card: process that abstracts car interface and CAN (#32380)

* format card

* standalone process

* no class member CS, there's no point

also can be confusing; what else could be using this?

* rename CoS

* Update selfdrive/controls/controlsd.py

* never works first time :D

* canRcvTimeout is bool

* hack

* add cpu

* see what testing closet comes up with

* first

* some clean up

* support passable CI, fix test models

* fix startup alert

* process replay changes

* test_fuzzy

* gate carOutput valid on carControl valid

* we should publish after we update carOutput

* controlsd was using actuatorsOutput from 2 frames ago for torque, not the most up to date

* check all checks for carControl in case controlsd dies

* log more timestamps

* more generic latency logger; needs some clean up

latency_logger.py was difficult to understand and modify

* card polls on can and carControl to get latest carControl possible

* temp try to send earlier

* add log

* remove latencylogger

* no mpld3!

* old loop

* detect first event

* normal send

* revert "card polls on can and carControl to get latest carControl possible"

how it was is best

* sheesh! update should be first

* first timestamp

* temp comment ( timestamp is slow :( )

* more final ordering, and make polling on/off test repeatable

* Received can

* new plot timestamps

* clean up

* no poll

* add controllers (draft)

* Revert "add controllers (draft)"

This reverts commit e2c3f01b2f.

* fix that

* conventions

* just use CS

* consider controlsd state machine in card: not fully done

* hmm it's just becoming controlsd

* rm debugging

* Revert "hmm it's just becoming controlsd"

This reverts commit 534a357ee9.

* Revert "just use CS"

This reverts commit 9fa7406f30.

* add vCruise

* migrate car state

* Revert "migrate car state"

This reverts commit 4ae86ca163.

* Revert "add vCruise"

This reverts commit af247a8da4.

* simple state machine in card (doesn't work as is)

* Revert "simple state machine in card (doesn't work as is)"

This reverts commit b4af8a9b0a.

* poll carState without conflate

* bump

* remove state transition

* fix

* update refs

* ignore cumLagMs and don't ignore valid

* fix controls mismatch; controlsd used to set alt exp

* controlsd_config_callback not needed for card

* revert ref temp

* update refs

* no poll

* not builder!

* test fix

* need to migrate initialized

* CC will be a reader

* more as_reader!

* fix None

* init after publish like before - no real difference

* controlsd clean up

* remove redundant check and check passive for init

* stash

* flip

* migrate missing carOutput for controlsd

* Update ref_commit

* bump cereal

* comment

* no class params

* no class

* Revert "no class"

This reverts commit 5499b83c2d.

* add todo

* regen and update refs

* fix

* update refs

* and fix that

* should be controlsstate

* remove controlsState migration

CoS.initialized isn't needed yet

* fix

* flip!

* bump

* fix that

* update refs

* fix

* if canValid goes false, controlsd would still send

* bump

* rm diff

* need to be very careful with initializing

* update refs

cereal

@@ -1 +1 @@
-Subproject commit 0a9b426e55653daea6cc9d3c40c3f7600ec0db49
+Subproject commit 5812f2c075a5364cecafe4e8ed68a12b12a5631f

selfdrive/car/body/carcontroller.py

@@ -75,7 +75,7 @@ class CarController(CarControllerBase):
     can_sends = []
     can_sends.append(bodycan.create_control(self.packer, torque_l, torque_r))
 
-    new_actuators = CC.actuators.copy()
+    new_actuators = CC.actuators.as_builder()
     new_actuators.accel = torque_l
     new_actuators.steer = torque_r
     new_actuators.steerOutputCan = torque_r

selfdrive/car/card.py

@@ -9,7 +9,7 @@ from cereal import car
 from panda import ALTERNATIVE_EXPERIENCE
 
 from openpilot.common.params import Params
-from openpilot.common.realtime import DT_CTRL
+from openpilot.common.realtime import config_realtime_process, Priority, Ratekeeper, DT_CTRL
 
 from openpilot.selfdrive.boardd.boardd import can_list_to_can_capnp
 from openpilot.selfdrive.car.car_helpers import get_car, get_one_can
@@ -21,22 +21,24 @@ REPLAY = "REPLAY" in os.environ
 EventName = car.CarEvent.EventName
 
 
-class CarD:
+class Car:
   CI: CarInterfaceBase
 
   def __init__(self, CI=None):
     self.can_sock = messaging.sub_sock('can', timeout=20)
-    self.sm = messaging.SubMaster(['pandaStates'])
+    self.sm = messaging.SubMaster(['pandaStates', 'carControl', 'onroadEvents'])
     self.pm = messaging.PubMaster(['sendcan', 'carState', 'carParams', 'carOutput'])
 
     self.can_rcv_timeout_counter = 0  # consecutive timeout count
     self.can_rcv_cum_timeout_counter = 0  # cumulative timeout count
 
     self.CC_prev = car.CarControl.new_message()
+    self.CS_prev = car.CarState.new_message()
+    self.initialized_prev = False
 
