- docs/SAUL-TEE-SYSTEM-REFERENCE.md: authoritative architecture doc for the new 4-wheel wagon. Covers ESP32-S3 BALANCE (Waveshare LCD 1.28, QMI8658, SN65HVD230 CAN), ESP32-S3 IO (TBS Crossfire, ELRS, BTS7960, NFC/baro/ToF, WS2812), inter-board UART protocol (460800 baud, [0xAA][len][type][payload][crc8]), CAN IDs (VESCs 68/56, Orin 0x300-0x303 cmd / 0x400-0x401 telemetry), RC channel map, power architecture, safety systems, and firmware layout. - docs/wiring-diagram.md: banner pointing to new reference doc; old Mamba F722S UART summary marked OBSOLETE. Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
445 lines
18 KiB
Markdown
445 lines
18 KiB
Markdown
# SAUL-TEE — System Reference
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**Rev A — 2026-04-04**
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_Authoritative architecture reference for all agents. Source: hal (Orin), max._
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---
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## 1. Robot Overview
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| Parameter | Value |
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|-----------|-------|
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| **Name** | SAUL-TEE |
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| **Config** | 4-wheel wagon (replaces 2-wheel self-balancing bot) |
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| **Dimensions** | 870 × 510 × 550 mm (L × W × H) |
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| **Mass** | ~23 kg |
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| **Drive** | 4× hub motors via 2× VESC 6.7 (dual channel each) |
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| **Power** | 36V battery bus |
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| **AI brain** | Jetson Orin Nano Super (25W) |
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| **CAN bus** | 500 kbps, CANable 2.0 USB↔CAN on Orin |
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> ⚠️ **ARCHITECTURE CHANGE (2026-04-03):** Mamba F722S / STM32F722 / BlackPill are retired.
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> New embedded stack: **ESP32-S3 BALANCE** + **ESP32-S3 IO** (see §2–3 below).
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---
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## 2. ESP32-S3 BALANCE Board
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### Hardware
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| Item | Detail |
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|------|--------|
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| **Module** | Waveshare ESP32-S3 Touch LCD 1.28 |
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| **MCU** | ESP32-S3 (dual-core 240 MHz, 512KB SRAM, 8MB flash, 8MB PSRAM) |
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| **USB** | CH343G USB-UART bridge (UART0 / GPIO43 TX, GPIO44 RX) |
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| **Display** | 1.28" round GC9A01 240×240 LCD (SPI) |
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| **Touch** | CST816S capacitive touch (I2C) |
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| **IMU** | QMI8658 6-axis (gyro + accel), I2C on-board |
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| **CAN transceiver** | SN65HVD230, external, wired to ESP32-S3 TWAI peripheral |
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### Role
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- Runs the **PID balance / drive loop** (or stability assist for wagon mode)
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- Reads QMI8658 IMU at high rate for tilt / attitude
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- Sends drive commands to VESCs over **500 kbps CAN** (VESC native protocol)
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- Receives high-level velocity commands from Orin over CAN (0x300–0x303)
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- Publishes telemetry to Orin over CAN (0x400–0x401)
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- Bridges ESP32-IO sensor data over **inter-board UART** @ 460800 baud
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### On-Board Pin Map (fixed by Waveshare PCB)
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| Signal | GPIO | Notes |
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|--------|------|-------|
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| LCD SCLK | 10 | GC9A01 SPI clock |
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| LCD MOSI | 11 | GC9A01 SPI data |
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| LCD CS | 9 | GC9A01 chip select |
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| LCD DC | 8 | GC9A01 data/cmd |
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| LCD BL | 2 | Backlight PWM |
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| Touch SDA | 6 | CST816S / I2C-0 |
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| Touch SCL | 7 | CST816S / I2C-0 |
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| Touch INT | 5 | Active-low interrupt |
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| Touch RST | 4 | Active-low reset |
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| IMU SDA | 6 | QMI8658 shares I2C-0 |
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| IMU SCL | 7 | QMI8658 shares I2C-0 |
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| IMU INT1 | 3 | Data-ready interrupt |
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| CH343 USB TX | 43 | UART0 TX (USB serial) |
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| CH343 USB RX | 44 | UART0 RX (USB serial) |
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### External Wiring (user-soldered, confirm with calipers/multimeter)
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| Signal | GPIO | Notes |
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|--------|------|-------|
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| CAN TX | **TBD** | → SN65HVD230 D pin; use free header GPIO |
