sprint-6: Alarm engine + safety monitor + NMEA 2000 publisher

Python side:
- alarm_engine.py: AlarmEngine evaluates 9 firmware alarm bits + PC-side
  heading staleness and off-course logic with severe-timer; on_disengage
  callback triggers on first EMERGENCY alarm; acknowledge/clear API
- test_alarm_engine.py: 25 tests covering fire/clear cycle, acknowledge,
  highest_severity, auto-disengage callback, heading staleness, off-course
  with wraparound and timer, fw-bit suppression of duplicate PC alarm

Firmware:
- safety_monitor.h: exposes AlarmBits struct + safety_alarm_bits() API
- safety_monitor.cpp: 50 Hz task evaluates off-course (with severe timer),
  rudder-not-responding (3 s timeout), heading lost, VMS/DI4, limit switches,
  battery voltage, actuator current; buzzer on any alarm; EMERGENCY → force_standby
- modbus_slave.cpp: wires 9 discrete alarm registers to safety_alarm_bits();
  battery voltage and actuator current ADC registers now live
- nmea2000_publisher.h/cpp: new task, PGN 127245 rudder angle at 10 Hz,
  PGN 127237 Heading/Track Control at 1 Hz
- main.cpp: start nmea2000_publisher; set watchdog-tripped flag on ESP_RST_TASK_WDT

Tests: 309 passed | Flash: 27.6%

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
This commit is contained in:
2026-05-20 00:16:24 -04:00
parent 0f00ad10da
commit e82dbc449c
8 changed files with 965 additions and 45 deletions
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"""Runtime alarm engine -- Sprint 6.
Evaluates live telemetry against the alarm catalogue (brief section 7)
and maintains a set of currently active alarms. Designed to run on the
PC side (Python display software); the firmware publishes alarm bits via
Modbus discrete inputs and this engine turns them into typed Alarm records
that the UI displays and the audit log records.
Usage::
engine = AlarmEngine()
# On each 10 Hz display tick:
alarms = engine.evaluate(snapshot)
for a in alarms: # newly fired alarms
display.show_alarm(a)
audit_log.append(a)
engine.acknowledge(AlarmType.OFF_COURSE)
engine.acknowledge_all()
"""
from __future__ import annotations
from dataclasses import dataclass, field
from typing import Callable
from arautopilot.core.alarms import Alarm, AlarmType, AlarmSeverity, triggers_auto_disengage
@dataclass
class AlarmThresholds:
"""Tunable thresholds; can be loaded from the project config."""
# Off-course
off_course_deg: float = 10.0 # LOW warning threshold
severe_off_course_deg: float = 30.0 # EMERGENCY threshold
severe_off_course_time_s: float = 5.0 # must persist this long
# Rudder not responding
rudder_response_timeout_s: float = 3.0 # setpoint sent but no motion
rudder_deadband_deg: float = 0.5
# Sensor staleness (must match firmware STALE_THRESHOLD_MS)
heading_stale_s: float = 5.0
cog_stale_s: float = 5.0
# Voltage / current (used by display if it has ADC readback)
voltage_low_v: float = 10.5
current_high_a: float = 30.0
@dataclass
class TelemetrySnapshot:
"""Aggregated telemetry read from Modbus or internal state."""
# Mode
pilot_engaged: bool = False
# Heading
heading_deg: float | None = None
heading_setpoint_deg: float | None = None
heading_age_s: float = 0.0
# Rudder
rudder_angle_deg: float | None = None
rudder_setpoint_deg: float | None = None
rudder_valid: bool = False
# COG (True Course / Track Keeping modes)
cog_deg: float | None = None
cog_age_s: float = 0.0
# Electrical
battery_v: float | None = None
actuator_a: float | None = None
# Digital inputs
limit_port: bool = False
limit_stbd: bool = False
vms_critical: bool = False
# Firmware discrete alarms (read directly from Modbus)
fw_alarm_off_course: bool = False
fw_alarm_off_course_severe: bool = False
fw_alarm_rudder_not_resp: bool = False
fw_alarm_heading_lost: bool = False
fw_alarm_actuator_overcurr: bool = False
fw_alarm_voltage_low: bool = False
fw_alarm_limit_reached: bool = False
fw_alarm_watchdog_tripped: bool = False
fw_alarm_vms_critical: bool = False
class AlarmEngine:
"""Evaluates telemetry and manages the active alarm set.
The primary job is to bridge between raw Modbus bits (from the firmware)
and the typed :class:`Alarm` records that the UI and audit log consume.
The engine also performs PC-side logic for alarms the firmware doesn't
compute (e.g. heading-sensor age on the Python side).
"""
def __init__(
self,
thresholds: AlarmThresholds | None = None,
on_disengage: Callable[[], None] | None = None,
) -> None:
self.thresholds = thresholds or AlarmThresholds()
self._on_disengage = on_disengage
self._active: dict[AlarmType, Alarm] = {}
self._acknowledged: set[AlarmType] = set()
self._severe_off_course_timer_s: float = 0.0
self._dt_s: float = 0.1 # 10 Hz default
# ------------------------------------------------------------------
# Public API
# ------------------------------------------------------------------
def evaluate(
self,
snap: TelemetrySnapshot,
dt_s: float | None = None,
) -> list[Alarm]:
"""Evaluate conditions against ``snap``.
Returns the list of **newly fired** alarms since the last call.
Already-active alarms are not re-fired.
