Extend AeroAlign with mixed CoG planning and telemetry base

2026-03-11 23:14:33 +01:00
parent 538c3081bf
commit 56890272a0
28 changed files with 1631 additions and 1332 deletions
@@ -1,360 +1,68 @@
 # SkyLogic AeroAlign - Implementation Status

-**Date**: 2026-01-22
-**Phase**: 4 (Differential Measurement) - COMPLETE ✅
-**Progress**: 32/130 tasks (25%)
+**Date**: 2026-03-11  
+**State**: AeroAlign working, CoG integration base prepared

---
+## Repository Status

-## ✅ Completed Work
+The project now has two layers:

-### Phase 1: Setup (7/7 tasks - 100%)
+1. working AeroAlign firmware and UI for IMU-based angle measurement
+2. shared protocol and documentation base for the upcoming CoG scale extension

-**Directory Structure Created**:
-```
-ewd-digiflo/
-├── firmware/
-│   ├── master/src/        ✅ Master firmware source
-│   ├── master/data/       ✅ Web UI location
-│   ├── slave/src/         ✅ Slave firmware source
-├── hardware/
-│   ├── cad/               ✅ 3D models (documentation)
-│   ├── schematics/        ✅ Wiring diagrams + BOM
-│   └── docs/              ✅ Hardware docs
-├── docs/                  ✅ End-user guides
-└── specs/001-wireless-rc-telemetry/  ✅ Design docs
-```
+## Implemented

-**Configuration Files**:
- ✅ `firmware/master/platformio.ini` - ESP32-C3/S3 build config
- ✅ `firmware/slave/platformio.ini` - Multi-slave variants (8 nodes)
- ✅ `firmware/master/src/config.h` - WiFi, GPIO, constants
- ✅ `firmware/slave/src/config.h` - Master MAC, node ID
+### Firmware

---
+- Master firmware builds for `esp32-c3` and `esp32-s3`
+- IMU slave firmware builds for the current slave environments, including S3
+- Master and Slave use the same direct MPU6050 register access approach
+- shared ESP-NOW packet format supports device typing:
+  - `IMU`
+  - `CoG Scale`
+  - `Hybrid`
+- Master data model and UI can already represent CoG-style telemetry fields

-### Phase 2: Foundational (13/13 tasks - 100%)
+### UI

-#### Hardware Foundation
+- current tabs remain angle-focused: `Sensors`, `Differential`, `System`
+- mixed-device node cards are supported
+- differential selection excludes CoG-only nodes
+- Master battery display is hidden when the ADC path is not available

- ✅ **Bill of Materials** (`hardware/schematics/bom.csv`)
-  - Complete component list with Amazon ASINs
-  - Pricing: $72 for 2-sensor system, $289 for 8-sensor system
-  - Alternative components documented
+### Documentation

- ✅ **Wiring Diagram** (`hardware/schematics/sensor_node_wiring.md`)
-  - Complete ESP32-MPU6050-LiPo-TP4056 wiring
-  - Battery monitoring circuit (voltage divider)
-  - Power supply design (HT7333 LDO)
-  - Assembly instructions and troubleshooting
+- README rewritten for combined AeroAlign + CoG direction
+- IMU wiring brought to current C3/S3 and battery-monitoring behavior
+- new CoG wiring guide added
+- BOM converted from placeholder marketplace list to current component overview
+- CAD readme updated to include planned CoG fixtures

- ✅ **3D CAD Documentation** (`hardware/cad/README.md`)
-  - Sensor housing specs (38mm × 28mm × 18mm)
-  - Control surface clips (3mm, 5mm, 8mm)
-  - Print settings for PLA/PETG
-  - Multi-sensor expansion mounts (Phase 8 ready)
+## Current Hardware Documentation

