Merge pull request #3171 from mhkabir/commander_prearm

Commander : Effectively track failure reporting and handle hotplug sensors

msg/vehicle_status.msg

@@ -120,6 +120,8 @@ bool in_transition_mode
 bool condition_battery_voltage_valid
 bool condition_system_in_air_restore		# true if we can restore in mid air
 bool condition_system_sensors_initialized
+bool condition_system_prearm_error_reported	# true if errors have already been reported 
+bool condition_system_hotplug_timeout		# true if the hotplug sensor search is over
 bool condition_system_returned_to_home
 bool condition_auto_mission_available
 bool condition_global_position_valid		# set to true by the commander app if the quality of the position estimate is good enough to use it for navigation
@@ -139,6 +141,7 @@ bool rc_signal_lost_cmd				# true if RC lost mode is commanded
 bool rc_input_blocked				# set if RC input should be ignored temporarily
 uint8 rc_input_mode				# set to 1 to disable the RC input, 2 to enable manual control to RC in mapping.
 
+bool data_link_found_new			# new datalink to GCS found
 bool data_link_lost				# datalink to GCS lost
 bool data_link_lost_cmd				# datalink to GCS lost mode commanded
 uint8 data_link_lost_counter			# counts unique data link lost events

src/modules/commander/PreflightCheck.cpp

@@ -114,7 +114,7 @@ int check_calibration(int fd, const char* param_template, int &devid)
 	return !calibration_found;
 }
 
-static bool magnometerCheck(int mavlink_fd, unsigned instance, bool optional, int &device_id)
+static bool magnometerCheck(int mavlink_fd, unsigned instance, bool optional, int &device_id, bool report_fail)
 {
 	bool success = true;
 
@@ -124,7 +124,7 @@ static bool magnometerCheck(int mavlink_fd, unsigned instance, bool optional, in
 
 	if (fd < 0) {
 		if (!optional) {
-			mavlink_and_console_log_critical(mavlink_fd,
+			if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 							 "PREFLIGHT FAIL: NO MAG SENSOR #%u", instance);
 		}
 
@@ -134,7 +134,7 @@ static bool magnometerCheck(int mavlink_fd, unsigned instance, bool optional, in
 	int ret = check_calibration(fd, "CAL_MAG%u_ID", device_id);
 
 	if (ret) {
-		mavlink_and_console_log_critical(mavlink_fd,
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 						 "PREFLIGHT FAIL: MAG #%u UNCALIBRATED", instance);
 		success = false;
 		goto out;
@@ -143,7 +143,7 @@ static bool magnometerCheck(int mavlink_fd, unsigned instance, bool optional, in
 	ret = px4_ioctl(fd, MAGIOCSELFTEST, 0);
 
 	if (ret != OK) {
-		mavlink_and_console_log_critical(mavlink_fd,
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 						 "PREFLIGHT FAIL: MAG #%u SELFTEST FAILED", instance);
 		success = false;
 		goto out;
@@ -154,7 +154,7 @@ out:
 	return success;
 }
 
-static bool accelerometerCheck(int mavlink_fd, unsigned instance, bool optional, bool dynamic, int &device_id)
+static bool accelerometerCheck(int mavlink_fd, unsigned instance, bool optional, bool dynamic, int &device_id, bool report_fail)
 {
 	bool success = true;
 
@@ -164,7 +164,7 @@ static bool accelerometerCheck(int mavlink_fd, unsigned instance, bool optional,
 
 	if (fd < 0) {
 		if (!optional) {
-			mavlink_and_console_log_critical(mavlink_fd,
+			if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 							 "PREFLIGHT FAIL: NO ACCEL SENSOR #%u", instance);
 		}
 
@@ -174,7 +174,7 @@ static bool accelerometerCheck(int mavlink_fd, unsigned instance, bool optional,
 	int ret = check_calibration(fd, "CAL_ACC%u_ID", device_id);
 
 	if (ret) {
-		mavlink_and_console_log_critical(mavlink_fd,
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 						 "PREFLIGHT FAIL: ACCEL #%u UNCALIBRATED", instance);
 		success = false;
 		goto out;
@@ -183,7 +183,7 @@ static bool accelerometerCheck(int mavlink_fd, unsigned instance, bool optional,
 	ret = px4_ioctl(fd, ACCELIOCSELFTEST, 0);
 
