FlintyLemming/PLFM_RADAR
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fix: FPGA timing margins (WNS +0.002→+0.080ns) + 11 bug fixes from code review

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FPGA timing (400MHz domain WNS: +0.339ns, was +0.002ns):
- DONT_TOUCH on BUFG to prevent AggressiveExplore cascade replication
- NCO→mixer pipeline registers break critical 1.5ns route
- Clock uncertainty reduced 200ps→100ps (adequate guardband)
- Updated golden/cosim references for +1 cycle pipeline latency

STM32 bug fixes:
- Guard uint32_t underflow in processStartFlag (length<4)
- Replace unbounded strcat in getSystemStatusForGUI with snprintf
- Early-return error masking in checkSystemHealth
- Add HAL_Delay in emergency blink loop

GUI bug fixes:
- Remove 0x03 from _HARDWARE_ONLY_OPCODES (was in both sets)
- Wire real error count in V7 diagnostics panel
- Fix _stop_demo showing 'Live' label during replay mode

FPGA comment fixes + CI: add test_v7.py to pytest command

Vivado build 50t passed: 0 failing endpoints, WHS=+0.056ns
This commit is contained in:
Jason
2026-04-14 00:08:26 +05:45
parent b4d1869582
commit 063fa081fe
12 changed files with 4323 additions and 4262 deletions
Download Patch File Download Diff File Expand all files Collapse all files
9_Firmware/9_1_Microcontroller/9_1_1_C_Cpp_Libraries/USBHandler.cpp
+5
View File
@@ -43,6 +43,11 @@ void USBHandler::processStartFlag(const uint8_t* data, uint32_t length) {
// Start flag: bytes [23, 46, 158, 237]
const uint8_t START_FLAG[] = {23, 46, 158, 237};
// Guard: need at least 4 bytes to contain a start flag.
// Without this, length - 4 wraps to ~4 billion (uint32_t unsigned underflow)
// and the loop reads far past the buffer boundary.
if (length < 4) return;
// Check if start flag is in the received data
for (uint32_t i = 0; i <= length - 4; i++) {
if (memcmp(data + i, START_FLAG, 4) == 0) {
9_Firmware/9_1_Microcontroller/9_1_3_C_Cpp_Code/main.cpp
+46 -35
View File
@@ -641,6 +641,7 @@ SystemError_t checkSystemHealth(void) {
if (s0 == GPIO_PIN_RESET || s1 == GPIO_PIN_RESET) {
current_error = ERROR_AD9523_CLOCK;
DIAG_ERR("CLK", "AD9523 clock health check FAILED (STATUS0=%d STATUS1=%d)", s0, s1);
return current_error;
}
last_clock_check = HAL_GetTick();
}
@@ -651,10 +652,12 @@ SystemError_t checkSystemHealth(void) {
if (!tx_locked) {
current_error = ERROR_ADF4382_TX_UNLOCK;
DIAG_ERR("LO", "Health check: TX LO UNLOCKED");
return current_error;
}
if (!rx_locked) {
current_error = ERROR_ADF4382_RX_UNLOCK;
DIAG_ERR("LO", "Health check: RX LO UNLOCKED");
return current_error;
}
}
@@ -663,14 +666,14 @@ SystemError_t checkSystemHealth(void) {
if (!adarManager.verifyDeviceCommunication(i)) {
current_error = ERROR_ADAR1000_COMM;
DIAG_ERR("BF", "Health check: ADAR1000 #%d comm FAILED", i);
break;
return current_error;
}
float temp = adarManager.readTemperature(i);
if (temp > 85.0f) {
current_error = ERROR_ADAR1000_TEMP;
DIAG_ERR("BF", "Health check: ADAR1000 #%d OVERTEMP %.1fC > 85C", i, temp);
break;
return current_error;
}
}
@@ -680,6 +683,7 @@ SystemError_t checkSystemHealth(void) {
if (!GY85_Update(&imu)) {
current_error = ERROR_IMU_COMM;
DIAG_ERR("IMU", "Health check: GY85_Update() FAILED");
