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>
132 lines
5.6 KiB
Markdown
132 lines
5.6 KiB
Markdown
# SaltyBot Chassis — Assembly Notes
|
||
**Task:** bd-1iy5 — Rev A — 2026-02-28
|
||
|
||
---
|
||
|
||
## Overview
|
||
|
||
```
|
||
[Front bumper rail — 22mm EMT]
|
||
├─ bumper_bracket(front=+1) ──────────────────────┐
|
||
│ │
|
||
┌───────┴──────────── Main Deck (640×220×6mm Al) ─────────┴───────┐
|
||
│ ← Jetson mount plate (rear/+X) FC mount (front/−X) → │
|
||
│ [Battery tray hanging below centre] │
|
||
└───┬──────────────────────────────────────────────────────────┬───┘
|
||
│ │
|
||
Motor fork (L) Motor fork (R)
|
||
Hub motor CL: ±300mm from deck centre │
|
||
Axle height: 310mm above ground │
|
||
├─ bumper_bracket(front=-1) ──────────────────────┘
|
||
[Rear bumper rail — 22mm EMT]
|
||
```
|
||
|
||
---
|
||
|
||
## Step-by-step Assembly
|
||
|
||
### 1 Fabricate / print parts
|
||
- Send deck plate DXF (export from OpenSCAD → DXF) to CNC router or waterjet cutter.
|
||
- Print motor fork brackets in PETG 5 perimeters / 40% gyroid for prototype, or send STEP to machine shop.
|
||
- Print battery tray, FC pad, Jetson plate, bumper brackets in PETG.
|
||
- Export STEP: OpenSCAD → Render (F6) → Export as STL, then convert with FreeCAD for STEP.
|
||
|
||
### 2 Verify motor axle dimensions
|
||
- Measure actual hoverboard motor axle: diameter and flat-to-flat.
|
||
- Adjust `MOTOR_AXLE_D` and `MOTOR_AXLE_FLAT` in `chassis_frame.scad`.
|
||
- Re-export fork dropout slot.
|
||
|
||
### 3 Motor forks → deck
|
||
1. Thread M5 T-nuts into underside of deck edge slots (or use M5 rivet nuts).
|
||
2. Align fork bracket to deck edge; fasten with 4× M5×16 SHCS + flat washer each side.
|
||
3. Apply Loctite 243 to threads. Torque to 4 N·m.
|
||
|
||
### 4 Motors into forks
|
||
1. Slide hub motor axle into dropout slot (flat side aligns with slot).
|
||
2. Fit flat washer then flanged M14 axle nut; torque to 35–40 N·m.
|
||
3. Feed motor phase wires and hall-sensor cable through deck cable slot.
|
||
|
||
### 5 Longitudinal ribs
|
||
1. Align ribs with edge grooves on deck underside.
|
||
2. Secure with M4×12 SHCS through pre-drilled holes; torque 2.5 N·m.
|
||
|
||
### 6 Battery tray
|
||
1. Pass any wiring harness through deck wire-pass hole before mounting tray.
|
||
2. Align tray mounting ears to deck M4 threaded inserts (or rivet nuts).
|
||
3. Fasten 4× M4×12 SHCS. Torque 2.5 N·m.
|
||
4. Insert battery pack; route Velcro straps through slots and cinch.
|
||
|
||
<<<<<<< HEAD
|
||
### 7 MCU mount (ESP32 BALANCE + ESP32 IO)
|
||
|
||
> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** ESP32 BALANCE retired. Two ESP32 boards replace it.
|
||
> Board dimensions and hole patterns TBD — await spec from max before machining mount plate.
|
||
|
||
=======
|
||
### 7 FC mount (ESP32-S3 BALANCE)
|
||
>>>>>>> 291dd68 (feat: remove all STM32/Mamba/BlackPill references — ESP32-S3 only)
|
||
1. Place silicone anti-vibration grommets onto nylon M3 standoffs.
|
||
2. Lower ESP32 BALANCE board onto standoffs; secure with M3×6 BHCS. Snug only.
|
||
3. Mount ESP32 IO board adjacent — exact placement TBD pending board dimensions.
|
||
4. Orient USB connectors toward front of robot for cable access.
|
||
|
||
### 8 Jetson Orin Nano Super mount plate
|
||
1. Press or thread M3 nylon standoffs (8mm) into plate holes.
|
||
2. Bolt plate to deck: 4× M3×10 SHCS at deck corners.
|
||
3. Set Jetson Orin Nano Super B01 carrier onto plate standoffs; fasten M3×6 BHCS.
|
||
|
||
### 9 Bumper brackets
|
||
1. Slide 22mm EMT conduit through saddle clamp openings.
|
||
2. Bolt bracket to deck edge: 4× M5×16 SHCS per bracket.
|
||
3. Position bumper rail flush with motor OD outer edge; tighten saddle clamp bolts.
|
||
|
||
### 10 Cable routing
|
||
- Route motor phase cables along longitudinal ribs; secure with cable clips.
|
||
- FC ↔ ESC/VESC harness exits through front cable slot.
|
||
- Jetson USB/UART ribbon exits through rear cable slot.
|
||
- Power harness (battery XT60 → BMS → 24V bus) runs under deck along centreline.
|
||
|
||
---
|
||
|
||
## Critical Dimensions (verify before machining)
|
||
|
||
| Dimension | Nominal | Tolerance |
|
||
|-----------|---------|-----------|
|
||
| Wheelbase (axle C/L to C/L) | 600 mm | ±1 mm |
|
||
| Motor fork slot width | 24 mm | +0.5 / 0 |
|
||
| Motor fork dropout depth | 60 mm | ±0.5 mm |
|
||
| ESP32 BALANCE hole pattern | TBD — await spec from max | ±0.2 mm |
|
||
| ESP32 IO hole pattern | TBD — await spec from max | ±0.2 mm |
|
||
| Jetson hole pattern | 58 × 58 mm | ±0.2 mm |
|
||
| Battery tray inner | 185 × 72 × 52 mm | +2 / 0 mm |
|
||
|
||
---
|
||
|
||
## OpenSCAD Rendering Notes
|
||
|
||
```bash
|
||
# Render full assembly preview (F5 in GUI)
|
||
openscad chassis_frame.scad
|
||
|
||
# Export individual part STL for slicing
|
||
openscad chassis_frame.scad -D "PART=\"motor_fork\"" -o motor_fork_right.stl
|
||
|
||
# Export deck DXF (set DECK_THICKNESS=0.01 for 2D projection)
|
||
openscad chassis_frame.scad -D "RENDER_2D=true" -o deck_plate.dxf
|
||
```
|
||
|
||
**Slicing profile (PETG, structural parts):**
|
||
- Nozzle: 0.4mm | Layer: 0.2mm
|
||
- Perimeters: 5 | Infill: 40% gyroid
|
||
- Supports: Yes (motor fork dropout slot)
|
||
- Orientation: Fork bracket printed vertically (load axis = layer direction)
|
||
|
||
---
|
||
|
||
## Safety Notes
|
||
|
||
- Verify axle nut torque after first 10-minute ride — hub motors vibrate and may back off.
|
||
- Battery tray is rated for packs ≤185×72×52mm; confirm dimensions before ordering cells.
|
||
- Ground all aluminium chassis parts to power-common to avoid RF interference with FC.
|
||
- Do **not** run robot without bumpers fitted — uncontrolled runaway risk.
|