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| CAN RX | **TBD** | ← SN65HVD230 R pin; use free header GPIO |
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| Inter-board UART TX | **TBD** | → ESP32-IO UART RX @ 460800 |
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| Inter-board UART RX | **TBD** | ← ESP32-IO UART TX @ 460800 |
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> ⚠️ **Verify GPIO assignments in `esp32/balance/src/config.h` before writing firmware.**
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### QMI8658 Details
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| Item | Value |
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|------|-------|
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| I2C address | 0x6A (SA0 pin low) or 0x6B (SA0 high) |
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| Gyro full-scale | ±2048 °/s (configurable ±16/32/64/128/256/512/1024/2048) |
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| Accel full-scale | ±16 g (configurable ±2/4/8/16) |
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| Output data rate | Up to 7174.4 Hz |
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| Interface | I2C or SPI (board routes I2C) |
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---
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## 3. ESP32-S3 IO Board
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### Hardware
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| Item | Detail |
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|------|--------|
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| **Module** | ESP32-S3 bare dev board (JTAG USB) |
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| **MCU** | ESP32-S3 (dual-core 240 MHz) |
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| **USB** | Built-in USB-JTAG/Serial (no external bridge) |
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### Role
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- All **physical I/O**: motors, RC, sensors, indicators, accessories
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- TBS Crossfire primary RC (UART0)
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- ELRS failover RC (UART2)
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- BTS7960 half-bridge motor drivers (4-wheel PWM drive)
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- NFC, barometer, ToF range sensors (I2C)
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- WS2812B LED strip
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- Horn, headlight, cooling fan, buzzer
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### Pin Map
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| Signal | GPIO | Protocol | Notes |
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|--------|------|----------|-------|
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| **TBS Crossfire RX** UART TX | 43 | CRSF @ 420000 baud | Telemetry out to TBS TX module |
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| **TBS Crossfire RX** UART RX | 44 | CRSF @ 420000 baud | UART0 — RC frames in |
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| **ELRS failover** UART TX | **TBD** | CRSF @ 420000 baud | UART2 |
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| **ELRS failover** UART RX | **TBD** | CRSF @ 420000 baud | UART2 |
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| **Inter-board UART TX** | **TBD** | Binary @ 460800 | → BALANCE UART RX |
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| **Inter-board UART RX** | **TBD** | Binary @ 460800 | ← BALANCE UART TX |
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| **BTS7960 — FL** RPWM | **TBD** | PWM | Front-left forward |
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| **BTS7960 — FL** LPWM | **TBD** | PWM | Front-left reverse |
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| **BTS7960 — FL** R_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — FL** L_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — FR** RPWM | **TBD** | PWM | Front-right forward |
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| **BTS7960 — FR** LPWM | **TBD** | PWM | Front-right reverse |
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| **BTS7960 — FR** R_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — FR** L_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — RL** RPWM | **TBD** | PWM | Rear-left forward |
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| **BTS7960 — RL** LPWM | **TBD** | PWM | Rear-left reverse |
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| **BTS7960 — RL** R_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — RL** L_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — RR** RPWM | **TBD** | PWM | Rear-right forward |
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| **BTS7960 — RR** LPWM | **TBD** | PWM | Rear-right reverse |
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| **BTS7960 — RR** R_EN | **TBD** | GPIO | Enable H |
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| **BTS7960 — RR** L_EN | **TBD** | GPIO | Enable H |
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| **I2C SDA** | **TBD** | I2C | NFC + baro + ToF shared bus |
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| **I2C SCL** | **TBD** | I2C | NFC + baro + ToF shared bus |
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| **WS2812B data** | **TBD** | RMT | LED strip |
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| **Horn** | **TBD** | GPIO/PWM | MOSFET or relay |
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| **Headlight** | **TBD** | GPIO/PWM | MOSFET |
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| **Fan** | **TBD** | PWM | ESC/electronics cooling |
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| **Buzzer** | **TBD** | GPIO/PWM | Piezo or active buzzer |
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> ⚠️ **TBD pin assignments** — to be confirmed in `esp32/io/src/config.h` once wiring is set.
