Quality of life tweaks: Enhance motor temp handling in ESC, chill range

inc/sp140/altimeter.h

@@ -10,8 +10,8 @@
 #define VARIO_BUFFER_SIZE 25  // Number of samples to average for vertical speed
 #define MAX_VERTICAL_SPEED 250.0f  // Maximum vertical speed to display (m/s)
 
-// Set up the barometer
-bool setupAltimeter(bool alt_wire = false);
+// Set up the barometer
+bool setupAltimeter();
 
 // Get the altitude (in meters)
 float getAltitude(const STR_DEVICE_DATA_140_V1& deviceData);

inc/sp140/esc.h

@@ -2,21 +2,26 @@
 #define INC_SP140_ESC_H_
 
 #include <Arduino.h>
+
+// Motor temp validity range (disconnected/invalid readings are represented as NaN)
+constexpr float MOTOR_TEMP_VALID_MIN_C = -20.0f;
+constexpr float MOTOR_TEMP_VALID_MAX_C = 140.0f;
+
+inline bool isMotorTempValidC(float tempC) {
+  return tempC > MOTOR_TEMP_VALID_MIN_C && tempC <= MOTOR_TEMP_VALID_MAX_C;
+}
 #include "sp140/structs.h"
 #include "../../inc/sp140/esp32s3-config.h"
 #include <SineEsc.h>
 #include <CanardAdapter.h>
 
-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);
-
 // ESC Error Decoding Functions
-String decodeRunningError(uint16_t errorCode);
+String decodeRunningError(uint16_t errorCode);
 String decodeSelfCheckError(uint16_t errorCode);
 bool hasRunningError(uint16_t errorCode);
 bool hasSelfCheckError(uint16_t errorCode);

inc/sp140/simple_monitor.h

@@ -3,6 +3,7 @@
 
 #include <vector>
 #include <functional>
+#include <math.h>
 #include <Arduino.h>
 #include "sp140/structs.h"
 
@@ -148,6 +149,14 @@ struct SensorMonitor : public IMonitor {
 
   void check() override {
     float v = read();
+    if (isnan(v)) {
+      if (last != AlertLevel::OK) {
+        logger->log(id, AlertLevel::OK, v);
+        last = AlertLevel::OK;
+      }
+      return;
+    }
+
     AlertLevel now = AlertLevel::OK;
 
     if      (v <= thr.critLow)  now = AlertLevel::CRIT_LOW;
@@ -182,6 +191,14 @@ struct HysteresisSensorMonitor : public SensorMonitor {
 
   void check() override {
     float v = read();
+    if (isnan(v)) {
+      if (last != AlertLevel::OK) {
+        logger->log(id, AlertLevel::OK, v);
+        last = AlertLevel::OK;
+      }
+      return;
+    }
+
     AlertLevel now = last;  // Start with current state
 
     // Hysteresis logic to prevent bouncing

inc/sp140/structs.h

@@ -147,7 +147,7 @@ typedef struct {
   float mos_temp;               // MOSFET temperature (°C)
   float cap_temp;               // Capacitor temperature (°C)
   float mcu_temp;               // MCU temperature (°C)
-  float motor_temp;             // Motor temperature (°C)
+  float motor_temp;             // Motor temperature (°C), NaN if sensor invalid/disconnected
   int32_t eRPM;                 // Electrical RPM
   uint16_t inPWM;               // Input PWM value
   uint16_t running_error;       // Runtime error bitmask

inc/sp140/throttle.h

@@ -44,9 +44,22 @@ uint16_t readThrottleRaw();
 /** Get the most recently sampled raw throttle value (0..4095). */
 uint16_t getLastThrottleRaw();
 
-/** Convert raw pot reading (0..4095) to PWM microseconds. */
+/** Convert raw pot reading (0..4095) to PWM microseconds (full range). */
 int potRawToPwm(uint16_t raw);
 
