9 Commits

Author SHA1 Message Date
alro65 e4812e9b44 sprint-4: Project Editor + .appack compiler + IRudderActuator HAL + dual sensor config
Cherry-pick of ab28cb7 onto main (was missing from main branch history).

Python:
- arautopilot/core/sensor_config.py: RudderSensorConfig + DualRudderSensorConfig
  (AS5048A SPI / potentiometer, dual with cross-validation thresholds)
- arautopilot/core/vessel_config.py: add sensors: DualRudderSensorConfig field
- arautopilot/studio/compiler/appack.py: .appack compiler (ZIP with
  manifest.json + project.yaml + firmware_config.h + install_notes.txt)
- arautopilot/studio/editors/project_editor.py: full project config editor
  (vessel / actuator / sensors / PID, RBAC-gated fields, save/load .yaml/.json)
- arautopilot/studio/main_window.py: wire ProjectEditorWidget into Project tab
- tests: test_sensor_config.py (11 tests) + test_appack_compiler.py (10 tests)

Firmware:
- hal/rudder_actuator_iface.h: IRudderActuator abstract interface
- hal/rudder_actuator_hydraulic.h: reversible hydraulic pump (LEDC PWM)
- hal/rudder_actuator_electric.h: reversible DC motor + deadband compensation
- hal/rudder_actuator_factory.h: build-time type selection via AR_ACTUATOR_TYPE

Tests: 483 passed (was 462, +21 Sprint 4)

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-05-20 10:29:17 -04:00
alro65 a2f3e82f17 sprint-9: integration tests + hardening + operator manual
Integration tests (64 new tests, 462 total):
- test_integration_cascade: full cascade closed-loop simulation --
  outer PID → inner PID → rudder dynamics → vessel heading; verifies
  convergence across small/90°/180° turns, wrap-around, and low speed
- test_integration_ekf_pid: EKF-smoothed heading feeding outer PID;
  confirms EKF reduces rudder total-variation vs raw noisy heading
- test_integration_alarm_audit: alarm engine → audit log hash-chain;
  verify, tamper detection, cross-session reload, multi-alarm logging
- test_modbus_utils: 38 tests for scale/raw conversion, bounds checking,
  heading/rudder helpers, signed int16 two's-complement round-trip

Hardening:
- heading_ekf: guard NaN/inf in update_heading() and update_rot() -- skip
  bad measurements silently rather than corrupting filter state
- adaptive_tuner: guard NaN/inf in step() -- ignore corrupt error samples
- modbus_utils.py: new shared module with scale_to_raw, scale_to_raw_signed,
  raw_signed_to_scaled, clamp_uint16, validate_holding_write,
  heading_deg_to_raw, rudder_deg_to_raw_signed

Documentation:
- docs/operator_manual.md: 15-section operator manual covering safety,
  installation, all operating modes, alarm reference, commissioning,
  fault-finding, Modbus register summary, and activation/audit log procedure

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-05-20 03:35:23 -04:00
alro65 45642fda0e sprint-8: EKF + adaptive tuner + HWID + SHA-256 audit hash-chain
- heading_ekf.py: 2-state Kalman filter fusing PGN 127250 heading and
  127251 ROT with shortest-arc innovation and symmetric covariance update
- adaptive_tuner.py: gradient-descent outer-loop Kp/Ki adjuster bounded
  to ±adaptive_max_deviation_pct; oscillation vs steady-state detection
- hwid.py: HMAC-SHA256 activation token (verify side); hwid_from_mac_words
  converts three Modbus uint16 MAC words to 12-char hex HWID
- audit.py: SHA-256 hash-chain -- each JSONL line carries prev_hash and
  line_hash; verify_chain() detects tampering, deletion, insertion
- firmware/system/hwid.h+cpp: esp_efuse_mac_get_default wrapper + FNV-32
  hash + "AA:BB:CC:DD:EE:FF" formatter
- modbus_registers.yaml + generated .h/.py: HWID_MAC_01/23/45 at
  input addrs 9/10/11 (three 16-bit words = 6-byte MAC)
- modbus_slave.cpp: INPUT_HWID_MAC_01/23/45 cases read eFuse MAC
- main.cpp: logs HWID string + FNV-32 hash at boot (activation traceability)
- tests: 72 new tests (audit signing, EKF, adaptive tuner, HWID) -- 398 total

