3d-models for more numberplates, case for 5 gauges and VFD-holder added

This reverts commit 7fb3b5e1fd.

config.example.json

@@ -28,5 +28,5 @@
   "red_led_entity_name": "Selsyn 1 Red LED",
   "green_led_entity_name": "Selsyn 1 Green LED",
   "backlight_entity_name": "Selsyn 1 Backlight",
-  "backlight_unit": "%"
+  "ws2812_order": "GRB"
 }

config.multi.example.json

@@ -47,6 +47,7 @@
     "pin": 23,
     "num_leds_per_gauge": 3,
     "num_status_leds_per_gauge": 2
+    "ws2812_order": "GRB"
   },
   
   "device": {

gauge_vid6008.py

@@ -75,6 +75,7 @@ class Gauge:
 
         self._current_step = 0
         self._zeroed = False
+        self._last_dir = None
 
     def zero(self):
         overrun = _OVERRUN_STEPS
@@ -108,7 +109,7 @@ class Gauge:
         else:
             for _ in range(abs(delta)):
                 self._step(1 if delta > 0 else -1)
-                utime.sleep_ms(self._step_us)
+                utime.sleep_us(self._step_us)
 
         self._current_step = target_step
 
@@ -128,6 +129,20 @@ class Gauge:
         self._pin_step.value(0)
         utime.sleep_us(delay_us)
 
+    def steps_toward(self, value, limit=5, deadband=0.5):
+        """Return the step delta needed to move toward value, clamped to ±limit.
+
+        deadband: If error is less than this fraction of one step, return 0 to prevent
+        micro-corrections due to floating-point rounding. Default 0.5 means
+        no movement if error < half a step.
+        """
+        target_step = self._val_to_step(value)
+        delta = target_step - self._current_step
+        deadband_steps = deadband
+        if abs(delta) < deadband_steps:
+            return 0
+        return max(-limit, min(limit, delta))
+
     def get(self):
         return self._step_to_val(self._current_step)
 

gaugemqttcontinuous.py

@@ -1,9 +1,9 @@
 """
-gaugemqtt.py — MQTT-based gauge controller for ESP32 / MicroPython
+gaugemqttcontinuous.py — MQTT-based gauge controller for ESP32 / MicroPython
 
 Deploy these files to the ESP32:
-  gauge.py        — stepper driver
-  gaugemqtt.py    — this file
+  gauge_vid6008.py        — stepper driver
+  gaugemqttcontinuous.py  — this file
   umqtt/simple.py         — MicroPython built-in
   umqtt/robust.py         — https://raw.githubusercontent.com/micropython/micropython-lib/master/micropython/umqtt.robust/umqtt/robust.py
   config.json             — configuration (see below)
@@ -81,6 +81,7 @@ _cfg = _load_config()
 
 DEBUG = _cfg.get("debug", False)
 _DEBUG = DEBUG
+_WS2812_ORDER = _cfg.get("ws2812_order", "GRB").upper()
 
 WIFI_SSID = _cfg["wifi_ssid"]
 WIFI_PASSWORD = _cfg["wifi_password"]
@@ -149,13 +150,11 @@ else:
             "ws2812_green": tuple(_cfg.get("ws2812_green", [0, 255, 0])),
         }
     )
-BL_UNIT = _cfg.get("backlight_unit", "%")
 
 # ---------------------------------------------------------------------------
 # Gauge initialization
 # ---------------------------------------------------------------------------
 
-info("Initialising gauge objects...")
 gauge_objects = []
 for g in gauges:
     gauge_objects.append(
@@ -170,7 +169,6 @@ for g in gauges:
     info(
         f"Gauge {g['id']}: {g['name']} pins={g['pins']} mode={g['mode']} range=[{g['min']}, {g['max']}]"
     )
-info("Gauge objects done")
 
 gauge_targets = [g["min"] for g in gauges]  # target value per gauge
 gauge_last_rezero = [utime.ticks_ms() for _ in gauges]
@@ -207,41 +205,10 @@ def make_gauge_topics(prefix, gauge_id):
 
 gauge_topics = [make_gauge_topics(MQTT_PREFIX, g["id"]) for g in gauges]
 
