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i think we're basically done

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This commit is contained in:
Thaddeus Hughes
2026-04-27 17:22:34 -05:00
parent 9f4362b5fd
commit f47a29205e
35 changed files with 14893 additions and 1687 deletions
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150
main/bringup.c
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@@ -80,15 +80,29 @@ static float elapsed_s(void)
/* -------- output helpers -------- */
/* Build the line in a stack buffer and emit with a single write so concurrent
* ESP_LOGx output (notably the wifi driver during BU.WIFI.START) cannot slice
* into the middle of it. Leading '\n' protects against partial lines that
* another task may have written without a terminator. */
__attribute__((format(printf, 2, 3)))
static void emit(const char *kind, const char *fmt, ...)
{
printf("BU.%s ", kind);
char buf[256];
/* Reserve one byte at the end for the trailing '\n' so a long line is
* truncated within the body rather than dropping the newline. Without
* this, a body that filled the buffer would produce a line glued to
* whatever came next on the wire. */
const int cap = (int)sizeof(buf) - 1; // room for '\n'
int n = snprintf(buf, cap, "\nBU.%s ", kind);
if (n < 0) n = 0;
if (n > cap) n = cap;
va_list ap;
va_start(ap, fmt);
vprintf(fmt, ap);
int m = vsnprintf(buf + n, cap - n, fmt, ap);
va_end(ap);
printf("\n");
if (m > 0) n += (m < cap - n) ? m : cap - n;
buf[n++] = '\n';
fwrite(buf, 1, n, stdout);
fflush(stdout);
}
@@ -295,7 +309,12 @@ static void cmd_led_watch(char *args)
static void cmd_adc_once(void)
{
int bat_mv = get_bat_raw_mv();
float bat_V = get_battery_V();
/* Bypass the EMA — process_battery_voltage() runs in the FSM task,
* which is paused while bring-up is active, so get_battery_V() returns
* a stale value that never reflects V_SENS_K / V_SENS_OFFSET writes
* issued during calibration. Compute fresh from raw mV + current params. */
float bat_V = bat_mv * get_param_value_t(PARAM_V_SENS_K).f32
+ get_param_value_t(PARAM_V_SENS_OFFSET).f32;
#ifdef BOARD_V5
/* VOC and FAULT pins are unusable on V5 (input-only ESP32 GPIOs
* without external pulls — see README "V5 hardware caveats"); skip. */
@@ -345,6 +364,9 @@ static void cmd_sensors_watch(char *args)
* on UART0 (operator hit Enter on the host side).
* sec > 0 → watch for that many seconds, then return.
*/
/* Force the sensor rail (P10) up before we observe — covers cases where
* the FSM or sensor task drove it low between boot and BU.BEGIN. */
i2c_relays_idle();
char *s = args;
char *t = next_tok(&s);
int sec = t ? atoi(t) : 0;
@@ -462,7 +484,12 @@ static void cmd_relay(char *args)
if (ms < 10) ms = 10;
if (ms > 2000) ms = 2000;
if (!get_is_safe()) { SKIP("relay reason=\"safety open\""); return; }
/* Read SAFETY directly: sensors_check() runs in the FSM task, which is
* paused while bring-up is active, so is_safe / get_is_safe() are stale.
* Safety pin is active-LOW. */
extern uint8_t sensor_pins[N_SENSORS];
#define _BU_SAFETY_OPEN() (gpio_get_level(sensor_pins[SENSOR_SAFETY]) != 0)
if (_BU_SAFETY_OPEN()) { SKIP("relay reason=\"safety open\""); return; }
/* P10 / sensor power rail. Default is ON; pulse it OFF to prove the line
* can be driven, then restore. */
@@ -511,11 +538,44 @@ static void cmd_relay(char *args)
last_relay_state = rs;
i2c_set_relays(rs);
vTaskDelay(pdMS_TO_TICKS(ms / 2));
fsm_now = esp_timer_get_time();
process_bridge_current(b);
float I_mid = get_bridge_A(b);
vTaskDelay(pdMS_TO_TICKS(ms - ms / 2));
/* JACK DOWN should stop as soon as the JACK sensor goes active (LOW) so
* the bring-up pulse can't drive the actuator into its mechanical limit.