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### I2C Peripherals
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| Device | Address | Function |
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|--------|---------|----------|
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| NFC module | 0x24 (PN532) or 0x28 | NFC tag read/write |
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| Barometer | 0x76 (BMP280/BMP388) | Altitude + temp |
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| ToF range | 0x29 (VL53L0X) or 0x52 (VL53L4CD) | Proximity/obstacle |
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---
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## 4. Inter-Board UART Protocol (BALANCE ↔ IO)
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### Link Parameters
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| Parameter | Value |
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|-----------|-------|
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| Baud rate | 460800 |
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| Format | 8N1 |
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| Direction | Full-duplex |
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### Frame Format
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```
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Byte 0: 0xAA (start-of-frame magic)
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Byte 1: LEN (payload length in bytes, uint8)
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Byte 2: TYPE (message type, uint8)
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Byte 3…N: PAYLOAD (LEN bytes)
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Byte N+1: CRC8 (CRC-8/MAXIM over bytes 1..N)
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```
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### Message Types (draft — confirm in firmware)
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| Type | Direction | Payload | Description |
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|------|-----------|---------|-------------|
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| 0x01 | IO → BAL | `[ch1:u16][ch2:u16]…[ch16:u16][flags:u8]` | RC channels (16× uint16, 1000–2000 µs) + status flags |
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| 0x02 | IO → BAL | `[sensor_id:u8][value:f32]` | Sensor reading (ToF, baro, etc.) |
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| 0x03 | IO → BAL | `[nfc_uid:u8×7][len:u8]` | NFC tag detected |
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| 0x10 | BAL → IO | `[leds:u8][horn:u8][light:u8][fan:u8][buzz:u8]` | Actuator commands |
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| 0x11 | BAL → IO | `[state:u8][pitch:f32][speed:f32]` | Status for LED animations |
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| 0xFF | both | `[uptime_ms:u32]` | Heartbeat (watchdog reset) |
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> Frame types are **draft** — refer to `esp32/shared/protocol.h` for authoritative definitions.
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### CRC-8 Polynomial
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```
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Poly: 0x31 (CRC-8/MAXIM, also called CRC-8/1-Wire)
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Init: 0x00
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RefIn/RefOut: true
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XorOut: 0x00
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```
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---
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## 5. CAN Bus
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### Bus Parameters
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| Parameter | Value |
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|-----------|-------|
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| Bit rate | 500 kbps |
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| Topology | Single bus; all nodes share CANH/CANL + GND |
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| Termination | 120 Ω at each end of the bus |
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| Orin interface | CANable 2.0 USB↔CAN → `/dev/canable0` (or `can0` after `ip link`) |
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### Node Addresses
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| Node | CAN ID / Role |
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|------|--------------|
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| VESC left motor | ID **68** (0x44) — FSESC 6.7 Pro Mini Dual, left channel |
