Reverted a lot of cruft

Gaugecontroller/Gaugecontroller.ino

@@ -258,7 +258,7 @@ struct Gauge {
   long homingBackoffSteps = 3800; // Deliberately a touch past full reverse travel.
 
   float velocity = 0.0f;
-  float maxSpeed = 5000.0f;
+  float maxSpeed = 4000.0f;
   float accel = 6000.0f;
   float homingSpeed = 500.0f;
 

boot.py

@@ -0,0 +1,62 @@
+"""
+boot.py — runs before main.py on every ESP32 boot
+
+Connects WiFi, runs OTA update, then hands off to main.py.
+Keep this file as simple as possible — it is never OTA-updated itself
+(it lives outside the repo folder) so bugs here require USB to fix.
+"""
+#import gauge
+import network
+import gc
+import utime
+import sys
+
+import ota
+
+ota.load_config()
+WIFI_SSID, WIFI_PASSWORD = ota.WIFI_SSID, ota.WIFI_PASSWORD
+
+def _connect_wifi(timeout_s=20):
+    sta = network.WLAN(network.STA_IF)
+    sta.active(True)
+    sta.config(txpower=15)
+    if sta.isconnected():
+        return True
+    sta.connect(WIFI_SSID, WIFI_PASSWORD)
+    deadline = utime.time() + timeout_s
+    while not sta.isconnected():
+        if utime.time() > deadline:
+            return False
+        utime.sleep_ms(300)
+    return True
+
+if WIFI_SSID is None:
+    print("[boot] No WiFi credentials — cannot connect, skipping OTA")
+elif _connect_wifi():
+    ip = network.WLAN(network.STA_IF).ifconfig()[0]
+    print(f"[boot] WiFi connected — {ip}")
+
+    try:
+        ota.update()
+    except Exception as e:
+        print(f"[boot] OTA error: {e} — continuing with existing files")
+        sys.print_exception(e)
+    utime.sleep_ms(5000)
+    ota._fetch_commit_sha = None
+    ota._fetch_manifest = None
+    ota._fetch_dir = None
+    ota._api_get = None
+    ota._download = None
+    ota.urequests = None
+    del ota.urequests
+    del ota
+    gc.collect()
+    del sys.modules["ota"]
+    gc.collect()
+
+else:
+    print("[boot] WiFi failed — skipping OTA, booting with existing files")
+
+# main.py runs automatically after boot.py
+
+

gauge.py

@@ -151,19 +151,27 @@ ARDUINO_TX_PIN = int(_cfg.get("arduino_tx_pin", 17))
 ARDUINO_RX_PIN = int(_cfg.get("arduino_rx_pin", 16))
 ARDUINO_BAUD = int(_cfg.get("arduino_baud", 115200))
 
-_arduino = UART(ARDUINO_UART_ID, baudrate=ARDUINO_BAUD, tx=ARDUINO_TX_PIN, rx=ARDUINO_RX_PIN, timeout=10)
+_arduino = None
+
+
+def _ensure_arduino():
+    global _arduino
+    if _arduino is None:
+        _arduino = UART(ARDUINO_UART_ID, baudrate=ARDUINO_BAUD, tx=ARDUINO_TX_PIN, rx=ARDUINO_RX_PIN, timeout=10)
+    return _arduino
 
 
 def arduino_send(cmd):
     """Send a newline-terminated command to the Arduino."""
-    _arduino.write((cmd + "\n").encode())
+    _ensure_arduino().write((cmd + "\n").encode())
     info(f"Arduino → {cmd}")
 
 
 def arduino_recv():
     """Print any lines waiting in the Arduino RX buffer."""
-    while _arduino.any():
-        line = _arduino.readline()
+    uart = _ensure_arduino()
+    while uart.any():
+        line = uart.readline()
         if line:
             print(f"[{_ts()}] ARDU   {line.decode().strip()}")
 
