Sudden Uncommanded Roll Leading to Crash with external vision position

Hello PX4 Support Team,

Issue Summary:

I’m experiencing a critical issue with my drone where it suddenly rolls very rapidly and crashes during flight. This behavior occurs randomly, and I’m unsure whether it’s caused by PX4 or visual odometry.

Details:

  • Drone Setup:
    • Flight Controller: Kahuteh and hkust
    • Flight Mode Used: Offboard and Position
  • Problem Description:
    • The drone flies normally most of the time but occasionally exhibits a sudden, uncommanded roll leading to an immediate crash.
    • In the PX4 logs during the crash events, I observe a sudden jump in estimator_innovation_test_ratios/ev_hpos values.
    • I’m trying to determine whether the innovation jump occurs before the crash (indicating a potential cause) or after (indicating a symptom).
  • What I’ve Done So Far:
    • Reviewed the PX4 logs and noticed the spike in estimator innovation test ratios at the time of the crash.
    • Attempted to analyze the sequence of events but couldn’t conclusively determine causality between the innovation jump and the crash.
    • Checked for any obvious hardware issues or sensor failures but found none.

Request for Assistance:

  • Log Analysis:
    • Could you help me analyze the attached PX4 logs to identify whether the innovation jump is the cause or the result of the sudden roll and crash?
    • Specifically, I’d like guidance on determining the sequence of events leading up to the crash within the logs.
  • Diagnostic Guidance:
    • Advice on which parameters or log topics to focus on would be greatly appreciated.
    • Suggestions on potential causes or solutions based on similar experiences.

Attachments:

Additional Information:

  • If any further details about the drone setup, environment, or configurations are needed, please let me know, and I’ll provide them promptly.

Edit:

I’ve flown again, now using x500 and the v1.14.4 branch without any modifications (only some topics enabled/disabled in dds_topics.yaml) and the same thing happens again, suddenly there is a large rate setpoint (at around 101s) and the drone flies into the net.

Here is the log of the flight: https://review.px4.io/plot_app?log=dbc8359c-cece-4037-916c-b4f61798497f

Thank you in advance for your support!