--- tags: [project-drogheda, master-index, gps-rtk, hbox] project: Project Drogheda author: Helgen CTO date: 2026-06-20 status: Active --- # Project Drogheda — Master Index (CLAUDE.md) > **Source of truth for this workspace.** Read this first, then > [[00-Project-Management/PLAN|PLAN]] for current priorities. **Human engineers > onboarding** should start with [[00-Project-Management/Engineering-Handover|Engineering-Handover]] > (deep context: product, RCA, fixes, open items, glossary) and the repo `README.md`. > You are acting as the > **CTO/CSO of Helgen Technologies** — principal hardware/software architect for > the Drogheda GPS-RTK fleet. Tone: precise, fail-safe first. Keep this index and > its directory table current as files change. > **Codename:** the team / Google Drive / official manual call this project > **Drogheda (GPS RTK)**. This local folder was renamed from "Galway" → "Drogheda" > on 2026-06-20; all docs now use **Drogheda**. --- ## 0. Where we are (2026-06-20) Helgen deployed **HBOX** RTK trackers on heavy port equipment at **Hutchison Ports ICAVE (Veracruz)**. They worked "ish," then failed. We are mid-crisis and hardening the product for scale. Three independent failure fronts, all being fixed in parallel: 1. **Backend (confirmed in code).** The production `retranslator.py` blocks the whole fleet on any upstream slowness, and an anti-jump filter can permanently black-hole a healthy unit → some "dead" units may be backend victims, not dead radios. See [[02-Architecture-Software/backend-review|backend-review]]. 2. **Thermal (component-level).** The **ASA** HBOX (UV-stable, softens ~95–100 °C — the case is fine) sits sealed inside a sealed **ABS IP67** cabinet that also holds the **Mean Well** supply → nested heat trap that cooks the **battery / boost / modem** in full sun. See [[06-Testing-Validation/RCA-2026-06-field-failures|RCA]]. 3. **Prototype hardware.** Dupont, hand-wiring, 18650 + PowerBoost — the client's (ICAVE) own indictment. Fix = ruggedize now + production PCB. **Status of units:** all pulled from machines. **4 in hand (3 dead, 1 working-ish)**, physically in **Veracruz**; team in **Querétaro** → remote debug. Units run **firmware v1** (no thermal log). Triage: [[06-Testing-Validation/remote-diagnostic-protocol|remote-diagnostic-protocol]]. **Commercial reality:** productized across **ICAVE, TIMSA, EIT, LCT** (Hutchison terminals); target **30 units operational by August**; hundreds of cabinets planned. The fix must be production-grade and repeatable. **Logs & observability (2026-06-20).** Analyzed the first real bench + healthy-baseline log set (u-blox `.ubx`, 4G-NTRIP console `.log`, server retranslator tcpdump) + the caster/F9P config. **GNSS receivers are healthy but no unit reached RTK — all SPS** (corrections not applied: free **rtk2go** caster + **RAM-only** F9P config + indoor sky). The **4G-NTRIP console is an unreliable health signal** (see §6 — "master-14 fault" retracted; only **master 21** confirmed). Built **`hbox-log-tools`** (Log Explorer + analyzer + dashboard + manual) and a **Blackpill v2.1 logging spec** to fix observability. Canonical: `06-Testing-Validation/2026-06-20_Drogheda_GNSS-Findings-Summary.md`. **Electrical / PCB (2026-06-24).** Watchdog v3 KiCad schematic (`03-Architecture-Hardware/kicad/hbox-watchdog-v3.kicad_sch`, ERC-clean). **DFR1015 folded on-board → GX16 pin 3 now carries RAW machine ignition (12–24 V)**, not pre-conditioned 5 V. **Battery re-added** with a proper charger — **LTC4040 + NTC temperature-qualified charging** on the 1S4P pack; the Blackpill cuts charge when the cell is hot (answers the RCA's #1 failure). Added **reset** (on-board + external), a **4-LED battery gauge**, and a **power-cutoff** switch; fixed two real schematic bugs (EXT_LED disconnect, panel-LED short). Proto = **3 boards** of easy-to-find parts (`watchdog-protoboard-BOM-3boards.xlsx` + Spanish shop list `watchdog-LISTA-DE-COMPRAS-ES.xlsx`). **Canonical electrical state → `03-Architecture-Hardware/watchdog-electrical-design-state.md` — read first for any electrical context.