-    self.last_actuators = None
+    self.last_actuators_output = car.CarControl.Actuators.new_message()
 
-    self.params = Params()
+    params = Params()
 
     if CI is None:
       # wait for one pandaState and one CAN packet
@@ -44,18 +46,18 @@ class CarD:
       get_one_can(self.can_sock)
 
       num_pandas = len(messaging.recv_one_retry(self.sm.sock['pandaStates']).pandaStates)
-      experimental_long_allowed = self.params.get_bool("ExperimentalLongitudinalEnabled")
+      experimental_long_allowed = params.get_bool("ExperimentalLongitudinalEnabled")
       self.CI, self.CP = get_car(self.can_sock, self.pm.sock['sendcan'], experimental_long_allowed, num_pandas)
     else:
       self.CI, self.CP = CI, CI.CP
 
     # set alternative experiences from parameters
-    self.disengage_on_accelerator = self.params.get_bool("DisengageOnAccelerator")
+    self.disengage_on_accelerator = params.get_bool("DisengageOnAccelerator")
     self.CP.alternativeExperience = 0
     if not self.disengage_on_accelerator:
       self.CP.alternativeExperience |= ALTERNATIVE_EXPERIENCE.DISABLE_DISENGAGE_ON_GAS
 
-    openpilot_enabled_toggle = self.params.get_bool("OpenpilotEnabledToggle")
+    openpilot_enabled_toggle = params.get_bool("OpenpilotEnabledToggle")
 
     controller_available = self.CI.CC is not None and openpilot_enabled_toggle and not self.CP.dashcamOnly
 
@@ -66,22 +68,20 @@ class CarD:
       self.CP.safetyConfigs = [safety_config]
 
     # Write previous route's CarParams
-    prev_cp = self.params.get("CarParamsPersistent")
+    prev_cp = params.get("CarParamsPersistent")
     if prev_cp is not None:
-      self.params.put("CarParamsPrevRoute", prev_cp)
+      params.put("CarParamsPrevRoute", prev_cp)
 
     # Write CarParams for controls and radard
     cp_bytes = self.CP.to_bytes()
-    self.params.put("CarParams", cp_bytes)
-    self.params.put_nonblocking("CarParamsCache", cp_bytes)
-    self.params.put_nonblocking("CarParamsPersistent", cp_bytes)
+    params.put("CarParams", cp_bytes)
+    params.put_nonblocking("CarParamsCache", cp_bytes)
+    params.put_nonblocking("CarParamsPersistent", cp_bytes)
 
-    self.CS_prev = car.CarState.new_message()
     self.events = Events()
 
-  def initialize(self):
-    """Initialize CarInterface, once controls are ready"""
-    self.CI.init(self.CP, self.can_sock, self.pm.sock['sendcan'])
+    # card is driven by can recv, expected at 100Hz
+    self.rk = Ratekeeper(100, print_delay_threshold=None)
 
   def state_update(self) -> car.CarState:
     """carState update loop, driven by can"""
@@ -106,11 +106,6 @@ class CarD:
     if can_rcv_valid and REPLAY:
       self.can_log_mono_time = messaging.log_from_bytes(can_strs[0]).logMonoTime
 
-    self.update_events(CS)
-    self.state_publish(CS)
-
-    CS = CS.as_reader()
-    self.CS_prev = CS
     return CS
 
   def update_events(self, CS: car.CarState) -> car.CarState:
@@ -129,12 +124,6 @@ class CarD:
   def state_publish(self, CS: car.CarState):
     """carState and carParams publish loop"""
 
-    # carState
-    cs_send = messaging.new_message('carState')
-    cs_send.valid = CS.canValid
-    cs_send.carState = CS
-    self.pm.send('carState', cs_send)
-
     # carParams - logged every 50 seconds (> 1 per segment)
     if self.sm.frame % int(50. / DT_CTRL) == 0:
       cp_send = messaging.new_message('carParams')
@@ -144,17 +133,60 @@ class CarD:
 
     # publish new carOutput
     co_send = messaging.new_message('carOutput')
-    co_send.valid = True
-    if self.last_actuators is not None:
-      co_send.carOutput.actuatorsOutput = self.last_actuators
+    co_send.valid = self.sm.all_checks(['carControl'])
+    co_send.carOutput.actuatorsOutput = self.last_actuators_output
     self.pm.send('carOutput', co_send)
 