+
 T_SET = f"{MQTT_PREFIX}/set"
-T_STATE = f"{MQTT_PREFIX}/state"
-T_STATUS = f"{MQTT_PREFIX}/status"
 T_ZERO = f"{MQTT_PREFIX}/zero"
 
-T_DISC_GAUGE = f"homeassistant/number/{MQTT_CLIENT_ID}/config"
-T_DISC_RED = f"homeassistant/switch/{MQTT_CLIENT_ID}_red/config"
-T_DISC_GREEN = f"homeassistant/switch/{MQTT_CLIENT_ID}_green/config"
-T_DISC_BL = f"homeassistant/light/{MQTT_CLIENT_ID}_bl/config"
-
-
-def make_gauge_topics(prefix, gauge_id):
-    return {
-        "set": f"{prefix}/gauge{gauge_id}/set",
-        "state": f"{prefix}/gauge{gauge_id}/state",
-        "status": f"{prefix}/gauge{gauge_id}/status",
-        "zero": f"{prefix}/gauge{gauge_id}/zero",
-        "disc": f"homeassistant/number/{MQTT_CLIENT_ID}_g{gauge_id}/config",
-        "led_red": f"{prefix}/gauge{gauge_id}/led/red/set",
-        "led_green": f"{prefix}/gauge{gauge_id}/led/green/set",
-        "led_bl": f"{prefix}/gauge{gauge_id}/led/backlight/set",
-        "led_red_state": f"{prefix}/gauge{gauge_id}/led/red/state",
-        "led_green_state": f"{prefix}/gauge{gauge_id}/led/green/state",
-        "led_bl_state": f"{prefix}/gauge{gauge_id}/led/backlight/state",
-        "led_red_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_red/config",
-        "led_green_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_green/config",
-        "led_bl_disc": f"homeassistant/light/{MQTT_CLIENT_ID}_g{gauge_id}_bl/config",
-        "status_red": f"{prefix}/gauge{gauge_id}/status_led/red/set",
-        "status_green": f"{prefix}/gauge{gauge_id}/status_led/green/set",
-        "status_red_state": f"{prefix}/gauge{gauge_id}/status_led/red/state",
-        "status_green_state": f"{prefix}/gauge{gauge_id}/status_led/green/state",
-        "status_red_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_status_red/config",
-        "status_green_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_status_green/config",
-    }
-
 
 _DEVICE = {
     "identifiers": [MQTT_CLIENT_ID],
@@ -255,12 +222,10 @@ _DEVICE = {
 # WiFi
 # ---------------------------------------------------------------------------
 
-_wifi_reconnect_delay_s = 5
 _wifi_check_interval_ms = 30000
 _last_wifi_check = 0
 _wifi_sta = None
 
-
 def connect_wifi(ssid, password, timeout_s=15):
     global _wifi_sta
     _wifi_sta = network.WLAN(network.STA_IF)
@@ -288,7 +253,7 @@ def connect_wifi(ssid, password, timeout_s=15):
 
 
 def check_wifi():
-    global _wifi_sta, _last_wifi_check, _wifi_reconnect_delay_s
+    global _wifi_sta, _last_wifi_check
     now = utime.ticks_ms()
     if utime.ticks_diff(now, _last_wifi_check) < _wifi_check_interval_ms:
         return
@@ -316,27 +281,15 @@ def check_wifi():
         log_err(f"WiFi reconnect failed: {e}")
 
