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Add PowerPack Flash/Test QC tool firmware
Standalone firmware for the ESP32-S3 hand controller that serves as a factory QC tool for PowerPack assemblies. Separate PlatformIO environment (PowerPack-FlashTest) with its own source tree under src/powerpack/. Features: - ESC firmware update over CAN bus (DroneCAN protocol) - Full state machine: restart -> bootloader -> chunk transfer -> verify - Embedded SE24250D V2.33.102 firmware binary (90KB, 360 chunks) - 150ms timeout with 10 retries per message - ESC configuration writer via DroneCAN param.GetSet (service ID 11) - Hand-coded encode/decode for param.GetSet and ExecuteOpcode - 97 production parameters from OpenPPG V1.11 config - Save to flash via ExecuteOpcode(SAVE) + restart - Comprehensive QC sensor validation with motor spin-up test - Phase 1: Idle checks (HW ID, FW version, temps, voltage, errors) - Phase 2: Smooth ramp to full throttle tracking peaks - Phase 3: Hold at max, record peak RPM/current/voltage - Phase 4: Ramp down, cooldown, post-run temp measurement - Evaluates: direction, peak RPM, phase current, voltage sag, temp rise, self-check errors, spin errors - Safety abort on critical faults during motor run - ST7735 display UI with progress bars and color-coded results - NeoPixel LED status (blue=waiting, yellow=working, green=pass, red=fail) - Button control: short press=config+test, long press=flash+config+test - USB serial CLI: start, config, test, status, help Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
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‎inc/powerpack/config.h‎

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#ifndef POWERPACK_CONFIG_H_
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#define POWERPACK_CONFIG_H_
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// CAN bus pins (same hardware as SP140 hand controller)
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#define ESC_TX_PIN 2
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#define ESC_RX_PIN 3
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// Local CAN node ID for this tool
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#define LOCAL_NODE_ID 0x01
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// Default ESC node ID
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#define ESC_NODE_ID 0x20
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// Firmware update settings
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#define FW_UPDATE_TIMEOUT_MS 150
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#define FW_UPDATE_MAX_RETRIES 10
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#define FW_CHUNK_SIZE 256
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// QC test thresholds
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#define QC_TEMP_MIN_C -10.0f // Minimum reasonable ambient temp
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#define QC_TEMP_MAX_C 80.0f // Max temp for idle ESC
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#define QC_MOTOR_TEMP_VALID_MIN_C -20.0f
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#define QC_MOTOR_TEMP_VALID_MAX_C 140.0f
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#define QC_VBUS_MIN_V 48.0f
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#define QC_VBUS_MAX_V 108.0f
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// Display (ST7735 via SPI)
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#define DISPLAY_CS_PIN 10
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#define DISPLAY_DC_PIN 14
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#define DISPLAY_RST_PIN 15
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#define SPI_MOSI_PIN 11
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#define SPI_MISO_PIN 13
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#define SPI_SCLK_PIN 12
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// Button (GPIO 1 on the SP140 hand controller hardware)
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#define BUTTON_PIN 1
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// NeoPixel LED
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#define NEOPIXEL_PIN 21
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// Buzzer
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#define BUZZER_PIN 8
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// Vibration motor
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#define VIBE_PIN 46
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#endif // POWERPACK_CONFIG_H_

