686 lines
21 KiB
Python
686 lines
21 KiB
Python
"""
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gaugemqtt.py — MQTT-based gauge controller for ESP32 / MicroPython
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Deploy these files to the ESP32:
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gauge.py — stepper driver
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gaugemqtt.py — this file
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umqtt/simple.py — MicroPython built-in
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umqtt/robust.py — https://raw.githubusercontent.com/micropython/micropython-lib/master/micropython/umqtt.robust/umqtt/robust.py
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config.json — configuration (see below)
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MQTT topics (all prefixed with mqtt_prefix from config.json):
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.../set ← HA publishes target value here
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.../state → ESP32 publishes current value
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.../status → ESP32 publishes online/offline
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.../zero ← publish anything to trigger zero
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.../led/red/set ← ON/OFF
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.../led/green/set ← ON/OFF
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.../led/backlight/set ← 0-100
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Serial log format: [HH:MM:SS.mmm] LEVEL message
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"""
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import network
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import utime
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import ujson
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from umqtt.robust import MQTTClient
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from machine import Pin
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from neopixel import NeoPixel
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from gauge_vid6008 import Gauge
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# ---------------------------------------------------------------------------
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# Logging
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# ---------------------------------------------------------------------------
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def _ts():
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ms = utime.ticks_ms()
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return f"{(ms // 3600000) % 24:02d}:{(ms // 60000) % 60:02d}:{(ms // 1000) % 60:02d}.{ms % 1000:03d}"
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def log(level, msg):
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print(f"[{_ts()}] {level:5s} {msg}")
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def info(msg):
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log("INFO", msg)
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def warn(msg):
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log("WARN", msg)
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def log_err(msg):
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log("ERROR", msg)
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# ---------------------------------------------------------------------------
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# Configuration
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# ---------------------------------------------------------------------------
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def _load_config():
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try:
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with open("/config.json") as f:
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cfg = ujson.load(f)
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info("Config loaded from /config.json")
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return cfg
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except OSError:
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log_err("config.json not found — cannot continue")
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raise
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except Exception as e:
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log_err(f"config.json parse error: {e} — cannot continue")
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raise
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_cfg = _load_config()
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WIFI_SSID = _cfg["wifi_ssid"]
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WIFI_PASSWORD = _cfg["wifi_password"]
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MQTT_BROKER = _cfg["mqtt_broker"]
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MQTT_PORT = int(_cfg.get("mqtt_port", 1883))
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MQTT_USER = _cfg["mqtt_user"]
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MQTT_PASSWORD = _cfg["mqtt_password"]
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MQTT_CLIENT_ID = _cfg["mqtt_client_id"]
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MQTT_PREFIX = _cfg["mqtt_prefix"]
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GAUGE_PINS = tuple(_cfg.get("gauge_pins", [12, 13]))
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GAUGE_MODE = _cfg.get("gauge_mode", "stepdir")
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GAUGE_MIN = float(_cfg.get("gauge_min", 0))
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GAUGE_MAX = float(_cfg.get("gauge_max", 7300))
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GAUGE_STEP_US = int(_cfg.get("gauge_step_us", 200))
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MICROSTEPS_PER_SECOND = 600 # microsteps per second (adjustable)
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HEARTBEAT_MS = int(_cfg.get("heartbeat_ms", 10000))
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REZERO_INTERVAL_MS = int(_cfg.get("rezero_interval_ms", 3600000))
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LED_RED_PIN = int(_cfg.get("led_red_pin", 33))
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LED_GREEN_PIN = int(_cfg.get("led_green_pin", 32))
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LED_BL_PIN = int(_cfg.get("led_bl_pin", 23))
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DEVICE_NAME = _cfg.get("device_name", "Selsyn 1")
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DEVICE_MODEL = _cfg.get("device_model", "Chernobyl Selsyn-inspired gauge")