 
-# ---------------------------------------------------------------------------
-# LEDs (per gauge)
-# ---------------------------------------------------------------------------
-
-info("Initialising LEDs...")
 num_gauges = len(gauges)
 leds_red = []
 leds_green = []
-leds_bl = []
 for g in gauges:
     leds_red.append(Pin(g["red_pin"], Pin.OUT, value=0))
     leds_green.append(Pin(g["green_pin"], Pin.OUT, value=0))
 
 total_backlight_leds = num_gauges * (BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE)
-info(f"Total backlight LEDs: {total_backlight_leds}")
-leds_bl = (
-    NeoPixel(Pin(BACKLIGHT_PIN), total_backlight_leds)
-    if total_backlight_leds > 0
-    else None
-)
-info("LEDs done")
+leds_bl = NeoPixel(Pin(BACKLIGHT_PIN), total_backlight_leds)
 
 backlight_color = [(0, 0, 0) for _ in range(num_gauges)]
 backlight_brightness = [100 for _ in range(num_gauges)]
@@ -349,22 +302,11 @@ _bl_dirty_since = None
 _BL_SAVE_DELAY_MS = 5000
 
 
-def _flush_backlight(client):
-    for i in range(num_gauges):
-        gt = gauge_topics[i]
-        payload = {
-            "state": "ON" if backlight_on[i] else "OFF",
-            "color": {
-                "r": backlight_color[i][0],
-                "g": backlight_color[i][1],
-                "b": backlight_color[i][2],
-            },
-            "brightness": int(backlight_brightness[i] * 2.55),
-        }
-        client.publish(gt["led_bl_state"], ujson.dumps(payload), retain=True)
-        info(
-            f"Gauge {i} backlight: {payload['state']} {backlight_color[i]} @ {backlight_brightness[i]}%"
-        )
+def _to_pixel(r, g, b):
+    """Reorder RGB to match the WS2812 variant's byte order (GRB or RGB)."""
+    if _WS2812_ORDER == "GRB":
+        return (g, r, b)
+    return (r, g, b)
 
 
 def _backlight_changed(gauge_idx, new_color, new_on, new_brightness):
@@ -380,6 +322,19 @@ def _mark_bl_dirty():
     _bl_dirty_since = utime.ticks_ms()
 
 
+def _apply_backlight(gauge_idx, r, g, b, brightness):
+    """Write RGB+brightness to the physical LEDs and mark dirty."""
+    scale = brightness / 100
+    leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
+    base_idx = gauge_idx * leds_per_gauge
+    pixel = _to_pixel(int(r * scale), int(g * scale), int(b * scale))
+    for j in range(BACKLIGHT_LEDS_PER_GAUGE):
+        leds_bl[base_idx + j] = pixel
+    _update_status_leds(gauge_idx)
+    leds_bl.write()
+    _mark_bl_dirty()
+
+
 def set_backlight_color(gauge_idx, r, g, b, brightness=None):
     global backlight_color, backlight_brightness, backlight_on
     if brightness is None:
@@ -391,17 +346,7 @@ def set_backlight_color(gauge_idx, r, g, b, brightness=None):
     if brightness > 0:
         backlight_brightness[gauge_idx] = brightness
     backlight_on[gauge_idx] = new_on
-
-    scale = brightness / 100
-    leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
-    base_idx = gauge_idx * leds_per_gauge
-    for j in range(BACKLIGHT_LEDS_PER_GAUGE):
-        if leds_bl:
-            leds_bl[base_idx + j] = (int(g * scale), int(r * scale), int(b * scale))
-    _update_status_leds(gauge_idx)
-    if leds_bl:
-        leds_bl.write()
-    _mark_bl_dirty()
+    _apply_backlight(gauge_idx, r, g, b, brightness)
 
 
 def set_backlight_brightness(gauge_idx, brightness):
@@ -414,21 +359,10 @@ def set_backlight_brightness(gauge_idx, brightness):
         backlight_brightness[gauge_idx] = clamped
     backlight_on[gauge_idx] = new_on
     r, g, b = backlight_color[gauge_idx]
-    scale = clamped / 100
-    leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
-    base_idx = gauge_idx * leds_per_gauge
-    for j in range(BACKLIGHT_LEDS_PER_GAUGE):
-        if leds_bl:
-            leds_bl[base_idx + j] = (int(g * scale), int(r * scale), int(b * scale))
-    _update_status_leds(gauge_idx)
-    if leds_bl:
-        leds_bl.write()
-    _mark_bl_dirty()
+    _apply_backlight(gauge_idx, r, g, b, clamped)
 
 
 def _update_status_leds(gauge_idx):
-    if not leds_bl:
-        return
     leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
     base_idx = gauge_idx * leds_per_gauge + BACKLIGHT_LEDS_PER_GAUGE
 