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-05-20 03:07:27 -04:00
alro65 5f9b445572 sprint-7: Commissioning wizard + relay ZN auto-tuner + NVS config + knob encoder
Python:
- autotuner.py: RelayAutoTuner (Astrom-Hagglund relay method) → TunerResult
  with Ku/Tu; TunerResult.to_pid_gains() applies ZN formulas
- commissioning_wizard.py: 4-phase state machine (RUDDER_LIMITS → SENSOR_CAL
  → AUTO_TUNE → DONE); transport-injected for testability; abort on invalid cal
- test_autotuner.py: 17 tests covering relay convergence, ZN formulas,
  wizard full-run, abort, ADC swap, identical-ADC guard

Firmware:
- nvs_config.h/cpp: NVS-backed CalibrationData store (adc limits, rudder angles,
  outer Kp/Ki/Kd, commissioned flag); float stored as uint32 via memcpy
- knob_encoder.h/cpp: quadrature rotary encoder on GPIO 16/17 with ISR Gray-code
  decode; knob_arm coil arms for 5 s window; updates heading setpoint ±1 deg/detent
- modbus_slave.cpp: COIL_CMD_KNOB_ARM now calls knob_encoder_set_armed()
- main.cpp: nvs_config_init/load at boot; apply commissioned calibration to
  rudder sensor and outer loop gains; start knob encoder task

Tests: 326 passed | Flash: 28.5%

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-05-20 02:55:26 -04:00
alro65 e82dbc449c 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>
2026-05-20 00:16:24 -04:00
alro65 0f00ad10da sprint-5: True Course + Track Keeping + XTE + PGN 129026/129284
- Python: NmeaNavData (COG/SOG/XTE data models with staleness tracking)
- Python: TrueCoursePilot with TRUE_COURSE and TRACK_KEEPING modes
- Python: 26 new tests (test_nmea_data, test_true_course)
- Modbus: COG/SOG/XTE input registers + TC setpoint/XTE-gain holdings
- Firmware: nmea2000_consumer handles PGN 129026 + 129284
- Firmware: pid_outer_task wired for TC + TK modes with live SOG scheduling
- YAML regenerated; 284 tests pass, firmware compiles clean

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-05-19 20:12:57 -04:00
alro65 13a2867ef6 sprint-2.5: RBAC 4 roles + Studio bootable + Flash Console
End-to-end implementation per docs/sprint-2.5-plan.md.

New requirement added by user mid-sprint: 4-role RBAC (Super Admin /
Engineer / Owner / User) with dual-auth for Engineer flashing firmware,
plus a "mini Arduino IDE" inside the Studio.

Tests: pytest 231/231 green (129 Sprint 2 + 102 Sprint 2.5 new).

RBAC core (arautopilot/core/):

- rbac.py: 4 roles, 12 capabilities, immutable capability matrix,
  has() / capabilities_of() / require() / requires_dual_auth() helpers.
  Engineer flashing firmware needs SA approval; everything else is
  single-factor.
- user.py: User model with PBKDF2-HMAC-SHA256 PIN hashing (200k iters,
  16-byte salt, self-describing hash format for future migrations).
  4-8 digit numeric PINs enforced.
- user_store.py: JSON-backed user database. seed_demo_users() for
  first-run UX.
- audit.py: append-only JSONL audit log. AuditEvent with timestamp,
  user_id, role, action, target, outcome, reason, secondary_user_id
  for dual-auth, optional extra payload. Crypto signing of lines
  deferred to Sprint 8.

Studio GUI (arautopilot/studio/):

- app.py: real entry point (replaces Sprint 0 stub). --seed-demo
  populates demo users without launching GUI; --data-dir overrides the
  ~/.ar-autopilot/studio/ default.
- session.py: Session + SessionHolder. check() always audits the
  decision; verify_super_admin_pin() + log_dual_auth_grant() for
  dual-auth flows.
- login_window.py: modal login dialog with user picker + PIN field.
  Audits login attempts (success and bad-PIN denials).
- main_window.py: top-level window with sidebar (user + role + caps)
  and tab area (Overview, Flash Console, Project placeholder,
  Telemetry placeholder).
- flash_console.py: the "mini Arduino IDE". Lists serial ports via
  pyserial; picks firmware variant (esp32-dev / esp32-debug); compiles
  via 'pio run'; flashes via 'pio run -t upload --upload-port <port>';
  streams pio output to a dark-themed read-only console; supports
  cancel. For Engineer flashes, asks the Super Admin for their PIN
  inline before invoking pio. Records dual-auth grant + pio exit code
  in the audit log.