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DEVICE_MFR = _cfg.get("device_manufacturer", "AdeBaumann")
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DEVICE_AREA = _cfg.get("device_area", "Control Panels")
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GAUGE_ENTITY = _cfg.get("gauge_entity_name", "Selsyn 1 Power")
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GAUGE_UNIT = _cfg.get("gauge_unit", "W")
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RED_ENTITY = _cfg.get("red_led_entity_name", "Selsyn 1 Red LED")
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GREEN_ENTITY = _cfg.get("green_led_entity_name", "Selsyn 1 Green LED")
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BL_ENTITY = _cfg.get("backlight_entity_name", "Selsyn 1 Backlight")
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BL_UNIT = _cfg.get("backlight_unit", "%")
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# ---------------------------------------------------------------------------
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# Topics
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# ---------------------------------------------------------------------------
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T_SET = f"{MQTT_PREFIX}/set"
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T_STATE = f"{MQTT_PREFIX}/state"
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T_STATUS = f"{MQTT_PREFIX}/status"
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T_ZERO = f"{MQTT_PREFIX}/zero"
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T_LED_RED = f"{MQTT_PREFIX}/led/red/set"
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T_LED_GREEN = f"{MQTT_PREFIX}/led/green/set"
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T_LED_BL = f"{MQTT_PREFIX}/led/backlight/set"
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T_LED_BL_STATE = f"{MQTT_PREFIX}/led/backlight/state"
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T_LED_RED_STATE = f"{MQTT_PREFIX}/led/red/state"
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T_LED_GREEN_STATE = f"{MQTT_PREFIX}/led/green/state"
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T_DISC_GAUGE = f"homeassistant/number/{MQTT_CLIENT_ID}/config"
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T_DISC_RED = f"homeassistant/switch/{MQTT_CLIENT_ID}_red/config"
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T_DISC_GREEN = f"homeassistant/switch/{MQTT_CLIENT_ID}_green/config"
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T_DISC_BL = f"homeassistant/light/{MQTT_CLIENT_ID}_bl/config"
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_DEVICE = {
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"identifiers": [MQTT_CLIENT_ID],
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"name": DEVICE_NAME,
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"model": DEVICE_MODEL,
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"manufacturer": DEVICE_MFR,
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"suggested_area": DEVICE_AREA,
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}
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# ---------------------------------------------------------------------------
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# WiFi
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# ---------------------------------------------------------------------------
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_wifi_reconnect_delay_s = 5
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_wifi_check_interval_ms = 5000
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_last_wifi_check = 0
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_wifi_sta = None
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def connect_wifi(ssid, password, timeout_s=15):
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global _wifi_sta
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_wifi_sta = network.WLAN(network.STA_IF)
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_wifi_sta.active(True)
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if _wifi_sta.isconnected():
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ip, mask, gw, dns = _wifi_sta.ifconfig()
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info("WiFi already connected")
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info(f" IP:{ip} mask:{mask} gw:{gw} dns:{dns}")
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return ip
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info(f"WiFi connecting to '{ssid}' ...")
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_wifi_sta.connect(ssid, password)
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deadline = utime.time() + timeout_s
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while not _wifi_sta.isconnected():
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if utime.time() > deadline:
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log_err(f"WiFi connect timeout after {timeout_s}s")
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raise OSError("WiFi connect timeout")
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utime.sleep_ms(200)
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ip, mask, gw, dns = _wifi_sta.ifconfig()
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mac = ":".join(f"{b:02x}" for b in _wifi_sta.config("mac"))
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info("WiFi connected!")
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info(f" SSID : {ssid}")
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info(f" MAC : {mac}")
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info(f" IP : {ip} mask:{mask} gw:{gw} dns:{dns}")
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return ip
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def check_wifi():
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global _last_wifi_check, _wifi_reconnect_delay_s
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now = utime.ticks_ms()
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if utime.ticks_diff(now, _last_wifi_check) < _wifi_check_interval_ms:
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return
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_last_wifi_check = now
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if _wifi_sta is None:
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_wifi_sta = network.WLAN(network.STA_IF)
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if _wifi_sta.isconnected():
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return
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log_err("WiFi lost connection — attempting reconnect...")