 	if (ret != OK) {
-		mavlink_and_console_log_critical(mavlink_fd,
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 						 "PREFLIGHT FAIL: ACCEL #%u SELFTEST FAILED", instance);
 		success = false;
 		goto out;
@@ -200,13 +200,13 @@ static bool accelerometerCheck(int mavlink_fd, unsigned instance, bool optional,
 			float accel_magnitude = sqrtf(acc.x * acc.x + acc.y * acc.y + acc.z * acc.z);
 
 			if (accel_magnitude < 4.0f || accel_magnitude > 15.0f /* m/s^2 */) {
-				mavlink_and_console_log_critical(mavlink_fd, "PREFLIGHT FAIL: ACCEL RANGE, hold still on arming");
+				if(report_fail) mavlink_and_console_log_critical(mavlink_fd, "PREFLIGHT FAIL: ACCEL RANGE, hold still on arming");
 				/* this is frickin' fatal */
 				success = false;
 				goto out;
 			}
 		} else {
-			mavlink_log_critical(mavlink_fd, "PREFLIGHT FAIL: ACCEL READ");
+			if(report_fail) mavlink_log_critical(mavlink_fd, "PREFLIGHT FAIL: ACCEL READ");
 			/* this is frickin' fatal */
 			success = false;
 			goto out;
@@ -219,7 +219,7 @@ out:
 	return success;
 }
 
-static bool gyroCheck(int mavlink_fd, unsigned instance, bool optional, int &device_id)
+static bool gyroCheck(int mavlink_fd, unsigned instance, bool optional, int &device_id, bool report_fail)
 {
 	bool success = true;
 
@@ -229,7 +229,7 @@ static bool gyroCheck(int mavlink_fd, unsigned instance, bool optional, int &dev
 
 	if (fd < 0) {
 		if (!optional) {
-			mavlink_and_console_log_critical(mavlink_fd,
+			if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 							 "PREFLIGHT FAIL: NO GYRO SENSOR #%u", instance);
 		}
 
@@ -239,7 +239,7 @@ static bool gyroCheck(int mavlink_fd, unsigned instance, bool optional, int &dev
 	int ret = check_calibration(fd, "CAL_GYRO%u_ID", device_id);
 
 	if (ret) {
-		mavlink_and_console_log_critical(mavlink_fd,
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 						 "PREFLIGHT FAIL: GYRO #%u UNCALIBRATED", instance);
 		success = false;
 		goto out;
@@ -248,7 +248,7 @@ static bool gyroCheck(int mavlink_fd, unsigned instance, bool optional, int &dev
 	ret = px4_ioctl(fd, GYROIOCSELFTEST, 0);
 
 	if (ret != OK) {
-		mavlink_and_console_log_critical(mavlink_fd,
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 						 "PREFLIGHT FAIL: GYRO #%u SELFTEST FAILED", instance);
 		success = false;
 		goto out;
@@ -259,7 +259,7 @@ out:
 	return success;
 }
 
-static bool baroCheck(int mavlink_fd, unsigned instance, bool optional, int &device_id)
+static bool baroCheck(int mavlink_fd, unsigned instance, bool optional, int &device_id, bool report_fail)
 {
 	bool success = true;
 
@@ -269,7 +269,7 @@ static bool baroCheck(int mavlink_fd, unsigned instance, bool optional, int &dev
 
 	if (fd < 0) {
 		if (!optional) {
-			mavlink_and_console_log_critical(mavlink_fd,
+			if(report_fail) mavlink_and_console_log_critical(mavlink_fd,
 							 "PREFLIGHT FAIL: NO BARO SENSOR #%u", instance);
 		}
 
@@ -294,7 +294,7 @@ static bool baroCheck(int mavlink_fd, unsigned instance, bool optional, int &dev
 	return success;
 }
 
-static bool airspeedCheck(int mavlink_fd, bool optional)
+static bool airspeedCheck(int mavlink_fd, bool optional, bool report_fail)
 {
 	bool success = true;
 	int ret;
@@ -304,13 +304,13 @@ static bool airspeedCheck(int mavlink_fd, bool optional)
 
 	if ((ret = orb_copy(ORB_ID(airspeed), fd, &airspeed)) ||
 	    (hrt_elapsed_time(&airspeed.timestamp) > (500 * 1000))) {
-		mavlink_and_console_log_critical(mavlink_fd, "PREFLIGHT FAIL: AIRSPEED SENSOR MISSING");
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd, "PREFLIGHT FAIL: AIRSPEED SENSOR MISSING");
 		success = false;
 		goto out;
 	}
 
 	if (fabsf(airspeed.indicated_airspeed_m_s) > 6.0f) {
-		mavlink_and_console_log_critical(mavlink_fd, "AIRSPEED WARNING: WIND OR CALIBRATION ISSUE");
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd, "AIRSPEED WARNING: WIND OR CALIBRATION ISSUE");
 		// XXX do not make this fatal yet
 	}
 