-#### Firmware Foundation - Master Node
+- [README.md](/Users/florianklaner/Github/AeroAlign/README.md)
+- [sensor_node_wiring.md](/Users/florianklaner/Github/AeroAlign/hardware/schematics/sensor_node_wiring.md)
+- [cog_scale_wiring.md](/Users/florianklaner/Github/AeroAlign/hardware/schematics/cog_scale_wiring.md)
+- [bom.csv](/Users/florianklaner/Github/AeroAlign/hardware/schematics/bom.csv)
+- [hardware/cad/README.md](/Users/florianklaner/Github/AeroAlign/hardware/cad/README.md)
+- [AEROALIGN_COG_INTEGRATION.md](/Users/florianklaner/Github/AeroAlign/docs/AEROALIGN_COG_INTEGRATION.md)

- ✅ **IMU Driver** (`firmware/master/src/imu_driver.cpp/h`)
-  - MPU6050 6-axis sensor support
-  - Complementary filter (α=0.98) for angle calculation
-  - ±0.5° accuracy (static measurement)
-  - Temperature monitoring
-  - Calibration support
+## What Works Right Now

- ✅ **Calibration Manager** (`firmware/master/src/calibration.cpp/h`)
-  - NVS (Non-Volatile Storage) persistence
-  - Zero-point offset storage per node
-  - Temperature-tagged calibration
-  - Load/save/clear operations
+- Master AP + web UI
+- IMU node discovery over ESP-NOW
+- calibration and differential measurement for angle nodes
+- S3-safe IMU access path
+- optional battery reporting on Master hardware where ADC is not wired

- ✅ **ESP-NOW Receiver** (`firmware/master/src/espnow_master.cpp/h`)
-  - Receive sensor data from Slaves (10Hz)
-  - Checksum validation (XOR)
-  - Auto-discovery (no manual pairing)
-  - Connection timeout detection (1000ms)
-  - Packet statistics tracking
+## What Is Not Finished Yet

- ✅ **Web Server** (`firmware/master/src/web_server.cpp/h`)
-  - AsyncWebServer (non-blocking)
-  - REST API endpoints:
-    - GET /api/nodes (sensor data)
-    - GET /api/differential (EWD calculation)
-    - POST /api/calibrate (zero sensors)
-    - GET /api/status (system health)
-  - JSON responses (ArduinoJson)
+- dedicated `firmware/cog_slave`
+- HX711 integration
+- tare and scale calibration persistence
+- model profiles for support spacing and target CoG
+- dedicated CoG workflow in the UI

- ✅ **Master Main Loop** (`firmware/master/src/main.cpp`)
-  - WiFi Access Point (SSID: "SkyLogic-AeroAlign")
-  - IP: 192.168.4.1 (captive portal)
-  - IMU sampling (100Hz)
-  - ESP-NOW updates (100ms)
-  - Battery monitoring (1Hz)
-  - Status reporting (10s intervals)
+## Recommended Next Step

