IQ.Pilot Release Commit @ bf3880a

artifacts/iqpilot_alc_private/manifest.json

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artifacts/iqpilot_commander_private/manifest.json

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artifacts/iqpilot_hephaestusd_private/manifest.json

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system/hardware/hardwared.py

@@ -34,6 +34,10 @@ TEMP_TAU = 5.   # 5s time constant
 DISCONNECT_TIMEOUT = 5.  # wait 5 seconds before going offroad after disconnect so you get an alert
 PANDA_STATES_TIMEOUT = round(1000 / SERVICE_LIST['pandaStates'].frequency * 1.5)  # 1.5x the expected pandaState frequency
 ONROAD_CYCLE_TIME = 1  # seconds to wait offroad after requesting an onroad cycle
+CAN_STARTUP_RECOVERY_DELAY = 3.  # require a persistent CAN timeout before cycling onroad processes
+CAN_STARTUP_RECOVERY_WINDOW = 30.  # only recover shortly after ignition turns on
+CAN_STARTUP_RECOVERY_COOLDOWN = 5.  # allow the restarted car stack time to initialize
+CAN_STARTUP_RECOVERY_MAX_ATTEMPTS = 2
 
 ThermalBand = namedtuple("ThermalBand", ['min_temp', 'max_temp'])
 HardwareState = namedtuple("HardwareState", ['network_type', 'network_info', 'network_strength', 'network_stats',
@@ -55,6 +59,54 @@ prev_offroad_states: dict[str, tuple[bool, str | None]] = {}
 ALLOWED_TICI_BRANCHES = {"release-new", "release-tici", "master-mici", "beta", "beta-pq", "release-prebuilt"}
 
 
+class CanStartupRecovery:
+  """Bounded recovery for a car stack that starts without a usable CAN stream."""
+
+  def __init__(self) -> None:
+    self.ignition_on_ts: float | None = None
+    self.timeout_started_ts: float | None = None
+    self.last_attempt_ts: float | None = None
+    self.attempts = 0
+
+  def update(self, now: float, ignition: bool, started: bool, engaged: bool,
+             car_state_alive: bool, can_timeout: bool, v_ego: float) -> bool:
+    if not ignition:
+      self.ignition_on_ts = None
+      self.timeout_started_ts = None
+      self.last_attempt_ts = None
+      self.attempts = 0
+      return False
+
+    if self.ignition_on_ts is None:
+      self.ignition_on_ts = now
+
+    eligible = (
+      started
+      and not engaged
+      and car_state_alive
+      and can_timeout
+      and abs(v_ego) < 0.1
+      and (now - self.ignition_on_ts) <= CAN_STARTUP_RECOVERY_WINDOW
+      and self.attempts < CAN_STARTUP_RECOVERY_MAX_ATTEMPTS
+      and (self.last_attempt_ts is None or (now - self.last_attempt_ts) >= CAN_STARTUP_RECOVERY_COOLDOWN)
+    )
+    if not eligible:
+      self.timeout_started_ts = None
+      return False
+
+    if self.timeout_started_ts is None:
+      self.timeout_started_ts = now
+      return False
+
+    if (now - self.timeout_started_ts) < CAN_STARTUP_RECOVERY_DELAY:
+      return False
+
+    self.attempts += 1
+    self.last_attempt_ts = now
+    self.timeout_started_ts = None
+    return True
+
+
 def get_top_memory_processes(limit: int = 5) -> list[dict[str, object]]:
   procs: list[dict[str, object]] = []
   for proc in psutil.process_iter(['pid', 'name', 'memory_info', 'memory_percent']):
@@ -212,7 +264,7 @@ def hw_state_thread(end_event, hw_queue):
 
 def hardware_thread(end_event, hw_queue) -> None:
   pm = messaging.PubMaster(['deviceState', 'iqPerfTrace'])
-  sm = messaging.SubMaster(["peripheralState", "gpsLocationExternal", "selfdriveState", "pandaStates"], poll="pandaStates")
+  sm = messaging.SubMaster(["peripheralState", "gpsLocationExternal", "selfdriveState", "pandaStates", "carState"], poll="pandaStates")
   perf = PerfTraceEmitter("hardwared", pubmaster=pm)
 