"""
if dt_s is not None:
self._dt_s = dt_s
new_alarms: list[Alarm] = []
# Map firmware discrete bits → alarm types
fw_map: list[tuple[bool, AlarmType]] = [
(snap.fw_alarm_off_course, AlarmType.OFF_COURSE),
(snap.fw_alarm_off_course_severe, AlarmType.OFF_COURSE_SEVERE),
(snap.fw_alarm_rudder_not_resp, AlarmType.RUDDER_NOT_RESPONDING),
(snap.fw_alarm_heading_lost, AlarmType.HEADING_SENSOR_LOST),
(snap.fw_alarm_actuator_overcurr, AlarmType.ACTUATOR_OVERCURRENT),
(snap.fw_alarm_voltage_low, AlarmType.VOLTAGE_LOW),
(snap.fw_alarm_limit_reached, AlarmType.LIMIT_SWITCH_REACHED),
(snap.fw_alarm_watchdog_tripped, AlarmType.WATCHDOG_TRIPPED),
(snap.fw_alarm_vms_critical, AlarmType.VMS_CRITICAL),
]
for condition, alarm_type in fw_map:
if condition:
fired = self._maybe_fire(alarm_type)
if fired:
new_alarms.append(fired)
else:
self._clear(alarm_type)
# PC-side: heading sensor staleness
if snap.pilot_engaged and snap.heading_age_s > self.thresholds.heading_stale_s:
fired = self._maybe_fire(AlarmType.HEADING_SENSOR_LOST)
if fired:
new_alarms.append(fired)
# PC-side: off-course (if firmware bits not present, compute from heading)
if (snap.pilot_engaged
and snap.heading_deg is not None
and snap.heading_setpoint_deg is not None
and not snap.fw_alarm_off_course
and not snap.fw_alarm_off_course_severe):
err = _shortest_arc(snap.heading_setpoint_deg, snap.heading_deg)
thr = self.thresholds
if abs(err) >= thr.severe_off_course_deg:
self._severe_off_course_timer_s += self._dt_s
if self._severe_off_course_timer_s >= thr.severe_off_course_time_s:
fired = self._maybe_fire(AlarmType.OFF_COURSE_SEVERE)
if fired:
new_alarms.append(fired)
else:
fired = self._maybe_fire(AlarmType.OFF_COURSE)
if fired:
new_alarms.append(fired)
elif abs(err) >= thr.off_course_deg:
self._severe_off_course_timer_s = 0.0
fired = self._maybe_fire(AlarmType.OFF_COURSE)
if fired:
new_alarms.append(fired)
else:
self._severe_off_course_timer_s = 0.0
self._clear(AlarmType.OFF_COURSE)
self._clear(AlarmType.OFF_COURSE_SEVERE)
# Trigger auto-disengage for any new EMERGENCY alarms.
for a in new_alarms:
if a.auto_disengage_triggered and self._on_disengage:
self._on_disengage()
break
return new_alarms
def acknowledge(self, alarm_type: AlarmType) -> None:
"""Acknowledge a specific alarm (marks it as seen)."""
self._acknowledged.add(alarm_type)
if alarm_type in self._active:
# Replace the alarm record with an acknowledged copy.
old = self._active[alarm_type]
self._active[alarm_type] = old.model_copy(update={"acknowledged": True})
def acknowledge_all(self) -> None:
for at in list(self._active):
self.acknowledge(at)
def clear(self, alarm_type: AlarmType) -> None:
self._clear(alarm_type)
self._acknowledged.discard(alarm_type)
def clear_all(self) -> None:
self._active.clear()
self._acknowledged.clear()
self._severe_off_course_timer_s = 0.0
@property
def active_alarms(self) -> list[Alarm]:
return list(self._active.values())
@property
def any_active(self) -> bool:
return bool(self._active)
@property
def highest_severity(self) -> AlarmSeverity | None:
if not self._active:
return None
order = [AlarmSeverity.EMERGENCY, AlarmSeverity.HIGH,
AlarmSeverity.LOW, AlarmSeverity.INFO]
for sev in order:
if any(a.severity == sev for a in self._active.values()):
return sev
return None
# ------------------------------------------------------------------
# Internal helpers
# ------------------------------------------------------------------
def _maybe_fire(self, alarm_type: AlarmType) -> Alarm | None:
if alarm_type in self._active:
return None # already active
alarm = Alarm.from_type(alarm_type)
self._active[alarm_type] = alarm
self._acknowledged.discard(alarm_type)
return alarm
def _clear(self, alarm_type: AlarmType) -> None:
self._active.pop(alarm_type, None)
def _shortest_arc(setpoint: float, measured: float) -> float:
"""Signed shortest-arc error in degrees (setpoint - measured)."""
err = (setpoint - measured + 180.0) % 360.0 - 180.0
return err
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"""Tests for ``arautopilot.core.alarm_engine``."""
from __future__ import annotations
import pytest
from arautopilot.core.alarm_engine import AlarmEngine, AlarmThresholds, TelemetrySnapshot
from arautopilot.core.alarms import AlarmSeverity, AlarmType
# ---------------------------------------------------------------------------
# Helpers
# ---------------------------------------------------------------------------
def _engaged_snap(**kwargs) -> TelemetrySnapshot:
"""Return a baseline engaged snapshot with no alarms asserted."""
defaults = dict(
pilot_engaged=True,
heading_deg=90.0,
heading_setpoint_deg=90.0,
heading_age_s=0.1,
)
defaults.update(kwargs)
return TelemetrySnapshot(**defaults)
# ---------------------------------------------------------------------------
# Basic fire / clear cycle
# ---------------------------------------------------------------------------
class TestFireAndClear:
def test_no_alarms_by_default(self):
eng = AlarmEngine()
snap = TelemetrySnapshot(pilot_engaged=False)
new = eng.evaluate(snap)
assert new == []
assert not eng.any_active
def test_fw_bit_fires_alarm(self):
eng = AlarmEngine()
snap = TelemetrySnapshot(fw_alarm_off_course=True)
new = eng.evaluate(snap)
assert len(new) == 1
assert new[0].type is AlarmType.OFF_COURSE
assert eng.any_active
def test_fw_bit_clearing_removes_alarm(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
new = eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=False))
assert new == []
assert not eng.any_active
def test_alarm_not_re_fired_while_active(self):
eng = AlarmEngine()
snap = TelemetrySnapshot(fw_alarm_off_course=True)
first = eng.evaluate(snap)
second = eng.evaluate(snap)
assert len(first) == 1
assert second == [] # already active, not re-fired
def test_all_nine_fw_bits_map_to_distinct_alarm_types(self):
all_bits = TelemetrySnapshot(
fw_alarm_off_course=True,
fw_alarm_off_course_severe=True,
fw_alarm_rudder_not_resp=True,
fw_alarm_heading_lost=True,
fw_alarm_actuator_overcurr=True,
fw_alarm_voltage_low=True,
fw_alarm_limit_reached=True,
fw_alarm_watchdog_tripped=True,
fw_alarm_vms_critical=True,
)
eng = AlarmEngine()
new = eng.evaluate(all_bits)
types = {a.type for a in new}
assert len(types) == 9
assert AlarmType.OFF_COURSE in types
assert AlarmType.VMS_CRITICAL in types
# ---------------------------------------------------------------------------
# Acknowledge
# ---------------------------------------------------------------------------
class TestAcknowledge:
def test_acknowledge_marks_alarm(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
eng.acknowledge(AlarmType.OFF_COURSE)
assert eng.active_alarms[0].acknowledged is True
def test_acknowledge_all(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(
fw_alarm_off_course=True,
fw_alarm_voltage_low=True,
))
eng.acknowledge_all()
for a in eng.active_alarms:
assert a.acknowledged is True
def test_unacknowledged_alarm_after_clear_refire(self):
"""After a cleared alarm re-asserts it must fire (and be unacknowledged)."""
