Lowered LED-Breathe-Frequency

CLAUDE.md

@@ -0,0 +1,107 @@
+# CLAUDE.md
+
+This file provides guidance to Claude Code (claude.ai/code) when working with code in this repository.
+
+## Build & Upload
+
+This is a single-file Arduino sketch (`Gaugecontroller.ino`). Requires the **FastLED** library (`arduino-cli lib install FastLED`). Use the Arduino IDE or `arduino-cli`:
+
+```bash
+# Compile (replace board/port as needed)
+arduino-cli compile --fqbn arduino:avr:mega Gaugecontroller.ino
+
+# Upload
+arduino-cli upload -p /dev/ttyACM0 --fqbn arduino:avr:mega Gaugecontroller.ino
+```
+
+Serial monitor: 115200 baud (`Serial` is both CMD_PORT and DEBUG_PORT).
+
+## Switching serial ports (debug → production)
+
+Two `#define`s at the top of `Gaugecontroller.ino` control where commands and debug output go:
+
+```cpp
+#define CMD_PORT   Serial   // command channel (host sends SET, HOME, etc.)
+#define DEBUG_PORT Serial   // diagnostic prints (homing, boot messages)
+```
+
+**Debug / USB-only (default):** both point to `Serial` (the USB-CDC port). Connect via `minicom` or the Arduino IDE serial monitor at 115200 baud.
+
+**Production (hardware UART):** change `CMD_PORT` to a hardware serial port so a host MCU or Raspberry Pi can drive it without occupying the USB port:
+
+```cpp
+#define CMD_PORT   Serial1  // TX1=pin18, RX1=pin19
+#define DEBUG_PORT Serial   // keep USB for monitoring, or silence it (see below)
+```
+
+Arduino Mega hardware UARTs:
+
+| Port    | TX pin | RX pin |
+|---------|--------|--------|
+| Serial1 | 18     | 19     |
+| Serial2 | 16     | 17     |
+| Serial3 | 14     | 15     |
+
+`setup()` calls `DEBUG_PORT.begin(115200)` only. If `CMD_PORT` differs from `DEBUG_PORT` you must also begin it — add a second `begin` call in `setup()`:
+
+```cpp
+CMD_PORT.begin(115200);
+```
+
+**Silencing debug output entirely:** point `DEBUG_PORT` at a null stream, or wrap all `DEBUG_PORT` calls in an `#ifdef DEBUG` guard. The simplest option is to replace the define with a no-op object, but the easiest production approach is just to leave `DEBUG_PORT Serial` and ignore the USB output.
+
+## Architecture
+
+The sketch controls `GAUGE_COUNT` stepper-motor gauges using a trapezoidal velocity profile and a simple text serial protocol.
+
+### Key data structures
+
+- `GaugePins` — hardware pin mapping per gauge (dir, step, enable, active-high/low polarity flags, `ledCount`). Declared `constexpr` so `TOTAL_LEDS` can be computed from it at compile time. Configured in the `gaugePins[]` array at the top.
+- `Gauge` — per-gauge runtime state: position, target, velocity, accel, homing state machine, sweep mode.
+
+### Motion control (`updateGauge`)
+
+Each call to `updateGauge(id)` in `loop()` computes `dt` since last call and updates velocity using a braking-distance check to produce smooth trapezoidal motion. Steps are accumulated as floating-point and emitted via `doStep` when the accumulator crosses ±1.
+
+### Homing sequence (`updateHoming`)
+
+State machine: `HS_START → HS_BACKING → HS_SETTLE → HS_DONE → HS_IDLE`.  
+Backs up `homingBackoffSteps` at `homingSpeed`, waits 100 ms settle, then declares `currentPos = 0`. No physical end-stop is used; homing is purely time/step-count based.
+
+### Sweep mode
+
+When `sweepEnabled`, `updateSweepTarget` bounces `targetPos` between `minPos` and `maxPos` autonomously.
+
+### LED strip
+
+One shared WS2812B strip is driven from `LED_DATA_PIN` (default 6). Each gauge owns a contiguous segment of the strip; `gaugePins[i].ledCount` sets the segment length (0 = no LEDs). `TOTAL_LEDS` is computed at compile time via `constexpr sumLedCounts()` — no manual constant to keep in sync. Per-gauge offsets into the flat `leds[]` array are computed once in `setup()` into `gaugeLedOffset[]`. `FastLED.show()` is called immediately after each `LED` command.
+
+### Serial command protocol
+
+Commands arrive as newline-terminated ASCII lines. Each `parse*` function in `processLine` handles one command family:
+
+| Command | Syntax | Effect |
+|---|---|---|
+| `SET` | `SET <id> <pos>` | Move gauge to absolute step position |
+| `SPEED` | `SPEED <id> <steps/s>` | Set max speed |
+| `ACCEL` | `ACCEL <id> <steps/s²>` | Set acceleration |
+| `ENABLE` | `ENABLE <id> <0\|1>` | Enable/disable driver output |
+| `ZERO` | `ZERO <id>` | Mark current position as home without moving |
+| `HOME` | `HOME <id>` / `HOMEALL` | Run homing sequence |
+| `SWEEP` | `SWEEP <id> <accel> <speed>` | Start sweep (0/0 stops) |
+| `POS?` | `POS?` | Query all gauges: `POS <id> <cur> <tgt> <homed> <homingState> <sweep>` |
+| `LED` | `LED <id> <idx> <r> <g> <b>` | Set one LED (0-based index within gauge segment) to RGB colour (0–255 each); `<idx>` may be a range `N-M` to set LEDs N through M in one command; also stops any active effect on those LEDs |
+| `LED?` | `LED?` | Query all LEDs: one `LED <id> <idx> <r> <g> <b>` line per LED, then `OK` |
+| `BLINK` | `BLINK <id> <idx> <on_ms> <off_ms> <r> <g> <b>` | Blink LED(s) at given colour; `<idx>` may be a range `N-M`; `on_ms`/`off_ms` both 0 stops blinking. 4-arg form (no colour) uses current LED colour |
+| `BREATHE` | `BREATHE <id> <idx> <period_ms> <r> <g> <b>` | Smooth triangle-wave fade between black and the given colour; `<idx>` may be a range `N-M` |
+| `DFLASH` | `DFLASH <id> <idx> <r> <g> <b>` | Two quick flashes (100 ms on/off each) followed by a 700 ms pause, then repeats; `<idx>` may be a range `N-M` |
+| `PING` | `PING` | Responds `PONG` |
+
+All commands reply `OK` or `ERR BAD_ID` / `ERR BAD_CMD` etc.
+
+### Adding gauges
+
+1. Increment `GAUGE_COUNT`.
+2. Add a `constexpr GaugePins` entry to `gaugePins[]` (including `ledCount`).
+3. Tune `maxPos` and `homingBackoffSteps` in the corresponding `Gauge` default or at runtime.
+4. `TOTAL_LEDS` and `gaugeLedOffset[]` update automatically — no manual changes needed.

