Skip to content

prototype-checklist.md

Latest commit

 

History

History
60 lines (49 loc) · 3.23 KB

prototype-checklist.md

File metadata and controls

60 lines (49 loc) · 3.23 KB
Raw

Testable Prototype Checklist

This checklist separates the validated control proof of concept from the work still required for a repeatable, mechanically integrated prototype.

Validated

  • AS5048A SPI position sensing on both MKS ESP32 FOC Mega boards
  • stored FOC calibration for both GM3506 motors (11 pole pairs)
  • bidirectional ESP-NOW haptic coupling and automatic peer synchronization
  • autonomous startup without a USB host
  • phase-current measurement with profile-specific foldback up to a 0.70 A hard ceiling in the supervised handoff profile
  • speed and position foldback without latched motion-error stops
  • synchronized gentle, normal, and strong software profiles
  • safe power-stage shutdown and recovery after a radio timeout
  • startup VIN measurement on GPIO13
  • packet protocol versioning with incompatible-peer rejection
  • bidirectional one-node reset, link-timeout shutdown, and automatic recovery
  • protocol-7 supervised handoff mode with fixed profile, 5-second startup, 10-minute session limit, locked tuning commands, and latched runtime link faults
  • versioned build instructions and a staged reproduction procedure

P0 - Before Unattended or Extended Testing

  • rework the swapped onboard RGB VDD/DI nets or add an external status LED
  • calibrate VIN against a multimeter at full, nominal, and low 3S battery voltage
  • use a protected 3S pack or BMS with cell-level undervoltage protection
  • add an accessible hardware power switch or emergency stop and an appropriate fuse
  • add mechanical travel limits and prevent fingers, cables, and linkages entering pinch points
  • perform a stationary 10-15 minute thermal test while logging motor and driver temperature
  • verify current readings against an external meter under representative load

P1 - Before Repeatable User Tests

  • provide continuous battery monitoring using an ADC1 pin or an external ADC/fuel gauge
  • add motor and power-stage temperature sensing with torque derating
  • test startup with one node missing, delayed, or powered from a different battery
  • test ESP-NOW dropout, range, interference, and automatic recovery
  • add a physical selector and external status indication for the validated software profiles
  • store and validate calibration version data
  • run repeated power-cycle, stall, rapid-motion, and one-sided-load tests
  • document the mechanical zero pose, allowed range, payload, and maximum user force
  • define multi-turn behavior: travel limit, accumulated spring energy, and thermal derating

P2 - Prototype Packaging

  • strain relief and keyed connectors for motor, encoder, battery, and programming cables
  • guarded electronics and battery enclosure with ventilation
  • accessible charge connector and battery state indication when motors are off
  • mechanical assembly drawings, dimensions, fasteners, and acceptance tolerances

Battery Measurement Limitation

The Mega board's VIN divider is connected to GPIO13, an ESP32 ADC2 channel. ADC2 is shared with Wi-Fi, so the current firmware measures battery voltage only before ESP-NOW starts. The serially reported percentage is therefore a startup estimate, not a live fuel gauge. A protected pack remains mandatory; continuous software cutoff requires moving the divider to ADC1 or adding an external voltage monitor.