Files
AR-Autopilot/firmware/ar_autopilot_v1/tools/modbus_client_test.py
T
alro65 65860948b4 sprint-1: firmware ESP32 base -- STANDBY + Modbus + NMEA 2000 + watchdog
End-to-end implementation of Sprint 1 per docs/sprint-1-plan.md.

Builds: pio run -e esp32-dev SUCCESS, RAM 6.7%, Flash 26.5% (347 KB).
Tests: pytest 110/110 green; pio test -e native deferred (needs host
       C++ compiler -- none on this Windows machine).

Firmware (firmware/ar_autopilot_v1/):

- platformio.ini: 4 envs (esp32-dev release, esp32-debug, native unity
  tests, check static analysis). NMEA2000-library@4.22, NMEA2000_esp32@
  1.0, eModbus@1.7.4 pinned.
- main.cpp: boot in STANDBY, FreeRTOS task spawn, returns to scheduler.
- system/: ar_log.h facade, task_config.h (priorities/stacks/cores
  central table), heartbeat (1 Hz LED + uptime).
- modes/: STANDBY-only state machine; non-STANDBY rejected.
- hal/: di_do.cpp (5 DI + 10 DO with debounce + last-state cache),
  rudder_sensor.cpp (100 Hz ADC + 5-sample median filter, Core 1),
  rudder_actuator.cpp (DO1/DO2/DO3 with three safety interlocks:
  power-off, STANDBY mode, limit switch).
- safety/: TWDT @ 2 s panic-on-expire; 50 Hz safety task on Core 1
  enforcing DI1 physical disengage button, DI4 external alarm,
  both-limit-switch interlock.
- protocols/modbus_slave.cpp: eModbus RTU server on UART2 @ 38400 8N1,
  slave ID 1. 17 inputs + 19 discretes + 5 holdings + 4 coils. Reads
  pull live telemetry; writes validate range and route to handlers.
- protocols/nmea2000_consumer.cpp: stack open with CAN TX=GPIO3
  RX=GPIO1, subscribed to PGN 127250 (Heading) + PGN 127251 (Rate of
  Turn). 5 s staleness flag built in for Sprint 6 alarm wiring.
- filters/median.h: templated MedianFilter<T,N> (host testable).

Cross-cutting:

- modbus_registers.yaml: single source of truth for the Modbus register
  map. 45 entries.
- tools/gen_modbus_registers.py: YAML -> C++ header + Python module
  generator with --check for drift detection.
- arautopilot/shared/modbus_register_map.py: generated Python mirror,
  imported by Studio + tools.
- arautopilot/tests/test_modbus_register_map.py: 30 tests covering
  schema, address uniqueness, range, spot-checks, and drift detection
  (fails if YAML edited without regenerating).
- firmware/ar_autopilot_v1/tools/modbus_client_test.py: manual Modbus
  client for poking the slave from a PC with USB-RS485 dongle.
- firmware/ar_autopilot_v1/test/test_median_filter/test_median.cpp:
  8 Unity tests of the median filter (host-side, no Arduino dependency).
- docs/firmware.md: full operator + integrator guide (toolchain, build,
  flash, expected boot log, troubleshooting, Sprint 1 capability matrix).

Architecture note: opted for Arduino-on-ESP32 only instead of the
proposed dual Arduino-as-ESP-IDF-component setup. Rationale documented
in CHANGELOG and docs/firmware.md -- Arduino-on-ESP32 already provides
the FreeRTOS primitives we need; dual framework adds fragility without
benefit at Sprint 1 scope. Reconsider in Sprint 8 (OTA + secure boot).

NOT in Sprint 1 (intentional per brief sec. 12):
  - PID loops (inner/outer)
  - True Course / Track Keeping
  - Full alarm catalogue beyond DI1/DI4
  - Knob driver
  - Studio GUI / dedicated display