@@ -437,12 +371,12 @@ def _update_status_leds(gauge_idx):
     green_color = g_cfg["ws2812_green"]
 
     if status_led_red[gauge_idx]:
-        leds_bl[base_idx] = (red_color[1], red_color[0], red_color[2])
+        leds_bl[base_idx] = _to_pixel(*red_color)
     else:
         leds_bl[base_idx] = (0, 0, 0)
 
     if status_led_green[gauge_idx]:
-        leds_bl[base_idx + 1] = (green_color[1], green_color[0], green_color[2])
+        leds_bl[base_idx + 1] = _to_pixel(*green_color)
     else:
         leds_bl[base_idx + 1] = (0, 0, 0)
 
@@ -454,18 +388,38 @@ def set_status_led(gauge_idx, led_type, state):
     elif led_type == "green":
         status_led_green[gauge_idx] = state
     _update_status_leds(gauge_idx)
-    if leds_bl:
     leds_bl.write()
 
 
-# ---------------------------------------------------------------------------
-# State
-# ---------------------------------------------------------------------------
+def publish_backlight_states(client):
+    """Publish current backlight state for all gauges as retained MQTT messages."""
+    for i in range(num_gauges):
+        gt = gauge_topics[i]
+        r, g, b = backlight_color[i]
+        brightness = backlight_brightness[i]
+        state = {
+            "state": "ON" if backlight_on[i] else "OFF",
+            "color_mode": "rgb",
+            "brightness": int(brightness * 2.55),
+            "color": {"r": r, "g": g, "b": b},
+        }
+        try:
+            client.publish(gt["led_bl_state"], ujson.dumps(state), retain=True)
+        except Exception as e:
+            log_err(f"Backlight state publish failed for gauge {i}: {e}")
 
-_last_rezero_ms = None  # set to ticks_ms() in main()
-client_ref = None
-_mqtt_connected = False
-_last_mqtt_check = 0
+
+def _flush_backlight_state():
+    global _bl_dirty_since
+    if _bl_dirty_since is None:
+        return
+    if utime.ticks_diff(utime.ticks_ms(), _bl_dirty_since) < _BL_SAVE_DELAY_MS:
+        return
+    if client_ref is None:
+        return
+    publish_backlight_states(client_ref)
+    _bl_dirty_since = None
+    info("Backlight state flushed to MQTT")
 
 
 def _publish(topic, payload, retain=False):
@@ -509,15 +463,6 @@ def on_message(topic, payload):
                 warn(f"Invalid set value for gauge {i}: '{payload}'")
             return
 
-    if topic == T_ZERO:
-        for i, g in enumerate(gauge_objects):
-            info(f"Zeroing all gauges")
-            g.zero()
-            gauge_last_rezero[i] = utime.ticks_ms()
-        info("All gauges zeroed")
-        return
-
-    for i, gt in enumerate(gauge_topics):
         if topic == gt["led_red"]:
             state = payload.upper() == "ON"
             leds_red[i].value(1 if state else 0)
@@ -581,12 +526,59 @@ def on_message(topic, payload):
             info(f"Gauge {i} status green → {'ON' if state else 'OFF'}")
             return
 