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try:
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_wifi_sta.active(True)
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_wifi_sta.connect(WIFI_SSID, WIFI_PASSWORD)
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deadline = utime.time() + 15
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while not _wifi_sta.isconnected():
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if utime.time() > deadline:
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log_err("WiFi reconnect timeout")
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return
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utime.sleep_ms(200)
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ip, mask, gw, dns = _wifi_sta.ifconfig()
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info(f"WiFi reconnected! IP:{ip}")
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except Exception as e:
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log_err(f"WiFi reconnect failed: {e}")
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# ---------------------------------------------------------------------------
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# Gauge
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# ---------------------------------------------------------------------------
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info("Initialising gauge ...")
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gauge = Gauge(
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pins=GAUGE_PINS,
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mode=GAUGE_MODE,
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min_val=GAUGE_MIN,
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max_val=GAUGE_MAX,
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step_us=GAUGE_STEP_US,
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)
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info(
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f"Gauge ready pins={GAUGE_PINS} mode={GAUGE_MODE} range=[{GAUGE_MIN}, {GAUGE_MAX}] step_us={GAUGE_STEP_US}"
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)
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# ---------------------------------------------------------------------------
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# LEDs
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# ---------------------------------------------------------------------------
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led_red = Pin(LED_RED_PIN, Pin.OUT, value=0)
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led_green = Pin(LED_GREEN_PIN, Pin.OUT, value=0)
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led_bl = NeoPixel(Pin(LED_BL_PIN), 3)
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_backlight_color = (0, 0, 0)
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_backlight_brightness = 100 # last *active* brightness — never set to 0
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_backlight_on = False
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_bl_dirty_since = None
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_BL_SAVE_DELAY_MS = 5000
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def _flush_backlight(client):
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payload = {
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"state": "ON" if _backlight_on else "OFF",
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"color": {
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"r": _backlight_color[0],
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"g": _backlight_color[1],
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"b": _backlight_color[2],
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},
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"brightness": int(_backlight_brightness * 2.55),
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}
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client.publish(T_LED_BL, ujson.dumps(payload), retain=True)
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info(
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f"Backlight state retained: {payload['state']} {_backlight_color} @ {_backlight_brightness}%"
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)
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def _backlight_changed(new_color, new_on, new_brightness):
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"""Return True if any backlight property differs from current state."""
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return (
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new_color != _backlight_color
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or new_on != _backlight_on
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or (new_on and new_brightness != _backlight_brightness)
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)
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def _mark_bl_dirty():
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global _bl_dirty_since
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_bl_dirty_since = utime.ticks_ms()
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def set_backlight_color(r, g, b, brightness=None):
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global _backlight_color, _backlight_brightness, _backlight_on
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if brightness is None:
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brightness = _backlight_brightness
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new_on = brightness > 0
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if not _backlight_changed((r, g, b), new_on, brightness):
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return
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_backlight_color = (r, g, b)
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if brightness > 0:
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_backlight_brightness = brightness
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_backlight_on = new_on
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scale = brightness / 100
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for i in range(3):
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led_bl[i] = (int(g * scale), int(r * scale), int(b * scale))
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led_bl.write()
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_mark_bl_dirty()
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def set_backlight_brightness(brightness):
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global _backlight_brightness, _backlight_on
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clamped = max(0, min(100, brightness))
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new_on = clamped > 0
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if not _backlight_changed(_backlight_color, new_on, clamped):
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return
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if clamped > 0:
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_backlight_brightness = clamped
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_backlight_on = new_on
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r, g, b = _backlight_color
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scale = clamped / 100
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for i in range(3):
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led_bl[i] = (int(g * scale), int(r * scale), int(b * scale))
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led_bl.write()
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_mark_bl_dirty()
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info(f"LEDs ready red={LED_RED_PIN} green={LED_GREEN_PIN} backlight={LED_BL_PIN}")
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# ---------------------------------------------------------------------------
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# State
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# ---------------------------------------------------------------------------
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_target_value = GAUGE_MIN
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_last_rezero_ms = None # set to ticks_ms() in main()
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client_ref = None
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_mqtt_connected = False
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def _publish(topic, payload, retain=False):
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"""Safely publish MQTT message, returning True on success."""