+    # kick off controlsd step while we actuate the latest carControl packet
+    cs_send = messaging.new_message('carState')
+    cs_send.valid = CS.canValid
+    cs_send.carState = CS
+    cs_send.carState.canRcvTimeout = self.can_rcv_timeout
+    cs_send.carState.canErrorCounter = self.can_rcv_cum_timeout_counter
+    cs_send.carState.cumLagMs = -self.rk.remaining * 1000.
+    self.pm.send('carState', cs_send)
+
   def controls_update(self, CS: car.CarState, CC: car.CarControl):
     """control update loop, driven by carControl"""
 
-    # send car controls over can
-    now_nanos = self.can_log_mono_time if REPLAY else int(time.monotonic() * 1e9)
-    self.last_actuators, can_sends = self.CI.apply(CC, now_nanos)
-    self.pm.send('sendcan', can_list_to_can_capnp(can_sends, msgtype='sendcan', valid=CS.canValid))
+    if not self.initialized_prev:
+      # Initialize CarInterface, once controls are ready
+      self.CI.init(self.CP, self.can_sock, self.pm.sock['sendcan'])
+
+    if self.sm.all_alive(['carControl']):
+      # send car controls over can
+      now_nanos = self.can_log_mono_time if REPLAY else int(time.monotonic() * 1e9)
+      self.last_actuators_output, can_sends = self.CI.apply(CC, now_nanos)
+      self.pm.send('sendcan', can_list_to_can_capnp(can_sends, msgtype='sendcan', valid=CS.canValid))
+
+      self.CC_prev = CC
+
+  def step(self):
+    CS = self.state_update()
+
+    self.update_events(CS)
+
+    self.state_publish(CS)
+
+    initialized = (not any(e.name == EventName.controlsInitializing for e in self.sm['onroadEvents']) and
+                   self.sm.seen['onroadEvents'])
+    if not self.CP.passive and initialized:
+      self.controls_update(CS, self.sm['carControl'])
+
+    self.initialized_prev = initialized
+    self.CS_prev = CS.as_reader()
+
+  def card_thread(self):
+    while True:
+      self.step()
+      self.rk.monitor_time()
+
+
+def main():
+  config_realtime_process(4, Priority.CTRL_HIGH)
+  car = Car()
+  car.card_thread()
+
 
-    self.CC_prev = CC
+if __name__ == "__main__":
+  main()

selfdrive/car/chrysler/carcontroller.py

@@ -78,7 +78,7 @@ class CarController(CarControllerBase):
 
     self.frame += 1
 
-    new_actuators = CC.actuators.copy()
+    new_actuators = CC.actuators.as_builder()
     new_actuators.steer = self.apply_steer_last / self.params.STEER_MAX
     new_actuators.steerOutputCan = self.apply_steer_last
 

selfdrive/car/ford/carcontroller.py

@@ -113,7 +113,7 @@ class CarController(CarControllerBase):
     self.steer_alert_last = steer_alert
     self.lead_distance_bars_last = hud_control.leadDistanceBars
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.curvature = self.apply_curvature_last
 
     self.frame += 1

selfdrive/car/gm/carcontroller.py

@@ -155,7 +155,7 @@ class CarController(CarControllerBase):
       if self.frame % 10 == 0:
         can_sends.append(gmcan.create_pscm_status(self.packer_pt, CanBus.CAMERA, CS.pscm_status))
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steer = self.apply_steer_last / self.params.STEER_MAX
     new_actuators.steerOutputCan = self.apply_steer_last
     new_actuators.gas = self.apply_gas

selfdrive/car/honda/carcontroller.py

@@ -244,7 +244,7 @@ class CarController(CarControllerBase):
         self.speed = pcm_speed
         self.gas = pcm_accel / self.params.NIDEC_GAS_MAX
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.speed = self.speed
     new_actuators.accel = self.accel
     new_actuators.gas = self.gas

selfdrive/car/hyundai/carcontroller.py

@@ -163,7 +163,7 @@ class CarController(CarControllerBase):
       if self.frame % 50 == 0 and self.CP.openpilotLongitudinalControl:
         can_sends.append(hyundaican.create_frt_radar_opt(self.packer))
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steer = apply_steer / self.params.STEER_MAX
     new_actuators.steerOutputCan = apply_steer
     new_actuators.accel = accel

selfdrive/car/mazda/carcontroller.py

@@ -58,7 +58,7 @@ class CarController(CarControllerBase):
     can_sends.append(mazdacan.create_steering_control(self.packer, self.CP,
                                                       self.frame, apply_steer, CS.cam_lkas))
 
