sl-firmware
fa75c442a7
Archive STM32 firmware to legacy/stm32/: - src/, include/, lib/USB_CDC/, platformio.ini, test stubs, flash_firmware.py - test/test_battery_adc.c, test_hw_button.c, test_pid_schedule.c, test_vesc_can.c, test_can_watchdog.c - USB_CDC_BUG.md Rename: stm32_protocol → esp32_protocol, mamba_protocol → balance_protocol, stm32_cmd_node → esp32_cmd_node, stm32_cmd_params → esp32_cmd_params, stm32_cmd.launch.py → esp32_cmd.launch.py, test_stm32_protocol → test_esp32_protocol, test_stm32_cmd_node → test_esp32_cmd_node Content cleanup across all files: - Mamba F722S → ESP32-S3 BALANCE - BlackPill → ESP32-S3 IO - STM32F722/F7xx → ESP32-S3 - stm32Mode/Version/Port → esp32Mode/Version/Port - STM32 State/Mode labels → ESP32 State/Mode - Jetson Nano → Jetson Orin Nano Super - /dev/stm32 → /dev/esp32 - stm32_bridge → esp32_bridge - STM32 HAL → ESP-IDF docs/SALTYLAB.md: - Update "Drone FC Details" to describe ESP32-S3 BALANCE board (Waveshare ESP32-S3 Touch LCD 1.28) - Replace verbose "Self-Balancing Control" STM32 section with brief note pointing to SAUL-TEE-SYSTEM-REFERENCE.md TEAM.md: Update Embedded Firmware Engineer role to ESP32-S3 / ESP-IDF No new functionality — cleanup only. Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
223 lines
9.1 KiB
Markdown
223 lines
9.1 KiB
Markdown
# SaltyRover — Modular Platform Design 🧂🛞
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## Design Philosophy
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- **Modular:** Standardized mounting points for swappable top decks
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- **Printable:** Main structural brackets on Bambu X1C (256x256x256mm) and A1 (256x256x256mm)
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- **Repairable:** Bolt-together, no permanent welds/glue on structural parts
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- **Weatherproof-ish:** Splash resistant for outdoor use, not submarine
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## Base Platform ("Skateboard")
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### Frame
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```
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FRONT
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┌─────────────────┐
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│ ┌─M1─┐ ┌─M2─┐ │ M1-M4: 6.5" hub motors
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│ │ │ │ │ │ ESC1 drives M1+M2 (front)
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│ └────┘ └────┘ │ ESC2 drives M3+M4 (rear)
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│ │
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│ ┌──────────────┐ │
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│ │ BATTERY │ │ Center-mounted battery bay
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│ │ BAY │ │ Fits 2x hoverboard packs (2P)
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│ └──────────────┘ │
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│ │
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│ ┌─ESC1─┐┌─ESC2─┐ │ ESCs flanking center
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│ └──────┘└──────┘ │
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│ ┌──5V──┐┌─12V──┐ │ DC-DC converters
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│ └──────┘└──────┘ │
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│ │
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│ ┌─M3─┐ ┌─M4─┐ │
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│ │ │ │ │ │
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│ └────┘ └────┘ │
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└─────────────────┘
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REAR
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Overall: ~600mm L × 450mm W × ~120mm H (base only)
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```
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### Dimensions
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- **Length:** 600mm (motor center to motor center ~500mm, +50mm overhang each end)
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- **Width:** 450mm (constrained by motor axle-to-axle, ~350mm inner + motor housings)
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- **Ground clearance:** ~50mm (bottom of frame to ground)
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- **Wheelbase:** 500mm (front axle to rear axle)
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- **Track width:** 350mm (left wheel center to right wheel center)
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### Frame Construction
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- **Main rails (x2):** Aluminum extrusion 2040 V-slot, 600mm length
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- Or: 40x20mm aluminum rectangular tube
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- Or: 3D printed with steel rod reinforcement
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- **Cross members (x3):** Front, center, rear — aluminum or printed
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- **Motor mounts (x4):** 3D printed brackets, bolted to frame rails
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- Must accommodate 6.5" hub motor axle (standard hoverboard M10 axle)
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- Axle clamp style — two-piece with bolts for easy wheel swap
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### Modular Top Deck Interface
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```
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┌─────────────────────┐
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│ ○ ○ ○ ○ │ ← M5 threaded inserts, 100mm grid
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│ │
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│ ○ ○ ○ ○ │ Standard mounting pattern:
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│ │ - 400mm × 300mm grid
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│ ○ ○ ○ ○ │ - M5 bolt holes on 100mm centers
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│ │ - 16 mount points total
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│ ○ ○ ○ ○ │
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└─────────────────────┘
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```
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**Top deck connector:**
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- 16x M5 threaded inserts in frame top rails
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- 100mm grid spacing
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- Any top deck just needs matching bolt holes
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- Power connector: XT30 (5V + 12V + GND) standardized position at rear-center
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- Data connector: USB-A hub mounted to frame, accessible from top
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## Top Deck Configurations
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### Config 1: "Follow Bot" (Primary)
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```
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┌─────────────────────┐
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│ [RPLIDAR A1M8] │ ← Top-mounted, unobstructed 360°
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│ ╱spinning╲ │ Raised on 100mm standoff
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│ │
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│ [RealSense D435i] │ ← Front-facing, angled down ~10°
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│ │ Height: ~400mm from ground
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│ [Jetson Orin Nano Super] │ ← Center, in ventilated enclosure
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│ [WiFi/4G module] │ Noctua fan draws air through
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│ │
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│ [Speaker] [LEDs] │ ← Rear: audio feedback + status
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│ [E-STOP button] │ Big red mushroom button
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└─────────────────────┘
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```
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**Parts:**
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- Sensor tower: 3D printed, 100mm tall, mounts LIDAR on top
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- RealSense bracket: 3D printed, adjustable tilt
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- Jetson enclosure: 3D printed, ventilated, vibration dampened
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- LED strip ring: NeoPixel/WS2812B around sensor tower (status indication)
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### Config 2: "Cargo Hauler"
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```
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┌─────────────────────┐
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│ ┌─────────────────┐ │
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│ │ │ │ Flat cargo platform
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│ │ CARGO AREA │ │ 400 × 300 × 150mm
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│ │ (open top) │ │ With tie-down points
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│ │ │ │
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│ └─────────────────┘ │
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│ [GPS] [Beacon] │ Minimal autonomy — follows beacon
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└─────────────────────┘
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```
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### Config 3: "Camera Rig"
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```
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┌─────────────────────┐
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│ [Gimbal] │ 2-axis stabilized camera mount
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│ [Action Cam] │ GoPro / Insta360
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│ │
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│ [Jetson + storage] │ Records while following
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│ [Large battery] │ Extended runtime for filming
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└─────────────────────┘
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```
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### Config 4: "Security Patrol"
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```
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┌─────────────────────┐
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│ [RPLIDAR] │ Autonomous waypoint patrol
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│ [PTZ Camera] │ Pan-tilt-zoom camera
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│ [Spotlight] │ High-power LED
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│ [Jetson + 4G] │ Streams to Frigate
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│ [Siren/Speaker] │
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└─────────────────────┘
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```
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## 3D Printed Parts List (Config 1: Follow Bot)
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All designed for Bambu X1C/A1 build plate (256x256mm max).