@@ -319,7 +319,7 @@ out:
 	return success;
 }
 
-static bool gnssCheck(int mavlink_fd)
+static bool gnssCheck(int mavlink_fd, bool report_fail)
 {
 	bool success = true;
 
@@ -342,7 +342,7 @@ static bool gnssCheck(int mavlink_fd)
 
 	//Report failure to detect module
 	if(!success) {
-		mavlink_and_console_log_critical(mavlink_fd, "PREFLIGHT FAIL: GPS RECEIVER MISSING");
+		if(report_fail) mavlink_and_console_log_critical(mavlink_fd, "PREFLIGHT FAIL: GPS RECEIVER MISSING");
 	}
 
 	px4_close(gpsSub);
@@ -350,7 +350,7 @@ static bool gnssCheck(int mavlink_fd)
 }
 
 bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro,
-		    bool checkBaro, bool checkAirspeed, bool checkRC, bool checkGNSS, bool checkDynamic)
+		    bool checkBaro, bool checkAirspeed, bool checkRC, bool checkGNSS, bool checkDynamic, bool reportFailures)
 {
 	bool failed = false;
 
@@ -365,7 +365,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 			bool required = (i < max_mandatory_mag_count);
 			int device_id = -1;
 
-			if (!magnometerCheck(mavlink_fd, i, !required, device_id) && required) {
+			if (!magnometerCheck(mavlink_fd, i, !required, device_id, reportFailures) && required) {
 				failed = true;
 			}
 
@@ -376,7 +376,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 
 		/* check if the primary device is present */
 		if (!prime_found && prime_id != 0) {
-			mavlink_log_critical(mavlink_fd, "warning: primary compass not operational");
+			if(reportFailures) mavlink_log_critical(mavlink_fd, "Warning: Primary compass not found");
 			failed = true;
 		}
 	}
@@ -392,7 +392,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 			bool required = (i < max_mandatory_accel_count);
 			int device_id = -1;
 
-			if (!accelerometerCheck(mavlink_fd, i, !required, checkDynamic, device_id) && required) {
+			if (!accelerometerCheck(mavlink_fd, i, !required, checkDynamic, device_id, reportFailures) && required) {
 				failed = true;
 			}
 
@@ -403,7 +403,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 
 		/* check if the primary device is present */
 		if (!prime_found && prime_id != 0) {
-			mavlink_log_critical(mavlink_fd, "warning: primary accelerometer not operational");
+			if(reportFailures) mavlink_log_critical(mavlink_fd, "Warning: Primary accelerometer not found");
 			failed = true;
 		}
 	}
@@ -419,7 +419,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 			bool required = (i < max_mandatory_gyro_count);
 			int device_id = -1;
 
-			if (!gyroCheck(mavlink_fd, i, !required, device_id) && required) {
+			if (!gyroCheck(mavlink_fd, i, !required, device_id, reportFailures) && required) {
 				failed = true;
 			}
 
@@ -430,7 +430,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 
 		/* check if the primary device is present */
 		if (!prime_found && prime_id != 0) {
-			mavlink_log_critical(mavlink_fd, "warning: primary gyro not operational");
+			if(reportFailures) mavlink_log_critical(mavlink_fd, "Warning: Primary gyro not found");
 			failed = true;
 		}
 	}
@@ -446,7 +446,7 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 			bool required = (i < max_mandatory_baro_count);
 			int device_id = -1;
 
-			if (!baroCheck(mavlink_fd, i, !required, device_id) && required) {
+			if (!baroCheck(mavlink_fd, i, !required, device_id, reportFailures) && required) {
 				failed = true;
 			}
 
@@ -458,29 +458,29 @@ bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc, bool checkGyro
 		// TODO there is no logic in place to calibrate the primary baro yet
 		// // check if the primary device is present 
 		if (!prime_found && prime_id != 0) {
-			mavlink_log_critical(mavlink_fd, "warning: primary barometer not operational");
+			if(reportFailures) mavlink_log_critical(mavlink_fd, "warning: primary barometer not operational");
 			failed = true;
 		}
 	}
 
 	/* ---- AIRSPEED ---- */
 	if (checkAirspeed) {
-		if (!airspeedCheck(mavlink_fd, true)) {
+		if (!airspeedCheck(mavlink_fd, true, reportFailures)) {
 			failed = true;
 		}
 	}
 