-    new_actuators = CC.actuators.copy()
+    new_actuators = CC.actuators.as_builder()
     new_actuators.steer = apply_steer / CarControllerParams.STEER_MAX
     new_actuators.steerOutputCan = apply_steer
 

selfdrive/car/mock/carcontroller.py

@@ -2,4 +2,4 @@ from openpilot.selfdrive.car.interfaces import CarControllerBase
 
 class CarController(CarControllerBase):
   def update(self, CC, CS, now_nanos):
-    return CC.actuators.copy(), []
+    return CC.actuators.as_builder(), []

selfdrive/car/nissan/carcontroller.py

@@ -75,7 +75,7 @@ class CarController(CarControllerBase):
           self.packer, CS.lkas_hud_info_msg, steer_hud_alert
         ))
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steeringAngleDeg = apply_angle
 
     self.frame += 1

selfdrive/car/subaru/carcontroller.py

@@ -136,7 +136,7 @@ class CarController(CarControllerBase):
         if self.frame % 2 == 0:
           can_sends.append(subarucan.create_es_static_2(self.packer))
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steer = self.apply_steer_last / self.p.STEER_MAX
     new_actuators.steerOutputCan = self.apply_steer_last
 

selfdrive/car/tesla/carcontroller.py

@@ -60,7 +60,7 @@ class CarController(CarControllerBase):
 
     # TODO: HUD control
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steeringAngleDeg = self.apply_angle_last
 
     self.frame += 1

selfdrive/car/tests/test_car_interfaces.py

@@ -91,14 +91,14 @@ class TestCarInterfaces:
     CC = car.CarControl.new_message(**cc_msg)
     for _ in range(10):
       car_interface.update(CC, [])
-      car_interface.apply(CC, now_nanos)
+      car_interface.apply(CC.as_reader(), now_nanos)
       now_nanos += DT_CTRL * 1e9  # 10 ms
 
     CC = car.CarControl.new_message(**cc_msg)
     CC.enabled = True
     for _ in range(10):
       car_interface.update(CC, [])
-      car_interface.apply(CC, now_nanos)
+      car_interface.apply(CC.as_reader(), now_nanos)
       now_nanos += DT_CTRL * 1e9  # 10ms
 
     # Test controller initialization

selfdrive/car/tests/test_models.py

@@ -15,7 +15,7 @@ from openpilot.common.basedir import BASEDIR
 from openpilot.common.params import Params
 from openpilot.common.realtime import DT_CTRL
 from openpilot.selfdrive.car import gen_empty_fingerprint
-from openpilot.selfdrive.car.card import CarD
+from openpilot.selfdrive.car.card import Car
 from openpilot.selfdrive.car.fingerprints import all_known_cars, MIGRATION
 from openpilot.selfdrive.car.car_helpers import FRAME_FINGERPRINT, interfaces
 from openpilot.selfdrive.car.honda.values import CAR as HONDA, HondaFlags
@@ -215,7 +215,7 @@ class TestCarModelBase(unittest.TestCase):
     # TODO: also check for checksum violations from can parser
     can_invalid_cnt = 0
     can_valid = False
-    CC = car.CarControl.new_message()
+    CC = car.CarControl.new_message().as_reader()
 
     for i, msg in enumerate(self.can_msgs):
       CS = self.CI.update(CC, (msg.as_builder().to_bytes(),))
@@ -308,17 +308,17 @@ class TestCarModelBase(unittest.TestCase):
 
     # Make sure we can send all messages while inactive
     CC = car.CarControl.new_message()
-    test_car_controller(CC)
+    test_car_controller(CC.as_reader())
 
     # Test cancel + general messages (controls_allowed=False & cruise_engaged=True)
     self.safety.set_cruise_engaged_prev(True)
     CC = car.CarControl.new_message(cruiseControl={'cancel': True})
-    test_car_controller(CC)
+    test_car_controller(CC.as_reader())
 
     # Test resume + general messages (controls_allowed=True & cruise_engaged=True)
     self.safety.set_controls_allowed(True)
     CC = car.CarControl.new_message(cruiseControl={'resume': True})
-    test_car_controller(CC)
+    test_car_controller(CC.as_reader())
 
   # Skip stdout/stderr capture with pytest, causes elevated memory usage
   @pytest.mark.nocapture
@@ -406,7 +406,7 @@ class TestCarModelBase(unittest.TestCase):
     controls_allowed_prev = False
     CS_prev = car.CarState.new_message()
     checks = defaultdict(int)
-    card = CarD(CI=self.CI)
+    card = Car(CI=self.CI)
     for idx, can in enumerate(self.can_msgs):
       CS = self.CI.update(CC, (can.as_builder().to_bytes(), ))
       for msg in filter(lambda m: m.src in range(64), can.can):

selfdrive/car/toyota/carcontroller.py

@@ -168,7 +168,7 @@ class CarController(CarControllerBase):
     if self.frame % 20 == 0 and self.CP.flags & ToyotaFlags.DISABLE_RADAR.value:
       can_sends.append([0x750, 0, b"\x0F\x02\x3E\x00\x00\x00\x00\x00", 0])
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steer = apply_steer / self.params.STEER_MAX
     new_actuators.steerOutputCan = apply_steer
     new_actuators.steeringAngleDeg = self.last_angle

selfdrive/car/volkswagen/carcontroller.py

@@ -112,7 +112,7 @@ class CarController(CarControllerBase):
       can_sends.append(self.CCS.create_acc_buttons_control(self.packer_pt, self.ext_bus, CS.gra_stock_values,
                                                            cancel=CC.cruiseControl.cancel, resume=CC.cruiseControl.resume))
 
