slop

server/src/services/overcurrentProtectionService/index.js

@@ -11,9 +11,10 @@ const DEFAULT_CONFIG = Object.freeze({
   encoderNoiseFloorMmPerSec: 15,
   fullStallProgressRatio: 0.1,
   movingProgressRatio: 0.6,
-  movingOrUnknownRatePerSec: 0.25,
+  movingOrUnknownRatePerSec: 0.2,
-  fullStallRatePerSec: 1,
+  fullStallRatePerSec: 0.6,
-  wheelRecoveryRatePerSec: 0.75,
+  wheelRecoveryDelaySec: 0.75,
+  wheelRecoveryRatePerSec: 0.4,
   brushOvercurrentRatePerSec: 1,
   brushRecoveryRatePerSec: 0.75,
   clearBeforeUnlockSec: 0.75,
@@ -44,6 +45,7 @@ function createMotorState() {
     classification: 'unknown',
     progressSamples: [],
     windowCommandSign: 0,
+    clearSec: 0,
     stress: 0,
     cap: 1,
   };
@@ -325,6 +327,7 @@ function createOvercurrentProtectionService(options = {}) {
     motor.commandedSpeed = commandNumber;
     motor.measuredSpeed = measuredValid ? measuredNumber : null;
     motor.currentMa = Number.isFinite(Number(currentMa)) ? Number(currentMa) : null;
+    motor.clearSec = motor.overcurrent ? 0 : motor.clearSec + deltaSec;
 
     if (!motor.overcurrent) {
       resetWheelProgressWindow(motor, commandSign);
@@ -354,9 +357,14 @@ function createOvercurrentProtectionService(options = {}) {
 
     const riseRate = config.movingOrUnknownRatePerSec
       + (config.fullStallRatePerSec - config.movingOrUnknownRatePerSec) * motor.stallFactor;
+    const recoveryAllowed = !motor.overcurrent && motor.clearSec >= config.wheelRecoveryDelaySec;
     motor.stress = clampUnit(
       motor.stress
-        + (motor.overcurrent ? riseRate * deltaSec : -config.wheelRecoveryRatePerSec * deltaSec),
+        + (motor.overcurrent
+          ? riseRate * deltaSec
+          : recoveryAllowed
+            ? -config.wheelRecoveryRatePerSec * deltaSec
+            : 0),
     );
     motor.cap = calculateCap(motor.stress);
   }
@@ -524,7 +532,11 @@ function createOvercurrentProtectionService(options = {}) {
     // still inside the transient grace region. Reporting it separately keeps
     // HUD visibility immediate without falsely claiming output is being scaled.
     if (anyOvercurrent) return 'overcurrent';
-    if (anyLimited) return 'recovering';
+    // Stress below the command-limiting grace threshold still represents a
+    // recent hardware event. Keeping recovery visible until it reaches zero
+    // prevents the HUD from vanishing the instant the raw flag clears.
+    const anyStress = MOTOR_KEYS.some((key) => state.motors[key].stress > 0);
+    if (anyStress) return 'recovering';
     return 'idle';
   }
 

server/src/services/overcurrentProtectionService/index.test.js

@@ -48,7 +48,9 @@ test('a short stalled-wheel spike remains inside the grace region', () => {
     wheelSpeedsMmPerSecond: { left: 0 },
   }), start + 100);
 
-  assert.equal(snapshot.motors.leftWheel.stress, 0.025);
+  // Stress is accumulated with floating-point time arithmetic, so compare
+  // within a tiny tolerance instead of depending on an exact binary decimal.
+  assert.ok(Math.abs(snapshot.motors.leftWheel.stress - 0.02) < 1e-9);
   assert.equal(snapshot.motors.leftWheel.cap, 1);
   // The hardware event is visible immediately even though the grace region
   // correctly leaves the command cap at full output.
@@ -62,7 +64,7 @@ test('persistent stalled-wheel overcurrent scales both wheels and then stops dri
     driveDirect: { left: 300, right: 200 },
   });
 
-  for (let step = 0; step <= 12; step += 1) {
+  for (let step = 0; step <= 18; step += 1) {
     service.processTelemetry('rover', makeSensors({
       wheelOvercurrents: { leftWheel: true },
       wheelSpeedsMmPerSecond: { left: 0, right: 200 },
@@ -70,15 +72,15 @@ test('persistent stalled-wheel overcurrent scales both wheels and then stops dri
   }
 
