Filter invalid motor temperature readings from ESC

Removed temperature state enums and thresholds, and updated logic to filter out invalid/disconnected motor temperature sensor readings (values >140°C) in telemetry processing. Adjusted UI and monitor code to only display valid motor temperature values, improving robustness against sensor disconnection or failure.

Author: zjwhitehead

inc/sp140/esc.h

@@ -7,28 +7,15 @@
 #include <SineEsc.h>
 #include <CanardAdapter.h>
 
-// Temperature thresholds
-#define ESC_MOS_WARN 90
-#define ESC_MOS_CRIT 110
-#define ESC_MCU_WARN 80
-#define ESC_MCU_CRIT 95
-#define ESC_CAP_WARN 85
-#define ESC_CAP_CRIT 100
-#define MOTOR_WARN 105
-#define MOTOR_CRIT 150
-
-void initESC();
+void initESC();
 void setESCThrottle(int throttlePWM);
 void readESCTelemetry();
 bool setupTWAI();
 
-// Get the highest temperature from all ESC sensors
-float getHighestTemp(const STR_ESC_TELEMETRY_140& telemetry);
-
-// Function declarations
-TempState checkTempState(float temp, TempComponent component);
-
-// ESC Error Decoding Functions
+// Get the highest temperature from all ESC sensors
+float getHighestTemp(const STR_ESC_TELEMETRY_140& telemetry);
+
+// ESC Error Decoding Functions
 String decodeRunningError(uint16_t errorCode);
 String decodeSelfCheckError(uint16_t errorCode);
 bool hasRunningError(uint16_t errorCode);

inc/sp140/structs.h

@@ -6,21 +6,6 @@
 
 #pragma pack(push, 1)
 
-// Temperature component enum
-enum TempComponent {
-  COMP_ESC_MOS = 0,
-  COMP_ESC_MCU = 1,
-  COMP_ESC_CAP = 2,
-  COMP_MOTOR = 3
-};
-
-enum TempState {
-  TEMP_INVALID = -1,  // Sensor reading is invalid
-  TEMP_NORMAL = 0,
-  TEMP_WARNING = 1,
-  TEMP_CRITICAL = 2
-};
-
 // Telemetry connection state
 enum class TelemetryState : uint8_t {
   NOT_CONNECTED,  // Never received data since boot
@@ -42,11 +27,6 @@ typedef struct {
   uint8_t statusFlag;
   word checksum;
   unsigned long lastUpdateMs;  // Timestamp of last telemetry update
-  TempState mos_state;         // MOS temperature state
-  TempState mcu_state;        // MCU temperature state
-  TempState cap_state;        // CAP temperature state
-  TempState motor_state;      // Motor temperature state
-  bool temp_sensor_error;     // True if any sensor is invalid
   TelemetryState escState;       // Current connection state
   uint16_t running_error;      // Runtime error bitmask
   uint16_t selfcheck_error;    // Self-check error bitmask

src/sp140/esc.cpp

@@ -94,28 +94,23 @@ void readESCTelemetry() {
       escTelemetryData.amps = res->bus_current / 10.0f;
       escTelemetryData.mos_temp = res->mos_temp / 10.0f;
       escTelemetryData.cap_temp = res->cap_temp / 10.0f;
-      escTelemetryData.mcu_temp = res->mcu_temp / 10.0f;
-      escTelemetryData.motor_temp = res->motor_temp / 10.0f;
+      escTelemetryData.mcu_temp = res->mcu_temp / 10.0f;
+      // Filter motor temp - only update if sensor is connected (valid range: -20°C to 140°C)
+      // Disconnected sensor reads ~149°C (thermistor pulled high)
+      float rawMotorTemp = res->motor_temp / 10.0f;
+      if (rawMotorTemp > -20.0f && rawMotorTemp <= 140.0f) {
+        escTelemetryData.motor_temp = rawMotorTemp;
+      }
+      // else: keep previous value (sensor disconnected or invalid)
       escTelemetryData.eRPM = res->speed;
       escTelemetryData.inPWM = res->recv_pwm / 10.0f;
       watts = escTelemetryData.amps * escTelemetryData.volts;
 