Gaugecontroller/Gaugecontroller.ino

@@ -1,11 +1,17 @@
 #include <Arduino.h>
 #include <math.h>
+#include <FastLED.h>
 
 static const uint8_t GAUGE_COUNT = 2;
 
+// LED strip — one shared WS2812B strip, segmented per gauge.
+// Set LED_DATA_PIN to the digital pin driving the strip data line.
+// TOTAL_LEDS is computed automatically from gaugePins[].ledCount.
+static const uint8_t LED_DATA_PIN = 22;
+
 // For now: commands come over USB serial
-#define CMD_PORT Serial
+#define CMD_PORT Serial1
-#define DEBUG_PORT Serial
+#define DEBUG_PORT Serial1
 
 struct GaugePins {
   uint8_t dirPin;
@@ -14,14 +20,20 @@ struct GaugePins {
   bool dirInverted;
   bool stepActiveHigh;
   bool enableActiveLow;
+  uint8_t ledCount;          // WS2812B LEDs on this gauge's strip segment (0 if none)
 };
 
-GaugePins gaugePins[GAUGE_COUNT] = {
+constexpr GaugePins gaugePins[GAUGE_COUNT] = {
-  // dir, step, en, dirInv, stepHigh, enActiveLow
+  // dir, step, en, dirInv, stepHigh, enActiveLow, leds
-  {50, 51, -1, false, true, true},   // Gauge 0
+  {50, 51, -1, false, true, true, 7},   // Gauge 0
-  {8, 9, -1, true, true, true},   // Gauge 1
+  {8,  9,  -1, true,  true, true, 7},   // Gauge 1
 };
 