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| VESC right motor | ID **56** (0x38) — FSESC 6.7 Pro Mini Dual, right channel |
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| ESP32-S3 BALANCE | transmits telemetry 0x400–0x401; receives Orin cmds 0x300–0x303 |
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| Orin (CANable2) | transmits cmds 0x300–0x303; receives telemetry 0x400–0x401 |
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### Orin → Robot Command Frames (0x300–0x303)
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| CAN ID | DLC | Payload | Description |
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|--------|-----|---------|-------------|
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| **0x300** | 8 | `[speed:i16][steer:i16][mode:u8][flags:u8][_:u16]` | Drive command (speed/steer ±1000, mode byte) |
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| **0x301** | 1 | `[arm:u8]` | Arm/disarm (0x01 = arm, 0x00 = disarm) |
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| **0x302** | 8 | `[kp:f16][ki:f16][kd:f16][_:u16]` | PID update (half-float) |
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| **0x303** | 1 | `[0xE5]` | Emergency stop (magic byte, cuts all motors) |
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### Robot → Orin Telemetry Frames (0x400–0x401)
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| CAN ID | DLC | Payload | Description |
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|--------|-----|---------|-------------|
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| **0x400** | 8 | `[pitch:f16][speed:f16][yaw_rate:f16][state:u8][flags:u8]` | Attitude + drive state |
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| **0x401** | 4 | `[vbat:u16][fault_code:u8][rssi:i8]` | Battery voltage (mV), fault, RC RSSI |
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### VESC Native CAN (standard VESC protocol)
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ESP32-S3 BALANCE sends VESC commands using the standard VESC CAN protocol:
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| Frame type | CAN ID formula | Notes |
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|------------|---------------|-------|
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| SET_DUTY | `(0x00 << 8) | VESC_ID` | Duty cycle −1.0..+1.0 × 100000 |
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| SET_CURRENT | `(0x01 << 8) | VESC_ID` | Current in mA |
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| SET_RPM | `(0x03 << 8) | VESC_ID` | Electrical RPM |
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| SET_CURRENT_BRAKE | `(0x02 << 8) | VESC_ID` | Braking current in mA |
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| STATUS_1 | `(0x09 << 8) | VESC_ID` | ERPMs + current + duty (rx) |
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| STATUS_4 | `(0x10 << 8) | VESC_ID` | Temp + input voltage + input current (rx) |
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---
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## 6. RC Channel Mapping
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### Primary: TBS Crossfire (UART0 on ESP32-IO, CRSF @ 420000 baud)
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| Channel | Function | Range | Notes |
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|---------|----------|-------|-------|
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| CH1 | Roll / Steer | 1000–2000 µs | Left stick X (mode 2) |
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| CH2 | Pitch / Speed | 1000–2000 µs | Left stick Y |
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| CH3 | Throttle | 1000–2000 µs | Right stick Y |
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| CH4 | Yaw | 1000–2000 µs | Right stick X |
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| CH5 | Arm | 1000 / 2000 µs | 2-pos switch — <1200=DISARM, >1800=ARM |
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| CH6 | Drive mode | 1000/1500/2000 µs | 3-pos: RC / Assisted / Autonomous |
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| CH7 | Speed limit | 1000–2000 µs | Analog knob, scales max speed |
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| CH8 | Aux / Horn | 1000 / 2000 µs | Momentary for horn; held = klaxon |
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### Failover: ELRS (UART2 on ESP32-IO, CRSF @ 420000 baud)
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Same channel mapping as TBS Crossfire. IO board switches to ELRS automatically if Crossfire link lost for > 300 ms.