 	/* ---- RC CALIBRATION ---- */
 	if (checkRC) {
-		if (rc_calibration_check(mavlink_fd) != OK) {
-			mavlink_log_critical(mavlink_fd, "RC calibration check failed");
+		if (rc_calibration_check(mavlink_fd, reportFailures) != OK) {
+			if(reportFailures) mavlink_log_critical(mavlink_fd, "RC calibration check failed");
 			failed = true;
 		}
 	}
 
 	/* ---- Global Navigation Satellite System receiver ---- */
 	if (checkGNSS) {
-		if(!gnssCheck(mavlink_fd)) {
+		if(!gnssCheck(mavlink_fd, reportFailures)) {
 			failed = true;
 		}
 	}

src/modules/commander/PreflightCheck.h

@@ -67,7 +67,7 @@ namespace Commander
 *   true if the GNSS receiver should be checked
 **/
 bool preflightCheck(int mavlink_fd, bool checkMag, bool checkAcc,
-    bool checkGyro, bool checkBaro, bool checkAirspeed, bool checkRC, bool checkGNSS, bool checkDynamic = false);
+    bool checkGyro, bool checkBaro, bool checkAirspeed, bool checkRC, bool checkGNSS, bool checkDynamic, bool reportFailures = false);
 
 const unsigned max_mandatory_gyro_count = 1;
 const unsigned max_optional_gyro_count = 3;

src/modules/commander/commander.cpp

@@ -148,6 +148,8 @@ static constexpr uint8_t COMMANDER_MAX_GPS_NOISE = 60;		/**< Maximum percentage
 #define OFFBOARD_TIMEOUT		500000
 #define DIFFPRESS_TIMEOUT		2000000
 
+#define HOTPLUG_SENS_TIMEOUT		(8 * 1000 * 1000)	/**< wait for hotplug sensors to come online for upto 10 seconds */
+
 #define PRINT_INTERVAL	5000000
 #define PRINT_MODE_REJECT_INTERVAL	10000000
 
@@ -377,9 +379,12 @@ int commander_main(int argc, char *argv[])
 
 	if (!strcmp(argv[1], "check")) {
 		int mavlink_fd_local = px4_open(MAVLINK_LOG_DEVICE, 0);
-		int checkres = prearm_check(&status, mavlink_fd_local);
+		int checkres = 0;
+		checkres = preflight_check(&status, mavlink_fd_local, false);
+		warnx("Preflight check: %s", (checkres == 0) ? "OK" : "FAILED");
+		checkres = preflight_check(&status, mavlink_fd_local, true);
+		warnx("Prearm check: %s", (checkres == 0) ? "OK" : "FAILED");
 		px4_close(mavlink_fd_local);
-		warnx("FINAL RESULT: %s", (checkres == 0) ? "OK" : "FAILED");
 		return 0;
 	}
 
@@ -891,6 +896,7 @@ int commander_thread_main(int argc, char *argv[])
 	/* not yet initialized */
 	commander_initialized = false;
 
+	bool sensor_fail_tune_played = false;
 	bool arm_tune_played = false;
 	bool was_landed = true;
 	bool was_armed = false;
@@ -1020,6 +1026,9 @@ int commander_thread_main(int argc, char *argv[])
 
 	// XXX for now just set sensors as initialized
 	status.condition_system_sensors_initialized = true;
+	
+	status.condition_system_prearm_error_reported = true;
+	status.condition_system_hotplug_timeout = false;
 
 	status.counter++;
 	status.timestamp = hrt_absolute_time();
@@ -1101,7 +1110,7 @@ int commander_thread_main(int argc, char *argv[])
 
 	bool updated = false;
 
-	rc_calibration_check(mavlink_fd);
+	rc_calibration_check(mavlink_fd, true);
 
 	/* Subscribe to safety topic */
 	int safety_sub = orb_subscribe(ORB_ID(safety));
@@ -1243,6 +1252,7 @@ int commander_thread_main(int argc, char *argv[])
 