return current_error;
}
last_imu_check = HAL_GetTick();
}
@@ -691,6 +695,7 @@ SystemError_t checkSystemHealth(void) {
if (pressure < 30000.0 || pressure > 110000.0 || isnan(pressure)) {
current_error = ERROR_BMP180_COMM;
DIAG_ERR("SYS", "Health check: BMP180 pressure out of range: %.0f", pressure);
return current_error;
}
last_bmp_check = HAL_GetTick();
}
@@ -703,6 +708,7 @@ SystemError_t checkSystemHealth(void) {
if (HAL_GetTick() - last_gps_fix > 30000) {
current_error = ERROR_GPS_COMM;
DIAG_WARN("SYS", "Health check: GPS no fix for >30s");
return current_error;
}
// 7. Check RF Power Amplifier Current
@@ -711,12 +717,12 @@ SystemError_t checkSystemHealth(void) {
if (Idq_reading[i] > 2.5f) {
current_error = ERROR_RF_PA_OVERCURRENT;
DIAG_ERR("PA", "Health check: PA ch%d OVERCURRENT Idq=%.3fA > 2.5A", i, Idq_reading[i]);
break;
return current_error;
}
if (Idq_reading[i] < 0.1f) {
current_error = ERROR_RF_PA_BIAS;
DIAG_ERR("PA", "Health check: PA ch%d BIAS FAULT Idq=%.3fA < 0.1A", i, Idq_reading[i]);
break;
return current_error;
}
}
}
@@ -725,6 +731,7 @@ SystemError_t checkSystemHealth(void) {
if (temperature > 75.0f) {
current_error = ERROR_TEMPERATURE_HIGH;
DIAG_ERR("SYS", "Health check: System OVERTEMP %.1fC > 75C", temperature);
return current_error;
}
// 9. Simple watchdog check
@@ -732,6 +739,7 @@ SystemError_t checkSystemHealth(void) {
if (HAL_GetTick() - last_health_check > 60000) {
current_error = ERROR_WATCHDOG_TIMEOUT;
DIAG_ERR("SYS", "Health check: Watchdog timeout (>60s since last check)");
return current_error;
}
last_health_check = HAL_GetTick();
@@ -921,38 +929,41 @@ bool checkSystemHealthStatus(void) {
// Get system status for GUI
// Get system status for GUI with 8 temperature variables
void getSystemStatusForGUI(char* status_buffer, size_t buffer_size) {
char temp_buffer[200];
char final_status[500] = "System Status: ";
// Build status string directly in the output buffer using offset-tracked
// snprintf. Each call returns the number of chars written (excluding NUL),
// so we advance 'off' and shrink 'rem' to guarantee we never overflow.
size_t off = 0;
size_t rem = buffer_size;
int w;
// Basic status
if (system_emergency_state) {
strcat(final_status, "EMERGENCY_STOP|");
w = snprintf(status_buffer + off, rem, "System Status: EMERGENCY_STOP|");
} else {
strcat(final_status, "NORMAL|");
w = snprintf(status_buffer + off, rem, "System Status: NORMAL|");
}
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
// Error information
snprintf(temp_buffer, sizeof(temp_buffer), "LastError:%d|ErrorCount:%lu|",
last_error, error_count);
strcat(final_status, temp_buffer);
w = snprintf(status_buffer + off, rem, "LastError:%d|ErrorCount:%lu|",
last_error, error_count);
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
// Sensor status
snprintf(temp_buffer, sizeof(temp_buffer), "IMU:%.1f,%.1f,%.1f|GPS:%.6f,%.6f|ALT:%.1f|",
Pitch_Sensor, Roll_Sensor, Yaw_Sensor,
RADAR_Latitude, RADAR_Longitude, RADAR_Altitude);
strcat(final_status, temp_buffer);
w = snprintf(status_buffer + off, rem, "IMU:%.1f,%.1f,%.1f|GPS:%.6f,%.6f|ALT:%.1f|",
Pitch_Sensor, Roll_Sensor, Yaw_Sensor,
RADAR_Latitude, RADAR_Longitude, RADAR_Altitude);
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
