initial commit
This commit is contained in:
huangweifeng
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/**
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* @file safe_controller.hpp
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* @brief safe controller to make robot safe
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* @author DeepRobotics
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* @version 1.0
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* @date 2025-11-07
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*
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* @copyright Copyright (c) 2025 DeepRobotics
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*
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*/
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/**
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* 一、关节端
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* 1.关节数据异常（nan值）
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* 2.关节数据不更新
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* 3.关节温度过温
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* 4.驱动器报错
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* 二、imu
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* 1.imu数据异常
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* 2.imu数据不更新
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* 三、电池
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* 1.电池电量过低
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* 2.电池数据不上报？
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* 3.电池温度？
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* 四、手柄
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* 1.手柄断连
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*
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*/
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#pragma once
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#include "robot_interface.h"
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#include "user_command_interface.h"
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union RobotErrorState {
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struct {
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uint32_t imu_num_error: 1;
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uint32_t imu_update_overtime: 1;
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uint32_t command_heartbeat_overtime: 1;
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uint32_t driver_error: 1;
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uint32_t motor_heat_warn: 1;
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uint32_t joint_num_error: 1;
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uint32_t joint_update_error: 1;
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uint32_t battery_low_warn: 1;
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uint32_t battery_heat_warn: 1;
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uint32_t cpu_heat_warn: 1;
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uint32_t cpu_freq_warn: 1;
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uint32_t reserved: 21;
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};
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uint32_t error_code;
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};
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class SafeController {
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private:
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RobotType robot_type_;
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std::shared_ptr<interface::RobotInterface> ri_ptr_;
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std::shared_ptr<interface::UserCommandInterface> uc_ptr_;
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std::thread judge_thread_;
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int run_cnt_ = 0;
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double last_imu_ts_, imu_check_time_;
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bool imu_check_flag_ = true;
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double ri_check_time_, last_ri_ts_;
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VecXf last_joint_pos_, last_joint_vel_, last_joint_tau_;
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std::vector<int> joint_data_same_cnt_;
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bool joint_check_flag_ = true;
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float max_temp_;
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int max_temp_idx_;
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double last_cmd_ts_, cmd_check_time_;
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bool cmd_check_flag_ = true;
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types::UserCommand *usr_cmd_;
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bool start_thread_flag_ = false;
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double driver_error_ts_;
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double joint_data_error_ts_;
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double current_time_;
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RobotErrorState robot_error_state_;
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uint32_t last_error_code_;
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std::map<uint8_t, uint16_t> error_driver_map_;
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uint32_t joint_update_state_;
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bool IsImuDataNormal() {
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double current_imu_ts_ = ri_ptr_->GetImuTimestamp();
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Vec3f rpy = ri_ptr_->GetImuRpy();
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Vec3f acc = ri_ptr_->GetImuAcc();
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Vec3f omg = ri_ptr_->GetImuOmega();
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if (imu_check_flag_) {
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last_imu_ts_ = current_imu_ts_;
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imu_check_time_ = current_time_;
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imu_check_flag_ = false;
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}
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bool res = true;
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robot_error_state_.imu_update_overtime = 0;
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if (current_imu_ts_ != last_imu_ts_) {
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last_imu_ts_ = current_imu_ts_;
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imu_check_time_ = current_time_;
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}
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if (current_time_ - imu_check_time_ == 0.2) {
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std::cout << "========== imu lag warning ========>> "
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<< current_time_ - imu_check_time_ << std::endl;
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}
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for (int i = 0; i < 3; ++i) {
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if (std::isnan(rpy(i)) || std::isnan(acc(i)) || std::isnan(omg(i))) {
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res = false;
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robot_error_state_.imu_num_error = 1;
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}
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}
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return res;
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}
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bool IsJointDataNormal() {
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double ri_ts_ = ri_ptr_->GetInterfaceTimeStamp();
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VecXf joint_pos = ri_ptr_->GetJointPosition();
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VecXf joint_vel = ri_ptr_->GetJointVelocity();
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VecXf joint_tau = ri_ptr_->GetJointTorque();
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std::vector<uint16_t> joint_id = ri_ptr_->GetJointDataID();
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if (joint_check_flag_) {
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joint_check_flag_ = false;
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last_ri_ts_ = ri_ts_;
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last_joint_pos_ = joint_pos;
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last_joint_vel_ = joint_vel;
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last_joint_tau_ = joint_tau;
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}
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bool res = true;
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robot_error_state_.joint_update_error = 0;
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static bool first_flag = false;
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if (last_ri_ts_ != ri_ts_) {
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last_ri_ts_ = ri_ts_;
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ri_check_time_ = current_time_;
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first_flag = true;
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}
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robot_error_state_.joint_num_error = 0;
