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>
401 lines
18 KiB
OpenSCAD
401 lines
18 KiB
OpenSCAD
// ============================================================
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// rover_electronics_bay.scad — SaltyRover Electronics Bay
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// Issue: #109 Agent: sl-mechanical Date: 2026-03-01
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// ============================================================
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//
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// Enclosed electronics housing sitting on the rover deck plate.
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// Houses: • Flight Controller (FC) — 30.5×30.5 mm M3 standoffs
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// • Jetson Orin NX / Nano — 58×49 mm M3 standoffs
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// • Battery access slot — left side slide-in
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// • RPLIDAR A1M8 tower — integrated on lid top
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// • Ventilation slots — all 4 walls + lid
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//
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// Shared mounting patterns (swappable with SaltyLab):
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// FC : 30.5 × 30.5 mm M3 (ESP32-S3 BALANCE / Pixhawk)
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// Jetson: 58 × 49 mm M3 (Orin NX / Nano Devkit carrier)
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//
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// Coordinate: bay centred at origin; Z=0 = deck top face.
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// Bay body rests directly on deck top (no additional standoffs).
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//
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// Print:
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// Material : PETG (bay body + lid)
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// Settings : 4 perimeters, 30% gyroid infill
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// Orientation: open top face up for body; lid printed flat.
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// Note: Bay is too large to print as one piece on most 220mm beds.
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// Use RENDER="front_half" and RENDER="rear_half" for split,
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// joined with 3× M3 bolts and alignment pins.
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//
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// Export commands:
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// Bay body (full, for large-bed printers):
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// openscad rover_electronics_bay.scad -D 'RENDER="bay_stl"' -o rover_elec_bay.stl
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// Front half:
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// openscad rover_electronics_bay.scad -D 'RENDER="front_half"' -o rover_elec_bay_front.stl
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// Rear half:
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// openscad rover_electronics_bay.scad -D 'RENDER="rear_half"' -o rover_elec_bay_rear.stl
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// Lid (with RPLIDAR tower):
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// openscad rover_electronics_bay.scad -D 'RENDER="lid_stl"' -o rover_elec_bay_lid.stl
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// Assembly preview:
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// openscad rover_electronics_bay.scad -D 'RENDER="assembly"'
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// ============================================================
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$fn = 64;
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e = 0.01;
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// ── Bay exterior dimensions ──────────────────────────────────────────────────
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BAY_L = 240.0; // length left-right (X in rover coords = Y here)
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BAY_W = 200.0; // width fore-aft (Y in rover = X here)
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BAY_H = 80.0; // interior height
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BAY_WALL = 3.0; // wall thickness (all sides)
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BAY_FLOOR = 4.0; // floor thickness (rests on deck)
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BAY_R = 8.0; // exterior corner radius
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// ── Ventilation slots ────────────────────────────────────────────────────────
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VENT_W = 20.0; // slot width
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VENT_H = 6.0; // slot height
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VENT_PITCH = 28.0; // slot centre-to-centre pitch
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VENT_FROM_BOT = 12.0; // lowest vent row height above floor exterior
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// ── Lid ─────────────────────────────────────────────────────────────────────
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LID_T = 4.0; // lid plate thickness
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LID_RIM_H = 8.0; // lip that drops inside bay walls (retention)
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LID_RIM_GAP = 0.4; // clearance between lid rim and bay inner wall
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// ── FC mount — 30.5×30.5 mm M3 (shared SaltyLab) ────────────────────────────
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FC_PITCH = 30.5;
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FC_HOLE_D = 3.2;
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FC_STANDOFF_H = 8.0;
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FC_STANDOFF_OD = 7.0;
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// FC positioned toward front-left inside bay (offset from centre)
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FC_OFF_X = -BAY_L/2 + 60.0; // left side (left = cable/ESC side)
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FC_OFF_Y = -BAY_W/2 + 50.0; // front side
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// ── Jetson Orin mount — 58×49 mm M3 (shared SaltyLab) ───────────────────────
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ORIN_HOLE_X = 58.0;
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ORIN_HOLE_Y = 49.0;
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ORIN_HOLE_D = 3.2;
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ORIN_STANDOFF_H = 10.0;
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ORIN_STANDOFF_OD = 7.0;
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// Jetson positioned toward rear-right (toward robot rear, USB/HDMI accessible)
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ORIN_OFF_X = BAY_L/2 - 70.0; // right side
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ORIN_OFF_Y = BAY_W/2 - 55.0; // rear side
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// ── Battery access slot (left wall slide-in) ──────────────────────────────────
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// The under-deck battery tray is separate (rover_battery_tray.scad).
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// A slot in the bay left wall allows BMS cable + main power harness.