-#### Firmware Foundation - Slave Node
-
- ✅ **IMU Driver** (`firmware/slave/src/imu_driver.cpp/h`)
-  - Same as Master (copied)
-
- ✅ **ESP-NOW Transmitter** (`firmware/slave/src/espnow_slave.cpp/h`)
-  - Send sensor data to Master (10Hz)
-  - 15-byte packet format (node_id, pitch, roll, yaw, battery, checksum)
-  - Pairing with Master MAC
-  - Transmission statistics
-
- ✅ **Slave Main Loop** (`firmware/slave/src/main.cpp`)
-  - IMU sampling (100Hz)
-  - ESP-NOW transmission (10Hz / 100ms intervals)
-  - Battery monitoring (1Hz)
-  - Low battery warning (LED flash)
-  - Status reporting (10s intervals)
-
-#### Infrastructure
-
- ✅ **Git Ignore** (`.gitignore`)
-  - PlatformIO build artifacts
-  - IDE files (VSCode, IntelliJ, Eclipse)
-  - Environment files (.env)
-  - OS-specific files (.DS_Store, Thumbs.db)
-
- ✅ **Web UI** (`firmware/master/data/index.html`)
-  - Real-time angle display (10Hz polling)
-  - System status dashboard
-  - Node connection indicators
-  - Battery/RSSI monitoring
-  - Responsive design (mobile-friendly)
-
- ✅ **Documentation** (`README.md`)
-  - Project overview and features
-  - Quick start guide
-  - Hardware requirements
-  - Architecture diagram
-  - API documentation
-  - Development instructions
-
---
-
-### Phase 3: User Story 1 - MVP (12/12 tasks - 100%)
-
-**Web UI Enhancements** (`firmware/master/data/index.html`):
- ✅ Three-tab interface (Sensors, Differential, System)
- ✅ Real-time angle display (10Hz polling)
- ✅ Calibration buttons for each sensor
- ✅ Connection indicators with pulse animation
- ✅ Battery warnings (orange card when <20%)
- ✅ Toast notifications for success/failure
- ✅ Node selectors for differential measurement
- ✅ Color-coded results (green <0.5°, yellow <2.0°, red >2.0°)
- ✅ Responsive mobile design
-
---
-
-### Phase 4: User Story 2 - Differential Measurement (8/8 tasks - 100%)
-
-**Median Filtering Implementation** (`firmware/master/src/web_server.cpp/h`):
- ✅ `DifferentialHistory` data structure
-  - Circular buffer for last 10 readings per node pair
-  - Supports up to 36 unique node pairs
-  - Automatic memory management
-
- ✅ **Median Calculation Algorithm**
-  - Bubble sort for small arrays (10 elements)
-  - Handles even/odd sample counts
-  - Non-destructive (preserves original data)
-
- ✅ **Standard Deviation Calculation**
-  - Sample standard deviation (n-1 denominator)
-  - Measures measurement stability
-  - Color-coded in UI (green <0.1°, yellow <0.3°, red >=0.3°)
-
- ✅ **Enhanced API Response**
-  - `median_diff`: Median of last 10 pitch readings
-  - `median_pitch`: Median pitch differential
-  - `median_roll`: Median roll differential
-  - `std_dev`: Standard deviation of pitch readings
-  - `std_dev_pitch`: Pitch standard deviation
-  - `std_dev_roll`: Roll standard deviation
-  - `readings_count`: Number of samples in buffer (0-10)
-
-**Web UI Enhancements**:
- ✅ Median value display (primary metric)
- ✅ Current reading display (real-time, unfiltered)
- ✅ Standard deviation indicator (measurement quality)
- ✅ Sample count display (buffer fill status)
- ✅ Color-coded stability feedback
-
-**Accuracy Achievement**:
- ✅ ±0.1° accuracy via median filtering (vs ±0.5° raw IMU)
- ✅ Real-time stability monitoring
- ✅ Configurable history depth (10 samples = 1 second at 10Hz)
-
---
-
-## 📊 Implementation Metrics
-
-### Code Statistics
-
-**Lines of Code**:
- Master firmware: ~1,500 lines
- Slave firmware: ~600 lines
- Web UI: ~400 lines
- **Total**: ~2,500 lines
-
-**Files Created**: 25+
- Firmware: 12 files
- Hardware: 3 files
- Documentation: 10+ files
-
-### Test Coverage
-
- ❌ **Unit Tests**: Not yet implemented (planned for Phase 7)
- ❌ **Integration Tests**: Pending hardware validation
- ✅ **API Contract**: Fully documented in contracts/
-
---
-
-## 🔧 What Works Now
-
-### Firmware Features
-
-1. **Master Node**:
-   - WiFi Access Point active
-   - REST API responding to HTTP requests
-   - ESP-NOW receiver listening for Slaves
-   - IMU reading pitch/roll angles
-   - Calibration stored to NVS
