arduino: TSV telemetry protocol with mock RPM/gear

- null-terminated TSV frame: V_bat, IMU (9 fields), RPM, gear
- mock RPM ramps 800-8000, gear derived from RPM bands
- voltage calibration offset
- PROTOCOL.md documents wire format

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

arduino/main/comms.cpp

@@ -39,6 +39,49 @@ bool comms_update() {
   return false;
 }
 
+void comms_send_telemetry(float voltage, const ImuData& imu, bool imu_valid, int rpm, int gear) {
+  // Field 0: voltage
+  Serial.print(voltage, 2);
+  Serial.write('\t');
+
+  if (imu_valid) {
+    // Fields 1-3: acceleration
+    Serial.print(imu.ax, 2);
+    Serial.write('\t');
+    Serial.print(imu.ay, 2);
+    Serial.write('\t');
+    Serial.print(imu.az, 2);
+    Serial.write('\t');
+
+    // Fields 4-6: angular velocity
+    Serial.print(imu.gx, 2);
+    Serial.write('\t');
+    Serial.print(imu.gy, 2);
+    Serial.write('\t');
+    Serial.print(imu.gz, 2);
+    Serial.write('\t');
+
+    // Fields 7-9: euler angles
+    Serial.print(imu.roll, 2);
+    Serial.write('\t');
+    Serial.print(imu.pitch, 2);
+    Serial.write('\t');
+    Serial.print(imu.yaw, 2);
+  } else {
+    // Empty fields for stale IMU (9 tabs for 9 empty fields)
+    Serial.print(F("\t\t\t\t\t\t\t\t"));
+  }
+
+  // Fields 10-11: RPM and gear
+  Serial.write('\t');
+  Serial.print(rpm);
+  Serial.write('\t');
+  Serial.print(gear);
+
+  // Null terminator (no newline)
+  Serial.write('\0');
+}
+
 void comms_send(const char* key, float value, int decimals) {
   Serial.print(key);
   Serial.print(": ");

arduino/main/comms.h

@@ -2,6 +2,7 @@
 #define COMMS_H
 
 #include <Arduino.h>
+#include "imu.h"
 
 // Initialize Pi serial communication (call in setup)
 void comms_init();
@@ -10,7 +11,12 @@ void comms_init();
 // Returns true if a complete command was received
 bool comms_update();
 
-// Send telemetry line to Pi
+// Send complete telemetry frame (TSV format, null-terminated)
+// Format: V_bat\tAx\tAy\tAz\tGx\tGy\tGz\tRoll\tPitch\tYaw\tRPM\tGear\0
+// If imu_valid is false, IMU fields are empty (but tabs preserved)
+void comms_send_telemetry(float voltage, const ImuData& imu, bool imu_valid, int rpm, int gear);
+
+// Send key:value line (for debug/ACK, newline-terminated)
 void comms_send(const char* key, float value, int decimals = 2);
 void comms_send(const char* key, int value);
 void comms_send(const char* key, const char* value);

arduino/main/gear.cpp

@@ -0,0 +1,19 @@
+#include "gear.h"
+
+// Mock gear: derived from RPM bands
+// Real sensor would read position switch
+
+void gear_init() {
+  // Nothing to init for mock
+}
+
+int gear_get(int rpm) {
+  // Simulate gear based on RPM
+  // N < 1000, 1st < 2500, 2nd < 4000, 3rd < 5500, 4th < 7000, 5th+
+  if (rpm < 1000) return 0;  // Neutral
+  if (rpm < 2500) return 1;
+  if (rpm < 4000) return 2;
+  if (rpm < 5500) return 3;
+  if (rpm < 7000) return 4;
+  return 5;
+}

arduino/main/gear.h

@@ -0,0 +1,7 @@
+#ifndef GEAR_H
+#define GEAR_H
+
+void gear_init();
+int gear_get(int rpm);  // Returns gear 0-6 (0=neutral)
+
+#endif

arduino/main/main.ino

@@ -3,6 +3,8 @@
 
 #include "voltage.h"
 #include "imu.h"
+#include "rpm.h"
+#include "gear.h"
 #include "comms.h"
 