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BATT_SLOT_W = 30.0; // harness slot width
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BATT_SLOT_H = 20.0; // harness slot height
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BATT_SLOT_Z = 20.0; // slot bottom above floor interior
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// ── RPLIDAR A1M8 tower (on lid, top centre) ───────────────────────────────────
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RPL_TOWER_OD = 28.0; // tower OD (hollow column)
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RPL_TOWER_ID = 16.0; // hollow core ID (cable routing)
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RPL_TOWER_H = 100.0; // tower height above lid top face
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// RPLIDAR A1M8 bolt circle: 58 mm dia, 4× M3 at 45°/135°/225°/315°
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RPL_BC = 58.0;
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RPL_HOLE_D = 3.3; // M3 clearance
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RPL_PLATFORM_D = 90.0; // platform disk at tower top
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// ── Bay-to-deck attachment ────────────────────────────────────────────────────
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// 8× M3 SHCS through bay floor flanges into deck (matching saltyrover_chassis_r2.scad)
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DECK_BOLT_D = 3.3;
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DECK_BOLT_INSET = 8.0; // bolt CL from exterior corner
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// ── Lid retention (M3 corner bolts) ──────────────────────────────────────────
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LID_BOLT_D = 3.3;
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LID_BOLT_POS = 8.0; // bolt CL from exterior wall
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M3_D = 3.3;
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M4_D = 4.3;
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// ============================================================
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// RENDER DISPATCH
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// ============================================================
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RENDER = "assembly";
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if (RENDER == "assembly") {
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assembly();
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} else if (RENDER == "bay_stl") {
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bay_body();
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} else if (RENDER == "front_half") {
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// Split along XZ plane (Y=0) — front half
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intersection() {
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bay_body();
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translate([0, -BAY_W/2 - BAY_WALL, 0])
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cube([BAY_L + 2*BAY_WALL + 2, BAY_W/2 + BAY_WALL + 1,
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BAY_H + BAY_FLOOR + LID_T + 2]);
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}
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} else if (RENDER == "rear_half") {
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// Split along XZ plane (Y=0) — rear half
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intersection() {
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bay_body();
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translate([0, 0, 0])
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cube([BAY_L + 2*BAY_WALL + 2, BAY_W/2 + BAY_WALL + 1,
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BAY_H + BAY_FLOOR + LID_T + 2]);
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}
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} else if (RENDER == "lid_stl") {
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bay_lid();
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}
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// ============================================================
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// ASSEMBLY PREVIEW
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// ============================================================
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module assembly() {
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color("OliveDrab", 0.80) bay_body();
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color("DarkOliveGreen", 0.70)
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translate([0, 0, BAY_FLOOR + BAY_H + 1])
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bay_lid();
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// FC standoffs + ghost board
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color("LightGray", 0.60) fc_standoffs();
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%color("DarkGreen", 0.30)
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translate([FC_OFF_X, FC_OFF_Y, BAY_FLOOR + FC_STANDOFF_H])
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cube([76, 42, 3], center = true);
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// Jetson standoffs + ghost board
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color("LightGray", 0.60) jetson_standoffs();
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%color("DarkBlue", 0.25)
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translate([ORIN_OFF_X, ORIN_OFF_Y,
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BAY_FLOOR + ORIN_STANDOFF_H])
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cube([100, 80, 5], center = true);
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}
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// ============================================================
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// BAY BODY (open-top box with ventilation + mounts)
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// ============================================================
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module bay_body() {
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outer_x = BAY_L + 2*BAY_WALL;
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outer_y = BAY_W + 2*BAY_WALL;
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outer_z = BAY_FLOOR + BAY_H;
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difference() {
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// ── Outer shell (rounded rectangle) ────────────────────────────
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linear_extrude(outer_z)
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minkowski() {
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square([outer_x - 2*BAY_R, outer_y - 2*BAY_R], center = true);
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circle(r = BAY_R);
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}
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// ── Inner cavity ───────────────────────────────────────────────
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translate([-BAY_L/2, -BAY_W/2, BAY_FLOOR])
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cube([BAY_L, BAY_W, BAY_H + e]);
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// ── Ventilation slots — left wall (−X) ────────────────────────
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for (i = [-2:2])
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translate([-(BAY_L/2 + BAY_WALL + e),
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i * VENT_PITCH - VENT_W/2,
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VENT_FROM_BOT])
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cube([BAY_WALL + 2*e, VENT_W, VENT_H]);
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// ── Ventilation slots — right wall (+X) ───────────────────────
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for (i = [-2:2])
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translate([BAY_L/2 - e,
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i * VENT_PITCH - VENT_W/2,
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VENT_FROM_BOT])
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cube([BAY_WALL + 2*e, VENT_W, VENT_H]);
