Dear ModalAI Support Team,

I am writing to report a critical issue with my Stinger drone (SKU: MRB-D0013). I have recently installed a brand new VOXL 2 Mini flight controller on this unit. Despite extensive troubleshooting, including resetting to factory defaults and comparing with a working Starling 2 (D0014), the VIO system fails to initialize correctly and diverges immediately.

We suspect a hardware defect related to the IMU orientation, camera focus/calibration, or an incompatibility with the default configuration for this specific unit.

Issue Summary

• Symptom: VIO (both QVIO and OpenVINS) diverges immediately or reports "BAD_CAM_CAL".
• Observation:
  • In VOXL Portal, the VIO overlay shows the drone's estimated position diverging.
  • When manually moving the drone, the VIO estimated motion is often inverted (e.g., pitching up is interpreted as pitching down) or axes are swapped, even with default extrinsics.
  • voxl-qvio-server reports BAD_CAM_CAL and NOT_STATIONARY errors.
  • voxl-calibrate-camera fails for both tracking_front and tracking_down with high re-projection errors (> 0.9), citing "motion blur" even in a well-lit, static environment.

Troubleshooting Steps Taken

1. Factory Reset:

   • Ran voxl-configure-mpa (factory reset).
   • Ran voxl-configure-extrinsics D0013_Stinger (reset to default D0013 extrinsics).
   • Ran voxl-configure-cameras 22 (reset to default Stinger Dual AR0144 config).
   • Result: VIO still diverges with BAD_CAM_CAL.

2. IMU Data Analysis:

   • Analyzed voxl-inspect-imu imu_apps raw data (with rotate_common_frame: false and true).
   • The IMU data suggests the physical orientation might be different from what the default configuration expects (Roll 180 + Yaw 180 vs just Roll 180), or the driver correction is not applying as intended for this specific unit.
   • Even when manually adjusting extrinsics.conf to match the observed IMU orientation (FLU) and Camera orientation (FRD), VIO stability could not be achieved.

3. Comparison with Starling 2 (D0014):

   • We have a working Starling 2 unit. Applying Starling 2's configuration to Stinger (as a test) also resulted in divergence, confirming the hardware configuration is indeed different or defective.

4. Camera Calibration:

   • Attempted voxl-calibrate-camera for both cameras.
   • Consistently fails with high re-projection error, suggesting potential lens focus issues or sensor alignment problems.

Request

Since we are using a brand new VOXL 2 Mini board, we want to ensure there are no configuration mismatches or firmware issues. However, given that it fails to operate with factory default settings and cannot be calibrated, we are concerned about a potential initial defect in the sensor modules or the board itself.

Please review the attached diagnostic logs (diagnostic_logs.txt) and advise on the next steps for troubleshooting.

Attached Files

• diagnostic_logs.txt: Output of voxl-inspect-sku, voxl-version, voxl-inspect-services, voxl-inspect-extrinsics, and voxl-camera-server.conf.

Thank you for your assistance.
diagnostic_logs.txt

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diagnostic_info

Subject: STINGER (D0013) Position Mode Fails after replacing VOXL 2 Mini: VIO Quality High but EKF2 Rejects Data

Hi ModalAI Team,

I am trying to restore a STINGER (D0013).
The drone crashed into the ceiling and stopped working, so I replaced the VOXL 2 Mini (M0104) with a new one.
I have set up the new board from scratch.

Current Status:

• Manual Flight: Works fine. Motors, RC, and basic stabilization are OK.
• Position Mode: Cannot engage. QGC says "No valid local position estimate".

Symptoms:

• voxl-qvio-server is running, voxl-inspect-qvio shows Quality: 100% (or High).
• PX4 receives data (px4-listener vehicle_odometry shows valid data).
• px4-listener vehicle_local_position shows xy_valid: False.
• px4-listener estimator_status shows pos_test_ratio: nan continuously.

What I have tried:

1. Reset parameters using voxl-configure-px4-params -p MRB-D0013.
2. Verified Extrinsics using voxl-configure-extrinsics D0013_Stinger.
3. Calibrated sensors in QGC.
4. Tried aligning settings with a working STARLING 2 unit:
   • EKF2_EV_CTRL = 15
   • SYS_HAS_GPS = 1
   • EKF2_HGT_REF = 0 (Baro)
   • Relaxed EKF2_REQ_SACC = 1.5, EKF2_REQ_GPS_H = 5.0.

Since this is a repaired unit with a new VOXL 2 Mini, I suspect I might be missing some calibration or configuration step specific to a board replacement.
Despite valid VIO data reaching PX4 (checked via listener), EKF2 seems to completely ignore it (pos_test_ratio: nan).

Attachments:

• voxl-inspect-services output (diagnostic_info.txt)
• Parameter file (stinger_support.params)
• Flight Log (latest_flight_log.ulg)

System Info:

• VOXL 2 Mini (M0104) - New replacement board
• Image: 1.8.04-M0104-14.1a-perf
• PX4: (Current version)

Any help would be appreciated.

daiagnostic_info.txt
stinger_support.params
latest_flight_log.ulg