 	// Run preflight check
 	int32_t rc_in_off = 0;
+	bool hotplug_timeout = hrt_elapsed_time(&commander_boot_timestamp) > HOTPLUG_SENS_TIMEOUT;
 	param_get(_param_autostart_id, &autostart_id);
 	param_get(_param_rc_in_off, &rc_in_off);
 	status.rc_input_mode = rc_in_off;
@@ -1251,14 +1261,10 @@ int commander_thread_main(int argc, char *argv[])
 		status.condition_system_sensors_initialized = false;
 		set_tune_override(TONE_STARTUP_TUNE); //normal boot tune
 	} else {
-		status.condition_system_sensors_initialized = Commander::preflightCheck(mavlink_fd, true, true, true, true,
-			checkAirspeed, (status.rc_input_mode == vehicle_status_s::RC_IN_MODE_DEFAULT), !status.circuit_breaker_engaged_gpsfailure_check);
-		if (!status.condition_system_sensors_initialized) {
-			set_tune_override(TONE_GPS_WARNING_TUNE); //sensor fail tune
-		}
-		else {
+			// sensor diagnostics done continiously, not just at boot so don't warn about any issues just yet
+			status.condition_system_sensors_initialized = Commander::preflightCheck(mavlink_fd, true, true, true, true,
+			checkAirspeed, (status.rc_input_mode == vehicle_status_s::RC_IN_MODE_DEFAULT), !status.circuit_breaker_engaged_gpsfailure_check, false);
 			set_tune_override(TONE_STARTUP_TUNE); //normal boot tune
-		}
 	}
 
 	commander_boot_timestamp = hrt_absolute_time();
@@ -1354,11 +1360,11 @@ int commander_thread_main(int argc, char *argv[])
 
 				if (map_mode_sw == 0 && map_mode_sw != map_mode_sw_new && map_mode_sw_new < input_rc_s::RC_INPUT_MAX_CHANNELS && map_mode_sw_new > 0) {
 					status.condition_system_sensors_initialized = Commander::preflightCheck(mavlink_fd, true, true, true, true, checkAirspeed,
-							!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status.circuit_breaker_engaged_gpsfailure_check);
+							!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status.circuit_breaker_engaged_gpsfailure_check, hotplug_timeout);
 				}
 
 				/* re-check RC calibration */
-				rc_calibration_check(mavlink_fd);
+				rc_calibration_check(mavlink_fd, true);
 			}
 
 			/* Safety parameters */
@@ -1446,6 +1452,8 @@ int commander_thread_main(int argc, char *argv[])
 				    !armed.armed) {
 
 				    	bool chAirspeed = false;
+				    	bool hotplug_timeout = hrt_elapsed_time(&commander_boot_timestamp) > HOTPLUG_SENS_TIMEOUT;
+				    	
 					/* Perform airspeed check only if circuit breaker is not
 					 * engaged and it's not a rotary wing */
 					if (!status.circuit_breaker_engaged_airspd_check && !status.is_rotary_wing) {
@@ -1456,11 +1464,11 @@ int commander_thread_main(int argc, char *argv[])
 					if (is_hil_setup(autostart_id)) {
 						/* HIL configuration: check only RC input */
 						(void)Commander::preflightCheck(mavlink_fd, false, false, false, false, false,
-								!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), false);
+								!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), false, true);
 					} else {
 						/* check sensors also */
 						(void)Commander::preflightCheck(mavlink_fd, true, true, true, true, chAirspeed,
-								!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status.circuit_breaker_engaged_gpsfailure_check);
+								!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status.circuit_breaker_engaged_gpsfailure_check, hotplug_timeout);
 					}
 				}
 
@@ -2177,9 +2185,14 @@ int commander_thread_main(int argc, char *argv[])
 				if (telemetry_lost[i] &&
 				    hrt_elapsed_time(&telemetry_last_dl_loss[i]) > datalink_regain_timeout * 1e6) {
 
-					/* only report a regain */
+					/* report a regain */
 					if (telemetry_last_dl_loss[i] > 0) {
 						mavlink_and_console_log_info(mavlink_fd, "data link #%i regained", i);
+					} else if (telemetry_last_dl_loss[i] == 0){
+					/* report a new link */
+						mavlink_and_console_log_info(mavlink_fd, "new data link connected : #%i", i);
+						status.data_link_found_new = true;
+						status_changed = true;
 					}
 
 					telemetry_lost[i] = false;
@@ -2189,6 +2202,10 @@ int commander_thread_main(int argc, char *argv[])
 					/* telemetry was healthy also in last iteration
 					 * we don't have to check a timeout */
 					have_link = true;
+					if(status.data_link_found_new) {
+						status.data_link_found_new = false;
+						status_changed = true;
+					}
 				}
 
 			} else {
@@ -2414,7 +2431,7 @@ int commander_thread_main(int argc, char *argv[])
 		} else {
 			set_tune(TONE_STOP_TUNE);
 		}
-
+		
 		/* reset arm_tune_played when disarmed */
 		if (!armed.armed || (safety.safety_switch_available && !safety.safety_off)) {
 