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// ── Ventilation slots — front wall (−Y) ───────────────────────
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for (i = [-2:2])
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translate([i * VENT_PITCH - VENT_W/2,
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-(BAY_W/2 + BAY_WALL + e),
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VENT_FROM_BOT])
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cube([VENT_W, BAY_WALL + 2*e, VENT_H]);
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// ── Ventilation slots — rear wall (+Y) ────────────────────────
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for (i = [-2:2])
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translate([i * VENT_PITCH - VENT_W/2,
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BAY_W/2 - e,
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VENT_FROM_BOT])
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cube([VENT_W, BAY_WALL + 2*e, VENT_H]);
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// ── Battery / harness slot (left wall) ────────────────────────
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translate([-(BAY_L/2 + BAY_WALL + e),
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-BATT_SLOT_W/2,
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BAY_FLOOR + BATT_SLOT_Z])
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cube([BAY_WALL + 2*e, BATT_SLOT_W, BATT_SLOT_H]);
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// ── FC mount holes through floor ──────────────────────────────
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for (dx = [-FC_PITCH/2, FC_PITCH/2])
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for (dy = [-FC_PITCH/2, FC_PITCH/2])
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translate([FC_OFF_X + dx, FC_OFF_Y + dy, -e])
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cylinder(d = FC_HOLE_D, h = BAY_FLOOR + 2*e);
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// ── Jetson mount holes through floor ──────────────────────────
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for (dx = [-ORIN_HOLE_X/2, ORIN_HOLE_X/2])
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for (dy = [-ORIN_HOLE_Y/2, ORIN_HOLE_Y/2])
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translate([ORIN_OFF_X + dx, ORIN_OFF_Y + dy, -e])
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cylinder(d = ORIN_HOLE_D, h = BAY_FLOOR + 2*e);
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// ── Bay-to-deck M3 bolt holes (8× corners, through floor flange)
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for (sx = [-1, 1])
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for (sy = [-1, 1]) {
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bx = sx * (BAY_L/2 + BAY_WALL - DECK_BOLT_INSET);
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by = sy * (BAY_W/2 + BAY_WALL - DECK_BOLT_INSET);
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translate([bx, by, -e])
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cylinder(d = DECK_BOLT_D, h = BAY_FLOOR + 2*e);
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}
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// Extra 2 bolts per long wall (centre)
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for (sy = [-1, 1])
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translate([0, sy * (BAY_W/2 + BAY_WALL - DECK_BOLT_INSET), -e])
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cylinder(d = DECK_BOLT_D, h = BAY_FLOOR + 2*e);
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// ── Lid retention M3 threaded bosses cut (4× top rim corners) ──
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for (sx = [-1, 1])
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for (sy = [-1, 1]) {
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lx = sx * (BAY_L/2 + BAY_WALL - LID_BOLT_POS);
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ly = sy * (BAY_W/2 + BAY_WALL - LID_BOLT_POS);
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translate([lx, ly, outer_z - 12])
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cylinder(d = LID_BOLT_D - 0.3, h = 14); // M3 self-tap bore
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}
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// ── Cable pass-through grommets slots (bottom, 2× for deck slots)
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for (sy = [-1, 1])
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hull() {
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translate([-15, sy * (BAY_W/2 - 6), -e])
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cylinder(d = 12, h = BAY_FLOOR + 2*e);
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translate([ 15, sy * (BAY_W/2 - 6), -e])
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cylinder(d = 12, h = BAY_FLOOR + 2*e);
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}
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}
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// ── FC standoffs ─────────────────────────────────────────────────────────
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fc_standoffs();
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// ── Jetson standoffs ─────────────────────────────────────────────────────
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jetson_standoffs();
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}
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// ── FC standoffs (inside bay, above floor) ───────────────────────────────────
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module fc_standoffs() {
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for (dx = [-FC_PITCH/2, FC_PITCH/2])
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for (dy = [-FC_PITCH/2, FC_PITCH/2])
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translate([FC_OFF_X + dx, FC_OFF_Y + dy, BAY_FLOOR])
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difference() {
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cylinder(d = FC_STANDOFF_OD, h = FC_STANDOFF_H);
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// Threaded bore (M3 screw from above)
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translate([0, 0, FC_STANDOFF_H - 6])
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cylinder(d = 2.5, h = 7); // M3 tap drill (Ø2.5)
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// Through clearance from floor (to match deck FC holes)
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cylinder(d = FC_HOLE_D, h = FC_STANDOFF_H - 6);
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}
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}
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// ── Jetson Orin standoffs (inside bay, above floor) ──────────────────────────
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module jetson_standoffs() {
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for (dx = [-ORIN_HOLE_X/2, ORIN_HOLE_X/2])
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for (dy = [-ORIN_HOLE_Y/2, ORIN_HOLE_Y/2])
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translate([ORIN_OFF_X + dx, ORIN_OFF_Y + dy, BAY_FLOOR])
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difference() {
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cylinder(d = ORIN_STANDOFF_OD, h = ORIN_STANDOFF_H);
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// M3 tap bore (top 8mm)
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translate([0, 0, ORIN_STANDOFF_H - 8])
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cylinder(d = 2.5, h = 9);
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// Clearance from floor
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cylinder(d = ORIN_HOLE_D, h = ORIN_STANDOFF_H - 8);
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}
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}
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// ============================================================
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// BAY LID (with RPLIDAR A1M8 tower and ventilation)
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// ============================================================
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// Lid drops over bay walls (retention lip) and is held with 4× M3 screws.