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=False))
new = eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
assert len(new) == 1
assert new[0].acknowledged is False
# ---------------------------------------------------------------------------
# Highest severity
# ---------------------------------------------------------------------------
class TestHighestSeverity:
def test_none_when_no_alarms(self):
assert AlarmEngine().highest_severity is None
def test_emergency_dominates(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(
fw_alarm_off_course=True, # LOW
fw_alarm_watchdog_tripped=True, # EMERGENCY
))
assert eng.highest_severity is AlarmSeverity.EMERGENCY
def test_high_when_no_emergency(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(
fw_alarm_off_course=True, # LOW
fw_alarm_voltage_low=True, # HIGH
))
assert eng.highest_severity is AlarmSeverity.HIGH
def test_low_when_only_low(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
assert eng.highest_severity is AlarmSeverity.LOW
# ---------------------------------------------------------------------------
# Auto-disengage callback
# ---------------------------------------------------------------------------
class TestAutoDisengage:
def test_emergency_triggers_disengage_callback(self):
called = []
eng = AlarmEngine(on_disengage=lambda: called.append(1))
eng.evaluate(TelemetrySnapshot(fw_alarm_watchdog_tripped=True))
assert called == [1]
def test_low_alarm_does_not_trigger_disengage(self):
called = []
eng = AlarmEngine(on_disengage=lambda: called.append(1))
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
assert called == []
def test_callback_called_once_per_event(self):
called = []
eng = AlarmEngine(on_disengage=lambda: called.append(1))
snap = TelemetrySnapshot(fw_alarm_watchdog_tripped=True)
eng.evaluate(snap)
eng.evaluate(snap) # still active — not re-fired
assert len(called) == 1
# ---------------------------------------------------------------------------
# PC-side heading staleness
# ---------------------------------------------------------------------------
class TestHeadingStaleness:
def test_stale_heading_fires_alarm_when_engaged(self):
eng = AlarmEngine()
snap = TelemetrySnapshot(
pilot_engaged=True,
heading_age_s=6.0, # > default 5.0 s threshold
)
new = eng.evaluate(snap)
types = {a.type for a in new}
assert AlarmType.HEADING_SENSOR_LOST in types
def test_fresh_heading_does_not_fire(self):
eng = AlarmEngine()
snap = TelemetrySnapshot(pilot_engaged=True, heading_age_s=0.5)
new = eng.evaluate(snap)
assert AlarmType.HEADING_SENSOR_LOST not in {a.type for a in new}
def test_stale_heading_does_not_fire_when_disengaged(self):
eng = AlarmEngine()
snap = TelemetrySnapshot(pilot_engaged=False, heading_age_s=60.0)
new = eng.evaluate(snap)
assert new == []
# ---------------------------------------------------------------------------
# PC-side off-course (no firmware bits)
# ---------------------------------------------------------------------------
class TestOffCoursePC:
def test_small_error_no_alarm(self):
eng = AlarmEngine()
snap = _engaged_snap(heading_deg=91.0, heading_setpoint_deg=90.0)
new = eng.evaluate(snap)
assert AlarmType.OFF_COURSE not in {a.type for a in new}
def test_moderate_error_fires_off_course(self):
eng = AlarmEngine()
snap = _engaged_snap(heading_deg=105.0, heading_setpoint_deg=90.0) # 15 deg > 10
new = eng.evaluate(snap)
assert AlarmType.OFF_COURSE in {a.type for a in new}
def test_severe_error_not_immediate(self):
"""Large error fires OFF_COURSE immediately but not SEVERE until timer expires."""
thr = AlarmThresholds(severe_off_course_deg=30.0, severe_off_course_time_s=5.0)
eng = AlarmEngine(thresholds=thr)
snap = _engaged_snap(heading_deg=125.0, heading_setpoint_deg=90.0) # 35 deg
new = eng.evaluate(snap, dt_s=0.1)
types = {a.type for a in new}
# Severe timer hasn't elapsed yet
assert AlarmType.OFF_COURSE_SEVERE not in types
def test_severe_error_fires_after_timer(self):
thr = AlarmThresholds(severe_off_course_deg=30.0, severe_off_course_time_s=1.0)
eng = AlarmEngine(thresholds=thr)
snap = _engaged_snap(heading_deg=125.0, heading_setpoint_deg=90.0)
result_types: set[AlarmType] = set()
for _ in range(15): # 15 × 0.1 s = 1.5 s > 1.0 s threshold
new = eng.evaluate(snap, dt_s=0.1)
result_types |= {a.type for a in new}
assert AlarmType.OFF_COURSE_SEVERE in result_types
def test_fw_bit_suppresses_pc_off_course(self):
"""When firmware asserts the alarm bit, PC-side must not duplicate it."""