** **PROD schematic complete + PCB layout kickoff (2026-07-02).** `hbox-watchdog-v3-PROD.kicad_sch` now carries **all blocks — ERC 0 errors**: LTC4040 Block B **sized to the 12 Ah pack** (RPROG 825 Ω → 2.42 A ≈ C/5 · RS 8 mΩ → 3.1 A input limit · PFI trip 4.60 V · backup 4.79 V · charge 4.00 V Li-ion via VSYS-referenced straps), Block E cutoff (P11, MAIN5V→SYS5V), Block F PA4→VEH5V re-tap, **Block H fail-safe Modo-B bypass** (K1 *normally-closed* signal relay — corrections survive a dead/absent MCU), Block I NTC→PB1 (block 11). New MCU pins live: PB1 · PB3 · PB4 · PB5 · PA8. **Same day (PM): CARRIER-BOARD conversion** — the PROD board now sockets **all three modules on female headers**: Blackpill (J1/J2) + **simpleRTK2B Pro as UNO-form shield** (MOD1, D0/D1=UART1, D2=RX2, D8=TX2, IOREF=3V3, 5V=SW_5V) + **4G NTRIP Master on an on-board XBee socket** (J7/J8 2 mm; VCC = **3V3_MODEM**, a second MP1584 buck off SW_5V — the HP XBee socket is 3.3 V not 5 V). Modo B + K1 NC bypass = permanent uplink; RTCM3 downlink direct; P3/P13/H3 DNP. **Board 120×100 mm**, shield field with SMD-only underneath, XBee field right, access parts outside; ERC 0; **carrier DRC baseline saved** (`…-drc-carrier-baseline.txt`; ~29 sub-mm placement kisses + by-design under-shield courtyard overlaps). **Next gate: placement review vs HBOX/cabinet mechanicals (+ verify D2/D8=RX2/TX2 on a physical Pro), then routing** (5 V ≥0.5 mm, SW_5V ≥0.8 mm per kicad-guide). Fab gate unchanged: bench-validate the LTC4040 backup + hot-cell charge cutoff on the proto first. Latest proto assumptions ledger = `Drogheda_Conexiones-por-Bloque_Proto_v1.xlsx` (*Estado y cambios*) + `Drogheda_Guia-Conexion-Protoboard_ES_v2.1.pdf` (LaTeX source now in repo: `Guia-Conexion-Protoboard/`). Wiring diagrams v2 (blocks 1–11) in `circuitikz-wiring/`; client decks Avance + RCA refreshed to v1.1. --- ## 1. System architecture (corrected from the BOM, 2026-06-20) ```text Machine power+ignition (12/24/48/110/230 V, per equipment) │ ▼ ┌──────────────── Gabinete IP67 (ABS, Yetlebox P3901) ─────────────────┐ breaker│ Phoenix SPD · fuse holder · DIN rail · SSR/opto (ignition isolation)│ + SPD ►│ Mean Well DDR-60G-24 ──► regulated 24 Vdc ───┐ │ │ │ GX16-5 connector │ │ ┌────────── HBOX (3D-printed ASA) ─────────┼────┐ │ │ │ Mean Well SD-15B-05 (18–36V→5V,3A) ──► 5V rail │ │ │ │ ├► PowerBoost 1000C (+18650 Li-ion 1S4P) backup │ │ │ ├► STM32F411 Blackpill WATCHDOG ──UART(PA2)──► simpleRTK2B Pro │ │ │ │ └ switches RTK 5V via 2N3904→IRF9540N (PA1) │ │ │ ├► simpleRTK2B Pro (ZED-F9P) + 4G NTRIP Master (XBee LTE) │ │ │ └► ignition 24V ──► DFR1015 buck ──► STM32 PA5 (ign sense) │ │ └──────────────────────────────────────────────────────────────┘ │ └───────────────────────────────────────────────────────────────────┘ 4G/LTE ▲ RTCM3 in (NTRIP) │ NMEA out (UDP) Base station (Ardusimple AS-PRO-CORS) ────┘ ▼ retranslator.py ─(anti-jump+speed filter)─► Wialon / Traccar ─► VERONICA ``` - **Power into HBOX = clean 24 V** from the cabinet (via **GX16-5**). Internal **Mean Well SD-15B-05** makes 5 V; **PowerBoost 1000C + 18650** is battery backup; **DFR1015** conditions ignition to the Blackpill. *(This diagram is the field as-built; the **v3 PCB design supersedes the battery + ignition path** — DFR1015 and an **LTC4040** battery-backup charger fold on-board, GX16 pin 3 carries raw ignition. See `03-Architecture-Hardware/watchdog-electrical-design-state.md`.)