‎inc/powerpack/dronecan_param.h‎

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#ifndef POWERPACK_DRONECAN_PARAM_H_
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#define POWERPACK_DRONECAN_PARAM_H_
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// Hand-coded DroneCAN param.GetSet (ID 11) and param.ExecuteOpcode (ID 10)
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// encode/decode. These are not generated by the DSDL compiler in the SINE ESC CAN
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// library, so we implement the subset needed for config writing.
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#include <stdint.h>
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#include <stdbool.h>
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#include <string.h>
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#include <canard.h>
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// =============================================================================
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// param.Value union (tag is 3 bits)
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// =============================================================================
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// Tag values:
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// 0 = empty
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// 1 = integer_value (int64)
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// 2 = real_value (float32)
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// 3 = boolean_value (uint8)
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// 4 = string_value (uint8[<=128])
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#define PARAM_VALUE_TAG_EMPTY 0
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#define PARAM_VALUE_TAG_INTEGER 1
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#define PARAM_VALUE_TAG_REAL 2
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#define PARAM_VALUE_TAG_BOOLEAN 3
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#define PARAM_VALUE_TAG_STRING 4
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struct ParamValue {
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uint8_t tag; // 3-bit union tag
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union {
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int64_t integer_value;
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float real_value;
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uint8_t boolean_value;
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struct {
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uint8_t data[128];
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uint8_t len;
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} string_value;
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};
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};
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// =============================================================================
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// param.GetSet (Service ID 11)
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// Signature: 0xA7B622F939D1A4D5
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// =============================================================================
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#define UAVCAN_PARAM_GETSET_ID 11
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#define UAVCAN_PARAM_GETSET_SIGNATURE 0xA7B622F939D1A4D5ULL
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struct ParamGetSetRequest {
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uint16_t index; // uint13 (we use uint16, top 3 bits ignored)
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ParamValue value; // Value to set (empty = read only)
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char name[93]; // uint8[<=92] name + null terminator
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uint8_t name_len;
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};
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struct ParamGetSetResponse {
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ParamValue value; // Actual value after set
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ParamValue default_value;
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char name[93];
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uint8_t name_len;
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};
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// =============================================================================
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// param.ExecuteOpcode (Service ID 10)
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// Signature: 0x3B131AC5EB69D2CDULL
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// =============================================================================
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#define UAVCAN_PARAM_EXECUTEOPCODE_ID 10
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#define UAVCAN_PARAM_EXECUTEOPCODE_SIGNATURE 0x3B131AC5EB69D2CDULL
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#define PARAM_OPCODE_SAVE 0
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#define PARAM_OPCODE_ERASE 1
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struct ParamExecuteOpcodeRequest {
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uint8_t opcode;
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int64_t argument; // int48 - reserved, keep zero
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};
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struct ParamExecuteOpcodeResponse {
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int64_t argument; // int48
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bool ok;
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};
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// =============================================================================
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// Encode/Decode functions
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// =============================================================================
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// Encode a ParamValue into a buffer at bit offset.
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// Returns number of bits written.
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uint32_t paramValue_encode(const ParamValue* val, uint8_t* buffer, uint32_t bit_ofs);
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// Decode a ParamValue from a transfer at bit offset.
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// Returns number of bits consumed.
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uint32_t paramValue_decode(const CanardRxTransfer* transfer, uint32_t bit_ofs, ParamValue* val);
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// Encode param.GetSet request
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uint32_t paramGetSetRequest_encode(const ParamGetSetRequest* req, uint8_t* buffer);
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// Decode param.GetSet response
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bool paramGetSetResponse_decode(const CanardRxTransfer* transfer, ParamGetSetResponse* res);
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// Encode param.ExecuteOpcode request
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uint32_t paramExecuteOpcodeRequest_encode(const ParamExecuteOpcodeRequest* req, uint8_t* buffer);
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// Decode param.ExecuteOpcode response
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bool paramExecuteOpcodeResponse_decode(const CanardRxTransfer* transfer, ParamExecuteOpcodeResponse* res);
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#endif // POWERPACK_DRONECAN_PARAM_H_

‎inc/powerpack/esc_config.h‎

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#ifndef POWERPACK_ESC_CONFIG_H_
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#define POWERPACK_ESC_CONFIG_H_
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#include <stdint.h>
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enum class ConfigState : uint8_t {
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IDLE,
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WRITING_PARAMS,
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SAVING, // ExecuteOpcode SAVE
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RESTARTING, // RestartNode after save
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SUCCESS,
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FAILED
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};
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struct ConfigProgress {
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ConfigState state;
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uint16_t currentParam;
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uint16_t totalParams;
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const char* currentParamName;
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const char* statusMsg;
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uint8_t percentComplete;
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};
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// Initialize the config writer (call after CAN is up)
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void escConfigInit();
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// Start writing the production config to the ESC.
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// Uses the embedded config table.
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void escConfigStart();
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// Drive the config writer state machine. Returns true while running.
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bool escConfigTick();
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// Get current progress
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const ConfigProgress& escConfigGetProgress();
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bool escConfigSucceeded();
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#endif // POWERPACK_ESC_CONFIG_H_