   /*
-    The first 400 ms establish that the wheel is making no net progress. Once
+    The first 400 ms establish that the wheel is making no net progress. The
-    classified, the faster stalled rate should approach—but not yet cross—the
+    tuned stalled rate should then approach—but not yet cross—the hard-stop
-    hard-stop boundary at 1.2 seconds.
+    boundary at 1.8 seconds.
   */
   assert.equal(service.getPublicState('rover').drive.blocked, false);
   service.processTelemetry('rover', makeSensors({
     wheelOvercurrents: { leftWheel: true },
     wheelSpeedsMmPerSecond: { left: 0, right: 200 },
-  }), start + 1300);
+  }), start + 1900);
 
   const snapshot = service.getPublicState('rover');
   assert.equal(snapshot.status, 'stopped');
@@ -140,7 +142,7 @@ test('encoder wobble around zero is classified as a full stall', () => {
     driveDirect: { left: 300, right: 300 },
   });
 
-  for (let step = 0; step <= 13; step += 1) {
+  for (let step = 0; step <= 19; step += 1) {
     const wobbleSpeed = step % 2 === 0 ? 10 : -9;
     service.processTelemetry('rover', makeSensors({
       wheelOvercurrents: { leftWheel: true },
@@ -222,7 +224,7 @@ test('wheel comparison follows scaled output and resets after reversal', () => {
     driveDirect: { left: 300, right: 300 },
   });
 
-  for (let step = 0; step <= 6; step += 1) {
+  for (let step = 0; step <= 8; step += 1) {
     service.processTelemetry('rover', makeSensors({
       wheelOvercurrents: { leftWheel: true },
       wheelSpeedsMmPerSecond: { left: 0 },
@@ -237,7 +239,7 @@ test('wheel comparison follows scaled output and resets after reversal', () => {
   const reversed = service.processTelemetry('rover', makeSensors({
     wheelOvercurrents: { leftWheel: true },
     wheelSpeedsMmPerSecond: { left: -250 },
-  }), start + 700);
+  }), start + 900);
   assert.equal(reversed.motors.leftWheel.classification, 'unknown');
   assert.equal(reversed.motors.leftWheel.progressRatio, null);
 });
@@ -248,14 +250,14 @@ test('a stopped drive stays blocked until both clear time and neutral are observ
   service.protectCommand('rover', 'drive', {
     driveDirect: { left: 300, right: 300 },
   });
-  for (let step = 0; step <= 13; step += 1) {
+  for (let step = 0; step <= 19; step += 1) {
     service.processTelemetry('rover', makeSensors({
       wheelOvercurrents: { leftWheel: true },
       wheelSpeedsMmPerSecond: { left: 0 },
     }), start + step * 100);
   }
 
-  for (let step = 14; step <= 28; step += 1) {
+  for (let step = 20; step <= 52; step += 1) {
     service.processTelemetry('rover', makeSensors(), start + step * 100);
   }
   assert.equal(service.getPublicState('rover').drive.blocked, true);
@@ -276,6 +278,34 @@ test('a stopped drive stays blocked until both clear time and neutral are observ
   assert.deepEqual(resumed.driveDirect, { left: 300, right: 300 });
 });
 
+test('cleared wheel stress remains visible through the hold and drains to idle', () => {
+  const { service } = createHarness();
+  const start = Date.now();
+  service.protectCommand('rover', 'drive', {
+    driveDirect: { left: 300, right: 300 },
+  });
+  service.processTelemetry('rover', makeSensors({
+    wheelOvercurrents: { leftWheel: true },
+    wheelSpeedsMmPerSecond: { left: 0 },
+  }), start);
+  service.processTelemetry('rover', makeSensors({
+    wheelOvercurrents: { leftWheel: true },
+    wheelSpeedsMmPerSecond: { left: 0 },
+  }), start + 100);
+
+  const justCleared = service.processTelemetry('rover', makeSensors(), start + 200);
+  assert.equal(justCleared.status, 'recovering');
+  assert.ok(justCleared.motors.leftWheel.stress > 0);
+
+  const held = service.processTelemetry('rover', makeSensors(), start + 800);
+  assert.equal(held.status, 'recovering');
+  assert.ok(held.motors.leftWheel.stress > 0);
+
+  const recovered = service.processTelemetry('rover', makeSensors(), start + 1000);
+  assert.equal(recovered.status, 'idle');
+  assert.equal(recovered.motors.leftWheel.stress, 0);
+});
+
 test('brush stress limits only the brush that reports overcurrent', () => {
   const { service } = createHarness();
   const start = Date.now();