-    new_actuators = actuators.copy()
+    new_actuators = actuators.as_builder()
     new_actuators.steer = self.apply_steer_last / self.CCP.STEER_MAX
     new_actuators.steerOutputCan = self.apply_steer_last
 

selfdrive/controls/controlsd.py

@@ -18,8 +18,7 @@ from openpilot.common.params import Params
 from openpilot.common.realtime import config_realtime_process, Priority, Ratekeeper, DT_CTRL
 from openpilot.common.swaglog import cloudlog
 
-from openpilot.selfdrive.car.car_helpers import get_startup_event
-from openpilot.selfdrive.car.card import CarD
+from openpilot.selfdrive.car.car_helpers import get_car_interface, get_startup_event
 from openpilot.selfdrive.controls.lib.alertmanager import AlertManager, set_offroad_alert
 from openpilot.selfdrive.controls.lib.drive_helpers import VCruiseHelper, clip_curvature
 from openpilot.selfdrive.controls.lib.events import Events, ET
@@ -61,16 +60,19 @@ ENABLED_STATES = (State.preEnabled, *ACTIVE_STATES)
 
 class Controls:
   def __init__(self, CI=None):
-    self.card = CarD(CI)
-
     self.params = Params()
 
-    with car.CarParams.from_bytes(self.params.get("CarParams", block=True)) as msg:
-      # TODO: this shouldn't need to be a builder
-      self.CP = msg.as_builder()
-
-    self.CI = self.card.CI
+    if CI is None:
+      cloudlog.info("controlsd is waiting for CarParams")
+      with car.CarParams.from_bytes(self.params.get("CarParams", block=True)) as msg:
+        # TODO: this shouldn't need to be a builder
+        self.CP = msg.as_builder()
+      cloudlog.info("controlsd got CarParams")
 
+      # Uses car interface helper functions, altering state won't be considered by card for actuation
+      self.CI = get_car_interface(self.CP)
+    else:
+      self.CI, self.CP = CI, CI.CP
 
     # Ensure the current branch is cached, otherwise the first iteration of controlsd lags
     self.branch = get_short_branch()
@@ -83,6 +85,9 @@ class Controls:
 
     self.log_sock = messaging.sub_sock('androidLog')
 
+    # TODO: de-couple controlsd with card/conflate on carState without introducing controls mismatches
+    self.car_state_sock = messaging.sub_sock('carState', timeout=20)
+
     ignore = self.sensor_packets + ['testJoystick']
     if SIMULATION:
       ignore += ['driverCameraState', 'managerState']
@@ -110,6 +115,7 @@ class Controls:
     if not self.CP.openpilotLongitudinalControl:
       self.params.remove("ExperimentalMode")
 
+    self.CS_prev = car.CarState.new_message()
     self.AM = AlertManager()
     self.events = Events()
 
@@ -161,7 +167,7 @@ class Controls:
     elif self.CP.passive:
       self.events.add(EventName.dashcamMode, static=True)
 
-    # controlsd is driven by can recv, expected at 100Hz
+    # controlsd is driven by carState, expected at 100Hz
     self.rk = Ratekeeper(100, print_delay_threshold=None)
 
   def set_initial_state(self):
@@ -308,7 +314,7 @@ class Controls:
     # generic catch-all. ideally, a more specific event should be added above instead
     has_disable_events = self.events.contains(ET.NO_ENTRY) and (self.events.contains(ET.SOFT_DISABLE) or self.events.contains(ET.IMMEDIATE_DISABLE))
     no_system_errors = (not has_disable_events) or (len(self.events) == num_events)
-    if (not self.sm.all_checks() or self.card.can_rcv_timeout) and no_system_errors:
+    if (not self.sm.all_checks() or CS.canRcvTimeout) and no_system_errors:
       if not self.sm.all_alive():
         self.events.add(EventName.commIssue)
       elif not self.sm.all_freq_ok():
@@ -320,7 +326,7 @@ class Controls:
         'invalid': [s for s, valid in self.sm.valid.items() if not valid],
         'not_alive': [s for s, alive in self.sm.alive.items() if not alive],
         'not_freq_ok': [s for s, freq_ok in self.sm.freq_ok.items() if not freq_ok],
-        'can_rcv_timeout': self.card.can_rcv_timeout,
+        'can_rcv_timeout': CS.canRcvTimeout,
       }
       if logs != self.logged_comm_issue:
         cloudlog.event("commIssue", error=True, **logs)
@@ -380,9 +386,10 @@ class Controls:
         self.events.add(EventName.modeldLagging)
 
   def data_sample(self):
-    """Receive data from sockets and update carState"""
+    """Receive data from sockets"""
 