-      // Store error bitmasks
-      escTelemetryData.running_error = res->running_error;
-      escTelemetryData.selfcheck_error = res->selfcheck_error;
-
-      // Temperature states
-      escTelemetryData.mos_state = checkTempState(escTelemetryData.mos_temp, COMP_ESC_MOS);
-      escTelemetryData.mcu_state = checkTempState(escTelemetryData.mcu_temp, COMP_ESC_MCU);
-      escTelemetryData.cap_state = checkTempState(escTelemetryData.cap_temp, COMP_ESC_CAP);
-      escTelemetryData.motor_state = checkTempState(escTelemetryData.motor_temp, COMP_MOTOR);
-      escTelemetryData.temp_sensor_error =
-        (escTelemetryData.mos_state == TEMP_INVALID) ||
-        (escTelemetryData.mcu_state == TEMP_INVALID) ||
-        (escTelemetryData.cap_state == TEMP_INVALID) ||
-        (escTelemetryData.motor_state == TEMP_INVALID);
-
-      // Record the time of this successful communication using the local clock
+      // Store error bitmasks
+      escTelemetryData.running_error = res->running_error;
+      escTelemetryData.selfcheck_error = res->selfcheck_error;
+
+      // Record the time of this successful communication using the local clock
       lastSuccessfulCommTimeMs = millis();
     }  // else: Timestamp hasn't changed, treat as stale data, don't update local timer or telemetry
 
@@ -309,46 +304,12 @@ double mapDouble(double x, double in_min, double in_max, double out_min, double
  * @param telemetry ESC telemetry data structure
  * @return The highest temperature value among motor, MOSFET, and capacitor temps
  */
-float getHighestTemp(const STR_ESC_TELEMETRY_140& telemetry) {
-  return max(telemetry.motor_temp, max(telemetry.mos_temp, telemetry.cap_temp));
-}
-
-/**
- * Check temperature state for a specific component
- * @param temp Temperature value to check
- * @param component Component type (ESC_MOS, ESC_MCU, ESC_CAP, or MOTOR)
- * @return Temperature state (NORMAL, WARNING, CRITICAL, or INVALID)
- */
-TempState checkTempState(float temp, TempComponent component) {
-  // Check for invalid temperature readings
-  if (temp < -50 || temp > 200) {
-      return TEMP_INVALID;
-  }
-
-  switch (component) {
-    case COMP_ESC_MOS:
-      return temp >= ESC_MOS_CRIT ? TEMP_CRITICAL :
-              temp >= ESC_MOS_WARN ? TEMP_WARNING : TEMP_NORMAL;
-
-    case COMP_ESC_MCU:
-      return temp >= ESC_MCU_CRIT ? TEMP_CRITICAL :
-              temp >= ESC_MCU_WARN ? TEMP_WARNING : TEMP_NORMAL;
-
-    case COMP_ESC_CAP:
-      return temp >= ESC_CAP_CRIT ? TEMP_CRITICAL :
-              temp >= ESC_CAP_WARN ? TEMP_WARNING : TEMP_NORMAL;
-
-    case COMP_MOTOR:
-      return temp >= MOTOR_CRIT ? TEMP_CRITICAL :
-              temp >= MOTOR_WARN ? TEMP_WARNING : TEMP_NORMAL;
-
-    default:
-      return TEMP_INVALID;
-  }
-}
-
-/**
- * Decode running error bitmask into human-readable string
+float getHighestTemp(const STR_ESC_TELEMETRY_140& telemetry) {
+  return max(telemetry.motor_temp, max(telemetry.mos_temp, telemetry.cap_temp));
+}
+
+/**
+ * Decode running error bitmask into human-readable string
  * @param errorCode 16-bit running error code from ESC
  * @return String containing decoded error messages
  */

src/sp140/esc_monitors.cpp

@@ -51,6 +51,7 @@ void addESCMonitors() {
   monitors.push_back(escCapTemp);
 
   // Motor Temperature Monitor - with hysteresis
+  // Note: Invalid readings (>140°C = disconnected) are filtered in esc.cpp
   static HysteresisSensorMonitor* motorTemp = new HysteresisSensorMonitor(
     SensorID::Motor_Temp,
     SensorCategory::ESC,

src/sp140/lvgl/lvgl_updates.cpp

@@ -704,7 +704,9 @@ void updateLvglMainScreen(
     lv_obj_remove_style(motor_temp_bg, &style_warning, 0);
     lv_obj_remove_style(motor_temp_bg, &style_critical, 0);
 
-    if (escTelemetry.escState == TelemetryState::CONNECTED && motorTemp > -20.0f) {
+    // Show motor temp if ESC connected and reading is valid (not disconnected)
+    // Disconnected sensor reads ~149°C, so treat > 140°C as invalid
+    if (escTelemetry.escState == TelemetryState::CONNECTED && motorTemp > -20.0f && motorTemp <= 140.0f) {
       lv_label_set_text_fmt(motor_temp_label, "%d", static_cast<int>(motorTemp));
 
       if (motorTemp >= motorTempThresholds.critHigh) {