+/**
+ * Convert raw pot reading (0..4095) to PWM microseconds using the
+ * mode-specific maximum.  In chill mode the full physical range maps to
+ * ESC_MIN_PWM..CHILL_MODE_MAX_PWM; in sport mode it maps to the full
+ * ESC_MIN_PWM..ESC_MAX_PWM range.  This gives chill mode full granular
+ * control over its limited output range instead of a hard clamp.
+ *
+ * @param raw              Raw ADC value (0..4095)
+ * @param performance_mode 0 = CHILL, 1 = SPORT
+ * @return PWM microseconds in the mode's range
+ */
+int potRawToModePwm(uint16_t raw, uint8_t performance_mode);
+
 /**
  * Apply mode-based ramp (us/tick) and clamp to the mode's max PWM.
  * Updates `prevPwm` with the final value.
@@ -86,10 +99,13 @@ bool throttleEngaged();
 /**
  * Read throttle input and return smoothed PWM value.
  * This is the core throttle processing pipeline without any state logic.
+ * Uses mode-aware mapping so the full physical range covers the mode's
+ * PWM output range.
  *
+ * @param performance_mode 0 = CHILL, 1 = SPORT
  * @return Smoothed PWM value from throttle input
  */
-int getSmoothedThrottlePwm();
+int getSmoothedThrottlePwm(uint8_t performance_mode);
 
 /**
  * Reset throttle state for clean startup/disarm.
@@ -107,8 +123,8 @@ void handleThrottle();
 
 /**
  * Calculate the cruise control PWM value from a raw pot reading.
- * Uses the same mapping as normal throttle (full range then clamp to mode max).
- * Also applies the absolute cruise max cap.
+ * Uses the same mode-aware mapping as normal throttle, then applies
+ * the absolute cruise max cap.
  *
  * @param potVal           Raw potentiometer value (0..4095)
  * @param performance_mode 0 = CHILL, 1 = SPORT

inc/sp140/utilities.h

@@ -1,15 +1,10 @@
-#ifndef INC_SP140_UTILITIES_H_
-#define INC_SP140_UTILITIES_H_
-
-#include <Arduino.h>
-
-double mapd(double x, double in_min, double in_max, double out_min, double out_max);
-
-// Function for digital time display - adds leading zeros
-String convertToDigits(byte digits);
-
-// Function to get unique chip ID
-String chipId();
+#ifndef INC_SP140_UTILITIES_H_
+#define INC_SP140_UTILITIES_H_
+
+#include <Arduino.h>
+
+// Function to get unique chip ID
+String chipId();
 
 // Definitions for main rainbow colors in WRGB format for NeoPixel.
 // The 32-bit color value is WRGB. W (White) is ignored for RGB pixels.

inc/sp140/vibration_pwm.h

@@ -74,35 +74,4 @@ void pulseVibration(uint16_t duration_ms, uint8_t intensity);
  */
 void stopVibration();
 
-/**
- * @brief Initializes the critical alert service.
- *
- * This function sets up the necessary resources for handling synchronized critical alerts.
- * It should be called once during system initialization.
- */
-void initCriticalAlertService();
-
-/**
- * @brief Starts the critical alert notifications.
- *
- * Activates the synchronized vibration and border flashing. If alerts are
- * already running, this function has no effect.
- */
-void startCriticalAlerts();
-
-/**
- * @brief Stops the critical alert notifications.
- *
- * Deactivates the vibration and border flashing. If alerts are not currently
- * running, this function has no effect.
- */
-void stopCriticalAlerts();
-
-/**
- * @brief Checks if the critical alert system is currently active.
- *
- * @return true if critical alerts are active, false otherwise.
- */
-bool isCriticalAlertActive();
-
 #endif  // INC_SP140_VIBRATION_PWM_H_

src/sp140/alert_display.cpp

@@ -43,9 +43,6 @@ void initAlertDisplay() {
     return;
   }
 
-  // Init the new alert service
-  initCriticalAlertService();
-
   // Create aggregation task (low priority)
   xTaskCreate(alertAggregationTask, "AlertAgg", 4096, NULL, 1, &alertAggregationTaskHandle);
   USBSerial.println("[AlertDisplay] Init complete");

src/sp140/altimeter.cpp

@@ -75,13 +75,11 @@ float getBaroPressure() {
   return __FLT_MIN__;  // Return a very small number if BMP is not present
 }
 
-// Start the bmp3XX sensor
-bool setupAltimeter(bool altWire) {
-  TwoWire* wire = &Wire;
-
-  // pull down pin 40 to high to set the address
-  pinMode(40, OUTPUT);
-  digitalWrite(40, HIGH);
+// Start the bmp3XX sensor
+bool setupAltimeter() {
+  // pull down pin 40 to high to set the address
+  pinMode(40, OUTPUT);
+  digitalWrite(40, HIGH);
   if (!bmp.begin_I2C(BMP3XX_DEFAULT_ADDRESS, &Wire)) return false;
 
   bmp.setOutputDataRate(BMP3_ODR_25_HZ);