* - **Corrections arrive over the 4G modem** (RTCM3 via NTRIP), not the GNSS — so a GNSS reset can't fix a dead link; recover by power-cycling the stack (v2 does). - **Watchdog** = STM32F411; see [[03-Architecture-Hardware/watchdog-schematic|watchdog-schematic]]. --- ## 1b. Canonical invariants (inherits `Helgen Project Ethos`) The rules this system must never violate. Check every design/code output against these before presenting; if it breaks one, say so and propose the compliant fix. 1. **Power-off is the safe state.** The RTK stack defaults OFF (gate pull-up) until the MCU asserts; loss of confidence → safe state, not best-guess. 2. **Never vanish, never loop.** A unit must keep reporting (standalone if needed) rather than go silent, and must never enter an infinite fast-reboot loop. 3. **Corrections ride the 4G modem, not the GNSS** — recover the link by power-cycling the stack; a GNSS reset is never a fix for lost NTRIP. 4. **No material that softens below ~80 °C (PLA-class) in the thermal path** — the current **ASA** enclosure complies. Design to the measured cabinet-interior temperature, not spec-sheet ambient. 5. **Backend reads/forwards without head-of-line blocking**, and the anti-jump filter must never permanently lock out a healthy unit. 6. **No secrets in the repo — ever.** (The committed MSSQL password is a live violation to remediate.) ## 1c. Hard constraints (non-negotiables) - HBOX input is the cabinet's **regulated 24 V** + isolated ignition; don't re-implement the cabinet's surge/breaker/SSR on the HBOX. - **IP67 maintained** — cooling by conduction only; no IP-breaking vents/fans. - **Bench-test firmware before any field flash** (no STM32 build in the sandbox). - Client-facing docs are **Spanish**, routed through Leo. - Use the **file tools** for file changes; verify the shell mount before bulk moves. --- ## 2. Directory (Helgen English `NN-` standard — keep this table current) | Folder | Holds | Key files | |---|---|---| | `00-Project-Management` | plan, ethos, hackathon, **financials**, **handover**, client comms, Drive tooling | [[00-Project-Management/PLAN\|PLAN]] · [[00-Project-Management/Engineering-Handover\|Engineering-Handover]] · `ethos.md` · `hackathon-plan.md` · `Financials.md` · `Drive-Upload/` · `client-comms/` | | `01-Requirements` | what we build | `SRS.md` · `HBOX-product-spec.md` | | `02-Architecture-Software` | backend/software analysis, ADRs | `backend-review.md` | | `03-Architecture-Hardware` | HBOX/cabinet, wiring, BOM, **watchdog PCB v3** | `hardware-respec-and-pcb-brief.md` · `cabinet-electrical-bom.md` · `watchdog-schematic.md` · `watchdog-health-telemetry.md` · `firmware-review.md` · `BOM-master.md` (+§5 Block B/E/H/I parts) · **`watchdog-pcb-v3-design.md`** (schematic spec) · `watchdog-pcb-v3-bom.xlsx` · `watchdog-pcb-v3-kicad-guide.md` (KiCad→JLCPCB) · `watchdog-pcb-v3-blockdiagram.svg` · `watchdog-protoboard-bringup.md` + `watchdog-proto-bench-bringup-v3.md` · `watchdog-connections.xlsx` (PCB pin/net list; H1 DNP; +B/H/I rows) · `watchdog-connections-rationale.md` (+§7 additions 2026-07-02) · **`watchdog-electrical-design-state.md`** (CANONICAL — read first) · **`watchdog-production-schematic-delta.md`** (PROD build spec; LTC4040 §4 values) · `kicad/` — `hbox-watchdog-v3.kicad_sch` (**DEV/proto**) · `hbox-watchdog-v3-PROD.kicad_sch/.kicad_pcb` (**PRODUCTION**: ERC 0, layout started, DRC baseline) · `Drogheda-sym.kicad_sym` (MP1584EN · LTC4040EUFD · AO4406A) · `Drogheda_Conexiones-por-Bloque_Proto_v1.xlsx` (**proto assumptions ledger**) · `Guia-Conexion-Protoboard/` (LaTeX source) → `Drogheda_Guia-Conexion-Protoboard_ES_v2.1.pdf` · `circuitikz-wiring/` (sheet + Beamer v2, blocks 1–11) · `watchdog-protoboard-BOM-3boards.xlsx` + `watchdog-LISTA-DE-COMPRAS-ES.xlsx` (proto BOMs) | | `04-Source-Code` | firmware + backend repos | `firmware/` (**own git repo `hbox-firmware`**: `blackpillrtkcode_v2/` deploy · `legacy/` v1 · `docs/LOGGING-SPEC.md` v2.1) · `htracker/` · `notifications/` · `rtk-config/` | | `05-Analytics-Reports` | SQL views, dashboards (VERONICA/PowerBI), **observability** | `2026-06-22_Drogheda_Manual-Logs-Grafana_v1.0.pdf` (Grafana/Loki log-consultation manual) | | `06-Testing-Validation` | RCA, diagnostics, test evidence, **log analysis & tooling** | `RCA-2026-06-field-failures.md` · `remote-diagnostic-protocol.md` · `2026-06-20_Drogheda_Bench-Log-Analysis_v1.0.md` (rev-3) · `2026-06-20_Drogheda_GNSS-Findings-Summary.md` · `log-analysis/` (repo **`hbox-log-tools`**: `log-explorer.html` · `analyze_logs.py` · `build_dashboard.py` · `docs/manual.pdf`) | | `Marketing` | product-facing collateral (LaTeX→PDF) | `HBOX-Datasheet/` (industrial spec sheet) · `HBOX-Brochure-RTK/` (flyer) | | `99-Archive` | superseded raw inputs (read-only) | `situation_ORIGINAL.md` | | `.claude/skills/` | vendored project skill | `project-drogheda/` | > Structure follows the **[[Helgen Project Template]]** (English `NN-`). The Google > Drive mirror keeps the legacy Spanish `00_…99_` scheme (Drive manual); finalized > deliverables export there. Naming: `AAAA-MM-DD_Drogheda_Descripción_vX.X` — no > loose files in root except this index. **Empty legacy Spanish dirs remain (the > mount can't delete them) — remove locally:** `rmdir 0?_* 99_Archivo docs hardware …` --- ## 3. HBOX BOM (per unit, 24 V variant — see `03-Architecture-Hardware/BOM-master`) simpleRTK2B **Pro** (AS-RTK2B-PROF9P-L1L2-NH-00) · 4G NTRIP Master (AS-XBEE-4G-NA-UFL-00) · Blackpill STM32F411 · U-blox multiband antenna (AS-ANT2B-ANN-L1L2-50SMA) + 2× LTE antennas (AR1582) · **Mean Well SD-15B-05** (24→5 V) · **PowerBoost 1000C** + **18650 1S4P** · **DFR1015** (ignition) · 2N3904 + IRF9540N + 2N7000 watchdog · **GX16-5** HBOX↔cabinet · ASA case/top/ brackets · Telcel micro-SIM. --- ## 4. Deployment & people **BUs / terminals:** ICAVE (stress lab, live), TIMSA, EIT, LCT. **ICAVE machine voltages:** RTG 24 V, Reach Stacker 24 V, Empty Handler 24 V, Tractoplana 12 V, Montacargas 12 V. **Target:** 30 units by August. | Name | Email | Role | |---|---|---| | Leo Rodriguez | leo@helgen.tech / ceo@helgen.tech | Helgen — founder/CEO | | Adriana Del Angel | adriana@helgen.tech | Helgen — implementation/plan | | Paola Rodriguez | paola@helgen.tech | Helgen | | Angel Daniel Martinez | daniel@helgen.tech | Helgen | | Gibran Ortega | gibran@helgen.tech | Helgen — GPS/telemetry | | **Agustín Alfonseca** | alfonseca.agustin@icave.com.mx | **Client** — ICAVE Tech Research Supervisor | | Leon David Piña | pina.david@hutchisonports.com.mx | Hutchison Ports | --- ## 5. Where things live (off this workspace) - **Google Drive (team source of truth):** `Drogheda (GPS RTK)` — official numbered structure 00–99 + manual `LEEME_Drogheda_Estructura_y_Uso`. Mirror this workspace's structure to it for finalized deliverables. - **Second Brain vault** (`~/Documents/Second Brain/03 Projects/Helgen/`): only polished, evergreen notes (decisions, lessons, contacts) — see `Project-Drogheda/` once synced. - **Backend repo:** `ssh://git.helgen.dev:6611/htracker` (retranslator + monitor), cloned at `04-Source-Code/htracker` (branch `feature/test500unidades`). - **Observability (logs):** backend logs ship off-box to **Grafana Loki** (free tier, 50 GB/mo, 14-day) via **Vector** (default) or **Grafana Alloy** reading journald (capped 200 MB) — `04-Source-Code/htracker/log-shipping/` (`README.md` runbook · `setup-logging.sh` · `vector.toml`). Read in Grafana → Explore → Loki: `{job="htracker"}` (Vector) or `{unit="htracker.service"}` (Alloy). Consultation manual (PDF): `05-Analytics-Reports/2026-06-22_Drogheda_Manual-Logs-Grafana_v1.0.pdf`. Creds in `/etc/vector/htracker.env` (server) — never in the repo. - **Firmware repo:** `ssh://git.helgen.dev:6611/hbox-firmware` (STM32F411 