@@ -2425,6 +2442,21 @@ int commander_thread_main(int argc, char *argv[])
 
 			arm_tune_played = false;
 		}
+		
+		/* play sensor failure tunes if we already waited for hotplug sensors to come up and failed */
+		hotplug_timeout = hrt_elapsed_time(&commander_boot_timestamp) > HOTPLUG_SENS_TIMEOUT;
+		
+		if (!sensor_fail_tune_played && (!status.condition_system_sensors_initialized && hotplug_timeout)) {
+			set_tune_override(TONE_GPS_WARNING_TUNE);
+			sensor_fail_tune_played = true;
+			status_changed = true;
+		}
+		
+		/* update timeout flag */
+		if(!(hotplug_timeout == status.condition_system_hotplug_timeout)) {
+			status.condition_system_hotplug_timeout = hotplug_timeout;
+			status_changed = true;
+		}
 
 		counter++;
 
@@ -2508,19 +2540,24 @@ control_status_leds(vehicle_status_s *status_local, const actuator_armed_s *actu
 	/* driving rgbled */
 	if (changed) {
 		bool set_normal_color = false;
-
+		bool hotplug_timeout = hrt_elapsed_time(&commander_boot_timestamp) > HOTPLUG_SENS_TIMEOUT;
+		
 		/* set mode */
 		if (status_local->arming_state == vehicle_status_s::ARMING_STATE_ARMED) {
 			rgbled_set_mode(RGBLED_MODE_ON);
 			set_normal_color = true;
 
-		} else if (status_local->arming_state == vehicle_status_s::ARMING_STATE_ARMED_ERROR || !status.condition_system_sensors_initialized) {
+		} else if (status_local->arming_state == vehicle_status_s::ARMING_STATE_ARMED_ERROR || (!status.condition_system_sensors_initialized && hotplug_timeout)) {
 			rgbled_set_mode(RGBLED_MODE_BLINK_FAST);
 			rgbled_set_color(RGBLED_COLOR_RED);
 
 		} else if (status_local->arming_state == vehicle_status_s::ARMING_STATE_STANDBY) {
 			rgbled_set_mode(RGBLED_MODE_BREATHE);
 			set_normal_color = true;
+		
+		} else if (!status.condition_system_sensors_initialized && !hotplug_timeout) {
+			rgbled_set_mode(RGBLED_MODE_BREATHE);
+			set_normal_color = true;
 
 		} else {	// STANDBY_ERROR and other states
 			rgbled_set_mode(RGBLED_MODE_BLINK_NORMAL);
@@ -3197,6 +3234,7 @@ void *commander_low_prio_loop(void *arg)
 						// so this would be prone to false negatives.
 
 						bool checkAirspeed = false;
+						bool hotplug_timeout = hrt_elapsed_time(&commander_boot_timestamp) > HOTPLUG_SENS_TIMEOUT;
 						/* Perform airspeed check only if circuit breaker is not
 						 * engaged and it's not a rotary wing */
 						if (!status.circuit_breaker_engaged_airspd_check && !status.is_rotary_wing) {
@@ -3204,7 +3242,7 @@ void *commander_low_prio_loop(void *arg)
 						}
 
 						status.condition_system_sensors_initialized = Commander::preflightCheck(mavlink_fd, true, true, true, true, checkAirspeed,
-							!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status.circuit_breaker_engaged_gpsfailure_check);
+							!(status.rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status.circuit_breaker_engaged_gpsfailure_check, hotplug_timeout);
 
 						arming_state_transition(&status, &safety, vehicle_status_s::ARMING_STATE_STANDBY, &armed, false /* fRunPreArmChecks */, mavlink_fd);
 

src/modules/commander/state_machine_helper.cpp

@@ -93,8 +93,6 @@ static const char * const state_names[vehicle_status_s::ARMING_STATE_MAX] = {
 	"ARMING_STATE_IN_AIR_RESTORE",
 };
 
-static bool sensor_feedback_provided = false;
-
 transition_result_t
 arming_state_transition(struct vehicle_status_s *status,		///< current vehicle status
 			const struct safety_s   *safety,		///< current safety settings
@@ -122,10 +120,18 @@ arming_state_transition(struct vehicle_status_s *status,		///< current vehicle s
 		 */
 		int prearm_ret = OK;
 
