Drone fc

Drone

A learning project: build a quadcopter from scratch — own hardware, own firmware, no existing flight stack.

The drone is the artefact; understanding the whole stack end-to-end is the deliverable.

What we're building

• Platform: BBC micro:bit v2 (nRF52833) for Phases 1–3; custom nRF5340 PCBA for Phases 4–5.
• Language: Rust (no_std, embassy-nrf) on the firmware; Rust on the PC-side ground-station application too.
• IMU: ICM-42688-P on SPI (external; micro:bit's onboard sensor has no gyro).
• Airframe: quadcopter.
• Flight stack: rolling our own — no PX4 / ArduPilot.

See doc/00-vision.md for the full vision and the phased milestone plan.

Status

Phase 2 (advanced prototyping) in progress. The whole stack runs on hardware. The drone has made first free flights — brief untethered, self-levelling hops on its own battery under closed-loop control — with telemetry over a two-hop radio link and PID gains tuned live from the ground station and now persisted to flash (ADR 0025): tune, save, power-cycle, and the gains survive.

• Round trip, ~100 Hz, ~25–30 ms. The groundstation app sends four-axis pilot commands (sliders or a gamepad) over USB-CDC to a remote micro:bit, which relays to the drone over IEEE 802.15.4 (ADR 0014). Telemetry returns the same path as a high/low-rate split frame (ADR 0027), postcard + COBS framed, every buffer sized at compile time from the shared types.
• Firmware — an Embassy task graph. A supervisor failsafe (ADR 0017) is the sole publisher of motor commands: a five-state machine with a stick arm/disarm gesture, idle auto-disarm, and loss-of-link detection within ~100 ms.
• Sense → estimate → control. The ICM-42688-P IMU (ADR 0003) is read over SPI at 1 kHz; a complementary filter (ADR 0022) gives a roll/pitch estimate; a single-loop angle-mode PID (ADR 0024) mixes it and the pilot command into a four-motor demand. IMU zeroing is re-runnable from the ground station; every gain is a runtime message, saveable to flash.
• Actuation + ESC telemetry. DShot300 drives a 4-in-1 AM32 ESC (parts list); each ESC's KISS serial telemetry — RPM, pack voltage, temperature — is read back over an idle-framed UART and logged.
• Discipline. Frames, signs and command newtypes are fixed in ADR 0021; the pure logic (filter, controller, supervisor, wire types) is host-tested in firmware-drone-core.

The ground station plots and logs every signal live, times the round trip, pushes and saves PID gains, shows a live 3D view of the drone's attitude, and pairs with an offline analyze tool that turns a telemetry log into a legible flight report.

Recent tuning work — validating the integral term as a centre-of-mass trim corrector, balancing the airframe by the per-motor effort split, and re-zeroing out a one-directional drift — is consolidated into a new control-troubleshooting field guide (doc/06-control-troubleshooting.md).

Next (to finish Phase 2): rebuild on the lighter next-generation frame — the previous flight frame was retired in a lost-control crash — with the IMU mounted near the centre of mass (which should cut the estimator lag at its source) and a fresh, softer re-tune; plus a firmware power-limit mode and the netted test enclosure (doc/07-safety.md). In parallel, Phase 4 is well underway — the custom nRF5340 flight controller (drone_fc v2, ADR 0026, ADR 0028) is fully routed with turnkey PCBA fab exports out to PCBWay; the micro:bit stays the tuning platform meanwhile.

See doc/progress.md for the dated milestone history, doc/dev-environment.md for the toolchain, and doc/decisions/ for the full decision history.

Repository layout

• AGENTS.md — shared context file for AI coding assistants (Copilot, Claude, etc.). Read first.
• crates/ — Cargo workspace. firmware-drone-microbit (on-target binary), firmware-drone-shared (board-agnostic tasks/signals), firmware-drone-core (host-testable logic).
• doc/ — design notes, vision, architecture, hardware/software/control docs.
• doc/02-architecture.md — system architecture overview (two micro:bits, RF link, ground-station evolution).
• doc/decisions/ — Architecture Decision Records (ADRs).
• hardware/ — mechanical (Fusion 360) and electrical (KiCad).

Testing

Host-testable logic (wire types, the supervisor state machine, the ground-station helpers) is unit-tested and run with cargo-nextest:

cargo nextest run                                                 # workspace host crates
cargo nextest run --manifest-path crates/groundstation/Cargo.toml # the GUI crate

A tracked pre-push git hook runs the suite before every push, and GitHub Actions runs fmt + clippy + tests on every push and pull request (the badge above). On-target firmware is exercised on hardware, not in CI. See doc/ci-and-testing.md for the details and the one-time hook setup.