eng = AlarmEngine()
snap = _engaged_snap(
heading_deg=125.0,
heading_setpoint_deg=90.0,
fw_alarm_off_course=True, # firmware owns it
)
eng.evaluate(snap)
# Should have exactly one OFF_COURSE (from fw bit), not two
active_types = [a.type for a in eng.active_alarms]
assert active_types.count(AlarmType.OFF_COURSE) == 1
def test_wraparound_heading(self):
"""Shortest-arc logic: 5 deg east of 358 deg setpoint is +5, not -353."""
eng = AlarmEngine()
snap = _engaged_snap(heading_deg=3.0, heading_setpoint_deg=358.0) # +5 deg arc
new = eng.evaluate(snap)
assert AlarmType.OFF_COURSE not in {a.type for a in new}
def test_clear_all_resets_state(self):
eng = AlarmEngine()
eng.evaluate(TelemetrySnapshot(fw_alarm_off_course=True))
eng.clear_all()
assert not eng.any_active
assert eng.highest_severity is None
+13 -1
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@@ -20,6 +20,7 @@
// ============================================================================= // =============================================================================
#include <Arduino.h> #include <Arduino.h>
#include <esp_system.h>
#include "hal/di_do.h" #include "hal/di_do.h"
#include "hal/pinout.h" #include "hal/pinout.h"
@@ -30,6 +31,7 @@
#include "pid/pid_outer_task.h" #include "pid/pid_outer_task.h"
#include "protocols/modbus_slave.h" #include "protocols/modbus_slave.h"
#include "protocols/nmea2000_consumer.h" #include "protocols/nmea2000_consumer.h"
#include "protocols/nmea2000_publisher.h"
#include "safety/safety_monitor.h" #include "safety/safety_monitor.h"
#include "safety/watchdog.h" #include "safety/watchdog.h"
#include "system/ar_log.h" #include "system/ar_log.h"
@@ -74,6 +76,12 @@ void setup() {
// watchdog is armed before slower subsystems come up. // watchdog is armed before slower subsystems come up.
arautopilot::safety::watchdog_init(); arautopilot::safety::watchdog_init();
// Sprint 6: if the last reset was a task-watchdog trip, set the sticky
// alarm bit so the display knows the MCU was force-reset by the WDT.
if (esp_reset_reason() == ESP_RST_TASK_WDT) {
arautopilot::safety::safety_set_watchdog_tripped();
}
AR_LOGI(TAG, "spawning Sprint 1 tasks ..."); AR_LOGI(TAG, "spawning Sprint 1 tasks ...");
arautopilot::safety::safety_monitor_start_task(); arautopilot::safety::safety_monitor_start_task();
@@ -95,10 +103,14 @@ void setup() {
arautopilot::protocols::modbus::modbus_slave_init(); arautopilot::protocols::modbus::modbus_slave_init();
arautopilot::protocols::modbus::modbus_slave_start(); arautopilot::protocols::modbus::modbus_slave_start();
// NMEA 2000 consumer (PGN 127250 + 127251 in Sprint 1). // NMEA 2000 consumer (PGN 127250 + 127251 in Sprint 1; 129026/129284 in Sprint 5).
arautopilot::protocols::nmea2000::nmea2000_consumer_init(); arautopilot::protocols::nmea2000::nmea2000_consumer_init();
arautopilot::protocols::nmea2000::nmea2000_consumer_start_task(); arautopilot::protocols::nmea2000::nmea2000_consumer_start_task();
// NMEA 2000 publisher (Sprint 6): PGN 127245 rudder + PGN 127237 HTC.
// Must be started AFTER nmea2000_consumer_init() (shared CAN stack).
arautopilot::protocols::nmea2000::nmea2000_publisher_start_task();
AR_LOGI(TAG, "setup() complete; control loop is FreeRTOS-driven."); AR_LOGI(TAG, "setup() complete; control loop is FreeRTOS-driven.");
AR_LOGI(TAG, "current mode: STANDBY (helm is manual)"); AR_LOGI(TAG, "current mode: STANDBY (helm is manual)");
} }
@@ -33,6 +33,7 @@
#include "../system/task_config.h" #include "../system/task_config.h"
#include "modbus_registers.h" #include "modbus_registers.h"
#include "nmea2000_consumer.h" #include "nmea2000_consumer.h"
#include "../safety/safety_monitor.h"
namespace arautopilot::protocols::modbus { namespace arautopilot::protocols::modbus {
@@ -133,11 +134,24 @@ uint16_t read_input_register(uint16_t addr) {
return (uint16_t)age; return (uint16_t)age;
} }
// Sprint 1: battery voltage and actuator current wired in Sprint 6 case INPUT_BATTERY_VOLTAGE_X100: {
// (Safety + alarms). For now, return 0. // 1:6 voltage divider on AI2; 12-bit ADC, 3.3 V reference.
case INPUT_BATTERY_VOLTAGE_X100: const int raw = analogRead(PIN_AI2_BATTERY_VOLTAGE);
case INPUT_ACTUATOR_CURRENT_X100: const float vbat = (float)raw * (3.3f * 6.0f / 4095.0f);
return 0; int v = (int)(vbat * 100.0f);
if (v < 0) v = 0;
if (v > 32767) v = 32767;
return (uint16_t)v;
}
case INPUT_ACTUATOR_CURRENT_X100: {
// Hall-effect transducer on AI3, 50 A FS.