* Other directions/bridges run for the full requested duration. SAFETY
* is checked every iteration regardless of bridge — multi-second pulses
* during bring-up must still kill the motor on a safety break. */
bool jack_down = (b == BRIDGE_JACK && dir == BRIDGE_REV);
bool stopped_by_sensor = false;
bool stopped_by_safety = false;
int64_t pulse_start_us = esp_timer_get_time();
int64_t mid_us = pulse_start_us + (int64_t)(ms / 2) * 1000;
int64_t end_us = pulse_start_us + (int64_t)ms * 1000;
float I_mid = NAN;
while (esp_timer_get_time() < end_us) {
if (_BU_SAFETY_OPEN()) {
stopped_by_safety = true;
break;
}
if (jack_down && gpio_get_level(sensor_pins[SENSOR_JACK]) == 0) {
stopped_by_sensor = true;
break;
}
if (isnan(I_mid) && esp_timer_get_time() >= mid_us) {
fsm_now = esp_timer_get_time();
process_bridge_current(b);
I_mid = get_bridge_A(b);
}
esp_task_wdt_reset();
vTaskDelay(pdMS_TO_TICKS(10));
}
if (isnan(I_mid)) {
/* Sensor tripped before we hit the midpoint; sample current now so
* the response still has a meaningful I_mid. */
fsm_now = esp_timer_get_time();
process_bridge_current(b);
I_mid = get_bridge_A(b);
}
relay_port_t idle = {.bridges = {.SENSORS = 1}};
last_relay_state = idle;
@@ -530,8 +590,15 @@ static void cmd_relay(char *args)
? get_sensor_isr_edges(which_sensor) : 0;
uint32_t edges = edges_after - edges_before;
OK("relay bridge=%s dir=%s ms=%d I_before=%+.2f I_mid=%+.2f I_after=%+.2f heat=%.3f tripped=%d edges=%u",
t_bridge, t_dir, ms, I_before, I_mid, I_after, heat, tripped, (unsigned)edges);
int actual_ms = (int)((esp_timer_get_time() - pulse_start_us) / 1000);
const char *stop_reason =
stopped_by_safety ? "safety" :
stopped_by_sensor ? "sensor" : "time";
OK("relay bridge=%s dir=%s ms=%d actual_ms=%d stop=%s "
"I_before=%+.2f I_mid=%+.2f I_after=%+.2f heat=%.3f tripped=%d edges=%u",
t_bridge, t_dir, ms, actual_ms, stop_reason,
I_before, I_mid, I_after, heat, tripped, (unsigned)edges);
#undef _BU_SAFETY_OPEN
}
static void cmd_rf_watch(char *args)
@@ -588,7 +655,24 @@ static void cmd_wifi_wait(char *args)
(void)args; /* no timeout — BRINGUP.md §4 Stage 6. Operator aborts via Ctrl+C. */
wifi_sta_list_t sta = {0};
int last_n = 0;
bool aborted = false;
while (1) {
/* Abort on any UART input — the host sends a stray byte to break out
* of the wait so that a follow-up BU.END is actually dispatched
* (otherwise the dispatcher stays blocked here forever). */
size_t available = 0;
if (uart_get_buffered_data_len(UART_NUM_0, &available) == ESP_OK
&& available > 0) {
uint8_t drain[64];
while (available > 0) {
int n = uart_read_bytes(UART_NUM_0, drain, sizeof(drain), 0);
if (n <= 0) break;
available = (size_t)n < available ? available - (size_t)n : 0;
}
aborted = true;
break;
}
if (esp_wifi_ap_get_sta_list(&sta) == ESP_OK && sta.num > last_n) {
EVT("wifi.assoc n=%d t=%.2f", sta.num, elapsed_s());
last_n = sta.num;
@@ -599,7 +683,8 @@ static void cmd_wifi_wait(char *args)
esp_task_wdt_reset();
vTaskDelay(pdMS_TO_TICKS(200));
}
OK("wifi.wait clients=%d http_reqs=%d", last_n, s_http_reqs);
OK("wifi.wait clients=%d http_reqs=%d aborted=%d",
last_n, s_http_reqs, aborted ? 1 : 0);
}
static void cmd_fsm(char *args)
@@ -652,6 +737,11 @@ static void cmd_param(char *args)
}
if (strcmp(op, "SET") == 0) {
/* SET writes flash. Require BU.BEGIN to prevent accidental persistence
* from stray BU.PARAM lines outside of an active bring-up session. */
if (!s_active) {
ERR("param reason=\"BU.BEGIN required first\""); return;
}
char *val = next_tok(&s);
if (!val) { ERR("param reason=\"missing value\""); return; }
esp_err_t e = ESP_OK;
@@ -673,6 +763,12 @@ static void cmd_param(char *args)
if (e != ESP_OK) { ERR("param reason=\"set failed\" err=%s", esp_err_to_name(e)); return; }
e = commit_params();
if (e != ESP_OK) { ERR("param reason=\"commit failed\" err=%s", esp_err_to_name(e)); return; }
/* If the conversion params changed, refresh the battery EMA so
* get_battery_V() returns a value consistent with the new K/OFFSET
* immediately rather than decaying through the EMA. */
if (idx == PARAM_V_SENS_K || idx == PARAM_V_SENS_OFFSET) {
reset_battery_ema();
}
OK("param key=%s set=ok committed=yes", key);
return;
}
@@ -680,6 +776,33 @@ static void cmd_param(char *args)
ERR("param reason=\"unknown op\" op=%s", op);
}
/* BU.FACTORY_RESET — wipe all params back to defaults, erase log partition,
* then reboot. Equivalent to the cold-boot button-hold path in main.c, but
* reachable from a host without physical access. Destructive — operator
* must explicitly invoke it. */
static void cmd_factory_reset(char *args)
{
(void)args;
/* Refuse without an explicit BU.BEGIN. Without this guard, any party
* that can write to UART0 can wipe params/log just by sending the
* command — and uart_comms.c forwards bare BU.* lines to the dispatcher
* even when bring-up mode is off. */
if (!s_active) {
ERR("factory_reset reason=\"BU.BEGIN required first\"");
return;
}
OK("factory_reset stage=start");
esp_err_t e = factory_reset();
if (e != ESP_OK) {
ERR("factory_reset stage=apply err=%s", esp_err_to_name(e));
return;
}
OK("factory_reset stage=done reboot=2s");
fflush(stdout);
vTaskDelay(pdMS_TO_TICKS(2000));
esp_restart();
}
/* -------- dispatcher -------- */
typedef void (*cmd_fn)(char *args);
@@ -707,6 +830,7 @@ static const struct cmd_entry CMDS[] = {
{ "FSM", cmd_fsm },
{ "SOLAR.TICK", cmd_solar_tick },
{ "PARAM", cmd_param },
{ "FACTORY_RESET", cmd_factory_reset},
};
void bringup_handle_line(char *line)