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### Failsafe
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- **RC lost > 300 ms**: motors stop, DISARM state, wait for link restoration
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- **Arm switch** must be cycled to DISARM→ARM to re-arm after failsafe
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---
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## 7. Serial Commands (Orin → ESP32-S3 BALANCE via CAN 0x300)
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All high-level commands from the Orin go over CAN. The BALANCE board also accepts direct USB-serial commands on its CH343 port for bench debugging:
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```
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# Arm / disarm
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ARM
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DISARM
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# Set drive (speed -1000..1000, steer -1000..1000)
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DRIVE <speed> <steer>
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# Set mode
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MODE RC # full RC passthrough
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MODE ASSISTED # Orin sends velocity, BALANCE does stability
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MODE AUTO # full autonomous (Orin CAN commands only)
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# PID update
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PID <kp> <ki> <kd>
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# Emergency stop (same as CAN 0x303)
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ESTOP
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# Status query
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STATUS # returns JSON telemetry line
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# IMU calibration
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IMU CAL
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```
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---
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## 8. System Wiring Diagram
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```
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┌──────────────────────────────────────────────────────────┐
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│ JETSON ORIN NANO SUPER │
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│ (Top plate, 25W) │
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│ │
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│ USB-A ─── CANable 2.0 USB↔CAN (can0, 500 kbps) │
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│ USB-A ─── RealSense D435i (USB 3.1) │
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│ USB-A ─── RPLIDAR A1M8 (CP2102, 115200) │
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│ USB-C ─── SIM7600A 4G/LTE modem │
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│ CSI-A ─── 2× IMX219 cameras │
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│ CSI-B ─── 2× IMX219 cameras │
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│ 40-pin ── ReSpeaker 2-Mic HAT │
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└──────────────────────┬───────────────────────────────────┘
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│ USB-A
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│ CANable 2.0
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│ 500 kbps CAN
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┌────────────────────────────────┴──────────────────────────────────┐
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│ CAN BUS (CANH / CANL) │
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│ 120Ω ───┤ (all nodes) ├─── 120Ω │
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└───┬──────────────────────────┬───────────────────┬────────────────┘
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│ │ │
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▼ ▼ ▼
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┌─────────────────────┐ ┌─────────────────────┐ (CAN ID 56/68)
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│ ESP32-S3 BALANCE │ │ VESC left (ID 68)│ VESC right (ID 56)
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│ Waveshare LCD 1.28 │ │ FSESC 6.7 Pro Mini│
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│ │ │ Dual │
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│ QMI8658 IMU (I2C) │ └────────┬────────────┘
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│ SN65HVD230 (CAN) │ │ Phase wires
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│ CH343 USB (debug) │ ┌─────┴────────────────┐
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│ │ │ Hub motors (4×) │
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│ UART ─────────────────┐ │ FL / FR / RL / RR │
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└─────────────────────┘ │ └──────────────────────┘
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↑ 460800 baud binary │
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↓ inter-board protocol │
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┌─────────────────────────┘
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│ ESP32-S3 IO (bare board)
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│ JTAG USB (debug)
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│
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│ UART0 ── TBS Crossfire RX (CRSF, 420000)