+    if topic == T_ZERO:
+        for i, g in enumerate(gauge_objects):
+            g.zero()
+            gauge_last_rezero[i] = utime.ticks_ms()
+        info("All gauges zeroed")
+        return
+
+    if topic == T_SET:
+        try:
+            data = ujson.loads(payload)
+            if isinstance(data, dict):
+                for i, val in enumerate(data.values()):
+                    if i < len(gauges):
+                        g = gauges[i]
+                        gauge_targets[i] = max(g["min"], min(g["max"], float(val)))
+                        info(f"Gauge {i} target → {gauge_targets[i]:.1f}")
+            else:
+                val = float(payload)
+                for i in range(len(gauges)):
+                    gauge_targets[i] = max(gauges[i]["min"], min(gauges[i]["max"], val))
+                info(f"All gauges target → {val:.1f}")
+        except Exception:
+            try:
+                val = float(payload)
+                for i in range(len(gauges)):
+                    gauge_targets[i] = max(gauges[i]["min"], min(gauges[i]["max"], val))
+                info(f"All gauges target → {val:.1f}")
+            except:
+                warn(f"Invalid set value: '{payload}'")
+        return
+
+
+
 
 # ---------------------------------------------------------------------------
 # MQTT connect + discovery
 # ---------------------------------------------------------------------------
 
 
+def _subscribe_all(c):
+    c.subscribe(f"{MQTT_PREFIX}/set")
+    c.subscribe(f"{MQTT_PREFIX}/zero")
+    for i in range(num_gauges):
+        prefix = f"{MQTT_PREFIX}/gauge{i}"
+        c.subscribe(f"{prefix}/set")
+        c.subscribe(f"{prefix}/zero")
+        c.subscribe(f"{prefix}/led/red/set")
+        c.subscribe(f"{prefix}/led/green/set")
+        c.subscribe(f"{prefix}/led/backlight/set")
+        c.subscribe(f"{prefix}/status_led/red/set")
+        c.subscribe(f"{prefix}/status_led/green/set")
+
+
 def connect_mqtt():
     global client_ref, _mqtt_connected
     info(f"Connecting to MQTT broker {MQTT_BROKER}:{MQTT_PORT} ...")
@@ -596,29 +588,22 @@ def connect_mqtt():
         port=MQTT_PORT,
         user=MQTT_USER,
         password=MQTT_PASSWORD,
-        keepalive=60,
+        keepalive=30,
     )
-    client.set_last_will(gauge_topics[0]["status"], b"offline", retain=True, qos=0)
+    # Don't set last will - it might be causing issues
+    # client.set_last_will(T_STATUS, b"offline", retain=True, qos=0)
     client.set_callback(on_message)
     client.connect()
     client_ref = client
-    client.subscribe(T_SET)
-    client.subscribe(T_ZERO)
-    for gt in gauge_topics:
-        client.subscribe(gt["set"])
-        client.subscribe(gt["zero"])
-        client.subscribe(gt["led_red"])
-        client.subscribe(gt["led_green"])
-        client.subscribe(gt["led_bl"])
-        client.subscribe(gt["status_red"])
-        client.subscribe(gt["status_green"])
     _mqtt_connected = True
     info(f"MQTT connected  client_id={MQTT_CLIENT_ID}")
-    return client
 
 
 _mqtt_check_interval_ms = 30000
 _last_mqtt_check = 0
+client_ref = None
+_mqtt_connected = False
+
 
 
 def check_mqtt():
@@ -649,27 +634,16 @@ def check_mqtt():
                 port=MQTT_PORT,
                 user=MQTT_USER,
                 password=MQTT_PASSWORD,
-                keepalive=60,
-            )
-            client_ref.set_last_will(
-                gauge_topics[0]["status"], b"offline", retain=True, qos=0
+                keepalive=30,
             )
             client_ref.set_callback(on_message)
             client_ref.connect()
-            client_ref.subscribe(T_SET)
-            client_ref.subscribe(T_ZERO)
-            for gt in gauge_topics:
-                client_ref.subscribe(gt["set"])
-                client_ref.subscribe(gt["zero"])
-                client_ref.subscribe(gt["led_red"])
-                client_ref.subscribe(gt["led_green"])
-                client_ref.subscribe(gt["led_bl"])
-                client_ref.subscribe(gt["status_red"])
-                client_ref.subscribe(gt["status_green"])
             _mqtt_connected = True
             info("MQTT reconnected!")
             publish_discovery(client_ref)
+            _subscribe_all(client_ref)
             publish_state(client_ref)
+            publish_backlight_states(client_ref)
             return True
         except Exception as e2:
             log_err(f"MQTT reconnect attempt {attempt + 1} failed: {e2}")
@@ -679,15 +653,10 @@ def check_mqtt():
     return False
 