+constexpr uint8_t sumLedCounts(uint8_t i = 0) {
+  return i >= GAUGE_COUNT ? 0 : gaugePins[i].ledCount + sumLedCounts(i + 1);
+}
+static const uint8_t TOTAL_LEDS = sumLedCounts();
+
 enum HomingState : uint8_t {
   HS_IDLE,
   HS_START,
@@ -35,12 +47,12 @@ struct Gauge {
   long targetPos = 0;
 
   long minPos = 0;
-  long maxPos = 3610;             // adjust to your usable travel
+  long maxPos = 3780;             // adjust to your usable travel
-  long homingBackoffSteps = 3700; // should exceed reverse travel slightly
+  long homingBackoffSteps = 3800; // should exceed reverse travel slightly
 
   float velocity = 0.0f;
-  float maxSpeed = 8000.0f;
+  float maxSpeed = 5000.0f;
-  float accel = 9000.0f;
+  float accel = 6000.0f;
   float homingSpeed = 500.0f;
 
   float stepAccumulator = 0.0f;
@@ -58,9 +70,32 @@ struct Gauge {
   bool sweepTowardMax = true;
 };
 
+enum LedFx : uint8_t { FX_BLINK = 0, FX_BREATHE = 1, FX_DFLASH = 2 };
+
+struct BlinkState {
+  bool          active      = false;
+  LedFx         fx          = FX_BLINK;
+  CRGB          onColor;
+  unsigned long lastMs      = 0;
+  // FX_BLINK
+  uint16_t      onMs        = 500;
+  uint16_t      offMs       = 500;
+  bool          currentlyOn = false;
+  // FX_BREATHE: smooth triangle-wave fade
+  uint16_t      periodMs    = 2000;
+  uint16_t      cyclePos    = 0;
+  // FX_DFLASH: two quick flashes then pause
+  uint8_t       dphase      = 0;
+};
+
 Gauge gauges[GAUGE_COUNT];
 String rxLine;
 
+CRGB leds[TOTAL_LEDS];
+uint8_t gaugeLedOffset[GAUGE_COUNT];
+BlinkState blinkState[TOTAL_LEDS];
+bool ledsDirty = false;
+
 void sendReply(const String& s) {
   CMD_PORT.println(s);
 }
@@ -481,6 +516,213 @@ bool parsePing(const String& line) {
   return false;
 }
 