-   - Battery monitoring active
-
-2. **Slave Node**:
-   - ESP-NOW transmitter sending data
-   - IMU sampling at 100Hz
-   - Battery percentage calculated
-   - Low battery warnings
-   - Connection status LED
-
-3. **Web Interface**:
-   - Real-time angle display
-   - System status dashboard
-   - Connection indicators
-   - API endpoint links
-
-### Testing Status
-
-**Compilation**: ✅ Both Master and Slave compile successfully
-**Runtime**: ⏳ Awaiting hardware testing
-**API**: ✅ Endpoints respond with proper JSON
-
---
-
-## 🚧 What's Next (Phase 5: User Story 3)
-
-### Immediate Tasks (8 remaining)
-
-1. **Multi-Node Support** (T041-T043):
-   - Support 4-6 simultaneous sensor nodes
-   - Implement scrollable node list in UI
-   - Add node discovery status indicators
-
-2. **Enhanced Node Management** (T044-T046):
-   - Node labeling/naming functionality
-   - Connection quality indicators
-   - Battery status for all nodes
-
-3. **System Scalability** (T047-T048):
-   - Optimize web UI for multiple nodes
-   - Test with 6 physical nodes
-   - Performance validation
-
-### Hardware Validation
-
-**Required Equipment**:
- 2× ESP32-C3 DevKits
- 2× MPU6050 IMU modules
- 2× LiPo batteries (250-400mAh)
- USB-C cables
- Breadboard + jumper wires
-
-**Test Procedure**:
-1. Flash Master firmware
-2. Note Master MAC address from serial output
-3. Update Slave config.h with Master MAC
-4. Flash Slave firmware
-5. Power on both nodes
-6. Connect smartphone to "SkyLogic-AeroAlign" WiFi
-7. Open http://192.168.4.1
-8. Verify real-time angle updates
-
---
-
-## 💡 Key Achievements
-
-### Technical Excellence
-
-1. **Auto-Discovery**: Slaves automatically register with Master (no manual pairing)
-2. **Low Latency**: <20ms ESP-NOW transmission + 100ms web UI refresh = <120ms total
-3. **Robust Protocol**: Checksum validation prevents corrupted data
-4. **Persistent Calibration**: NVS storage survives power cycles
-5. **Multi-Node Ready**: Architecture supports 8 sensors (Phase 8)
-
-### Constitution Compliance
-
-✅ **Cost-Efficiency**: $72 for 2-sensor system (vs. $600 competitors)
-✅ **3D Printing**: All parts <200mm³, <30% support
-✅ **Lightweight**: Target 23g per node (vs. 25g spec)
-✅ **Plug-and-Play**: 3-step setup (power, WiFi, browser)
-
---
-
-## 🐛 Known Issues
-
-1. **Master MAC Hardcoding**: Slave requires manual MAC entry in config.h
-   - **Impact**: Medium (one-time setup)
-   - **Workaround**: Serial monitor shows Master MAC
-   - **Fix**: Phase 8 auto-discovery feature
-
-2. **Web UI Placeholder**: Basic HTML/JS (not full React)
-   - **Impact**: Low (functional but not polished)
-   - **Status**: Phase 3 will add React components
-
-3. **No Physical Testing**: Firmware untested on hardware
-   - **Impact**: High (may have runtime bugs)
-   - **Status**: Awaiting hardware delivery
-
-4. **Missing STL Files**: 3D models documented but not created
-   - **Impact**: Medium (blocks physical assembly)
-   - **Status**: Requires FreeCAD design (Phase 7)
-
---
-
-## 📈 Timeline Estimate
-
-**Completed** (Phases 1-4): ~14 hours
- Phase 1-2 (Setup + Foundation): ~8 hours
- Phase 3 (MVP): ~3 hours
- Phase 4 (Differential): ~3 hours
-
-**Remaining**:
- Phase 5-6 (US3-US4): 6-8 hours
- Phase 7 (Polish): 6-8 hours
- Phase 8 (Multi-Sensor): 10-12 hours
-
-**Total Project**: ~40-50 hours for full feature set
-
---
-
-## 🎯 Next Session Goals
-
-1. **Hardware testing** with 2 physical nodes (validate Phase 3-4 implementation)
-2. **Phase 5**: Multi-node support (4-6 sensors)
-   - Implement scrollable node list in web UI
-   - Add node labeling functionality
-   - Test with multiple Slave nodes
-3. **Phase 6**: Throw gauge mode (control surface deflection)
-4. **3D Printing**: Generate STL files for sensor housing
-5. **Documentation**: Assembly guides and troubleshooting
-
---
-
-**Status**: MVP + Differential Measurement complete! Ready for multi-node expansion. 🚀
+Implement the actual CoG node firmware next, because the protocol, Master-side data path and baseline documentation are now in place.