-    CS = self.card.state_update()
+    car_state = messaging.recv_one(self.car_state_sock)
+    CS = car_state.carState if car_state else self.CS_prev
 
     self.sm.update(0)
 
@@ -396,9 +403,6 @@ class Controls:
         if VisionStreamType.VISION_STREAM_WIDE_ROAD not in available_streams:
           self.sm.ignore_alive.append('wideRoadCameraState')
 
-        if not self.CP.passive:
-          self.card.initialize()
-
         self.initialized = True
         self.set_initial_state()
         self.params.put_bool_nonblocking("ControlsReady", True)
@@ -709,7 +713,6 @@ class Controls:
       hudControl.visualAlert = current_alert.visual_alert
 
     if not self.CP.passive and self.initialized:
-      self.card.controls_update(CS, CC)
       CO = self.sm['carOutput']
       if self.CP.steerControlType == car.CarParams.SteerControlType.angle:
         self.steer_limited = abs(CC.actuators.steeringAngleDeg - CO.actuatorsOutput.steeringAngleDeg) > \
@@ -757,7 +760,6 @@ class Controls:
     controlsState.cumLagMs = -self.rk.remaining * 1000.
     controlsState.startMonoTime = int(start_time * 1e9)
     controlsState.forceDecel = bool(force_decel)
-    controlsState.canErrorCounter = self.card.can_rcv_cum_timeout_counter
     controlsState.experimentalMode = self.experimental_mode
     controlsState.personality = self.personality
 
@@ -807,6 +809,8 @@ class Controls:
     # Publish data
     self.publish_logs(CS, start_time, CC, lac_log)
 
+    self.CS_prev = CS
+
   def read_personality_param(self):
     try:
       return int(self.params.get('LongitudinalPersonality'))

selfdrive/controls/tests/test_startup.py

@@ -87,6 +87,7 @@ def test_startup_alert(expected_event, car_model, fw_versions, brand):
     os.environ['SKIP_FW_QUERY'] = '1'
 
   managed_processes['controlsd'].start()
+  managed_processes['card'].start()
 
   assert pm.wait_for_readers_to_update('can', 5)
   pm.send('can', can_list_to_can_capnp([[0, 0, b"", 0]]))
@@ -104,7 +105,7 @@ def test_startup_alert(expected_event, car_model, fw_versions, brand):
 
   msgs = [[addr, 0, b'\x00'*length, 0] for addr, length in finger.items()]
   for _ in range(1000):
-    # controlsd waits for boardd to echo back that it has changed the multiplexing mode
+    # card waits for boardd to echo back that it has changed the multiplexing mode
     if not params.get_bool("ObdMultiplexingChanged"):
       params.put_bool("ObdMultiplexingChanged", True)
 

selfdrive/manager/process_config.py

@@ -64,6 +64,7 @@ procs = [
   PythonProcess("calibrationd", "selfdrive.locationd.calibrationd", only_onroad),
   PythonProcess("torqued", "selfdrive.locationd.torqued", only_onroad),
   PythonProcess("controlsd", "selfdrive.controls.controlsd", only_onroad),
+  PythonProcess("card", "selfdrive.car.card", only_onroad),
   PythonProcess("deleter", "system.loggerd.deleter", always_run),
   PythonProcess("dmonitoringd", "selfdrive.monitoring.dmonitoringd", driverview, enabled=(not PC or WEBCAM)),
   PythonProcess("qcomgpsd", "system.qcomgpsd.qcomgpsd", qcomgps, enabled=TICI),

selfdrive/test/process_replay/migration.py

@@ -14,6 +14,7 @@ def migrate_all(lr, old_logtime=False, manager_states=False, panda_states=False,
   msgs = migrate_carParams(msgs, old_logtime)
   msgs = migrate_gpsLocation(msgs)
   msgs = migrate_deviceState(msgs)
+  msgs = migrate_carOutput(msgs)
   if manager_states:
     msgs = migrate_managerState(msgs)
   if panda_states:
@@ -69,6 +70,23 @@ def migrate_deviceState(lr):
   return all_msgs
 