+bool parseLedQuery(const String& line) {
+  if (line == "LED?") {
+    for (uint8_t i = 0; i < GAUGE_COUNT; i++) {
+      for (uint8_t j = 0; j < gaugePins[i].ledCount; j++) {
+        const CRGB& c = leds[gaugeLedOffset[i] + j];
+        CMD_PORT.print("LED ");
+        CMD_PORT.print(i);
+        CMD_PORT.print(' ');
+        CMD_PORT.print(j);
+        CMD_PORT.print(' ');
+        CMD_PORT.print(c.r);
+        CMD_PORT.print(' ');
+        CMD_PORT.print(c.g);
+        CMD_PORT.print(' ');
+        CMD_PORT.println(c.b);
+      }
+    }
+    sendReply("OK");
+    return true;
+  }
+  return false;
+}
+
+bool parseLed(const String& line) {
+  int id, r, g, b;
+  char idxToken[16];
+  if (sscanf(line.c_str(), "LED %d %15s %d %d %d", &id, idxToken, &r, &g, &b) == 5) {
+    if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; }
+    char* dash = strchr(idxToken, '-');
+    int idxFirst = atoi(idxToken);
+    int idxLast  = dash ? atoi(dash + 1) : idxFirst;
+    if (idxFirst < 0 || idxLast >= gaugePins[id].ledCount || idxFirst > idxLast) {
+      sendReply("ERR BAD_IDX"); return true;
+    }
+    CRGB color(constrain(r, 0, 255), constrain(g, 0, 255), constrain(b, 0, 255));
+    for (int i = idxFirst; i <= idxLast; i++) {
+      blinkState[gaugeLedOffset[id] + i].active = false;
+      leds[gaugeLedOffset[id] + i] = color;
+    }
+    ledsDirty = true;
+    sendReply("OK");
+    return true;
+  }
+  return false;
+}
+
+bool parseBlink(const String& line) {
+  int id, onMs, offMs, r, g, b;
+  char idxToken[16];
+  // Accept both forms:
+  //   BLINK <id> <idx> <on_ms> <off_ms>           — use current LED colour
+  //   BLINK <id> <idx> <on_ms> <off_ms> <r> <g> <b> — set colour in same command
+  int count = sscanf(line.c_str(), "BLINK %d %15s %d %d %d %d %d",
+                     &id, idxToken, &onMs, &offMs, &r, &g, &b);
+  if (count != 4 && count != 7) return false;
+
+  if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; }
+  char* dash = strchr(idxToken, '-');
+  int idxFirst = atoi(idxToken);
+  int idxLast  = dash ? atoi(dash + 1) : idxFirst;
+  if (idxFirst < 0 || idxLast >= gaugePins[id].ledCount || idxFirst > idxLast) {
+    sendReply("ERR BAD_IDX"); return true;
+  }
+
+  if (onMs == 0 && offMs == 0) {
+    for (int i = idxFirst; i <= idxLast; i++)
+      blinkState[gaugeLedOffset[id] + i].active = false;
+    sendReply("OK");
+    return true;
+  }
+  if (onMs <= 0 || offMs <= 0) { sendReply("ERR BAD_TIME"); return true; }
+
+  CRGB color = (count == 7)
+    ? CRGB(constrain(r, 0, 255), constrain(g, 0, 255), constrain(b, 0, 255))
+    : CRGB(0, 0, 0);  // placeholder; overwritten per-LED below when count==4
+
+  unsigned long nowMs = millis();
+  for (int i = idxFirst; i <= idxLast; i++) {
+    uint8_t globalIdx = gaugeLedOffset[id] + i;
+    BlinkState& bs = blinkState[globalIdx];
+    bs.fx       = FX_BLINK;
+    bs.onColor  = (count == 7) ? color : leds[globalIdx];
+    bs.onMs     = (uint16_t)onMs;
+    bs.offMs    = (uint16_t)offMs;
+    bs.currentlyOn = true;
+    bs.lastMs   = nowMs;
+    bs.active   = true;
+    leds[globalIdx] = bs.onColor;
+  }
+  ledsDirty = true;
+  sendReply("OK");
+  return true;
+}
+
+bool parseBreathe(const String& line) {
+  int id, periodMs, r, g, b;
+  char idxToken[16];
+  if (sscanf(line.c_str(), "BREATHE %d %15s %d %d %d %d",
+             &id, idxToken, &periodMs, &r, &g, &b) != 6) return false;
+  if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; }
+  char* dash = strchr(idxToken, '-');
+  int idxFirst = atoi(idxToken);
+  int idxLast  = dash ? atoi(dash + 1) : idxFirst;
+  if (idxFirst < 0 || idxLast >= gaugePins[id].ledCount || idxFirst > idxLast) {
+    sendReply("ERR BAD_IDX"); return true;
+  }
+  if (periodMs <= 0) { sendReply("ERR BAD_TIME"); return true; }