Dependencies:

- New [project.optional-dependencies] group 'studio': PySide6>=6.6,
  pyserial>=3.5, platformio>=6.1. Kept optional so the core can be
  installed in lean / CI environments.

Tests (arautopilot/tests/):

- test_rbac.py: 32 tests for capability matrix, dual-auth policy,
  no-privilege-escalation invariants, partial overlap between roles.
- test_user.py: 11 tests for PIN hashing, verification, salting,
  serialisation, field validators.
- test_audit.py: 9 tests for JSONL append, immutability, round-trip,
  corrupt-line detection, dual-auth event shape, blank-line tolerance.
- test_user_store.py: 10 tests for CRUD, persistence, role filtering,
  demo seed idempotency.
- test_session.py: 9 tests for capability checks + audit side effects,
  SA PIN verification, dual-auth recording, SessionHolder lifecycle.
- test_studio_smoke.py: 5 headless tests verifying Studio modules
  import without a display server, --seed-demo works, helpers safe to
  call without hardware.

NOT in Sprint 2.5 (intentional):
  - Crypto signing of audit log lines (hash-chain) -- Sprint 8
  - HWID binding of the user store -- Sprint 8
  - Project configurator + .appack compiler -- Sprint 4
  - Flutter bridge display -- Sprint 4
  - Telemetry dashboard tab -- Sprint 4
  - Serial monitor as a separate tab -- future enhancement

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-18 18:04:27 -04:00
alro65 8d4a698144 polish(sprint-0): clean code per ruff + mypy strict
Run the dev linters over Sprint 0's core/library/shared modules and
address every finding. Behaviour unchanged; tests still 80/80 green.

Changes:

- Replace `class Foo(str, Enum)` with `class Foo(StrEnum)` (PEP 663
  / Python 3.11+) in 7 enum classes: ActuatorType, AlarmSeverity,
  AlarmType, KnobMode, KnobFunction, AutopilotMode, AccessLevel,
  VesselType. Pydantic v2 serialises StrEnum the same way, so YAML/JSON
  round-trips are byte-identical.
- Use `datetime.UTC` alias in place of `datetime.timezone.utc`
  (UP017) across alarms.py, knob_state.py, project_config.py, and
  test_knob_state.py.
- Remove now-unnecessary forward-reference quotes from method return
  type annotations (UP037) — `from __future__ import annotations` is
  already in scope everywhere.
- Tighten `_read_json_resource` / `_read_yaml_resource` in the library
  loader: validate that the deserialised payload is actually a dict
  before returning, instead of leaking `Any` from json.loads /
  yaml.safe_load. Fixes the only two `mypy --strict` findings.
- Add `.claude/settings.local.json` to .gitignore (personal
  Claude Code overrides are not committed).

Verification:
  ruff check arautopilot/                 -> All checks passed
  mypy arautopilot/core library shared    -> Success, 0 issues, 12 files
  pytest                                  -> 80 passed in 0.25s

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-18 07:26:37 -04:00
alro65 700756c16f sprint-0: foundations -- data model, seed library, tests, demo
Initial commit. Delivers what the brief calls 'Sprint 0 - Foundations'
(see docs/AR_Autopilot_brief.md section 12):

- Complete repository structure (arautopilot package + firmware, display,
  installer, tools placeholders + docs).
- Core data model (Pydantic v2): modes, alarms, actuator config, PID
  config + gain scheduling, vessel config, knob state machine, project
  config with YAML/JSON serialisation.
- Seed library: 2 actuator profiles (hydraulic & electric DC reversible)
  and 2 default tunings (yacht motor planeo 30 m and 40 m). Conservative
  literature values, NOT the integrator's production tuning IP.
- Firmware skeleton: only src/hal/pinout.h with the 21 I/O contract for
  the AR-NMEA-IO v1.0 board. No drivers, no main loop.
- Studio stubs (real PySide6 app starts in Sprint 4).
- pytest suite (80 tests, all green): modes, alarms, actuator, PID
  (incl. gain interpolation and the +/-50% adaptive bound from brief
  section 6), vessel, knob state, project config, library loader,
  end-to-end roundtrip.
- examples/sprint0_demo.py - the acceptance demo from the brief.

Acceptance criteria met:
- pytest green (80/80)
- demo creates, saves (YAML + JSON), reloads, and verifies a full
  ProjectConfig using the seed library
- repository ready for tag `sprint-0-approved`

See CHANGELOG.md for the detailed scope.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-17 23:57:18 -04:00