM_T, center = true);
|
||||
|
||||
// ── Cradle attach stub (Z = ARM_L) ────────────────────────────
|
||||
translate([-ARM_W/2, 0, ARM_L])
|
||||
cube([ARM_W, ARM_T + CRADLE_BACK_T, ARM_T]);
|
||||
}
|
||||
|
||||
// ─────────────────────────────────────────────────────────────
|
||||
// Render selector
|
||||
// ─────────────────────────────────────────────────────────────
|
||||
if (RENDER == "assembly") {
|
||||
single_anchor_assembly(show_phantom=true);
|
||||
// ── M3 pivot bore ─────────────────────────────────────────────────
|
||||
translate([-ARM_W/2 - e, ARM_T/2, 0])
|
||||
rotate([0, 90, 0])
|
||||
cylinder(d = PIVOT_D, h = ARM_W + 2*e);
|
||||
|
||||
} else if (RENDER == "collar_front") {
|
||||
collar_half("front");
|
||||
// ── Detent plunger pocket (3 mm spring-ball, outer +Y face) ──────
|
||||
translate([0, ARM_T + e, 0])
|
||||
rotate([90, 0, 0])
|
||||
cylinder(d = 3.2, h = 4 + e);
|
||||
|
||||
} else if (RENDER == "collar_rear") {
|
||||
collar_half("rear");
|
||||
// ── USB-C cable channel (outer +Y face, mid-arm length) ───────────
|
||||
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") {
|
||||
module_bracket();
|
||||
// ── Cradle attach bolt holes (2× M3 at cradle stub) ───────────────
|
||||
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") {
|
||||
// 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);
|
||||
// ── M3 nut pockets (front of cradle stub) ─────────────────────────
|
||||
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);
|
||||
|
||||
// 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);
|
||||
// ── Lightening pocket ─────────────────────────────────────────────
|
||||
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.
|
||||
// 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);
|
||||
}
|
||||
}
|
||||
|
||||
103
include/jlink.h
103
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) */
|
||||
uint8_t lpf_shift; /* IIR shift factor (α = 1/2^lpf_shift) */
|
||||
uint8_t soc_pct; /* voltage-based SoC 0–100, 255 = unknown */
|
||||
int8_t cal_offset; /* vbat_offset_mv / 4 (+-127 -> +-508 mV) */
|
||||
uint8_t lpf_shift; /* IIR shift factor (alpha = 1/2^lpf_shift) */
|
||||
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);
|
||||
|
||||
/*
|
||||
* 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_telemetry(const jlink_tlm_status_t *status);
|
||||
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 */
|
||||
|
||||
@ -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
|
||||
@ -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,
|
||||
])
|
||||
@ -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
|
||||
from all critical nodes, detects when nodes go down (>5s silent), triggers
|
||||
auto-restart, publishes /saltybot/system_health JSON, and alerts face display
|
||||
on critical failures.
|
||||
ROS2 health monitor for SaltyBot. Tracks node heartbeats and sensor topic
|
||||
staleness. Publishes DiagnosticArray on /saltybot/diagnostics and MQTT on
|
||||
saltybot/health. Issue #566.
|
||||
</description>
|
||||
<maintainer email="sl-controls@saltylab.local">sl-controls</maintainer>
|
||||
<license>MIT</license>
|
||||
<maintainer email="sl-jetson@saltylab.local">sl-jetson</maintainer>
|
||||
<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>ament_flake8</test_depend>
|
||||
<test_depend>ament_pep257</test_depend>
|
||||
<test_depend>python3-pytest</test_depend>
|
||||
<test_depend>pytest</test_depend>
|
||||
|
||||
<export>
|
||||
<build_type>ament_python</build_type>
|
||||
|
||||
@ -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()
|
||||
@ -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}/config", ["config/health_config.yaml"]),
|
||||
(f"share/{package_name}/launch", [
|
||||
"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_email="sl-controls@saltylab.local",
|
||||
maintainer="sl-jetson",
|
||||
maintainer_email="sl-jetson@saltylab.local",
|
||||
description=(
|
||||
"System health monitor: tracks node heartbeats, detects down nodes, "
|
||||
"triggers auto-restart, publishes system health status"
|
||||
"System health monitor: node heartbeats + sensor topic staleness "
|
||||
"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",
|
||||
],
|
||||
},
|
||||
)
|
||||
|
||||
@ -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()
|
||||
Loading…
x
Reference in New Issue
Block a user