+  CRGB color(constrain(r, 0, 255), constrain(g, 0, 255), constrain(b, 0, 255));
+  unsigned long nowMs = millis();
+  for (int i = idxFirst; i <= idxLast; i++) {
+    uint8_t gi = gaugeLedOffset[id] + i;
+    BlinkState& bs = blinkState[gi];
+    bs.fx       = FX_BREATHE;
+    bs.onColor  = color;
+    bs.periodMs = (uint16_t)constrain(periodMs, 100, 30000);
+    bs.cyclePos = 0;
+    bs.lastMs   = nowMs;
+    bs.active   = true;
+    leds[gi]    = CRGB::Black;
+  }
+  ledsDirty = true;
+  sendReply("OK");
+  return true;
+}
+
+bool parseDflash(const String& line) {
+  int id, r, g, b;
+  char idxToken[16];
+  if (sscanf(line.c_str(), "DFLASH %d %15s %d %d %d",
+             &id, idxToken, &r, &g, &b) != 5) return false;
+  if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; }
+  char* dash = strchr(idxToken, '-');
+  int idxFirst = atoi(idxToken);
+  int idxLast  = dash ? atoi(dash + 1) : idxFirst;
+  if (idxFirst < 0 || idxLast >= gaugePins[id].ledCount || idxFirst > idxLast) {
+    sendReply("ERR BAD_IDX"); return true;
+  }
+  CRGB color(constrain(r, 0, 255), constrain(g, 0, 255), constrain(b, 0, 255));
+  unsigned long nowMs = millis();
+  for (int i = idxFirst; i <= idxLast; i++) {
+    uint8_t gi = gaugeLedOffset[id] + i;
+    BlinkState& bs = blinkState[gi];
+    bs.fx      = FX_DFLASH;
+    bs.onColor = color;
+    bs.dphase  = 0;
+    bs.lastMs  = nowMs;
+    bs.active  = true;
+    leds[gi]   = color;  // phase 0 = on
+  }
+  ledsDirty = true;
+  sendReply("OK");
+  return true;
+}
+
+void updateBlink() {
+  unsigned long nowMs = millis();
+  bool changed = false;
+
+  for (uint8_t i = 0; i < GAUGE_COUNT; i++) {
+    for (uint8_t j = 0; j < gaugePins[i].ledCount; j++) {
+      uint8_t gi = gaugeLedOffset[i] + j;
+      BlinkState& bs = blinkState[gi];
+      if (!bs.active) continue;
+
+      switch (bs.fx) {
+        case FX_BLINK: {
+          uint32_t period = bs.currentlyOn ? bs.onMs : bs.offMs;
+          if ((nowMs - bs.lastMs) >= period) {
+            bs.currentlyOn = !bs.currentlyOn;
+            bs.lastMs = nowMs;
+            leds[gi] = bs.currentlyOn ? bs.onColor : CRGB::Black;
+            changed = true;
+          }
+          break;
+        }
+        case FX_BREATHE: {
+          unsigned long dt = nowMs - bs.lastMs;
+          if (dt < 64) break;
+          uint32_t newPos = (uint32_t)bs.cyclePos + dt;
+          bs.cyclePos = (uint16_t)(newPos % bs.periodMs);
+          bs.lastMs = nowMs;
+          uint16_t half = bs.periodMs >> 1;
+          uint8_t bri = (bs.cyclePos < half)
+              ? (uint8_t)((uint32_t)bs.cyclePos * 255 / half)
+              : (uint8_t)((uint32_t)(bs.periodMs - bs.cyclePos) * 255 / half);
+          leds[gi] = bs.onColor;
+          leds[gi].nscale8(bri ? bri : 1);
+          changed = true;
+          break;
+        }
+        case FX_DFLASH: {
+          static const uint16_t dur[4] = {100, 100, 100, 700};
+          if ((nowMs - bs.lastMs) >= dur[bs.dphase]) {
+            bs.lastMs = nowMs;
+            bs.dphase = (bs.dphase + 1) & 3;
+            leds[gi] = (bs.dphase == 0 || bs.dphase == 2) ? bs.onColor : CRGB::Black;
+            changed = true;
+          }
+          break;
+        }
+      }
+    }
+  }
+
+  if (changed) ledsDirty = true;
+}
+
 void processLine(const String& line) {
   if (parseSet(line)) return;
   if (parseSpeed(line)) return;
@@ -490,6 +732,11 @@ void processLine(const String& line) {
   if (parseHome(line)) return;
   if (parseSweep(line)) return;
   if (parsePosQuery(line)) return;
+  if (parseLedQuery(line)) return;
+  if (parseLed(line)) return;
+  if (parseBlink(line)) return;
+  if (parseBreathe(line)) return;
+  if (parseDflash(line)) return;
   if (parsePing(line)) return;
 