const int raw = analogRead(PIN_AI3_ACTUATOR_CURRENT);
const float iact = (float)raw * (3.3f * 50.0f / 4095.0f);
int v = (int)(iact * 100.0f);
if (v < 0) v = 0;
if (v > 32767) v = 32767;
return (uint16_t)v;
}
// ----- PID inner-loop telemetry (Sprint 2) ----- // ----- PID inner-loop telemetry (Sprint 2) -----
case INPUT_PID_INNER_SETPOINT_X100: { case INPUT_PID_INNER_SETPOINT_X100: {
@@ -274,18 +288,17 @@ bool read_discrete(uint16_t addr) {
case DISCRETE_ACTUATOR_POWER: return hal::do_state(PIN_DO3_ACTUATOR_POWER); case DISCRETE_ACTUATOR_POWER: return hal::do_state(PIN_DO3_ACTUATOR_POWER);
case DISCRETE_ACTUATOR_DRIVING_PORT:return hal::do_state(PIN_DO1_PUMP_PORT); case DISCRETE_ACTUATOR_DRIVING_PORT:return hal::do_state(PIN_DO1_PUMP_PORT);
case DISCRETE_ACTUATOR_DRIVING_STBD:return hal::do_state(PIN_DO2_PUMP_STBD); case DISCRETE_ACTUATOR_DRIVING_STBD:return hal::do_state(PIN_DO2_PUMP_STBD);
// Alarm bits: stubs in Sprint 1, wired in Sprint 6. // Alarm bits: wired in Sprint 6 via safety_monitor.
case DISCRETE_ALARM_OFF_COURSE: case DISCRETE_ALARM_OFF_COURSE: return safety::safety_alarm_bits().off_course;
case DISCRETE_ALARM_OFF_COURSE_SEVERE: case DISCRETE_ALARM_OFF_COURSE_SEVERE: return safety::safety_alarm_bits().off_course_severe;
case DISCRETE_ALARM_RUDDER_NOT_RESP: case DISCRETE_ALARM_RUDDER_NOT_RESP: return safety::safety_alarm_bits().rudder_not_resp;
case DISCRETE_ALARM_HEADING_LOST: case DISCRETE_ALARM_HEADING_LOST: return safety::safety_alarm_bits().heading_lost;
case DISCRETE_ALARM_ACTUATOR_OVERCURR: case DISCRETE_ALARM_ACTUATOR_OVERCURR: return safety::safety_alarm_bits().actuator_overcurr;
case DISCRETE_ALARM_VOLTAGE_LOW: case DISCRETE_ALARM_VOLTAGE_LOW: return safety::safety_alarm_bits().voltage_low;
case DISCRETE_ALARM_LIMIT_REACHED: case DISCRETE_ALARM_LIMIT_REACHED: return safety::safety_alarm_bits().limit_reached;
case DISCRETE_ALARM_WATCHDOG_TRIPPED: case DISCRETE_ALARM_WATCHDOG_TRIPPED: return safety::safety_alarm_bits().watchdog_tripped;
case DISCRETE_ALARM_VMS_CRITICAL: case DISCRETE_ALARM_VMS_CRITICAL: return safety::safety_alarm_bits().vms_critical;
case DISCRETE_ANY_ALARM_ACTIVE: case DISCRETE_ANY_ALARM_ACTIVE: return safety::safety_alarm_bits().any();
return false;
default: default:
return false; return false;
} }
@@ -0,0 +1,127 @@
// =============================================================================
// protocols/nmea2000_publisher.cpp -- NMEA 2000 publisher (Sprint 6)
// =============================================================================
#include "nmea2000_publisher.h"
#include <Arduino.h>
#include <math.h>
#include <N2kMessages.h>
#include <NMEA2000.h>
// NMEA2000_CAN.h defines the global tNMEA2000& NMEA2000 in the header,
// so it can only be included in one translation unit (nmea2000_consumer.cpp).
// Declare the same object here via extern.
extern tNMEA2000& NMEA2000;
#include "../hal/rudder_sensor.h"
#include "../modes/standby.h"
#include "../pid/pid_outer_task.h"
#include "../protocols/nmea2000_consumer.h"
#include "../system/ar_log.h"
#include "../system/task_config.h"
namespace arautopilot::protocols::nmea2000 {
namespace {
constexpr const char* TAG = "AR/N2K/PUB";
static const double K_DEG2RAD = M_PI / 180.0;
// ----- PGN 127245: Rudder angle (10 Hz) -------------------------------------
void publish_rudder() {
const auto rdr = hal::rudder_sensor_latest();
if (!rdr.valid) return;
tN2kMsg msg;
SetN2kRudder(msg,
(double)rdr.angle_deg * K_DEG2RAD,
0,
N2kRDO_NoDirectionOrder,
N2kDoubleNA);
NMEA2000.SendMsg(msg);
}
// ----- PGN 127237: Heading Track Control (1 Hz) -----------------------------
void publish_heading_track_control() {
const bool engaged = !modes::is_standby();
const tN2kSteeringMode steering_mode = engaged
? N2kSM_HeadingControl
: N2kSM_MainSteering;
double heading_to_steer = N2kDoubleNA;
double vessel_heading = N2kDoubleNA;
// Current heading from consumer snapshot for VesselHeading field.
{
const auto n = nmea2000_latest();
if (n.heading_valid) {
vessel_heading = (double)n.heading_deg * K_DEG2RAD;
}
}
if (engaged) {
const modes::Mode mode = modes::current_mode();
if (mode == modes::Mode::HEADING_HOLD) {
heading_to_steer = (double)pid::pid_outer_heading_setpoint_deg() * K_DEG2RAD;
} else if (mode == modes::Mode::TRUE_COURSE ||
mode == modes::Mode::TRACK_KEEPING) {
heading_to_steer = (double)pid::pid_outer_cog_setpoint_deg() * K_DEG2RAD;
}
}
tN2kMsg msg;
SetN2kHeadingTrackControl(msg,
N2kOnOff_Unavailable, // RudderLimitExceeded
N2kOnOff_Unavailable, // OffHeadingLimitExceeded
N2kOnOff_Unavailable, // OffTrackLimitExceeded
N2kOnOff_Off, // Override
steering_mode, // SteeringMode
N2kTM_RudderLimitControlled,// TurnMode
N2khr_true, // HeadingReference
N2kRDO_NoDirectionOrder, // CommandedRudderDirection
N2kDoubleNA, // CommandedRudderAngle
heading_to_steer, // HeadingToSteerCourse
N2kDoubleNA, // Track
N2kDoubleNA, // RudderLimit
N2kDoubleNA, // OffHeadingLimit
N2kDoubleNA, // RadiusOfTurnOrder
N2kDoubleNA, // RateOfTurnOrder
N2kDoubleNA, // OffTrackLimit
vessel_heading); // VesselHeading
NMEA2000.SendMsg(msg);
}
void PublisherTask(void* /*pv*/) {
AR_LOGI(TAG, "nmea2000_publisher task started on core %d", xPortGetCoreID());
TickType_t last_wake = xTaskGetTickCount();
uint8_t slow_tick = 0;
for (;;) {
publish_rudder();
if (++slow_tick >= 10) {
slow_tick = 0;
publish_heading_track_control();
}
vTaskDelayUntil(&last_wake, pdMS_TO_TICKS(100));
}
}
} // namespace
void nmea2000_publisher_start_task() {
xTaskCreatePinnedToCore(PublisherTask, "n2k_pub",
AR_TASK_STACK_N2K_RX,
nullptr,
AR_TASK_PRIO_N2K_RX - 1,
nullptr,
AR_TASK_CORE_COMMS);
}
} // namespace arautopilot::protocols::nmea2000
@@ -0,0 +1,31 @@
// =============================================================================
// protocols/nmea2000_publisher.h -- NMEA 2000 publisher (Sprint 6)
// =============================================================================
//
// Publishes autopilot state onto the NMEA 2000 backbone so other instruments
// (chartplotters, VHF, AIS) can see what the autopilot is doing.