-		/* only perform the check if we have to */
+		/* only perform the pre-arm check if we have to */
 		if (fRunPreArmChecks && new_arming_state == vehicle_status_s::ARMING_STATE_ARMED
 				&& status->hil_state == vehicle_status_s::HIL_STATE_OFF) {
-			prearm_ret = prearm_check(status, mavlink_fd);
+			prearm_ret = preflight_check(status, mavlink_fd, true /* pre-arm */ );
+		}
+		/* re-run the pre-flight check as long as sensors are failing */
+		if (!status->condition_system_sensors_initialized 
+				&& (new_arming_state == vehicle_status_s::ARMING_STATE_ARMED ||
+				    new_arming_state == vehicle_status_s::ARMING_STATE_STANDBY)
+             			&& status->hil_state == vehicle_status_s::HIL_STATE_OFF) {
+            		prearm_ret = preflight_check(status, mavlink_fd, false /* pre-flight */);
+			status->condition_system_sensors_initialized = !prearm_ret;
 		}
 
 		/*
@@ -243,9 +249,11 @@ arming_state_transition(struct vehicle_status_s *status,		///< current vehicle s
 			(new_arming_state == vehicle_status_s::ARMING_STATE_STANDBY) &&
 			(status->arming_state != vehicle_status_s::ARMING_STATE_STANDBY_ERROR) &&
 			(!status->condition_system_sensors_initialized)) {
-			if (!sensor_feedback_provided || (new_arming_state == vehicle_status_s::ARMING_STATE_ARMED)) {
+			if ((!status->condition_system_prearm_error_reported && 
+			      status->condition_system_hotplug_timeout) || 
+			     (new_arming_state == vehicle_status_s::ARMING_STATE_ARMED)) {
 				mavlink_and_console_log_critical(mavlink_fd, "Not ready to fly: Sensors need inspection");
-				sensor_feedback_provided = true;
+				status->condition_system_prearm_error_reported = true;
 			}
 			feedback_provided = true;
 			valid_transition = false;
@@ -262,7 +270,11 @@ arming_state_transition(struct vehicle_status_s *status,		///< current vehicle s
 		/* reset feedback state */
 		if (status->arming_state != vehicle_status_s::ARMING_STATE_STANDBY_ERROR &&
 			valid_transition) {
-			sensor_feedback_provided = false;
+			status->condition_system_prearm_error_reported = false;
+		}
+		if(status->data_link_found_new == true)
+		{
+			status->condition_system_prearm_error_reported = false;
 		}
 
 		/* end of atomic state update */
@@ -731,11 +743,13 @@ bool set_nav_state(struct vehicle_status_s *status, const bool data_link_loss_en
 	return status->nav_state != nav_state_old;
 }
 
-int prearm_check(const struct vehicle_status_s *status, const int mavlink_fd)
+int preflight_check(const struct vehicle_status_s *status, const int mavlink_fd, bool prearm)
 {
-	/* at this point this equals the preflight check, but might add additional
-	 * quantities later.
+	/* 
 	 */
+	bool reportFailures = false;
+	reportFailures = !status->condition_system_prearm_error_reported && status->condition_system_hotplug_timeout;
+	
 	bool checkAirspeed = false;
 	/* Perform airspeed check only if circuit breaker is not
 	 * engaged and it's not a rotary wing */
@@ -743,12 +757,12 @@ int prearm_check(const struct vehicle_status_s *status, const int mavlink_fd)
 		checkAirspeed = true;
 	}
 
-	bool prearm_ok = Commander::preflightCheck(mavlink_fd, true, true, true, true, checkAirspeed, !(status->rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status->circuit_breaker_engaged_gpsfailure_check, true);
-
-	if (status->usb_connected) {
-		prearm_ok = false;
-		mavlink_log_critical(mavlink_fd, "NOT ARMING: Flying with USB connected prohibited");
+	bool preflight_ok = Commander::preflightCheck(mavlink_fd, true, true, true, true, checkAirspeed, !(status->rc_input_mode == vehicle_status_s::RC_IN_MODE_OFF), !status->circuit_breaker_engaged_gpsfailure_check, true, reportFailures);
+		
+	if (status->usb_connected && prearm) {
+		preflight_ok = false;
+		if(reportFailures) mavlink_log_critical(mavlink_fd, "NOT ARMING: Flying with USB connected prohibited");
 	}
 
-	return !prearm_ok;
+	return !preflight_ok;
 }

src/modules/commander/state_machine_helper.h

@@ -65,6 +65,6 @@ transition_result_t hil_state_transition(hil_state_t new_state, orb_advert_t sta
 
 bool set_nav_state(struct vehicle_status_s *status, const bool data_link_loss_enabled, const bool mission_finished, const bool stay_in_failsafe);
 
-int prearm_check(const struct vehicle_status_s *status, const int mavlink_fd);
+int preflight_check(const struct vehicle_status_s *status, const int mavlink_fd, bool prearm);
 