‎inc/powerpack/esc_flasher.h‎

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#ifndef POWERPACK_ESC_FLASHER_H_
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#define POWERPACK_ESC_FLASHER_H_
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#include <stdint.h>
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enum class FlashState : uint8_t {
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IDLE,
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RESTARTING, // Sent RestartNode, waiting for ESC to reboot
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CHECKING_BOOT, // Sent GetBootStatus, waiting for bootloader confirmation
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STARTING, // Sent StartFwUpgrade with header info
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SENDING_DATA, // Sending firmware chunks via SendFwData
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ENDING, // Sent EndFwUpgrade, waiting for confirmation
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SUCCESS,
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FAILED
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};
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struct FlashProgress {
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FlashState state;
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uint16_t currentChunk;
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uint16_t totalChunks;
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uint8_t retryCount;
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const char* statusMsg;
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uint8_t percentComplete; // 0-100
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};
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// Initialize the flasher module (call after CAN is up)
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void escFlasherInit();
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// Start the firmware update process.
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// fwData points to the complete firmware file (including 32-byte header).
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// fwLen is the total file size in bytes.
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void escFlasherStart(const uint8_t* fwData, uint32_t fwLen);
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// Call this repeatedly from a task/loop to drive the state machine.
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// Returns true while the process is still running.
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bool escFlasherTick();
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// Get current progress for display
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const FlashProgress& escFlasherGetProgress();
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// Check if flasher is idle (not running)
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bool escFlasherIsIdle();
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// Check if last flash was successful
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bool escFlasherSucceeded();
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#endif // POWERPACK_ESC_FLASHER_H_