 
+
 def publish_discovery(client):
     """Publish all HA MQTT discovery payloads for gauges and LEDs."""
-    _dev_ref = {
-        "identifiers": [MQTT_CLIENT_ID],
-        "name": DEVICE_NAME,
-        "model": DEVICE_MODEL,
-        "manufacturer": DEVICE_MFR,
-        "suggested_area": DEVICE_AREA,
-    }
+    _dev_ref = _DEVICE
 
     for i, g in enumerate(gauges):
         gt = gauge_topics[i]
@@ -713,6 +682,11 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} ({g['name']})")
         
+        # Process MQTT messages between gauges
+        for _ in range(5):
+            client.check_msg()
+            utime.sleep_ms(10)
+        
         client.publish(
             gt["led_red_disc"],
             ujson.dumps(
@@ -751,6 +725,11 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} green LED")
         
+        # Process MQTT messages
+        for _ in range(5):
+            client.check_msg()
+            utime.sleep_ms(10)
+
         client.publish(
             gt["led_bl_disc"],
             ujson.dumps(
@@ -808,14 +787,17 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} status green")
 
+        # Process between gauges to avoid MQTT blocking
+        for _ in range(5):
+            client.check_msg()
+            utime.sleep_ms(10)
+
 
 def publish_state(client):
     for i, g in enumerate(gauge_objects):
         gt = gauge_topics[i]
         val = g.get()
-        client.publish(gt["state"], str(round(val, 1)), retain=True)
-        client.publish(gt["status"], "online", retain=True)
-        info(f"Gauge {i} state: {val:.1f} step={g._current_step}")
+        client.publish(gt["state"], str(val))
 
 
 # ---------------------------------------------------------------------------
@@ -824,47 +806,58 @@ def publish_state(client):
 
 
 def main():
-    utime.sleep_ms(0)
     info("=" * 48)
     info("Gauge MQTT controller starting")
     info("=" * 48)
 
-    info("Connecting WiFi...")
     connect_wifi(WIFI_SSID, WIFI_PASSWORD)
-    info("WiFi done")
 
+    # Connect MQTT (no subscriptions yet — keeps broker silent during discovery)
+    connect_mqtt()
+
+    # Publish discovery — broker has nothing to send back yet
+    info("Publishing discovery...")
+    publish_discovery(client_ref)
+
+    # Subscribe now — retained messages will start arriving from here
+    _subscribe_all(client_ref)
+    info("Draining initial retained messages...")
+    for _ in range(50):
+        client_ref.check_msg()
+        utime.sleep_ms(20)
+
+    # Now initialize gauges
     info("Zeroing gauges on startup ...")
     for i, g in enumerate(gauge_objects):
         g.zero()
         info(f"Zeroed gauge {i}")
-    info("Zero done")
+    info("Zero complete")
 
-    info("Connecting MQTT...")
-    connect_mqtt()
-    info("MQTT done")
-
-    info("Publishing discovery...")
-    publish_discovery(client_ref)
+    info("Publishing state...")
     publish_state(client_ref)
-    info("Discovery done")
+    utime.sleep_ms(50)
+    for _ in range(5):
+        client_ref.check_msg()
+        utime.sleep_ms(20)
 
     info("Entering main loop")
     info("-" * 48)
 
     try:
         import ota
-
         ota.mark_ok()
-        info("OTA OK flag set")
-    except ImportError:
+    except:
         pass
 