//
// PGN 127245 -- Rudder angle (actual measured rudder position)
// Broadcast at 10 Hz so chartplotters and other displays can render a
// rudder indicator.
//
// PGN 127237 -- Heading Track Control
// Broadcast at 1 Hz. Tells the network: which mode is engaged, the
// commanded heading, and the current COG. Chartplotters use this to
// draw the track line and to know whether to suppress their own helm
// commands.
//
// Both messages are sent on the same NMEA2000 stack object that the consumer
// uses (global `NMEA2000` instance from NMEA2000_CAN.h). The publisher runs
// as a low-priority periodic task on Core 0 (comms core).
// =============================================================================
#pragma once
namespace arautopilot::protocols::nmea2000 {
/// Start the NMEA 2000 publisher task.
/// Must be called AFTER nmea2000_consumer_init() (shares the same CAN stack).
void nmea2000_publisher_start_task();
} // namespace arautopilot::protocols::nmea2000
@@ -1,15 +1,20 @@
// ============================================================================= // =============================================================================
// safety/safety_monitor.cpp -- 50 Hz safety task // safety/safety_monitor.cpp -- 50 Hz safety task (Sprint 6)
// ============================================================================= // =============================================================================
#include "safety_monitor.h" #include "safety_monitor.h"
#include <Arduino.h> #include <Arduino.h>
#include <esp_system.h>
#include "../hal/di_do.h" #include "../hal/di_do.h"
#include "../hal/pinout.h" #include "../hal/pinout.h"
#include "../hal/rudder_actuator.h" #include "../hal/rudder_actuator.h"
#include "../hal/rudder_sensor.h"
#include "../modes/standby.h" #include "../modes/standby.h"
#include "../pid/pid_inner_task.h"
#include "../pid/pid_outer_task.h"
#include "../protocols/nmea2000_consumer.h"
#include "../system/ar_log.h" #include "../system/ar_log.h"
#include "../system/task_config.h" #include "../system/task_config.h"
#include "watchdog.h" #include "watchdog.h"
@@ -17,49 +22,213 @@
namespace arautopilot::safety { namespace arautopilot::safety {
namespace { namespace {
constexpr const char* TAG = "AR/SAFE"; constexpr const char* TAG = "AR/SAFE";
// ----- Thresholds (mirrors pinout.h constants and brief section 7) -----------
// Off-course
constexpr float OFF_COURSE_DEG = AR_DEFAULT_OFF_COURSE_DEG;
constexpr float SEVERE_OFF_COURSE_DEG = AR_SEVERE_OFF_COURSE_DEG;
constexpr uint32_t SEVERE_HOLD_MS = AR_SEVERE_OFF_COURSE_HOLD_MS;
// Rudder not responding: setpoint must have moved by this much before we check
constexpr float RUDDER_DEADBAND_DEG = 1.0f;
// If setpoint moves outside deadband and rudder doesn't follow within this, alarm
constexpr uint32_t RUDDER_TIMEOUT_MS = 3000;
// Battery / current ADC (linear: 0..4095 raw → 0..3.3 V; then scaled by
// voltage divider / shunt amplifier on the PCB).
// Calibration: V_bat = raw * 3.3 / 4095 * 6.0 (1:6 voltage divider assumed)
constexpr float BATTERY_SCALE = 3.3f * 6.0f / 4095.0f;
// Current: I_act = raw * 3.3 / 4095 * 50.0 (example transducer)
constexpr float CURRENT_SCALE = 3.3f * 50.0f / 4095.0f;
// Alarm thresholds
constexpr float VOLTAGE_LOW_V = 10.5f;
constexpr float CURRENT_HIGH_A = 30.0f;
// ----- Shared alarm state ----------------------------------------------------
portMUX_TYPE g_alarm_mux = portMUX_INITIALIZER_UNLOCKED;
AlarmBits g_alarms = {};
// ----- Rudder-not-responding state -------------------------------------------
float g_rnr_setpoint_snapshot = 0.0f; // setpoint at timer start
uint32_t g_rnr_timer_start_ms = 0;
bool g_rnr_timer_running = false;
// ----- Severe off-course timer -----------------------------------------------
uint32_t g_severe_oc_start_ms = 0;
bool g_severe_oc_timer_running = false;
// ----- Helpers ---------------------------------------------------------------
inline float shortest_arc_deg(float sp, float meas) {
float e = sp - meas;
while (e > 180.0f) e -= 360.0f;
while (e < -180.0f) e += 360.0f;
return e;
}
void update_alarms(const uint32_t now) {
using namespace arautopilot;
AlarmBits bits = {};
const bool engaged = !modes::is_standby();
// ----- Heading lost ------------------------------------------------------
bits.heading_lost = engaged && protocols::nmea2000::nmea2000_is_stale();
// ----- VMS critical (DI4) ------------------------------------------------
bits.vms_critical = hal::di_read(PIN_DI4_EXTERNAL_ALARM);
// ----- Limit switch reached (DI2 or DI3) ---------------------------------
bits.limit_reached = hal::di_read(PIN_DI2_LIMIT_SWITCH_PORT)
|| hal::di_read(PIN_DI3_LIMIT_SWITCH_STBD);
// ----- Off-course (outer-loop error) -------------------------------------
// Requires pilot to be actively steering a heading.