Decisions so far

• ADR 0001 — Real-hardware quadcopter, roll our own firmware, learning-first scope.
• ADR 0002 — BBC micro:bit v2 + Rust for Phases 1–3.
• ADR 0003 — External IMU: ICM-42688-P on SPI.
• ADR 0004 — Concurrency model: Embassy + channel-based actor pattern, no BSP.
• ADR 0005 — PC-side software in Rust; shared proto crate for the wire protocol.
• ADR 0006 — Mechanical CAD: Fusion 360; commit .f3d source + .stl mesh (STEP dropped, amended 2026-07-09).
• ADR 0007 — Testing and CI: unit-test everything possible, local-first feedback, core/task split, HIL deferred.
• ADR 0008 — Repository folder layout: crates/, doc/, hardware/{mechanical,electrical}/, all lowercase.
• ADR 0009 — Workspace bootstrap from day one; firmware-<role> naming; core/task split realised as sibling crates.
• ADR 0010 — Board Support Package layer: board module inside firmware-drone, Cargo-feature-selected, tasks take erased types.
• ADR 0011 — Task tracking: GitHub Issues as canonical backlog, Projects board as view, labels as taxonomy, batched filing.
• ADR 0012 — Lint and format policy: main stays rustfmt-clean and clippy-clean; suppressions require justification.
• ADR 0013 — Async inter-task communication: 2×2 rule over Channel / Watch / Signal / PubSubChannel.
• ADR 0014 — Radio link: IEEE 802.15.4 (raw PHY/MAC), channel 20.
• ADR 0015 — Host-testable no_std crates: cfg_attr(not(test), no_std), inline mod tests, cargo test honours default-members.
• ADR 0016 — Newtype per physical quantity for shared types: distinct newtypes per quantity, no shared PercentageValue base.
• ADR 0017 — Supervisor task as failsafe state machine: 4-state enum, tick-driven, pure logic in firmware-drone-core, supervisor is the sole publisher of motor commands.
• ADR 0018 — PC ground-station link: USB-CDC virtual COM port to nRF52833 UART, 115 200 8N1, postcard + COBS framing (Proposed; first cut shipped with plain ASCII).
• ADR 0019 — Airframe and propulsion class: 3" ducted cinewhoop, 4S LiPo, 1507-class motors, DShot 4-in-1 ESC, fully 3D-printed PETG frame (Proposed).
• ADR 0020 — Telemetry aggregator: a dedicated task is the sole publisher of TelemetryState, tick-sampling per-source Watches at 100 Hz and owning frame-level fields.
• ADR 0021 — Coordinate frames and command semantics: world NED + body FRD, right-hand sign conventions, angle (self-levelling) mode first, remote sends raw normalised stick deflections (Proposed).
• ADR 0022 — Attitude estimation: complementary filter for roll and pitch (fixed-gain accel/gyro blend); yaw stays rate-only; pure filter in firmware-drone-core (Proposed).
• ADR 0023 — Motor numbering, layout, and rotation directions: quad-X, Betaflight numbering (M1 rear-right … M4 front-left), props-out rotation, with the derived mixer sign table (Proposed).
• ADR 0024 — Control law: single-loop PD per axis, angle mode for roll/pitch and rate mode for yaw, derivative on the measured gyro; a single-publisher controller stage the supervisor mixes in Armed (Proposed).
• ADR 0025 — Persist control parameters to flash: log-structured parameter store in internal flash, disarmed-gated save-on-command from the ground station (Accepted).
• ADR 0026 — Phase 4 custom PCBA: nRF5340 module on a hand-designed KiCad carrier (Proposed).
• ADR 0027 — Split telemetry into high-rate and low-rate frames: fast flight data + slower housekeeping (Proposed).
• ADR 0028 — Fabricate the v2 flight-controller board: turnkey PCBA on PCBWay (Proposed).

Licence

Dual-licensed under either of:

• Apache License, Version 2.0 (LICENSE-APACHE or http://www.apache.org/licenses/LICENSE-2.0)
• MIT license (LICENSE-MIT or http://opensource.org/licenses/MIT)

at your option.

Unless you explicitly state otherwise, any contribution intentionally submitted for inclusion in this work, as defined in the Apache-2.0 license, shall be dual-licensed as above, without any additional terms or conditions.