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│ UART2 ── ELRS receiver (CRSF failover, 420000)
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│ PWM ──── 4× BTS7960 motor drivers
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│ I2C ──── NFC + Baro + ToF sensors
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│ GPIO ─── WS2812B LEDs
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│ GPIO ─── Horn / Headlight / Fan / Buzzer
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└─────────────────────────────────────────────
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```
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---
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## 9. Power Architecture
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```
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36V BATTERY
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│
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├── VESCs (36V direct) ──── 4× Hub motors
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│
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├── BTS7960 boards (36V → motor logic 5V via onboard reg)
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│
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├── DC-DC 12V ──── Fan / Headlight / Accessories
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│
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└── DC-DC 5V ─┬── Jetson Orin (USB-C PD or barrel)
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├── ESP32-S3 BALANCE (USB 5V or VIN)
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├── ESP32-S3 IO (USB 5V or VIN)
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├── TBS Crossfire RX (5V)
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├── ELRS RX (5V)
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├── WS2812B strip (5V)
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├── RPLIDAR A1M8 (5V via USB)
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└── Sensors / NFC / ToF / Baro (3.3V LDO from ESP32)
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```
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---
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## 10. Device Nodes (Orin)
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| Device | Node | Notes |
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|--------|------|-------|
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| CANable 2.0 | `can0` | `ip link set can0 up type can bitrate 500000` |
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| RealSense D435i | `/dev/bus/usb/...` | realsense-ros driver |
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| RPLIDAR A1M8 | `/dev/rplidar` | udev symlink from ttyUSB* |
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| SIM7600A 4G | `/dev/ttyUSB0–2` | AT, PPP, GNSS NMEA |
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| IMX219 cameras | `/dev/video0,2,4,6` | CSI-A: 0/2, CSI-B: 4/6 |
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| ESP32-S3 BAL debug | `/dev/ttyACM0` or `/dev/esp32-balance` | CH343 CDC |
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| ESP32-S3 IO debug | `/dev/ttyACM1` or `/dev/esp32-io` | JTAG/CDC |
|
||
|
||
---
|
||
|
||
## 11. Safety Systems
|
||
|
||
| System | Trigger | Action |
|
||
|--------|---------|--------|
|
||
| **HW kill switch** | Big red button (NC inline with 36V) | Cuts all power instantly |
|
||
| **Tilt cutoff** | `|pitch| > 25°` | Motors off → DISARM, manual re-arm required |
|
||
| **RC failsafe** | No RC frame > 300 ms | Motors off → DISARM |
|
||
| **CAN watchdog** | No Orin heartbeat > 500 ms | Drop to RC-only mode |
|
||
| **ESTOP CAN** | CAN frame 0x303 (magic 0xE5) | Immediate motor off, DISARM |
|
||
| **ESTOP inter-board** | Type 0xFF heartbeat missing > 200 ms | IO board stops BTS7960 enables |
|
||
| **Startup arming** | Cold power-on | Motors NEVER spin; need deliberate ARM |
|
||
|
||
---
|
||
|
||
## 12. Firmware Repository Layout
|
||
|
||
```
|
||
esp32/
|
||
├── balance/ — ESP32-S3 BALANCE firmware (PlatformIO)
|
||
│ ├── src/
|
||
│ │ ├── main.cpp
|
||
│ │ ├── config.h ← GPIO assignments live here
|
||
│ │ ├── imu_qmi8658.cpp/.h
|
||
│ │ ├── can_vesc.cpp/.h
|
||
│ │ └── protocol.cpp/.h
|
||
│ └── platformio.ini
|
||
├── io/ — ESP32-S3 IO firmware (PlatformIO)
|
||
│ ├── src/
|
||
│ │ ├── main.cpp
|
||
│ │ ├── config.h ← GPIO assignments live here
|
||
│ │ ├── rc_crsf.cpp/.h
|
||
│ │ ├── motor_bts7960.cpp/.h
|
||
│ │ └── protocol.cpp/.h
|
||
│ └── platformio.ini
|
||
└── shared/
|
||
└── protocol.h — inter-board frame types (authoritative)
|
||
|
||
src/ — LEGACY STM32 firmware (ARCHIVED — do not extend)
|
||
include/ — LEGACY STM32 headers (ARCHIVED — do not extend)
|
||
```
|
||
|
||
---
|
||
|
||
## 13. Open Questions / TBDs
|
||
|
||
| Item | Owner | Status |
|
||
|------|-------|--------|
|
||
| GPIO assignments for CAN TX/RX on BALANCE board | sl-firmware | **TBD** |
|
||
| GPIO assignments for IO board (all external pins) | sl-firmware | **TBD** |
|
||
| Inter-board protocol message type table (finalized) | sl-firmware | **TBD** |
|
||
| BTS7960 wiring — 4WD vs 2WD mode (all 4 or front 2 only) | max | **TBD** |
|
||
| UWB ESP-NOW receiver — BALANCE or IO board? | sl-uwb + max | **TBD** |
|
||
| VESC CAN IDs confirmed (68/56 left/right) | max | ✅ Confirmed |
|
||
| Robot dimensions 870×510×550 mm, 23 kg | max | ✅ Confirmed |
|
||
|
||
---
|
||
|
||
_Last updated: 2026-04-04. Contact max or hal on MQTT for corrections._
|