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if client_ref is None:
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return False
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try:
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client_ref.publish(topic, payload, retain=retain)
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return True
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except Exception as e:
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log_err(f"MQTT publish failed: {e}")
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return False
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# ---------------------------------------------------------------------------
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# MQTT callbacks
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# ---------------------------------------------------------------------------
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def on_message(topic, payload):
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if client_ref is None:
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return
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topic = topic.decode()
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payload = payload.decode().strip()
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info(f"MQTT rx {topic} {payload}")
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if topic == T_ZERO:
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global _last_rezero_ms
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info("Zero command received")
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gauge.zero()
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_last_rezero_ms = utime.ticks_ms()
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info("Zero complete")
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return
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if topic == T_LED_RED:
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state = payload.upper() == "ON"
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led_red.value(1 if state else 0)
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_publish(T_LED_RED_STATE, "ON" if state else "OFF", retain=True)
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info(f"Red LED → {'ON' if state else 'OFF'}")
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return
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if topic == T_LED_GREEN:
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state = payload.upper() == "ON"
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led_green.value(1 if state else 0)
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_publish(T_LED_GREEN_STATE, "ON" if state else "OFF", retain=True)
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info(f"Green LED → {'ON' if state else 'OFF'}")
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return
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if topic == T_LED_BL:
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info(f"Backlight raw payload: '{payload}'")
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try:
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data = ujson.loads(payload)
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info(
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f"Backlight parsed: state={data.get('state')} color={data.get('color')} brightness={data.get('brightness')}"
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)
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if data.get("state", "ON").upper() == "OFF":
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set_backlight_brightness(0)
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_publish(T_LED_BL_STATE, ujson.dumps({"state": "OFF"}), retain=True)
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info("Backlight → OFF")
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return
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color = data.get("color", {})
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r = max(0, min(255, int(color.get("r", _backlight_color[0]))))
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g = max(0, min(255, int(color.get("g", _backlight_color[1]))))
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b = max(0, min(255, int(color.get("b", _backlight_color[2]))))
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# HA sends brightness as 0-255; convert to 0-100
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raw_br = data.get("brightness", None)
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if raw_br is not None:
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brightness = max(0, min(100, round(int(raw_br) / 2.55)))
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elif _backlight_brightness > 0:
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brightness = _backlight_brightness
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else:
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brightness = 100
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except Exception as e:
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warn(f"Invalid backlight payload: '{payload}' ({e})")
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return
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set_backlight_color(r, g, b, brightness)
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color_hex = f"#{r:02x}{g:02x}{b:02x}"
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state = {
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"state": "ON",
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"color_mode": "rgb",
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"brightness": int(brightness * 2.55),
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"color": {"r": r, "g": g, "b": b},
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}
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_publish(T_LED_BL_STATE, ujson.dumps(state), retain=True)
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info(f"Backlight → {color_hex} @ {brightness}%")
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return
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if topic == T_SET:
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global _target_value
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try:
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_target_value = max(GAUGE_MIN, min(GAUGE_MAX, float(payload)))
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info(f"New target → {_target_value:.1f}")
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except ValueError:
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warn(f"Invalid set value: '{payload}'")
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# ---------------------------------------------------------------------------
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# MQTT connect + discovery
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# ---------------------------------------------------------------------------
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def connect_mqtt():
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global client_ref, _mqtt_connected
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info(f"Connecting to MQTT broker {MQTT_BROKER}:{MQTT_PORT} ...")
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client = MQTTClient(
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client_id=MQTT_CLIENT_ID,
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server=MQTT_BROKER,
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port=MQTT_PORT,
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user=MQTT_USER,
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password=MQTT_PASSWORD,
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keepalive=60,
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)
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client.set_last_will(T_STATUS, b"offline", retain=True, qos=0)
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client.set_callback(on_message)
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client.connect()
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client_ref = client
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client.subscribe(T_SET)
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client.subscribe(T_ZERO)
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client.subscribe(T_LED_RED)
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client.subscribe(T_LED_GREEN)
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client.subscribe(T_LED_BL)
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_mqtt_connected = True
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info(f"MQTT connected client_id={MQTT_CLIENT_ID}")
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return client
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def check_mqtt():
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global client_ref, _mqtt_connected
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if client_ref is None:
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return False
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try:
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client_ref.ping()
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_mqtt_connected = True
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return True
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except Exception as e:
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log_err(f"MQTT connection lost: {e}")
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_mqtt_connected = False
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# Try to reconnect
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log_err("Attempting MQTT reconnection...")