-    global _bl_dirty_since
+    # Initialize variables for main loop
     last_heartbeat = utime.ticks_ms()
+    now = 0
+    was_moving = False
 
     while True:
-        utime.sleep_ms(0)
         try:
+            now = utime.ticks_ms()
+
             check_wifi()
 
             if not check_mqtt():
@@ -872,50 +865,33 @@ def main():
                 continue
 
             client_ref.check_msg()
+            _flush_backlight_state()
 
-            now = utime.ticks_ms()
-
-            moved_any = False
-            for i, g in enumerate(gauge_objects):
-                current_target = g._val_to_step(gauge_targets[i])
-                if current_target != g._current_step:
-                    direction = 1 if current_target > g._current_step else -1
-                    steps_to_move = current_target - g._current_step
-                    steps_to_move = max(-5, min(5, steps_to_move))
-                    for _ in range(abs(steps_to_move)):
-                        g.step(direction)
-                    moved_any = True
+            pending = [g.steps_toward(gauge_targets[i],limit=50) for i, g in enumerate(gauge_objects)]
 
+            moved_any = any(s != 0 for s in pending)
             if moved_any:
+                was_moving = True
                 delay_us = 1_000_000 // MICROSTEPS_PER_SECOND
-                utime.sleep_us(delay_us)
-
-            if (
-                REZERO_INTERVAL_MS > 0
-                and utime.ticks_diff(now, gauge_last_rezero[0]) >= REZERO_INTERVAL_MS
-            ):
+                for tick in range(max(abs(s) for s in pending)):
                     for i, g in enumerate(gauge_objects):
-                    info(f"Auto-rezero gauge {i}")
-                    saved = gauge_targets[i]
-                    g.zero()
-                    if saved > gauges[i]["min"]:
-                        g.set(saved)
-                    gauge_last_rezero[i] = now
+                        if tick < abs(pending[i]):
+                            g.step(1 if pending[i] > 0 else -1)
+                    utime.sleep_us(delay_us)
+            else:
+                if was_moving:
                     publish_state(client_ref)
-                info("Auto-rezero complete")
-
-            if (
-                _bl_dirty_since is not None
-                and utime.ticks_diff(now, _bl_dirty_since) >= _BL_SAVE_DELAY_MS
-            ):
-                _flush_backlight(client_ref)
-                _bl_dirty_since = None
+                    was_moving = False
+                utime.sleep_ms(10)
 
             if utime.ticks_diff(now, last_heartbeat) >= HEARTBEAT_MS:
+                info(f"Heartbeat: {gauge_targets}")
                 publish_state(client_ref)
                 last_heartbeat = now
 
         except Exception as e:
+            import sys
+            sys.print_exception(e)
             log_err(f"Main loop error: {e} — continuing")
             utime.sleep_ms(100)
 

ota.py

@@ -198,9 +198,9 @@ def _fetch_manifest():
     )
     try:
         r = urequests.get(url, headers=_headers())
+        try:
             if r.status_code == 200:
                 data = r.json()
-            r.close()
                 if data.get("content"):
                     import ubinascii
 
@@ -209,6 +209,7 @@ def _fetch_manifest():
                     return [p for p in patterns if p and not p.startswith("#")]
             else:
                 warn(f"Manifest not found at {OTA_MANIFEST}")
+        finally:
             r.close()
     except Exception as e:
         log_err(f"Failed to fetch manifest: {e}")
@@ -284,13 +285,6 @@ def _save_manifest(manifest, commit_sha=None):
         warn(f"Could not save manifest: {e}")
 
 
-def _wipe_manifest():
-    try:
-        os.remove(MANIFEST_FILE)
-        info("Manifest wiped — full re-fetch on next update")
-    except OSError:
-        pass
-
 
 def _ok_flag_exists():
     try:
@@ -349,8 +343,6 @@ def _fetch_file_list():
                         break
             else:
                 name = entry["name"]
-                if not name.endswith(".py"):
-                    continue
                 for p in patterns:
                     p = p.rstrip("/")
                     if _match_pattern(name, p) or _match_pattern(entry["path"], p):