 
+def migrate_carOutput(lr):
+  # migration needed only for routes before carOutput
+  if any(msg.which() == 'carOutput' for msg in lr):
+    return lr
+
+  all_msgs = []
+  for msg in lr:
+    if msg.which() == 'carControl':
+      co = messaging.new_message('carOutput')
+      co.valid = msg.valid
+      co.logMonoTime = msg.logMonoTime
+      co.carOutput.actuatorsOutput = msg.carControl.actuatorsOutputDEPRECATED
+      all_msgs.append(co.as_reader())
+    all_msgs.append(msg)
+  return all_msgs
+
+
 def migrate_pandaStates(lr):
   all_msgs = []
   # TODO: safety param migration should be handled automatically

selfdrive/test/process_replay/process_replay.py

@@ -317,12 +317,12 @@ class ProcessContainer:
     return output_msgs
 
 
-def controlsd_fingerprint_callback(rc, pm, msgs, fingerprint):
+def card_fingerprint_callback(rc, pm, msgs, fingerprint):
   print("start fingerprinting")
   params = Params()
   canmsgs = [msg for msg in msgs if msg.which() == "can"][:300]
 
-  # controlsd expects one arbitrary can and pandaState
+  # card expects one arbitrary can and pandaState
   rc.send_sync(pm, "can", messaging.new_message("can", 1))
   pm.send("pandaStates", messaging.new_message("pandaStates", 1))
   rc.send_sync(pm, "can", messaging.new_message("can", 1))
@@ -356,12 +356,20 @@ def get_car_params_callback(rc, pm, msgs, fingerprint):
     for m in canmsgs[:300]:
       can.send(m.as_builder().to_bytes())
     _, CP = get_car(can, sendcan, Params().get_bool("ExperimentalLongitudinalEnabled"))
+
+    if not params.get_bool("DisengageOnAccelerator"):
+      CP.alternativeExperience |= ALTERNATIVE_EXPERIENCE.DISABLE_DISENGAGE_ON_GAS
+
   params.put("CarParams", CP.to_bytes())
   return CP
 
 
 def controlsd_rcv_callback(msg, cfg, frame):
-  # no sendcan until controlsd is initialized
+  return (frame - 1) == 0 or msg.which() == 'carState'
+
+
+def card_rcv_callback(msg, cfg, frame):
+  # no sendcan until card is initialized
   if msg.which() != "can":
     return False
 
@@ -461,18 +469,28 @@ CONFIGS = [
   ProcessConfig(
     proc_name="controlsd",
     pubs=[
-      "can", "deviceState", "pandaStates", "peripheralState", "liveCalibration", "driverMonitoringState",
+      "carState", "deviceState", "pandaStates", "peripheralState", "liveCalibration", "driverMonitoringState",
       "longitudinalPlan", "liveLocationKalman", "liveParameters", "radarState",
       "modelV2", "driverCameraState", "roadCameraState", "wideRoadCameraState", "managerState",
-      "testJoystick", "liveTorqueParameters", "accelerometer", "gyroscope"
+      "testJoystick", "liveTorqueParameters", "accelerometer", "gyroscope", "carOutput"
     ],
-    subs=["controlsState", "carState", "carControl", "carOutput", "sendcan", "onroadEvents", "carParams"],
+    subs=["controlsState", "carControl", "onroadEvents"],
     ignore=["logMonoTime", "controlsState.startMonoTime", "controlsState.cumLagMs"],
     config_callback=controlsd_config_callback,
-    init_callback=controlsd_fingerprint_callback,
+    init_callback=get_car_params_callback,
     should_recv_callback=controlsd_rcv_callback,
     tolerance=NUMPY_TOLERANCE,
     processing_time=0.004,
+  ),
+  ProcessConfig(
+    proc_name="card",
+    pubs=["pandaStates", "carControl", "onroadEvents", "can"],
+    subs=["sendcan", "carState", "carParams", "carOutput"],
+    ignore=["logMonoTime", "carState.cumLagMs"],
+    init_callback=card_fingerprint_callback,
+    should_recv_callback=card_rcv_callback,
+    tolerance=NUMPY_TOLERANCE,
+    processing_time=0.004,
     main_pub="can",
   ),
   ProcessConfig(

selfdrive/test/process_replay/ref_commit

@@ -1 +1 @@
-cc4e23ca0fceb300a3048c187ae9bc793794c095
+c84b55c256ccb0ee042643a8a7f7f4dc429ff157

selfdrive/test/process_replay/test_fuzzy.py

@@ -12,7 +12,7 @@ import openpilot.selfdrive.test.process_replay.process_replay as pr
 # These processes currently fail because of unrealistic data breaking assumptions
 # that openpilot makes causing error with NaN, inf, int size, array indexing ...
 # TODO: Make each one testable
-NOT_TESTED = ['controlsd', 'plannerd', 'calibrationd', 'dmonitoringd', 'paramsd', 'dmonitoringmodeld', 'modeld']
+NOT_TESTED = ['controlsd', 'card', 'plannerd', 'calibrationd', 'dmonitoringd', 'paramsd', 'dmonitoringmodeld', 'modeld']
 