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for attempt in range(3):
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try:
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client_ref = MQTTClient(
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client_id=MQTT_CLIENT_ID,
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server=MQTT_BROKER,
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port=MQTT_PORT,
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user=MQTT_USER,
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password=MQTT_PASSWORD,
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keepalive=60,
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)
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client_ref.set_last_will(T_STATUS, b"offline", retain=True, qos=0)
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client_ref.set_callback(on_message)
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client_ref.connect()
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client_ref.subscribe(T_SET)
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client_ref.subscribe(T_ZERO)
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client_ref.subscribe(T_LED_RED)
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client_ref.subscribe(T_LED_GREEN)
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client_ref.subscribe(T_LED_BL)
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_mqtt_connected = True
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info("MQTT reconnected!")
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publish_discovery(client_ref)
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publish_state(client_ref)
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return True
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except Exception as e2:
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log_err(f"MQTT reconnect attempt {attempt + 1} failed: {e2}")
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utime.sleep_ms(2000)
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log_err("MQTT reconnection failed after 3 attempts")
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return False
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def publish_discovery(client):
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"""Publish all HA MQTT discovery payloads using short-form keys to stay under 512 bytes."""
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# Full device block only on first payload; subsequent use identifiers-only ref
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_dev_ref = {"identifiers": [MQTT_CLIENT_ID]}
|
|
|
|
client.publish(
|
|
T_DISC_GAUGE,
|
|
ujson.dumps(
|
|
{
|
|
"name": GAUGE_ENTITY,
|
|
"unique_id": MQTT_CLIENT_ID,
|
|
"cmd_t": T_SET,
|
|
"stat_t": T_STATE,
|
|
"avty_t": T_STATUS,
|
|
"min": GAUGE_MIN,
|
|
"max": GAUGE_MAX,
|
|
"step": 1,
|
|
"unit_of_meas": GAUGE_UNIT,
|
|
"icon": "mdi:gauge",
|
|
"dev": _DEVICE,
|
|
}
|
|
),
|
|
retain=True,
|
|
)
|
|
info("Discovery: gauge")
|
|
|
|
client.publish(
|
|
T_DISC_RED,
|
|
ujson.dumps(
|
|
{
|
|
"name": RED_ENTITY,
|
|
"uniq_id": f"{MQTT_CLIENT_ID}_led_red",
|
|
"cmd_t": T_LED_RED,
|
|
"stat_t": T_LED_RED_STATE,
|
|
"pl_on": "ON",
|
|
"pl_off": "OFF",
|
|
"icon": "mdi:led-on",
|
|
"dev": _dev_ref,
|
|
"ret": True,
|
|
}
|
|
),
|
|
retain=True,
|
|
)
|
|
info("Discovery: red LED")
|
|
|
|
client.publish(
|
|
T_DISC_GREEN,
|
|
ujson.dumps(
|
|
{
|
|
"name": GREEN_ENTITY,
|
|
"uniq_id": f"{MQTT_CLIENT_ID}_led_green",
|
|
"cmd_t": T_LED_GREEN,
|
|
"stat_t": T_LED_GREEN_STATE,
|
|
"pl_on": "ON",
|
|
"pl_off": "OFF",
|
|
"icon": "mdi:led-on",
|
|
"dev": _dev_ref,
|
|
"ret": True,
|
|
}
|
|
),
|
|
retain=True,
|
|
)
|
|
info("Discovery: green LED")
|
|
|
|
client.publish(
|
|
T_DISC_BL,
|
|
ujson.dumps(
|
|
{
|
|
"name": BL_ENTITY,
|
|
"uniq_id": f"{MQTT_CLIENT_ID}_led_bl",
|
|
"cmd_t": T_LED_BL,
|
|
"stat_t": T_LED_BL_STATE,
|
|
"schema": "json",
|
|
"supported_color_modes": ["rgb"],
|
|
"icon": "mdi:led-strip",
|
|
"dev": _dev_ref,
|
|
"ret": True,
|
|
}
|
|
),
|
|
retain=True,
|
|
)
|
|
info("Discovery: backlight")
|
|
|
|
|
|
def publish_state(client):
|
|
val = gauge.get()
|
|
client.publish(T_STATE, str(round(val, 1)), retain=True)
|
|
client.publish(T_STATUS, "online", retain=True)
|
|
info(f"State published value={val:.1f} step={gauge._current_step}")
|
|
|
|
|
|
# ---------------------------------------------------------------------------
|
|
# Main
|
|
# ---------------------------------------------------------------------------
|
|
|
|
|
|
def main():
|
|
info("=" * 48)
|
|
info("Gauge MQTT controller starting")
|
|
info("=" * 48)
|
|
|
|
connect_wifi(WIFI_SSID, WIFI_PASSWORD)
|
|
|
|
info("Zeroing gauge on startup ...")