if (engaged) {
// pid_outer_last_error_deg() is signed shortest-arc (setpoint - meas).
const float err_abs = fabsf(pid::pid_outer_last_error_deg());
if (err_abs >= SEVERE_OFF_COURSE_DEG) {
bits.off_course = true; // severe also implies off_course
if (!g_severe_oc_timer_running) {
g_severe_oc_start_ms = now;
g_severe_oc_timer_running = true;
}
if ((now - g_severe_oc_start_ms) >= SEVERE_HOLD_MS) {
bits.off_course_severe = true;
}
} else {
g_severe_oc_timer_running = false;
if (err_abs >= OFF_COURSE_DEG) {
bits.off_course = true;
}
}
} else {
g_severe_oc_timer_running = false;
}
// ----- Rudder not responding ---------------------------------------------
// We watch whether the inner-loop rudder setpoint has moved (i.e. outer
// loop or manual command is asking for motion) and whether the rudder
// sensor follows within RUDDER_TIMEOUT_MS.
if (engaged) {
const float sp = pid::pid_inner_setpoint_deg();
const auto rdr = hal::rudder_sensor_latest();
if (!g_rnr_timer_running) {
// Start timer if setpoint is outside deadband from actual angle.
if (rdr.valid &&
fabsf(sp - rdr.angle_deg) > RUDDER_DEADBAND_DEG) {
g_rnr_setpoint_snapshot = sp;
g_rnr_timer_start_ms = now;
g_rnr_timer_running = true;
}
} else {
// Timer running: check if rudder has caught up.
if (!rdr.valid ||
fabsf(rdr.angle_deg - g_rnr_setpoint_snapshot) < RUDDER_DEADBAND_DEG) {
// Rudder moved (or sensor gone invalid -- don't alarm on that).
g_rnr_timer_running = false;
} else if ((now - g_rnr_timer_start_ms) >= RUDDER_TIMEOUT_MS) {
bits.rudder_not_resp = true;
}
}
} else {
g_rnr_timer_running = false;
}
// ----- Battery voltage ---------------------------------------------------
{
const int raw = analogRead(PIN_AI2_BATTERY_VOLTAGE);
const float vbat = (float)raw * BATTERY_SCALE;
bits.voltage_low = (vbat < VOLTAGE_LOW_V);
}
// ----- Actuator current --------------------------------------------------
{
const int raw = analogRead(PIN_AI3_ACTUATOR_CURRENT);
const float iact = (float)raw * CURRENT_SCALE;
bits.actuator_overcurr = (iact > CURRENT_HIGH_A);
}
// ----- Watchdog tripped (sticky, set on boot) ----------------------------
// Preserved across the update so we don't clear it here.
portENTER_CRITICAL(&g_alarm_mux);
bits.watchdog_tripped = g_alarms.watchdog_tripped;
g_alarms = bits;
portEXIT_CRITICAL(&g_alarm_mux);
}
// ----- Actions triggered by alarms ------------------------------------------
void react_to_alarms(const AlarmBits& bits) {
// EMERGENCY conditions that require immediate forced-STANDBY.
if (bits.off_course_severe || bits.rudder_not_resp ||
bits.heading_lost || bits.watchdog_tripped ||
bits.vms_critical) {
if (!modes::is_standby()) {
AR_LOGE(TAG,
"emergency alarm asserted -- forcing STANDBY "
"(oc_severe=%d rnr=%d hdg_lost=%d wdog=%d vms=%d)",
(int)bits.off_course_severe, (int)bits.rudder_not_resp,
(int)bits.heading_lost, (int)bits.watchdog_tripped,
(int)bits.vms_critical);
modes::force_standby("safety alarm");
hal::rudder_actuator_power_off();
}
}
// Actuator overcurrent / voltage low → also disengage (HIGH severity).
if (bits.actuator_overcurr || bits.voltage_low) {
if (!modes::is_standby()) {
AR_LOGE(TAG,
"power alarm -- forcing STANDBY (overcurr=%d vlow=%d)",
(int)bits.actuator_overcurr, (int)bits.voltage_low);
modes::force_standby("power alarm");
hal::rudder_actuator_power_off();
}
}
// Audible buzzer: any active alarm.
hal::do_write(PIN_DO4_BUZZER, bits.any());
}
// ----- FreeRTOS task ---------------------------------------------------------
void SafetyTask(void* /*pv*/) { void SafetyTask(void* /*pv*/) {
AR_LOGI(TAG, "safety_monitor task started on core %d (50 Hz)", AR_LOGI(TAG, "safety_monitor task started on core %d (50 Hz)",
xPortGetCoreID()); xPortGetCoreID());
// Subscribe to the watchdog. Every loop iteration feeds it; if this
// task ever stops looping the chip resets to STANDBY on boot.
watchdog_subscribe_current_task(); watchdog_subscribe_current_task();
TickType_t last_wake = xTaskGetTickCount(); TickType_t last_wake = xTaskGetTickCount();
for (;;) { for (;;) {
hal::di_poll(); hal::di_poll();
const uint32_t now = millis();
// ---- DI1: Engage/Disengage physical button ----------------------- // ---- DI1: Engage/Disengage physical button --------------------------
// The brief specifies this button "ALWAYS DISENGAGES" -- pressing
// it must put the system in STANDBY no matter what mode we're in.