   sendReply("ERR BAD_CMD");
@@ -516,7 +763,7 @@ void readCommands() {
 }
 
 void setup() {
-  DEBUG_PORT.begin(115200);
+  DEBUG_PORT.begin(38400);
   DEBUG_PORT.println("Gauge controller booting");
 
   for (uint8_t i = 0; i < GAUGE_COUNT; i++) {
@@ -534,6 +781,16 @@ void setup() {
     gauges[i].lastUpdateMicros = micros();
   }
 
+  // Compute per-gauge LED offsets and initialise the strip.
+  uint8_t ledOff = 0;
+  for (uint8_t i = 0; i < GAUGE_COUNT; i++) {
+    gaugeLedOffset[i] = ledOff;
+    ledOff += gaugePins[i].ledCount;
+  }
+  FastLED.addLeds<WS2812B, LED_DATA_PIN, GRB>(leds, TOTAL_LEDS);
+  FastLED.setBrightness(255);
+  FastLED.show();
+
   requestHomeAll();
 
   DEBUG_PORT.println("READY");
@@ -542,8 +799,14 @@ void setup() {
 
 void loop() {
   readCommands();
+  updateBlink();
+
+  if (ledsDirty) {
+    FastLED.show();
+    ledsDirty = false;
+  }
 
   for (uint8_t i = 0; i < GAUGE_COUNT; i++) {
     updateGauge(i);
   }
-}
+}

config.example.json

@@ -0,0 +1,55 @@
+{
+  "debug": false,
+
+  "wifi_ssid": "MyNetwork",
+  "wifi_password": "MyPassword",
+
+  "mqtt_broker": "192.168.1.10",
+  "mqtt_port": 1883,
+  "mqtt_user": "mqtt_user",
+  "mqtt_password": "mqtt_password",
+  "mqtt_client_id": "gauge_controller",
+  "mqtt_prefix": "gauges",
+
+  "heartbeat_ms": 10000,
+  "rezero_interval_ms": 3600000,
+
+  "device": {
+    "name": "Selsyn Multi",
+    "model": "Chernobyl Selsyn-inspired gauge",
+    "manufacturer": "AdeBaumann",
+    "area": "Control Panels"
+  },
+
+  "arduino_uart": 1,
+  "arduino_tx_pin": 17,
+  "arduino_rx_pin": 16,
+  "arduino_baud": 115200,
+
+  "gauges": [
+    {
+      "name": "Gauge 1",
+      "entity_name": "Selsyn 1 Power",
+      "min": 0,
+      "max": 7300,
+      "max_steps": 4000,
+      "unit": "W",
+      "leds": {
+        "ws2812_red":   [255, 0, 0],
+        "ws2812_green": [0, 255, 0]
+      }
+    },
+    {
+      "name": "Gauge 2",
+      "entity_name": "Selsyn 2 Power",
+      "min": 0,
+      "max": 7300,
+      "max_steps": 4000,
+      "unit": "W",
+      "leds": {
+        "ws2812_red":   [255, 0, 0],
+        "ws2812_green": [0, 255, 0]
+      }
+    }
+  ]
+}