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joint_update_state_ = 0;
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for (int i = 0; i < joint_pos.size(); ++i) {
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if (std::isnan(joint_pos(i)) || std::isnan(joint_vel(i)) || std::isnan(joint_tau(i))) {
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robot_error_state_.joint_num_error = 1;
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res = false;
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}
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if (joint_pos(i) == last_joint_pos_(i)
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&& joint_vel(i) == last_joint_vel_(i)
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&& joint_tau(i) == last_joint_tau_(i)) {
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joint_data_same_cnt_[i]++;
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} else {
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joint_data_same_cnt_[i] = 0;
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}
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// if (joint_data_same_cnt_[i] > 200) {
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// robot_error_state_.joint_num_error = 1;
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// joint_update_state_ |= (1 << i);
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// res = false;
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// }
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}
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last_joint_pos_ = joint_pos;
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last_joint_vel_ = joint_vel;
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last_joint_tau_ = joint_tau;
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if (run_cnt_ % 5000 == 0) {
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std::cout << "joint_pos: " << joint_pos.transpose() << std::endl;
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std::cout << "joint_vel: " << joint_vel.transpose() << std::endl;
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}
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return res;
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}
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bool IsDriverStatusNormal() {
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std::vector<uint16_t> status_word = ri_ptr_->GetDriverStatusWord();
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bool res = true;
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robot_error_state_.driver_error = 0;
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for (int i = 0; i < status_word.size(); ++i) {
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if (status_word[i] != 1) {
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error_driver_map_[uint8_t(i)] = status_word[i];
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robot_error_state_.driver_error = 1;
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res = false;
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}
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}
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if (robot_error_state_.driver_error == 0) {
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error_driver_map_.clear();
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}
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return res;
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}
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bool IsMotorTempertureNormal() {
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VecXf m_t = ri_ptr_->GetMotorTemperture();
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VecXf::Index max_idx, min_idx;
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float max_temp = m_t.maxCoeff(&max_idx);
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float min_temp = m_t.minCoeff(&min_idx);
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max_temp_ = max_temp;
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max_temp_idx_ = max_idx;
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if (run_cnt_ % 5000 == 0) {
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std::cout << "Motor Temperture: " << m_t.transpose() << std::endl;
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std::cout << "Max&Min: " << max_idx << " : " << max_temp << " | " << min_idx << " : " << min_temp
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<< std::endl;
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}
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if (max_temp > 100) {
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robot_error_state_.motor_heat_warn = 1;
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return false;
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} else {
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robot_error_state_.motor_heat_warn = 0;
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}
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return true;
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}
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bool IsBatteryNormal() {
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std::vector<uint16_t> battery_data = ri_ptr_->GetBatteryData();
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if (battery_data[0] < 10) {
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robot_error_state_.battery_low_warn = 1;
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return false;
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} else {
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robot_error_state_.battery_low_warn = 0;
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}
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return true;
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}
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bool IsUserCommandNormal() {
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double cmd_ts_ = uc_ptr_->GetUserCommand()->time_stamp;
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if (cmd_check_flag_) {
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cmd_check_flag_ = false;
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last_cmd_ts_ = cmd_ts_;
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cmd_check_time_ = current_time_;
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}
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robot_error_state_.command_heartbeat_overtime = 0;
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if (last_cmd_ts_ != cmd_ts_) {
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last_cmd_ts_ = cmd_ts_;
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cmd_check_time_ = current_time_;
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}
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if (current_time_ - cmd_check_time_ > 1000.0) {
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robot_error_state_.command_heartbeat_overtime = 1;
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return false;
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}
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return true;
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}
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void PrintRobotErrorState() {
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std::cout << "Error occurred!" << std::endl;
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if (robot_error_state_.imu_num_error) {
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std::cout << "IMU number error: invalid IMU data count | "
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<< ri_ptr_->GetImuRpy().transpose() << " | "
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<< ri_ptr_->GetImuAcc().transpose() << " | "
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<< ri_ptr_->GetImuOmega().transpose() << std::endl;
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}
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if (robot_error_state_.imu_update_overtime) {
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std::cout << "IMU update overtime: no IMU data received since timestamp " << last_imu_ts_ << std::endl;
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}
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if (robot_error_state_.command_heartbeat_overtime) {
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std::cout << "Heartbeat overtime: lost communication with controller (no heartbeat signal received)" << std::endl;
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}
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if (robot_error_state_.driver_error) {
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std::cout << "Driver error: motor driver reported fault(s):" << std::endl;
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for (const auto &pair : error_driver_map_) {
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std::cout << " Driver " << int(pair.first) << ": error code 0x" << std::hex << std::uppercase << int(pair.second) << std::dec << std::endl;
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}
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}
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if (robot_error_state_.motor_heat_warn) {
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std::cout << "Motor overheat warning: motor " << max_temp_idx_ << " reached " << max_temp_ << "°C" << std::endl;
