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alro65 42ee63b776 sprint-3: PID outer + Heading Hold + ROT feed-forward + gain scheduling

End-to-end implementation per docs/sprint-3-plan.md.

Closes the cascade: outer loop (heading control, 10 Hz on Core 1) drives
the inner loop (rudder position control, 50 Hz from Sprint 2). First real
mode other than STANDBY is now activable: HEADING_HOLD.

Builds: pio run -e esp32-dev SUCCESS, RAM 6.8%, Flash 27.1% (355 KB).
Tests: pytest 258/258 green (231 Sprint 2.5 + 27 Sprint 3 new).

Python (arautopilot/studio/simulator/):

- vessel_heading.py: first-order yaw model. ROT responds to
  rudder*speed; damping returns ROT to zero when rudder is centred.
  Defaults tuned so 5 deg rudder @ 10 kn -> ~3 dps steady-state ROT.
  Includes heading_error_deg() shortest-arc helper.
- pid_outer.py: pure-Python outer heading PID. Anti-windup via back-
  calculation, gain scheduling by SOG, deadband, derivative LPF,
  output saturation, ROT feed-forward (brief sec. 6 -- the term that
  distinguishes a premium autopilot from a basic one), rate limit on
  produced rudder setpoint, shortest-arc heading wrap-around.

Firmware (firmware/ar_autopilot_v1/src/pid/):

- pid_outer.h: header-only C++17 port. Same algorithm, same variables,
  same numerics. Fixed-capacity gain schedule (up to 8 points).
- pid_outer_task.{h,cpp}: 10 Hz FreeRTOS task on Core 1. Subscribes to
  TWDT. Reads heading + ROT from the NMEA 2000 snapshot. Uses
  operator-configurable SOG (default 15 kn until PGN 129026 wiring in
  Sprint 5). Pushes rudder setpoint into the inner loop only when
  current_mode == HEADING_HOLD.

Modes (firmware/ar_autopilot_v1/src/modes/standby.cpp):

- HEADING_HOLD activable via request_mode(). Pre-conditions:
    * NMEA 2000 heading sensor valid (fresh PGN 127250)
    * Rudder sensor valid (median filter filled)
  On success, captures current heading as initial setpoint so the
  operator doesn't get a sudden swing toward an old setpoint.

Modbus (regenerated from YAML):

- 7 new INPUTs (50-56): outer heading setpoint, produced rudder
  setpoint, error, current SOG, live kp/ki/kd.
- 5 new HOLDINGs (24-28): writable heading setpoint, SOG override,
  outer base gains. Writing any of kp/ki/kd disables the built-in
  3-point gain schedule (operator override).

Tests:

- test_vessel_heading_simulator.py: 6 dynamics tests + 9 parameterised
  heading_error_deg edge cases (wrap-around).
- test_pid_outer_python.py: 12 tests covering gain interpolation,
  per-tick PID behaviour (deadband, sign, ROT feed-forward,
  saturation, rate limit, allowed=false), and three end-to-end cascade
  tests (positive step, negative step, wrap-around 360->10).

Cascade verification: outer + inner + rudder dynamics + vessel-heading
simulator settles a 30 deg step within +-2 deg in 60 s.

NOT in Sprint 3 (intentional):
  - True Course / Track Keeping / Dodge -- Sprint 5
  - Off-course alarms + auto-disengage on sensor loss -- Sprint 6
  - COG / SOG / Position via N2K PGN 129025/9/6 -- Sprint 5

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

2026-05-18 18:20:23 -04:00

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Sprint 3 — PID outer loop + Heading Hold

Brief reference: §6 (cascaded PID), §12 Sprint 3.

Objetivo

Cerrar el lazo externo de rumbo: dado un rumbo deseado, calcular un setpoint de timón que el lazo interno (Sprint 2) lleva a hueso. Esto habilita el primer modo real distinto a STANDBY: HEADING_HOLD.

Estrategia

Misma topología que Sprint 2 (Python source-of-truth + C++ port):

vessel_heading.py — simulador del barco: yaw inertia, rate of turn (ROT), wash de timón (mayor velocidad sobre el agua = más yaw por grado de timón). Permite probar el PID outer sin barco real.
pid_outer.py — lazo externo. Inputs: rumbo deseado, rumbo actual, ROT actual, SOG. Output: setpoint de timón en grados que se pasa al PID inner. Incluye:
- Feed-forward de ROT: anticipa cuándo dejar de aplicar timón para que el barco no sobrepase por inercia (brief §6).
- Gain scheduling por SOG: interpola ganancias entre puntos de GainSchedulePoint (modelo de datos Sprint 0).
- Wrap-around de rumbo: el error entre 358° y 2° es +4°, no -356°.
- Anti-windup + rate limit del setpoint de timón producido.
pid_outer.h — port C++ header-only, byte-equivalente.
pid_outer_task.cpp — tarea FreeRTOS @ 10 Hz en Core 1. Lee rumbo de nmea2000_consumer (PGN 127250) + ROT (PGN 127251) + SOG (Sprint 1 todavía no la tenemos por PGN; Sprint 5 traerá COG/SOG vía PGN 129026; mientras tanto SOG=15 nudos hardcoded como default). Output: invoca pid_inner_set_setpoint_deg(rudder_setpoint).
Activación de HEADING_HOLD en modes.cpp: request_mode(HEADING_HOLD) ahora aceptada si:
- Sensor de rumbo válido (heading_valid == true)
- Sensor de timón válido
- Master power activado
Captura del heading actual como setpoint inicial al engage: cuando el operador hace engage en HH, el setpoint = rumbo actual, no el último valor escrito por Modbus.
Tests Python + cascada simulada inner+outer end-to-end (un barco virtual + PID outer + PID inner + simulador timón).

Lo que NO hace Sprint 3

True Course mode (compensación de deriva con COG). Sprint 5.
Track Keeping. Sprint 5.
Dodge. Sprint 5.
Alarmas off-course. Sprint 6.
Auto-disengage por pérdida de sensor. Sprint 6.

Verificación

pytest verde (objetivo: 250+)
Cascada Python inner+outer estabiliza el rumbo dentro de ±2° en <30s
pio run -e esp32-dev compila clean
Modbus expone: heading_setpoint (RW), rudder_setpoint_from_outer (read), outer gains live, current SOG used

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