‎inc/powerpack/param_table.h‎

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#ifndef POWERPACK_PARAM_TABLE_H_
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#define POWERPACK_PARAM_TABLE_H_
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#include <stdint.h>
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// Production configuration parameters from "OpenPPG V1.11 Config Shipping"
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// Each entry: { param_name, integer_value }
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// String and array params handled separately.
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struct ParamEntry {
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const char* name;
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int64_t value;
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};
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// Production config - derived from the JSON config file.
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// Array/curve params are excluded here (handled separately if needed).
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static const ParamEntry PRODUCTION_CONFIG[] = {
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// Board params
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{"node_id", 32},
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{"can_baudrate", 0}, // 0 = 1000K
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{"uart_baudrate", 0}, // 0 = 115200
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{"vbus_upper_limit", 108},
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{"vbus_lower_limit", 48},
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{"over_voltage_threshold", 105},
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{"overt_voltage_tolerance", 6},
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{"overt_voltage_tolerance2", 8},
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{"dcbus_lpf_hz", 500},
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{"led_color", 1}, // 1 = Green
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{"standby_led_type", 1}, // 1 = Always On
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{"rs485_led_port", 0}, // 0 = Led
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// Motor params
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{"motor_pole_pairs", 31},
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{"motor_rs", 147},
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{"motor_ld", 122},
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{"motor_lq", 122},
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{"ls_coef", 100},
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{"motor_kv", 340},
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{"motor_max_current", 2200},
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{"carrier_freq_khz", 16},
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{"current_loop_coef", 25},
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// Control params
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{"ctrl_input_type", 0}, // 0 = Pwm+CommPwm
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{"throttle_recover_check", 1}, // 1 = Enable
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{"direction", 1}, // 1 = Inversion
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{"idling_speed_rpm", 60},
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{"motor_max_rpm", 2500},
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{"stop_type", 0}, // 0 = Free Stop
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{"min_startup_speed_enable", 0}, // Disable
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{"min_startup_speed", 200},
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// Speed params
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{"idling_acc_krpmps", 300},
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{"max_acc_krpmps", 300},
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{"max_dec_krpmps", 300},
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{"max_accel_current", 2100},
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{"max_decel_current", -15},
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{"acc_type", 0}, // 0 = Normal Mode
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{"idling_acc_speed_rpm", 1},
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{"fast_stop_decel_krpmps", 1000},
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{"fast_stop_decel_current", -50},
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{"speed_ref_lpf", 650},
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{"f_speed_loop_kp", 300},
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{"f_speed_loop_ki", 59},
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{"s_speed_loop_kp", 150},
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{"s_speed_loop_ki", 29},
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{"speed_loop_anti_windup_enable", 0},
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{"speed_loop_anti_windup_coef", 1},
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// Throttle params
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{"ppm_period_tolerance", 1000},
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{"ppm_lost_time_ms", 300},
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{"hyst_ppm", 100},
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{"throttle_type", 0}, // 0 = Normal
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{"ppm_curve_type", 1}, // 1 = Linear Speed
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{"normal_pwm_start", 10500}, // 1050us in 0.1us units
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{"normal_pwm_end", 19500}, // 1950us
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{"normal_pwm_curve_comp_coef", 3000},
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// Advance params
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{"noload_detect_enable", 1},
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{"load_dectect_speed_rpm", 750},
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{"load_detect_current", 80},
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{"field_weakening_enable", 1},
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{"field_weakening_max_current", -200},
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{"acc_comp_enable", 1},
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{"acc_comp_coef", 30},
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{"rs_temp_comp_enable", 1},
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{"rs_temp_comp_coef", 100},
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{"motor_sound_enable", 1},
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{"pndef_motor_sound_volume", 3},
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// Observer params
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{"observer_type", 0},
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{"observer_coef", 20},
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{"observer_filter_freq", 1000},
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// Protect params
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{"stall_enable", 1},
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{"stall_idle_speed_current", 400},
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{"stall_full_speed_current", 2200},
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{"stall_protected_duration", 1000},
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{"stall_count", 2},
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{"stall_recover_enable", 0},
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{"overcurrent_count", 2},
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{"high_temp_protect_enable", 1},
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{"mos_high_temp_limit_1", 110},
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{"mos_high_temp_limit_2", 140},
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{"cap_high_temp_limit_1", 95},
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{"cap_high_temp_limit_2", 105},
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{"mcu_high_temp_limit_1", 100},
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{"mcu_high_temp_limit_2", 125},
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{"low_voltage_protect_enable", 0},
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{"low_protect_voltage_limit_1", 55},
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{"low_protect_voltage_limit_2", 35},
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{"low_protect_voltage_ratio", 40},
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{"ibus_max_current", 2000},
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{"ibus_limit_duration", 1000},
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{"max_power_limit", 25000},
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{"power_limit", 1},
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// Bidirectional throttle params
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{"positive_ppm_start", 15000},
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{"positive_ppm_end", 20000},
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{"negative_ppm_start", 10000},
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{"negative_ppm_end", 15000},
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{"postive_pwm_curve_comp_coef", 1905},
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{"negative_pwm_curve_comp_coef", 1905},
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// Position mode params
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{"position_mode_enable", 0},
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{"position_mode_enable_work_type", 0},
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{"position_mode_speed_loop_kp", 680},
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{"position_mode_speed_loop_ki", 1500},
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{"position_mode_speed_loop_kd", 480},
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{"position_loop_pid_limit_1", 300},
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{"position_loop_pid_limit_2", 1},
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{"position_loop_kp", 30},
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{"position_loop_ki", 10},
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{"position_loop_kd", 30},
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{"position_mode_current_loop_coef", 20},
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{"position_mode_max_current", 200},
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{"position_mode_acc_krpms", 50},
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{"position_mode_speed_pll_freq", 1200},
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};
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static const uint16_t PRODUCTION_CONFIG_COUNT = sizeof(PRODUCTION_CONFIG) / sizeof(PRODUCTION_CONFIG[0]);
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#endif // POWERPACK_PARAM_TABLE_H_

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