@@ -524,32 +532,60 @@ _DEVICE = {
 _wifi_check_interval_ms = 30000
 _last_wifi_check = 0
 _wifi_sta = None
+_WIFI_CONNECT_ATTEMPTS = 3
 
 
-def connect_wifi(ssid, password, timeout_s=15):
+def _reset_wifi_interface():
     global _wifi_sta
     _wifi_sta = network.WLAN(network.STA_IF)
-    _wifi_sta.active(True)
-    if _wifi_sta.isconnected():
+    if not _wifi_sta.active():
+        _wifi_sta.active(True)
+        utime.sleep_ms(500)
+    try:
+        _wifi_sta.disconnect()
+    except Exception:
+        pass
+    utime.sleep_ms(1000)
+
+
+def connect_wifi(ssid, password, timeout_s=15, force_reconnect=False):
+    global _wifi_sta
+    _wifi_sta = network.WLAN(network.STA_IF)
+
+    if _wifi_sta.isconnected() and not force_reconnect:
         ip, mask, gw, dns = _wifi_sta.ifconfig()
         info("WiFi already connected")
         info(f"  IP:{ip}  mask:{mask}  gw:{gw}  dns:{dns}")
+        utime.sleep_ms(250)
         return ip
-    info(f"WiFi connecting to '{ssid}' ...")
-    _wifi_sta.connect(ssid, password)
-    deadline = utime.time() + timeout_s
-    while not _wifi_sta.isconnected():
-        if utime.time() > deadline:
-            log_err(f"WiFi connect timeout after {timeout_s}s")
-            raise OSError("WiFi connect timeout")
-        utime.sleep_ms(200)
-    ip, mask, gw, dns = _wifi_sta.ifconfig()
-    mac = ":".join(f"{b:02x}" for b in _wifi_sta.config("mac"))
-    info("WiFi connected!")
-    info(f"  SSID    : {ssid}")
-    info(f"  MAC     : {mac}")
-    info(f"  IP      : {ip}  mask:{mask}  gw:{gw}  dns:{dns}")
-    return ip
+
+    last_error = None
+    for attempt in range(_WIFI_CONNECT_ATTEMPTS):
+        info(f"WiFi connecting to '{ssid}' (attempt {attempt + 1}/{_WIFI_CONNECT_ATTEMPTS}) ...")
+        if not _wifi_sta.isconnected():
+            _reset_wifi_interface()
+        try:
+            _wifi_sta.connect(ssid, password)
+            deadline = utime.time() + timeout_s
+            while not _wifi_sta.isconnected():
+                if utime.time() > deadline:
+                    raise OSError("WiFi connect timeout")
+                utime.sleep_ms(250)
+
+            ip, mask, gw, dns = _wifi_sta.ifconfig()
+            mac = ":".join(f"{b:02x}" for b in _wifi_sta.config("mac"))
+            info("WiFi connected!")
+            info(f"  SSID    : {ssid}")
+            info(f"  MAC     : {mac}")
+            info(f"  IP      : {ip}  mask:{mask}  gw:{gw}  dns:{dns}")
+            utime.sleep_ms(2000)
+            return ip
+        except Exception as e:
+            last_error = e
+            log_err(f"WiFi connect attempt {attempt + 1} failed: {e}")
+            utime.sleep_ms(1000)
+
+    raise last_error
 
 
 def check_wifi():
@@ -567,15 +603,7 @@ def check_wifi():
 