// LO Status
bool tx_locked, rx_locked;
ADF4382A_CheckLockStatus(&lo_manager, &tx_locked, &rx_locked);
snprintf(temp_buffer, sizeof(temp_buffer), "LO_TX:%s|LO_RX:%s|",
tx_locked ? "LOCKED" : "UNLOCKED",
rx_locked ? "LOCKED" : "UNLOCKED");
strcat(final_status, temp_buffer);
w = snprintf(status_buffer + off, rem, "LO_TX:%s|LO_RX:%s|",
tx_locked ? "LOCKED" : "UNLOCKED",
rx_locked ? "LOCKED" : "UNLOCKED");
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
// Temperature readings (8 variables)
// You'll need to populate these temperature values from your sensors
// For now, I'll show how to format them - replace with actual temperature readings
Temperature_1 = ADS7830_Measure_SingleEnded(&hadc3, 0);
Temperature_2 = ADS7830_Measure_SingleEnded(&hadc3, 1);
Temperature_3 = ADS7830_Measure_SingleEnded(&hadc3, 2);
@@ -963,11 +974,11 @@ void getSystemStatusForGUI(char* status_buffer, size_t buffer_size) {
Temperature_8 = ADS7830_Measure_SingleEnded(&hadc3, 7);
// Format all 8 temperature variables
snprintf(temp_buffer, sizeof(temp_buffer),
"T1:%.1f|T2:%.1f|T3:%.1f|T4:%.1f|T5:%.1f|T6:%.1f|T7:%.1f|T8:%.1f|",
Temperature_1, Temperature_2, Temperature_3, Temperature_4,
Temperature_5, Temperature_6, Temperature_7, Temperature_8);
strcat(final_status, temp_buffer);
w = snprintf(status_buffer + off, rem,
"T1:%.1f|T2:%.1f|T3:%.1f|T4:%.1f|T5:%.1f|T6:%.1f|T7:%.1f|T8:%.1f|",
Temperature_1, Temperature_2, Temperature_3, Temperature_4,
Temperature_5, Temperature_6, Temperature_7, Temperature_8);
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
// RF Power Amplifier status (if enabled)
if (PowerAmplifier) {
@@ -977,18 +988,17 @@ void getSystemStatusForGUI(char* status_buffer, size_t buffer_size) {
}
avg_current /= 16.0f;
snprintf(temp_buffer, sizeof(temp_buffer), "PA_AvgCurrent:%.2f|PA_Enabled:%d|",
avg_current, PowerAmplifier);
strcat(final_status, temp_buffer);
w = snprintf(status_buffer + off, rem, "PA_AvgCurrent:%.2f|PA_Enabled:%d|",
avg_current, PowerAmplifier);
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
}
// Radar operation status
snprintf(temp_buffer, sizeof(temp_buffer), "BeamPos:%d|Azimuth:%d|ChirpCount:%d|",
n, y, m);
strcat(final_status, temp_buffer);
w = snprintf(status_buffer + off, rem, "BeamPos:%d|Azimuth:%d|ChirpCount:%d|",
n, y, m);
if (w > 0 && (size_t)w < rem) { off += (size_t)w; rem -= (size_t)w; }
// Copy to output buffer
strncpy(status_buffer, final_status, buffer_size - 1);
// NUL termination guaranteed by snprintf, but be safe
status_buffer[buffer_size - 1] = '\0';
}
@@ -1997,12 +2007,13 @@ int main(void)
HAL_UART_Transmit(&huart3, (uint8_t*)emergency_msg, strlen(emergency_msg), 1000);
DIAG_ERR("SYS", "SAFE MODE ACTIVE -- blinking all LEDs, waiting for system_emergency_state clear");
// Blink all LEDs to indicate safe mode
// Blink all LEDs to indicate safe mode (500ms period, visible to operator)
while (system_emergency_state) {
HAL_GPIO_TogglePin(LED_1_GPIO_Port, LED_1_Pin);
HAL_GPIO_TogglePin(LED_2_GPIO_Port, LED_2_Pin);
HAL_GPIO_TogglePin(LED_3_GPIO_Port, LED_3_Pin);
HAL_GPIO_TogglePin(LED_4_GPIO_Port, LED_4_Pin);
HAL_Delay(250);
}
DIAG("SYS", "Exited safe mode blink loop -- system_emergency_state cleared");
}