|
|
gauge.zero()
|
|
info("Zero complete")
|
|
|
|
# umqtt.robust handles reconnection automatically — just connect once
|
|
connect_mqtt()
|
|
publish_discovery(client_ref)
|
|
publish_state(client_ref)
|
|
|
|
info("Entering main loop")
|
|
info("-" * 48)
|
|
|
|
try:
|
|
import ota
|
|
|
|
ota.mark_ok()
|
|
info("OTA OK flag set")
|
|
except ImportError:
|
|
pass
|
|
|
|
global _last_rezero_ms, _bl_dirty_since
|
|
last_heartbeat = utime.ticks_ms()
|
|
_last_rezero_ms = utime.ticks_ms()
|
|
|
|
target_step = gauge._val_to_step(_target_value)
|
|
|
|
# Period at which to publish state updates during movement
|
|
MOVE_STATE_INTERVAL_MS = 500
|
|
last_move_state = utime.ticks_ms()
|
|
|
|
while True:
|
|
try:
|
|
check_wifi()
|
|
|
|
if not check_mqtt():
|
|
utime.sleep_ms(1000)
|
|
continue
|
|
|
|
client_ref.check_msg()
|
|
|
|
now = utime.ticks_ms()
|
|
|
|
# Continuously move towards target at constant speed
|
|
current_target = gauge._val_to_step(_target_value)
|
|
moved = False
|
|
if current_target != gauge._current_step:
|
|
direction = 1 if current_target > gauge._current_step else -1
|
|
gauge.step(direction)
|
|
moved = True
|
|
|
|
# Publish state during movement at intervals
|
|
if (
|
|
moved
|
|
and utime.ticks_diff(now, last_move_state) >= MOVE_STATE_INTERVAL_MS
|
|
):
|
|
publish_state(client_ref)
|
|
last_move_state = now
|
|
|
|
# Sleep to achieve constant speed
|
|
if moved or (
|
|
current_target == gauge._current_step
|
|
and gauge._current_step != gauge._val_to_step(_target_value)
|
|
):
|
|
delay_us = 1_000_000 // MICROSTEPS_PER_SECOND
|
|
utime.sleep_us(delay_us)
|
|
|
|
# Periodic auto-rezero (disabled when interval is 0)
|
|
if (
|
|
REZERO_INTERVAL_MS > 0
|
|
and utime.ticks_diff(now, _last_rezero_ms) >= REZERO_INTERVAL_MS
|
|
):
|
|
info("Auto-rezero triggered")
|
|
saved = _target_value
|
|
gauge.zero()
|
|
if saved > GAUGE_MIN:
|
|
gauge.set(saved)
|
|
publish_state(client_ref)
|
|
_last_rezero_ms = now
|
|
info(f"Auto-rezero complete, restored to {saved:.1f}")
|
|
|
|
# Retain backlight state via MQTT after settling
|
|
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
|
|
|
|
# Heartbeat
|
|
if utime.ticks_diff(now, last_heartbeat) >= HEARTBEAT_MS:
|
|
publish_state(client_ref)
|
|
info(
|
|
f"step={gauge._current_step} phase={gauge._phase} target_step={gauge._val_to_step(_target_value)} expected_phase={gauge._current_step % 4}"
|
|
)
|
|
last_heartbeat = now
|
|
|
|
except Exception as e:
|
|
log_err(f"Main loop error: {e} — continuing")
|
|
utime.sleep_ms(100)
|
|
|
|
|
|
main()
|