     log_err("WiFi lost connection — attempting reconnect...")
     try:
-        _wifi_sta.active(True)
-        _wifi_sta.connect(WIFI_SSID, WIFI_PASSWORD)
-        deadline = utime.time() + 15
-        while not _wifi_sta.isconnected():
-            if utime.time() > deadline:
-                log_err("WiFi reconnect timeout")
-                return
-            utime.sleep_ms(200)
-        ip, mask, gw, dns = _wifi_sta.ifconfig()
+        ip = connect_wifi(WIFI_SSID, WIFI_PASSWORD, timeout_s=15)
         info(f"WiFi reconnected! IP:{ip}")
     except Exception as e:
         log_err(f"WiFi reconnect failed: {e}")
@@ -858,27 +886,38 @@ def _subscribe_all(c):
 def connect_mqtt():
     global client_ref, _mqtt_connected
     info(f"Connecting to MQTT broker {MQTT_BROKER}:{MQTT_PORT} ...")
-    client = MQTTClient(
-        client_id=MQTT_CLIENT_ID,
-        server=MQTT_BROKER,
-        port=MQTT_PORT,
-        user=MQTT_USER,
-        password=MQTT_PASSWORD,
-        keepalive=30,
-    )
-    client.set_callback(on_message)
-    client.connect()
-    client_ref = client
-    _mqtt_connected = True
-    info(f"MQTT connected  client_id={MQTT_CLIENT_ID}")
+    last_error = None
+    for attempt in range(3):
+        gc.collect()
+        try:
+            if client_ref is not None:
+                try:
+                    client_ref.disconnect()
+                except Exception:
+                    pass
 
+            client = MQTTClient(
+                client_id=MQTT_CLIENT_ID,
+                server=MQTT_BROKER,
+                port=MQTT_PORT,
+                user=MQTT_USER,
+                password=MQTT_PASSWORD,
+                keepalive=30,
+            )
+            client.set_callback(on_message)
+            client.connect()
+            client_ref = client
+            _mqtt_connected = True
+            info(f"MQTT connected  client_id={MQTT_CLIENT_ID}")
+            return
+        except Exception as e:
+            last_error = e
+            log_err(f"MQTT connect attempt {attempt + 1} failed: {type(e).__name__}: {e}")
+            gc.collect()
+            utime.sleep_ms(1000)
 
-_mqtt_check_interval_ms = 30000
-_last_mqtt_check = 0
-_discovery_queue = []
-_discovery_idx = 0
-_last_discovery_ms = 0
-_DISCOVERY_INTERVAL_MS = 200
+    _mqtt_connected = False
+    raise last_error
 
 
 def check_mqtt():
@@ -922,13 +961,23 @@ def check_mqtt():
             return True
         except Exception as e2:
             log_err(f"MQTT reconnect attempt {attempt + 1} failed: {e2}")
+            gc.collect()
             utime.sleep_ms(2000)
 
     log_err("MQTT reconnection failed after 3 attempts")
     return False
 
 
+_mqtt_check_interval_ms = 30000
+_last_mqtt_check = 0
+_discovery_queue = []
+_discovery_idx = 0
+_last_discovery_ms = 0
+_DISCOVERY_INTERVAL_MS = 350
+
+
 def _publish_discovery_entity(client, topic, payload, log_msg):
+    gc.collect()
     client.publish(topic, ujson.dumps(payload), retain=True)
     info(log_msg)
 
@@ -1124,10 +1173,7 @@ def _append_vfd_discovery(entries, dev_ref):
                 "cmd_t": vfd_topics["set"],
                 "stat_t": vfd_topics["state"],
                 "avty_t": gauge_topics[0]["status"],
-                "max": 4,
-                "mode": "text",
                 "icon": "mdi:alpha-box",
-                "pattern": "^[0-9A-Fa-f-]{0,4}$",
                 "dev": dev_ref,
             },
             "Discovery: VFD text",
@@ -1205,15 +1251,18 @@ def service_discovery():
     if _last_discovery_ms and utime.ticks_diff(now, _last_discovery_ms) < _DISCOVERY_INTERVAL_MS:
         return
 