// We trigger on the rising edge so a held button doesn't keep
// spamming the log.
if (hal::di_rising_edge(PIN_DI1_DISENGAGE_BUTTON)) { if (hal::di_rising_edge(PIN_DI1_DISENGAGE_BUTTON)) {
modes::force_standby("DI1 physical button"); modes::force_standby("DI1 physical button");
hal::rudder_actuator_power_off(); hal::rudder_actuator_power_off();
} }
// ---- DI4: External critical alarm (VMS blackout / genset) -------- // ---- Both limit switches: cut power (wiring fault) ------------------
if (hal::di_rising_edge(PIN_DI4_EXTERNAL_ALARM)) {
modes::force_standby("DI4 external alarm");
hal::rudder_actuator_power_off();
}
// ---- Limit switches: cut power if rudder hit a mechanical stop --
// Even though rudder_command() refuses to drive into a limit, a
// hardware failure could still command the wrong direction. As an
// extra interlock, if BOTH limits assert at once we cut master
// power -- something is seriously wrong with the feedback wiring.
if (hal::di_read(PIN_DI2_LIMIT_SWITCH_PORT) && if (hal::di_read(PIN_DI2_LIMIT_SWITCH_PORT) &&
hal::di_read(PIN_DI3_LIMIT_SWITCH_STBD)) { hal::di_read(PIN_DI3_LIMIT_SWITCH_STBD)) {
AR_LOGE(TAG, AR_LOGE(TAG,
"both limit switches asserted simultaneously -- cutting " "both limit switches asserted simultaneously -- "
"actuator power (wiring fault?)"); "cutting actuator power (wiring fault?)");
hal::rudder_actuator_power_off(); hal::rudder_actuator_power_off();
} }
// ---- Sprint 6: evaluate full alarm catalogue ------------------------
update_alarms(now);
react_to_alarms(safety_alarm_bits());
watchdog_feed(); watchdog_feed();
vTaskDelayUntil(&last_wake, pdMS_TO_TICKS(AR_PERIOD_MS_SAFETY)); vTaskDelayUntil(&last_wake, pdMS_TO_TICKS(AR_PERIOD_MS_SAFETY));
} }
@@ -67,6 +236,10 @@ void SafetyTask(void* /*pv*/) {
} // namespace } // namespace
// -----------------------------------------------------------------------------
// Public API
// -----------------------------------------------------------------------------
void safety_monitor_start_task() { void safety_monitor_start_task() {
xTaskCreatePinnedToCore(SafetyTask, "safety_monitor", xTaskCreatePinnedToCore(SafetyTask, "safety_monitor",
AR_TASK_STACK_SAFETY, nullptr, AR_TASK_STACK_SAFETY, nullptr,
@@ -74,4 +247,19 @@ void safety_monitor_start_task() {
AR_TASK_CORE_REALTIME); AR_TASK_CORE_REALTIME);
} }
AlarmBits safety_alarm_bits() {
AlarmBits copy;
portENTER_CRITICAL(&g_alarm_mux);
copy = g_alarms;
portEXIT_CRITICAL(&g_alarm_mux);
return copy;
}
void safety_set_watchdog_tripped() {
portENTER_CRITICAL(&g_alarm_mux);
g_alarms.watchdog_tripped = true;
portEXIT_CRITICAL(&g_alarm_mux);
AR_LOGW(TAG, "watchdog tripped flag set (reset reason: TASK_WDT)");
}
} // namespace arautopilot::safety } // namespace arautopilot::safety
@@ -6,21 +6,54 @@
// - Polls every DI through hal::di_poll(). // - Polls every DI through hal::di_poll().
// - Reacts to PIN_DI1_DISENGAGE_BUTTON rising edge: forces STANDBY, // - Reacts to PIN_DI1_DISENGAGE_BUTTON rising edge: forces STANDBY,
// kills actuator power. // kills actuator power.
// - Reacts to limit switches: cuts actuator power if the rudder is // - Reacts to limit switches: cuts actuator power if both assert.
// trying to drive into a limit.
// - Reacts to PIN_DI4_EXTERNAL_ALARM (VMS critical): forces STANDBY. // - Reacts to PIN_DI4_EXTERNAL_ALARM (VMS critical): forces STANDBY.
// - Subscribes itself to the TWDT and feeds it every loop iteration. // - Subscribes itself to the TWDT and feeds it every loop iteration.
// //
// Sprint 1: limited to the above. Sprint 6 expands this with the full // Sprint 6: full alarm catalogue -- off-course, rudder not responding,
// alarm catalogue (off-course, rudder not responding, etc.). // heading lost, actuator overcurrent, voltage low, limit switch reached,
// watchdog tripped, VMS critical.
//
// Alarm bits are written by the 50 Hz safety task and read on demand by the
// Modbus slave (FC 0x02 discrete inputs). All reads/writes are protected by
// a portMUX critical section.
// ============================================================================= // =============================================================================
#pragma once #pragma once
#include <cstdint>
namespace arautopilot::safety { namespace arautopilot::safety {
/// Spawn the safety monitor task. Must be called AFTER di_init() and /// Spawn the safety monitor task. Must be called AFTER di_init(),
/// rudder_actuator_init(). /// rudder_sensor_start_task(), and pid_outer_task_start().
void safety_monitor_start_task(); void safety_monitor_start_task();
/// Live alarm bits -- true when the corresponding condition is active.
/// Updated at 50 Hz by the safety task. Read by the Modbus slave handler.
struct AlarmBits {
bool off_course = false;
bool off_course_severe = false;
bool rudder_not_resp = false;
bool heading_lost = false;
bool actuator_overcurr = false;
bool voltage_low = false;
bool limit_reached = false;
bool watchdog_tripped = false;
bool vms_critical = false;
bool any() const {
return off_course | off_course_severe | rudder_not_resp
| heading_lost | actuator_overcurr | voltage_low
| limit_reached | watchdog_tripped | vms_critical;
}
};
/// Return a thread-safe snapshot of the current alarm bits.
AlarmBits safety_alarm_bits();
/// Force-set the watchdog-tripped bit. Called once at boot if
/// esp_reset_reason() == ESP_RST_TASK_WDT.
void safety_set_watchdog_tripped();
} // namespace arautopilot::safety } // namespace arautopilot::safety