   count = 0
@@ -250,6 +302,7 @@ def hardware_thread(end_event, hw_queue) -> None:
   low_power = False
   low_power_prev = False
   offroad_cycle_count = 0
+  can_startup_recovery = CanStartupRecovery()
 
   params = Params()
   power_monitor = PowerMonitoring()
@@ -274,6 +327,19 @@ def hardware_thread(end_event, hw_queue) -> None:
     if params.get_bool("OnroadCycleRequested"):
       params.put_bool("OnroadCycleRequested", False)
       offroad_cycle_count = sm.frame
+
+    car_state = sm['carState']
+    if can_startup_recovery.update(
+      time.monotonic(),
+      ignition=onroad_conditions["ignition"],
+      started=started_ts is not None,
+      engaged=sm['selfdriveState'].enabled,
+      car_state_alive=sm.alive['carState'],
+      can_timeout=car_state.canTimeout,
+      v_ego=car_state.vEgo,
+    ):
+      offroad_cycle_count = sm.frame
+      cloudlog.event("automatic CAN startup recovery", attempt=can_startup_recovery.attempts, error=True)
     onroad_conditions["not_onroad_cycle"] = (sm.frame - offroad_cycle_count) >= ONROAD_CYCLE_TIME * SERVICE_LIST['pandaStates'].frequency
 
     if sm.updated['pandaStates'] and len(pandaStates) > 0:

system/hardware/tests/test_hardwared.py

@@ -1,6 +1,13 @@
 from types import SimpleNamespace
 
-from openpilot.system.hardware.hardwared import ALLOWED_TICI_BRANCHES, is_supported_tici_branch
+from openpilot.system.hardware.hardwared import (
+  ALLOWED_TICI_BRANCHES,
+  CAN_STARTUP_RECOVERY_COOLDOWN,
+  CAN_STARTUP_RECOVERY_DELAY,
+  CAN_STARTUP_RECOVERY_MAX_ATTEMPTS,
+  CanStartupRecovery,
+  is_supported_tici_branch,
+)
 
 
 def test_beta_pq_allowed_for_tici():
@@ -17,3 +24,52 @@ def test_tici_channel_type_allowed():
 def test_unsupported_branch_rejected_for_tici():
   metadata = SimpleNamespace(channel="random-branch", channel_type="dev")
   assert not is_supported_tici_branch(metadata)
+
+
+def recovery_update(recovery: CanStartupRecovery, now: float, **kwargs) -> bool:
+  defaults = {
+    "ignition": True,
+    "started": True,
+    "engaged": False,
+    "car_state_alive": True,
+    "can_timeout": True,
+    "v_ego": 0.,
+  }
+  return recovery.update(now, **(defaults | kwargs))
+
+
+def test_can_startup_recovery_requires_persistent_timeout():
+  recovery = CanStartupRecovery()
+  assert not recovery_update(recovery, 10.)
+  assert not recovery_update(recovery, 10. + CAN_STARTUP_RECOVERY_DELAY - 0.1)
+  assert recovery_update(recovery, 10. + CAN_STARTUP_RECOVERY_DELAY)
+
+
+def test_can_startup_recovery_only_when_safe():
+  for unsafe_state in (
+    {"started": False},
+    {"engaged": True},
+    {"car_state_alive": False},
+    {"can_timeout": False},
+    {"v_ego": 0.2},
+  ):
+    recovery = CanStartupRecovery()
+    assert not recovery_update(recovery, 10., **unsafe_state)
+    assert not recovery_update(recovery, 10. + CAN_STARTUP_RECOVERY_DELAY, **unsafe_state)
+
+
+def test_can_startup_recovery_is_bounded_and_resets_next_ignition():
+  recovery = CanStartupRecovery()
+  now = 10.
+  for _ in range(CAN_STARTUP_RECOVERY_MAX_ATTEMPTS):
+    assert not recovery_update(recovery, now)
+    now += CAN_STARTUP_RECOVERY_DELAY
+    assert recovery_update(recovery, now)
+    now += CAN_STARTUP_RECOVERY_COOLDOWN
+
+  assert not recovery_update(recovery, now)
+  assert not recovery_update(recovery, now + CAN_STARTUP_RECOVERY_DELAY)
+
+  assert not recovery_update(recovery, now + 10., ignition=False)
+  assert not recovery_update(recovery, now + 11.)
+  assert recovery_update(recovery, now + 11. + CAN_STARTUP_RECOVERY_DELAY)