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| Part | Size (mm) | Material | Infill | Qty |
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|------|-----------|----------|--------|-----|
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| Motor mount bracket | 80×60×40 | PETG/ASA | 60% | 4 |
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| Motor mount clamp top | 80×40×15 | PETG/ASA | 60% | 4 |
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| Cross member front | 350×40×20 | PETG/ASA | 80% | 1 |
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| Cross member center | 350×60×20 | PETG/ASA | 80% | 1 |
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| Cross member rear | 350×40×20 | PETG/ASA | 80% | 1 |
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| Battery tray | 250×150×30 | PETG | 40% | 1 |
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| Battery strap anchor | 40×20×15 | PETG | 100% | 4 |
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| ESC mount tray | 150×100×15 | PETG | 40% | 2 |
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| DC-DC mount | 80×60×15 | PETG | 40% | 2 |
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| Sensor tower base | 120×120×10 | ASA | 80% | 1 |
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| Sensor tower tube | Ø80×100 | ASA | 40% | 1 |
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| LIDAR mount plate | Ø90×5 | ASA | 100% | 1 |
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| RealSense bracket | 100×50×60 | PETG | 60% | 1 |
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| Jetson enclosure bottom | 120×100×25 | PETG | 40% | 1 |
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| Jetson enclosure top | 120×100×25 | PETG | 40% | 1 |
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| E-stop mount | 50×50×30 | PETG | 60% | 1 |
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| Wire management clips | 20×15×10 | PETG | 100% | 10 |
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| Fender/splash guard | 200×80×60 | ASA | 30% | 4 |
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**Material notes:**
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- **ASA** for outdoor/exposed parts (UV resistant, weather resistant)
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- **PETG** for structural internal parts (strong, slight flex)
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- Avoid PLA — warps in summer sun
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## Electrical Wiring
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```
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PACK1 ═╤═ PACK2 (parallel, XT60)
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│
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├──→ ESC1 ──→ M1 (front-left) + M2 (front-right)
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│ │
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│ └── UART TX/RX ──→ Jetson GPIO
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│
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├──→ ESC2 ──→ M3 (rear-left) + M4 (rear-right)
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│ │
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│ └── UART TX/RX ──→ Jetson GPIO
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│
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├──→ DC-DC 36V→5V ──→ Jetson Orin Nano Super (barrel jack 5V/4A)
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│ ──→ USB hub (sensors)
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│
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├──→ DC-DC 36V→12V ──→ LED strips
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│ ──→ Speaker amp
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│ ──→ 4G modem
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│
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└──→ E-STOP (normally closed, inline with main power)
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```
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### ESC UART Protocol (FOC firmware)
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- Baud: 115200 (or 9600, configurable)
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- Each ESC: `steer` + `speed` as int16 values (-1000 to +1000)
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- ESC1 (front): Jetson UART1
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- ESC2 (rear): Jetson UART2 (or USB-serial adapter)
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### Differential Drive Control
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```
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Left speed = throttle - steering
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Right speed = throttle + steering
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For 4WD: front and rear ESCs get same commands
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(or: rear slightly less for better turning)
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```
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## Assembly Order
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1. Cut/prepare frame rails (aluminum extrusion or tube)
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2. Print all brackets and mounts
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3. Assemble frame with cross members
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4. Mount motors to brackets, attach to frame
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5. Install battery tray, strap packs
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6. Mount ESCs and DC-DC converters
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7. Wire power distribution (XT60 splitters)
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8. Install E-stop inline
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9. Mount top deck with sensor tower
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10. Wire data connections (UART, USB)
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11. First test: power on, spin motors manually via serial terminal
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12. Flash follow-bot software to Jetson
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13. Outdoor test in parking lot
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## Next Steps
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- [ ] Measure exact motor axle dimensions and spacing
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- [ ] Choose frame material (aluminum extrusion vs printed vs hybrid)
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- [ ] Design motor mount bracket in CAD (FreeCAD/Fusion360)
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- [ ] Print test motor mount, verify fit
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- [ ] Design and print sensor tower
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- [ ] Bench test: Jetson → UART → ESC → single motor spinning
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