 TEST_CASES = [(cfg.proc_name, copy.deepcopy(cfg)) for cfg in pr.CONFIGS if cfg.proc_name not in NOT_TESTED]
 

selfdrive/test/process_replay/test_processes.py

@@ -41,23 +41,23 @@ source_segments = [
 ]
 
 segments = [
-  ("BODY", "regen02ECB79BACC|2024-05-18--04-29-29--0"),
-  ("HYUNDAI", "regen845DC1916E6|2024-05-18--04-30-52--0"),
-  ("HYUNDAI2", "regenBAE0915FE22|2024-05-18--04-33-11--0"),
-  ("TOYOTA", "regen1108D19FC2E|2024-05-18--04-34-34--0"),
-  ("TOYOTA2", "regen846521F39C7|2024-05-18--04-35-58--0"),
-  ("TOYOTA3", "regen788C3623D11|2024-05-18--04-38-21--0"),
-  ("HONDA", "regenDE43F170E99|2024-05-18--04-39-47--0"),
-  ("HONDA2", "regen1EE0FA383C3|2024-05-18--04-41-12--0"),
-  ("CHRYSLER", "regen9C5A30F471C|2024-05-18--04-42-36--0"),
-  ("RAM", "regenCCA313D117D|2024-05-18--04-44-53--0"),
-  ("SUBARU", "regenA41511F882A|2024-05-18--04-47-14--0"),
-  ("GM", "regen9D7B9CE4A66|2024-05-18--04-48-36--0"),
-  ("GM2", "regen07CECA52D41|2024-05-18--04-50-55--0"),
-  ("NISSAN", "regen2D6B856D0AE|2024-05-18--04-52-17--0"),
-  ("VOLKSWAGEN", "regen2D3AC6A6F05|2024-05-18--04-53-41--0"),
-  ("MAZDA", "regen0D5A777DD16|2024-05-18--04-56-02--0"),
-  ("FORD", "regen235D0937965|2024-05-18--04-58-16--0"),
+  ("BODY", "regen29FD9FF7760|2024-05-21--06-58-51--0"),
+  ("HYUNDAI", "regen0B1B76A1C27|2024-05-21--06-57-53--0"),
+  ("HYUNDAI2", "regen3BB55FA5E20|2024-05-21--06-59-03--0"),
+  ("TOYOTA", "regenF6FB954C1E2|2024-05-21--06-57-53--0"),
+  ("TOYOTA2", "regen0AC637CE7BA|2024-05-21--06-57-54--0"),
+  ("TOYOTA3", "regenC7BE3FAE496|2024-05-21--06-59-01--0"),
+  ("HONDA", "regen58E9F8B695A|2024-05-21--06-57-55--0"),
+  ("HONDA2", "regen8695608EB15|2024-05-21--06-57-55--0"),
+  ("CHRYSLER", "regenB0F8C25C902|2024-05-21--06-59-47--0"),
+  ("RAM", "regenB3B2C7A105B|2024-05-21--07-00-47--0"),
+  ("SUBARU", "regen860FD736DCC|2024-05-21--07-00-50--0"),
+  ("GM", "regen8CB3048DEB9|2024-05-21--06-59-49--0"),
+  ("GM2", "regen379D446541D|2024-05-21--07-00-51--0"),
+  ("NISSAN", "regen24871108F80|2024-05-21--07-00-38--0"),
+  ("VOLKSWAGEN", "regenF390392F275|2024-05-21--07-00-52--0"),
+  ("MAZDA", "regenE5A36020581|2024-05-21--07-01-51--0"),
+  ("FORD", "regenDC288ED0D78|2024-05-21--07-02-18--0"),
 ]
 
 # dashcamOnly makes don't need to be tested until a full port is done
@@ -109,7 +109,7 @@ def test_process(cfg, lr, segment, ref_log_path, new_log_path, ignore_fields=Non
     if not check_openpilot_enabled(log_msgs):
       return f"Route did not enable at all or for long enough: {new_log_path}", log_msgs
 
-  if cfg.proc_name != 'ubloxd' or segment != 'regenBAE0915FE22|2024-05-18--04-33-11--0':
+  if cfg.proc_name != 'ubloxd' or segment != 'regen3BB55FA5E20|2024-05-21--06-59-03--0':
     seen_msgs = {m.which() for m in log_msgs}
     expected_msgs = set(cfg.subs)
     if seen_msgs != expected_msgs:

selfdrive/test/test_onroad.py

@@ -35,7 +35,8 @@ CPU usage budget
 MAX_TOTAL_CPU = 250.  # total for all 8 cores
 PROCS = {
   # Baseline CPU usage by process
-  "selfdrive.controls.controlsd": 46.0,
+  "selfdrive.controls.controlsd": 32.0,
+  "selfdrive.car.card": 22.0,
   "./loggerd": 14.0,
   "./encoderd": 17.0,
   "./camerad": 14.5,