 #endif /* STATE_MACHINE_HELPER_H_ */

src/modules/systemlib/rc_check.c

@@ -52,7 +52,7 @@
 
 #define RC_INPUT_MAP_UNMAPPED 0
 
-int rc_calibration_check(int mavlink_fd)
+int rc_calibration_check(int mavlink_fd, bool report_fail)
 {
 
 	char nbuf[20];
@@ -74,7 +74,8 @@ int rc_calibration_check(int mavlink_fd)
 		param_t map_parm = param_find(rc_map_mandatory[j]);
 
 		if (map_parm == PARAM_INVALID) {
-			mavlink_log_critical(mavlink_fd, "RC ERR: PARAM %s MISSING", rc_map_mandatory[j]);
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: PARAM %s MISSING", rc_map_mandatory[j]); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 			map_fail_count++;
@@ -86,14 +87,16 @@ int rc_calibration_check(int mavlink_fd)
 		param_get(map_parm, &mapping);
 
 		if (mapping > RC_INPUT_MAX_CHANNELS) {
-			mavlink_log_critical(mavlink_fd, "RC ERR: %s >= # CHANS", rc_map_mandatory[j]);
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: %s >= # CHANS", rc_map_mandatory[j]); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 			map_fail_count++;
 		}
 
 		if (mapping == 0) {
-			mavlink_log_critical(mavlink_fd, "RC ERR: Mandatory %s is unmapped", rc_map_mandatory[j]);
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: Mandatory %s is unmapped", rc_map_mandatory[j]); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 			map_fail_count++;
@@ -144,35 +147,44 @@ int rc_calibration_check(int mavlink_fd)
 		/* assert min..center..max ordering */
 		if (param_min < RC_INPUT_LOWEST_MIN_US) {
 			count++;
-			mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_MIN < %u", i + 1, RC_INPUT_LOWEST_MIN_US);
+
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_MIN < %u", i + 1, RC_INPUT_LOWEST_MIN_US); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 		}
 
 		if (param_max > RC_INPUT_HIGHEST_MAX_US) {
 			count++;
-			mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_MAX > %u", i + 1, RC_INPUT_HIGHEST_MAX_US);
+
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_MAX > %u", i + 1, RC_INPUT_HIGHEST_MAX_US); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 		}
 
 		if (param_trim < param_min) {
 			count++;
-			mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_TRIM < MIN (%d/%d)", i + 1, (int)param_trim, (int)param_min);
+
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_TRIM < MIN (%d/%d)", i + 1, (int)param_trim, (int)param_min); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 		}
 
 		if (param_trim > param_max) {
 			count++;
-			mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_TRIM > MAX (%d/%d)", i + 1, (int)param_trim, (int)param_max);
+
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_TRIM > MAX (%d/%d)", i + 1, (int)param_trim, (int)param_max); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 		}
 
 		/* assert deadzone is sane */
 		if (param_dz > RC_INPUT_MAX_DEADZONE_US) {
-			mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_DZ > %u", i + 1, RC_INPUT_MAX_DEADZONE_US);
+			if (report_fail) { mavlink_log_critical(mavlink_fd, "RC ERR: RC_%d_DZ > %u", i + 1, RC_INPUT_MAX_DEADZONE_US); }
+
 			/* give system time to flush error message in case there are more */
 			usleep(100000);
 			count++;
@@ -187,8 +199,11 @@ int rc_calibration_check(int mavlink_fd)
 
 	if (channels_failed) {
 		sleep(2);
-		mavlink_and_console_log_critical(mavlink_fd, "%d config error%s for %d RC channel%s.", total_fail_count,
-						 (total_fail_count > 1) ? "s" : "", channels_failed, (channels_failed > 1) ? "s" : "");
+
+		if (report_fail) mavlink_and_console_log_critical(mavlink_fd, "%d config error%s for %d RC channel%s.",
+					total_fail_count,
+					(total_fail_count > 1) ? "s" : "", channels_failed, (channels_failed > 1) ? "s" : "");
+
 		usleep(100000);
 	}
 

src/modules/systemlib/rc_check.h

@@ -47,6 +47,6 @@ __BEGIN_DECLS
  * @return			0 / OK if RC calibration is ok, index + 1 of the first
  *				channel that failed else (so 1 == first channel failed)
  */
-__EXPORT int	rc_calibration_check(int mavlink_fd);
+__EXPORT int	rc_calibration_check(int mavlink_fd, bool report_fail);
 
 __END_DECLS