src/sp140/ble/esc_service.cpp

@@ -92,6 +92,7 @@ void updateESCPackedTelemetry(const STR_ESC_TELEMETRY_140& telemetry) {
   packet.mos_temp = telemetry.mos_temp;
   packet.cap_temp = telemetry.cap_temp;
   packet.mcu_temp = telemetry.mcu_temp;
+  // motor_temp is NaN when sensor is disconnected/invalid.
   packet.motor_temp = telemetry.motor_temp;
   packet.eRPM = static_cast<int32_t>(telemetry.eRPM);
   packet.inPWM = static_cast<uint16_t>(telemetry.inPWM);
@@ -118,6 +119,7 @@ void updateESCTelemetryBLE(const STR_ESC_TELEMETRY_140& telemetry) {
   float voltage = telemetry.volts;
   float current = telemetry.amps;
   int32_t rpm = static_cast<int32_t>(telemetry.eRPM);
+  // motor_temp is NaN when sensor is disconnected/invalid.
   EscTempsPacket temps = {
     telemetry.mos_temp,
     telemetry.cap_temp,

src/sp140/esc.cpp

@@ -94,23 +94,25 @@ 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.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) {
+      if (isMotorTempValidC(rawMotorTemp)) {
         escTelemetryData.motor_temp = rawMotorTemp;
+      } else {
+        // Store invalid motor temp as NaN. Downstream consumers can skip on isnan().
+        escTelemetryData.motor_temp = NAN;
       }
-      // 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;
-
-      // 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
 
@@ -299,19 +301,10 @@ double mapDouble(double x, double in_min, double in_max, double out_min, double
   return (x - in_min) * (out_max - out_min) / (in_max - in_min) + out_min;
 }
 
-/**
- * Get the highest temperature reading from all ESC sensors
- * @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));
-}
-
 /**
  * Decode running error bitmask into human-readable string
- * @param errorCode 16-bit running error code from ESC
- * @return String containing decoded error messages
+ * @param errorCode 16-bit running error code from ESC
+ * @return String containing decoded error messages
  */
 String decodeRunningError(uint16_t errorCode) {
   if (errorCode == 0) {

src/sp140/esc_monitors.cpp

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

src/sp140/lvgl/lvgl_updates.cpp

@@ -4,6 +4,7 @@
 #include "../../../inc/sp140/globals.h"
 #include "../../../inc/sp140/vibration_pwm.h"
 #include "../../../inc/sp140/shared-config.h"
+#include <math.h>
 
 // Flash timer globals - definitions
 lv_timer_t* cruise_flash_timer = NULL;
@@ -704,9 +705,8 @@ void updateLvglMainScreen(
     lv_obj_remove_style(motor_temp_bg, &style_warning, 0);
     lv_obj_remove_style(motor_temp_bg, &style_critical, 0);
 
-    // 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) {
+    // Show motor temp only for a valid numeric reading while ESC is connected.
+    if (escTelemetry.escState == TelemetryState::CONNECTED && !isnan(motorTemp)) {
       lv_label_set_text_fmt(motor_temp_label, "%d", static_cast<int>(motorTemp));
 
       if (motorTemp >= motorTempThresholds.critHigh) {

src/sp140/sp140.ino

@@ -799,7 +799,7 @@ void setup140() {
   const int SDA_PIN = 44;
   const int SCL_PIN = 41;
   Wire.setPins(SDA_PIN, SCL_PIN);
-  if (!setupAltimeter(board_config.alt_wire)) {
+  if (!setupAltimeter()) {
     USBSerial.println("Error initializing BMP3xx barometer");
   }
   if (ENABLE_VIBE) {
@@ -1102,7 +1102,7 @@ void handleThrottle() {
       break;
 
     case ARMED:
-      int smoothedPwm = getSmoothedThrottlePwm();
+      int smoothedPwm = getSmoothedThrottlePwm(deviceData.performance_mode);
       finalPwm = applyModeRampClamp(smoothedPwm, prevPwm, deviceData.performance_mode);
       break;
   }
@@ -1178,7 +1178,7 @@ void afterCruiseEnd() {
   // Instead of clearing the buffer which causes throttle to drop to 0,
   // pre-populate it with the current throttle position to ensure smooth transition
   int currentPotVal = readThrottleRaw();
-  int currentPwmVal = potRawToPwm(currentPotVal);
+  int currentPwmVal = potRawToModePwm(currentPotVal, deviceData.performance_mode);
 
   // Pre-fill the buffer with current pot value for smooth transition
   throttleFilterReset(currentPwmVal);