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}
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if (robot_error_state_.joint_num_error) {
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std::cout << "Joint number error: mismatched joint count | pos: "
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<< ri_ptr_->GetJointPosition().transpose() << " | vel: "
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<< ri_ptr_->GetJointVelocity().transpose() << " | tau: "
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<< ri_ptr_->GetJointTorque().transpose() << std::endl;
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}
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if (robot_error_state_.joint_update_error) {
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std::cout << "Joint update error: no joint data update (current_time 0x" << std::hex << current_time_
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<< " vs last_check 0x" << ri_check_time_ << ")" << std::dec << std::endl;
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}
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if (robot_error_state_.battery_low_warn) {
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std::cout << "Battery low warning: battery voltage/level critically low" << std::endl;
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}
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if (robot_error_state_.battery_heat_warn) {
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std::cout << "Battery overheat warning: battery temperature too high" << std::endl;
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}
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if (robot_error_state_.cpu_heat_warn) {
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std::cout << "CPU overheat warning: CPU temperature exceeds safe limit" << std::endl;
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}
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if (robot_error_state_.cpu_freq_warn) {
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std::cout << "CPU frequency warning: CPU throttling due to thermal or power limits" << std::endl;
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}
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}
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public:
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SafeController(RobotType robot_type, const std::string &path) : robot_type_(robot_type) {
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robot_error_state_.error_code = 0;
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last_error_code_ = 0;
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error_driver_map_.clear();
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}
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~SafeController() {
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}
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void SetRobotDataSource(std::shared_ptr<interface::RobotInterface> ri) {
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ri_ptr_ = ri;
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joint_data_same_cnt_.resize(ri_ptr_->dof_num_, 0);
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}
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void SetUserCommandDataSource(std::shared_ptr<interface::UserCommandInterface> uc) {
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uc_ptr_ = uc;
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usr_cmd_ = uc_ptr_->GetUserCommand();
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}
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void Start() {
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start_thread_flag_ = true;
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judge_thread_ = std::thread(std::bind(&SafeController::Run, this));
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}
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void Run() {
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int tfd; //定时器描述符
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int efd; //epoll描述符
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int fds;
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uint64_t value;
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struct epoll_event ev, *evptr;
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struct itimerspec time_intv; //用来存储时间
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tfd = timerfd_create(CLOCK_MONOTONIC, 0); //创建定时器
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if (tfd == -1) return;
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time_intv.it_value.tv_sec = 1.;
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time_intv.it_value.tv_nsec = 1000 * 1000;
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time_intv.it_interval.tv_sec = 0;
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time_intv.it_interval.tv_nsec = time_intv.it_value.tv_nsec;
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timerfd_settime(tfd, 0, &time_intv, NULL); //启动定时器
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efd = epoll_create1(0); //创建epoll实例
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if (efd == -1) close(tfd);
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evptr = (struct epoll_event *) calloc(1, sizeof(struct epoll_event));
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if (evptr == NULL) {
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close(tfd);
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close(efd);
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}
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ev.data.fd = tfd;
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ev.events = EPOLLIN; //监听定时器读事件，当定时器超时时，定时器描述符可读。
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epoll_ctl(efd, EPOLL_CTL_ADD, tfd, &ev); //添加到epoll监听队列中
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while (start_thread_flag_) {
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fds = epoll_wait(efd, evptr, 1, -1); //阻塞监听，直到有事件发生
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if (evptr[0].events & EPOLLIN) {
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int ret = read(evptr->data.fd, &value, sizeof(uint64_t));
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if (ret == -1) {
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continue;
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} else {
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}
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}
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run_cnt_++;
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current_time_ = GetTimestampMs() / 1000;
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if (!IsDriverStatusNormal()) {
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usr_cmd_->safe_control_mode = 2;
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driver_error_ts_ = current_time_;
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std::cout << "Driver status error!" << std::endl;
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}
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if (!IsJointDataNormal()) {
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usr_cmd_->safe_control_mode = 3;
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joint_data_error_ts_ = current_time_;
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std::cout << "Joint data error!" << std::endl;
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}
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if (run_cnt_ % 1000 == 0 && !IsMotorTempertureNormal()) {
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usr_cmd_->safe_control_mode = 2;
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std::cout << "Motor temperture error!" << std::endl;
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}
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if (!IsImuDataNormal()) {
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std::cout << "IMU error!" << std::endl;
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usr_cmd_->safe_control_mode = 2;
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}
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if (last_error_code_ != robot_error_state_.error_code) {
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if (robot_error_state_.error_code != 0) {
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std::cout << "========== error_code ========>> " <<
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std::hex << robot_error_state_.error_code << std::endl;
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PrintRobotErrorState();
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}
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last_error_code_ = robot_error_state_.error_code;
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}
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}
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}
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void Stop() {
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start_thread_flag_ = false;
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if (judge_thread_.joinable()) {
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judge_thread_.join();
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}
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}
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};
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