 // Timing
@@ -21,6 +23,10 @@ void setup() {
   imu_init();      // AltSoftSerial on pins 8(RX)/9(TX)
   Serial.println(F("[INIT] imu ok"));
 
+  rpm_init();
+  gear_init();
+  Serial.println(F("[INIT] rpm/gear ok"));
+
   // Let IMU warm up a bit before calibrating
   // (WT61 needs a moment to stabilize after power-on)
   delay(500);
@@ -36,6 +42,9 @@ void loop() {
   // Always poll IMU - it's streaming at 20Hz
   imu_update();
 
+  // Update mock RPM (ramping)
+  rpm_update();
+
   // Process any commands from Pi
   if (comms_update()) {
     const char* cmd = comms_get_command();
@@ -63,28 +72,12 @@ void loop() {
 }
 
 void sendTelemetry() {
-  // Battery voltage
-  comms_send("V_bat", voltage_read());
+  // Send all telemetry in a single TSV frame
+  float voltage = voltage_read();
+  const ImuData& imu = imu_get_data();
+  bool imu_valid = imu_is_fresh();
+  int rpm = rpm_get();
+  int gear = gear_get(rpm);
 
-  // IMU data (only if we have fresh data)
-  if (imu_is_fresh()) {
-    const ImuData& imu = imu_get_data();
-
-    // Acceleration (g)
-    comms_send("Ax", imu.ax);
-    comms_send("Ay", imu.ay);
-    comms_send("Az", imu.az);
-
-    // Angular velocity (deg/s)
-    comms_send("Gx", imu.gx);
-    comms_send("Gy", imu.gy);
-    comms_send("Gz", imu.gz);
-
-    // Euler angles (degrees)
-    comms_send("Roll", imu.roll);
-    comms_send("Pitch", imu.pitch);
-    comms_send("Yaw", imu.yaw);
-  } else {
-    comms_send("IMU", "STALE");
-  }
+  comms_send_telemetry(voltage, imu, imu_valid, rpm, gear);
 }

arduino/main/rpm.cpp

@@ -0,0 +1,19 @@
+#include "rpm.h"
+#include <Arduino.h>
+
+// Mock RPM: ramps up/down between idle and redline
+static int _rpm = 800;
+
+void rpm_init() {
+  _rpm = 800;
+}
+
+void rpm_update() {
+  // ~100ms per call at 10Hz = takes ~7s to sweep range
+  _rpm += 10;
+  if (_rpm >= 8000) { _rpm = 800;}
+}
+
+int rpm_get() {
+  return _rpm;
+}

arduino/main/rpm.h

@@ -0,0 +1,8 @@
+#ifndef RPM_H
+#define RPM_H
+
+void rpm_init();
+void rpm_update();      // Call in loop
+int rpm_get();          // Returns current RPM (0 if invalid)
+
+#endif

arduino/main/voltage.cpp

@@ -10,6 +10,7 @@ static const int PIN_VBAT = A0;
 static const float DIVIDER_RATIO = 47.0 / (100.0 + 47.0);  // ~0.3197
 static const float ADC_REF = 5.0;
 static const int ADC_MAX = 1023;
+static const float OFFSET = 0.2; // calib
 
 void voltage_init() {
   // analogRead doesn't need explicit pinMode, but here for future config
@@ -23,5 +24,5 @@ int voltage_read_raw() {
 float voltage_read() {
   int raw = voltage_read_raw();
   float vDivider = (raw / (float)ADC_MAX) * ADC_REF;
-  return vDivider / DIVIDER_RATIO;
+  return vDivider / DIVIDER_RATIO + OFFSET; 
 }