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-18 10:45:56 -04:00

167 lines
5.9 KiB
Python

"""Manual Modbus RTU client for poking the AR-Autopilot ESP32 slave.
Usage (with the AR-NMEA-IO connected via a USB-to-RS485 adapter):
python firmware/ar_autopilot_v1/tools/modbus_client_test.py \
--port COM7
It does NOT require any extra dependency beyond ``pymodbus``, which is NOT
installed by default. Install on demand with:
pip install 'pymodbus>=3.6,<4'
The script:
1. Connects to the slave at the baudrate / framing declared in
``arautopilot.shared.modbus_register_map``.
2. Reads firmware version and uptime (input registers).
3. Reads the current pilot mode.
4. Reads the rudder angle (input register).
5. Writes a heading setpoint to a holding register, then reads it back.
6. Pulses the disengage coil and verifies the discrete bit goes high
(PILOT_ENGAGED is expected to remain false in Sprint 1).
"""
from __future__ import annotations
import argparse
import sys
import time
from pathlib import Path
# Make the project package importable when run from a fresh shell.
REPO_ROOT = Path(__file__).resolve().parents[3]
sys.path.insert(0, str(REPO_ROOT))
from arautopilot.shared import modbus_register_map as m # noqa: E402
try:
from pymodbus.client import ModbusSerialClient
except ImportError:
sys.stderr.write(
"ERROR: pymodbus is not installed. Run:\n"
" pip install 'pymodbus>=3.6,<4'\n"
)
sys.exit(2)
def main() -> int:
parser = argparse.ArgumentParser(description=__doc__)
parser.add_argument("--port", required=True, help="Serial port (e.g. COM7 or /dev/ttyUSB0)")
parser.add_argument("--baudrate", type=int, default=m.BAUDRATE)
parser.add_argument("--slave-id", type=int, default=m.SLAVE_ID)
parser.add_argument("--write-setpoint", type=float, default=180.0,
help="Heading setpoint to write, in degrees (default 180.0)")
args = parser.parse_args()
print(f"[connect] {args.port} @ {args.baudrate} 8{m.PARITY}1, slave={args.slave_id}")
client = ModbusSerialClient(
port=args.port,
baudrate=args.baudrate,
parity=m.PARITY,
stopbits=m.STOP_BITS,
bytesize=m.DATA_BITS,
timeout=1.0,
)
if not client.connect():
print("[connect] FAILED")
return 1
try:
# --- Firmware version + uptime ---------------------------------------
rr = client.read_input_registers(
address=m.INPUTS["FW_VERSION_MAJOR"].addr, count=6, slave=args.slave_id
)
if rr.isError():
print("[error] read input registers (version): ", rr)
return 1
major, minor, patch, schema, up_lo, up_hi = rr.registers
uptime_s = up_lo | (up_hi << 16)
print(
f"[fw ] version v{major}.{minor}.{patch} schema={schema} "
f"uptime={uptime_s}s"
)
# --- Mode -----------------------------------------------------------
rr = client.read_input_registers(
address=m.INPUTS["CURRENT_MODE"].addr, count=1, slave=args.slave_id
)
mode_names = {0: "STANDBY", 1: "HEADING_HOLD", 2: "TRUE_COURSE",
3: "TRACK_KEEPING", 4: "DODGE"}
print(f"[mode ] {mode_names.get(rr.registers[0], '?')} ({rr.registers[0]})")
# --- Rudder angle ---------------------------------------------------
rr = client.read_input_registers(
address=m.INPUTS["RUDDER_ANGLE_DEG_X100"].addr, count=3, slave=args.slave_id
)
angle_x100, raw_adc, valid = rr.registers
# interpret as signed int16
if angle_x100 >= 0x8000:
angle_x100 -= 0x10000
print(
f"[rudd ] angle={angle_x100 / 100.0:+.2f} deg raw_adc={raw_adc} "
f"valid={'yes' if valid else 'no'}"
)
# --- Heading + ROT (Sprint 1 wires these via NMEA 2000) -------------
rr = client.read_input_registers(
address=m.INPUTS["HEADING_DEG_X100"].addr, count=3, slave=args.slave_id
)
heading_x100, rot_x100, age_ms = rr.registers
if rot_x100 >= 0x8000:
rot_x100 -= 0x10000
print(
f"[n2k ] heading={heading_x100 / 100.0:7.2f} deg "
f"rot={rot_x100 / 100.0:+.2f} deg/s age={age_ms} ms"
)
# --- Write heading setpoint -----------------------------------------
sp_x100 = int(round(args.write_setpoint * 100.0))
if sp_x100 < -0x8000 or sp_x100 > 0x7FFF:
print(f"[error] setpoint out of int16 range")
return 1
wr_value = sp_x100 if sp_x100 >= 0 else (sp_x100 + 0x10000)
wr = client.write_register(
address=m.HOLDINGS["HEADING_SETPOINT_X100"].addr,
value=wr_value,
slave=args.slave_id,
)
if wr.isError():
print(f"[error] write holding (heading setpoint): {wr}")
return 1
rr = client.read_holding_registers(
address=m.HOLDINGS["HEADING_SETPOINT_X100"].addr,
count=1,
slave=args.slave_id,
)
read_back = rr.registers[0]
if read_back >= 0x8000:
read_back -= 0x10000
print(
f"[hold ] wrote heading setpoint {args.write_setpoint:.2f} deg, "
f"read back {read_back / 100.0:+.2f} deg"
)
# --- Disengage coil pulse -------------------------------------------
client.write_coil(
address=m.COILS["CMD_DISENGAGE_REQUEST"].addr,
value=True,
slave=args.slave_id,
)
time.sleep(0.05)
rr = client.read_discrete_inputs(
address=m.DISCRETES["PILOT_ENGAGED"].addr, count=1, slave=args.slave_id
)
print(
f"[coil ] disengage pulsed; PILOT_ENGAGED = "
f"{'YES (unexpected)' if rr.bits[0] else 'no (correct -- Sprint 1 is always STANDBY)'}"
)
return 0
finally:
client.close()
if __name__ == "__main__":
raise SystemExit(main())