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// RPLIDAR A1M8 tower rises from lid centre.
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// Lid ventilation slots allow convective air circulation.
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// ============================================================
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module bay_lid() {
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outer_x = BAY_L + 2*BAY_WALL;
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outer_y = BAY_W + 2*BAY_WALL;
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difference() {
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union() {
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// ── Lid plate ─────────────────────────────────────────────
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linear_extrude(LID_T)
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minkowski() {
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square([outer_x - 2*BAY_R, outer_y - 2*BAY_R],
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center = true);
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circle(r = BAY_R);
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}
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// ── Retention rim (drops inside bay walls) ─────────────────
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rim_x = BAY_L - 2*LID_RIM_GAP;
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rim_y = BAY_W - 2*LID_RIM_GAP;
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translate([0, 0, -LID_RIM_H + e])
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linear_extrude(LID_RIM_H)
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difference() {
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minkowski() {
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square([rim_x - 2*BAY_R, rim_y - 2*BAY_R],
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center = true);
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circle(r = BAY_R);
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}
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// Hollow interior
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offset(r = -BAY_WALL)
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minkowski() {
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square([rim_x - 2*BAY_R, rim_y - 2*BAY_R],
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center = true);
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circle(r = BAY_R);
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}
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}
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// ── RPLIDAR tower (centred on lid) ─────────────────────────
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translate([0, 0, LID_T])
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rplidar_tower();
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}
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// ── Lid ventilation slots (3× rows, 5 slots each) ─────────────
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for (i = [-2:2]) {
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translate([i * VENT_PITCH - VENT_W/2, -outer_y/2 + 20, -e])
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cube([VENT_W, outer_y - 40, LID_T + 2*e]);
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}
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// ── 4× M3 lid retention bolt holes ────────────────────────────
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for (sx = [-1, 1])
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for (sy = [-1, 1]) {
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lx = sx * (outer_x/2 - LID_BOLT_POS);
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ly = sy * (outer_y/2 - LID_BOLT_POS);
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translate([lx, ly, -e])
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cylinder(d = M3_D, h = LID_T + 2*e);
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}
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}
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}
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// ── RPLIDAR A1M8 tower (on lid) ──────────────────────────────────────────────
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// Hollow column provides height above bay for RPLIDAR 360° scan clearance.
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// Anti-vibration ring (rplidar_mount.scad) sits atop the platform.
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// Tower height: 100 mm above lid = ~185 mm total above deck.
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module rplidar_tower() {
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difference() {
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union() {
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// Hollow column
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cylinder(d = RPL_TOWER_OD, h = RPL_TOWER_H);
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// Flared base (distributes load, improves print adhesion)
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cylinder(d = RPL_TOWER_OD + 16, h = 8);
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// Top platform disk
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translate([0, 0, RPL_TOWER_H])
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cylinder(d = RPL_PLATFORM_D, h = 8);
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}
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// Hollow core (cable routing for RPLIDAR USB)
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translate([0, 0, -e])
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cylinder(d = RPL_TOWER_ID, h = RPL_TOWER_H + 9);
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// 4× base-to-lid M3 attachment holes (through flared base)
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for (a = [0, 90, 180, 270])
|
||
rotate([0, 0, a])
|
||
translate([(RPL_TOWER_OD + 12) / 2, 0, -e])
|
||
cylinder(d = M3_D, h = 10);
|
||
|
||
// RPLIDAR A1M8 mounting holes (4× M3, 58 mm BC, 45° offset)
|
||
// Matches rplidar_mount.scad / sensor_head.scad RPL_BC pattern
|
||
for (a = [45, 135, 225, 315])
|
||
translate([RPL_BC/2 * cos(a),
|
||
RPL_BC/2 * sin(a),
|
||
RPL_TOWER_H - e])
|
||
cylinder(d = RPL_HOLE_D, h = 10);
|
||
|
||
// Rotation alignment slot (sets RPLIDAR scan start angle)
|
||
translate([RPL_BC/2 - 3, -2, RPL_TOWER_H - e])
|
||
cube([8, 4, 10]);
|
||
}
|
||
}
|