watchdog), lives at `04-Source-Code/firmware` (branch `main`) — its own git repo with README, `docs/PINOUT.md`, redacted RTK-config template, CHANGELOG. Push instructions in its README. **v2.1 logging spec** at `docs/LOGGING-SPEC.md` (structured/parseable Blackpill log; not yet flashed). - **Log-tools repo:** `ssh://git.helgen.dev:6611/hbox-log-tools` (HBOX log analysis — in-browser **Log Explorer** + batch **analyzer** + dashboard + Spanish LaTeX **manual**), lives at `06-Testing-Validation/log-analysis/`. Raw logs + config files git-ignored (credentials). Built 2026-06-20. - **Project tracker:** Notion — **`HBOX Unit Status — Bench Triage`** board under *Project Drogheda — GPS RTK* (corrected to rev-3, 2026-06-20) + Mattermost (team chat). --- ## 6. Hard facts — don't relearn these - NMEA GGA quality ≥4 = healthy (4 = RTK-fixed, 5 = RTK-float). - ZED-F9P rated −40…+85 °C — heat casualties are the **18650/PowerBoost** and the **4G modem**, not the GNSS or the case. - **The case is ASA** (UV-stable, softens ~95–100 °C) — adequate for the nested ABS IP67 cabinet interior; the enclosure is **not** the liability. **A bare fan inside a sealed box does not cool it** — conduct heat out, or use a ducted fan (v3.0). See hardware brief §2b. - Corrections come over 4G → recover by power-cycling the stack (v2), not a GNSS reset. Backend can take healthy units off Wialon (HOL block + anti-jump lockout). - HBOX input = **24 V** from the cabinet; design the redesign around that. - Firmware: edit `04-Source-Code/firmware/blackpillrtkcode_v2/blackpillrtkcode_v2.ino` (own git repo `hbox-firmware`); **bench-test before field flash** (sandbox can't build STM32). - **20 Jun logs — receivers are fine; RTK is not being achieved.** Every board emits valid NMEA (good sats/HDOP) but **every epoch is SPS (1), zero RTK (4/5)**. Corrections aren't applied: **free public rtk2go caster** (no SLA), F9P config dumped from **RAM only** (verify saved to FLASH; check the Pro's XBEE↔UART2 switch), plus indoor sky. F9P message config is correct (GGA on UART2 @1 Hz). - **The 4G-NTRIP-Master console does NOT prove forwarding** — a healthy unit logs the same sparse console ("registered", no `State main`/`UDP Bytes sent`) as a failed-looking one. Confirm health only from a `.ubx` (fix), the Blackpill, or a server delivery capture. → **"master-14 ingest fault" RETRACTED**; only **master 21** (modem `0xFFFFF` + 511 AT errors) is a confirmed fault. - **Healthy GNSS baseline = `RTK14NTRIP14_440`** (server-verified 1 Hz delivery, 12 sats, HDOP 0.75, **but SPS not RTK**). Raise the bar to an open-sky fix-≥4 capture. - **Heat is NOT implicated** by the bench logs (faults reproduce cold; v1 has no thermal channel). Field thermal hypothesis still needs a thermocouple cabinet soak. - **`dashboard.html` predates the rev-3 retraction** (still marks the no-forward captures "Failed"); the canonical corrected record is the GNSS summary + the rev-3 findings doc. ## 7. Working notes - Use the **file tools** (Read/Write/Edit) for file changes; the shell mount can go stale — verify before bulk shell moves. Six empty legacy dirs (`docs`, `firmware`, …) remain from the restructure; delete them manually. - Client-facing docs are **Spanish** and route through Leo. ## Objectivity — partner, not sycophant I want an objective partner, not a sycophant. On every task: - **Genuine take first.** Lead with your real assessment. Don't mirror my tone or sentiment, and don't open by validating me. - **Disagree when you disagree.** Say so plainly and explain why — and pair the criticism with a concrete better option (direct *and* constructive). - **Self-check.** If a reply is about to start with something semantically like "You're right" / "Good point" / "Great question," stop and first answer: *"Is this true?"*