+    gc.collect()
     topic, payload, log_msg = _discovery_queue[_discovery_idx]
-    if isinstance(payload, bytes):
-        client_ref.publish(topic, payload, retain=True)
-    else:
-        _publish_discovery_entity(client_ref, topic, payload, log_msg)
+    try:
+        if isinstance(payload, bytes):
+            client_ref.publish(topic, payload, retain=True)
+        else:
+            _publish_discovery_entity(client_ref, topic, payload, log_msg)
+    except Exception as e:
+        log_err(f"Discovery publish failed for {topic}: {e}")
     _discovery_idx += 1
     _last_discovery_ms = utime.ticks_ms()
-    if (_discovery_idx & 3) == 0:
-        gc.collect()
+    gc.collect()
 
 
 def publish_online(client):
@@ -1237,22 +1286,70 @@ def apply_motion_defaults():
     send_vfd_state()
 
 
+def _restore_led_states():
+    for i in range(num_gauges):
+        gt = gauge_topics[i]
+        info(f"  red={_red_effect[i]} green={_green_effect[i]} status_r={_status_red_effect[i]} status_g={_status_green_effect[i]}")
+        for led_key, led_idx, color, effect_arr, state_topic in [
+            ("red", _LED_RED, gauges[i]["ws2812_red"], _red_effect, gt["led_red_state"]),
+            ("green", _LED_GREEN, gauges[i]["ws2812_green"], _green_effect, gt["led_green_state"]),
+            ("status_red", _LED_STATUS_RED, gauges[i]["ws2812_red"], _status_red_effect, gt["status_red_state"]),
+            ("status_green", _LED_STATUS_GREEN, gauges[i]["ws2812_green"], _status_green_effect, gt["status_green_state"]),
+        ]:
+            if effect_arr[i]:
+                pub = {"state": "ON", "effect": effect_arr[i]}
+                _publish(state_topic, ujson.dumps(pub), retain=True)
+        if _red_effect[i]:
+            _apply_blink_or_led(i, _LED_RED, gauges[i]["ws2812_red"], _red_effect[i])
+        if _green_effect[i]:
+            _apply_blink_or_led(i, _LED_GREEN, gauges[i]["ws2812_green"], _green_effect[i])
+        if _status_red_effect[i]:
+            _apply_blink_or_led(i, _LED_STATUS_RED, gauges[i]["ws2812_red"], _status_red_effect[i])
+        if _status_green_effect[i]:
+            _apply_blink_or_led(i, _LED_STATUS_GREEN, gauges[i]["ws2812_green"], _status_green_effect[i])
+
+
 # ---------------------------------------------------------------------------
 # Main
 # ---------------------------------------------------------------------------
 
 
 def main():
+    gc.collect()
+    _w = network.WLAN(network.STA_IF)
+    if not _w.active():
+        _w.active(True)
+    del _w
+    gc.collect()
+    _ensure_arduino()
+    gc.collect()
     info("=" * 48)
     info("Gauge MQTT controller starting")
+    info(f"Heap free: {gc.mem_free()} bytes")
     info("=" * 48)
 
+    gc.collect()
     connect_wifi(WIFI_SSID, WIFI_PASSWORD)
 
-    connect_mqtt()
+    mqtt_attempts = 0
+    while True:
+        try:
+            connect_mqtt()
+            break
+        except Exception as e:
+            mqtt_attempts += 1
+            log_err(f"MQTT connect failed: {e} (attempt {mqtt_attempts})")
+            if mqtt_attempts % 3 == 0:
+                log_err("WiFi may be stale — forcing reconnect...")
+                try:
+                    connect_wifi(WIFI_SSID, WIFI_PASSWORD)
+                except Exception as we:
+                    log_err(f"WiFi reconnect failed: {we}")
+            utime.sleep_ms(5000)
     _subscribe_all(client_ref)
     schedule_discovery()
 
+    publish_backlight_states(client_ref)
     apply_motion_defaults()
     info("Draining initial retained messages...")
     for _ in range(50):
@@ -1265,6 +1362,10 @@ def main():
         gauge_last_rezero[i] = utime.ticks_ms()
     info("Home command sent")
 
+    utime.sleep_ms(100)
+    _restore_led_states()
+    info("LED effects restored")
+
     info("Publishing state...")
     publish_online(client_ref)
     publish_state(client_ref)