main.py

@@ -0,0 +1 @@
+import gauge

ota.py

@@ -0,0 +1,474 @@
+"""
+ota.py — Gitea OTA updater for ESP32 / MicroPython
+
+Call ota.update() from boot.py before importing anything else.
+If the update or the subsequent boot fails, the updater retries
+on the next boot rather than bricking the device.
+
+Strategy
+--------
+1. Check if last boot was good (OK flag exists).
+2. If good, fetch remote commit SHA and compare with local — if unchanged,
+   skip file check entirely.
+3. If new commit or failed boot, fetch ota_manifest.txt from the repo
+   to determine which files to sync.
+4. Compare SHA1 hashes with a local manifest (.ota_manifest.json).
+5. Download only changed or missing files, writing to .tmp first.
+6. On success, rename .tmp files into place and update the manifest.
+7. If anything fails mid-update, the manifest is not updated, so the
+   next boot will retry. Partially written .tmp files are cleaned up.
+8. A "safety" flag file (.ota_ok) is written by main.py on successful
+   startup. If it is absent on boot, the previous update is suspected
+   bad — the manifest is wiped so all files are re-fetched cleanly.
+
+Manifest format (ota_manifest.txt)
+---------------------------------
+Each line specifies a file or directory to include:
+    boot.py          # specific file
+    ota.py           # another file
+    selsyn/          # entire directory (trailing slash)
+    lib/             # another directory
+    *.py             # wildcard (matches anywhere)
+    selsyn/*.py      # wildcard in subdirectory
+
+Usage in boot.py
+----------------
+    import ota
+    ota.update()
+    # imports of main etc. go here
+
+Configuration
+-------------
+Edit the block below, or override from a local config file
+(see SETTINGS_FILE).  All settings can be left as module-level
+constants or placed in /ota_config.json:
+    {
+        "gitea_base": "http://git.baumann.gr",
+        "repo_owner": "adebaumann",
+        "repo_name":  "HomeControlPanel",
+        "repo_folder": "firmware",
+        "repo_branch": "main",
+        "api_token":   "nicetry-nothere"
+    }
+"""
+
+import os
+import gc
+import sys
+import ujson
+import urequests
+import utime
+
+# ---------------------------------------------------------------------------
+# Default configuration — override via /ota_config.json
+# ---------------------------------------------------------------------------
+
+GITEA_BASE = "http://git.baumann.gr"  # no trailing slash
+REPO_OWNER = "adrian"
+REPO_NAME = "esp32-gauge"
+REPO_FOLDER = "firmware"  # folder inside repo to sync
+REPO_BRANCH = "main"
+API_TOKEN = None  # set to string for private repos
+
+WIFI_SSID = None
+WIFI_PASSWORD = None
+
+SETTINGS_FILE = "/ota_config.json"
+MANIFEST_FILE = "/.ota_manifest.json"
+OK_FLAG_FILE = "/.ota_ok"
+OTA_MANIFEST = "ota_manifest.txt"
+
+# ---------------------------------------------------------------------------
+# Logging
+# ---------------------------------------------------------------------------
+
+
+def _ts():
+    ms = utime.ticks_ms()
+    return f"{(ms // 3600000) % 24:02d}:{(ms // 60000) % 60:02d}:{(ms // 1000) % 60:02d}.{ms % 1000:03d}"
+
+
+def _log(level, msg):
+    print(f"[{_ts()}] {level:5s}  [OTA] {msg}")
+
+
+def info(msg):
+    _log("INFO", msg)
+
+
+def warn(msg):
+    _log("WARN", msg)
+
+
+def log_err(msg):
+    _log("ERROR", msg)
+
+
+# ---------------------------------------------------------------------------
+# HTTP helpers
+# ---------------------------------------------------------------------------
+
+
+def _headers():
+    h = {"Accept": "application/json"}
+    if API_TOKEN:
+        h["Authorization"] = f"token {API_TOKEN}"
+    return h
+
+
+# ---------------------------------------------------------------------------
+# Config loader
+# ---------------------------------------------------------------------------
+
+
+def load_config():
+    global \
+        GITEA_BASE, \
+        REPO_OWNER, \
+        REPO_NAME, \
+        REPO_FOLDER, \
+        REPO_BRANCH, \
+        API_TOKEN, \
+        WIFI_SSID, \
+        WIFI_PASSWORD
+    try:
+        with open(SETTINGS_FILE) as f:
+            cfg = ujson.load(f)
+        GITEA_BASE = cfg.get("gitea_base", GITEA_BASE)
+        REPO_OWNER = cfg.get("repo_owner", REPO_OWNER)
+        REPO_NAME = cfg.get("repo_name", REPO_NAME)
+        REPO_FOLDER = cfg.get("repo_folder", REPO_FOLDER)
+        REPO_BRANCH = cfg.get("repo_branch", REPO_BRANCH)
+        API_TOKEN = cfg.get("api_token", API_TOKEN)
+        WIFI_SSID = cfg.get("wifi_ssid", WIFI_SSID)
+        WIFI_PASSWORD = cfg.get("wifi_password", WIFI_PASSWORD)
+        info(f"Config loaded from {SETTINGS_FILE}")
+    except OSError:
+        info(f"No {SETTINGS_FILE} found — using defaults")
+    except Exception as e:
+        warn(f"Config parse error: {e} — using defaults")
+
+
+# ---------------------------------------------------------------------------
+# Helpers
+# ---------------------------------------------------------------------------
+
+
+def _match_pattern(name, pattern):
+    if "*" not in pattern:
+        return name == pattern
+    i, n = 0, len(pattern)
+    j, m = 0, len(name)
+    star = -1
+    while i < n and j < m:
+        if pattern[i] == "*":
+            star = i
+            i += 1
+        elif pattern[i] == name[j]:
+            i += 1
+            j += 1
+        elif star >= 0:
+            i = star + 1
+            j += 1
+        else:
+            return False
+    while i < n and pattern[i] == "*":
+        i += 1
+    return i == n and j == m
+
+
+def _fetch_commit_sha():
+    url = f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}/branches/{REPO_BRANCH}"
+    try:
+        r = urequests.get(url, headers=_headers())
+        if r.status_code == 200:
+            data = r.json()
+            r.close()
+            return data.get("commit", {}).get("id")
+        r.close()
+    except Exception as e:
+        log_err(f"Failed to fetch commit: {e}")
+    return None
+
+
+def _fetch_manifest():
+    url = (
+        f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}"
+        f"/contents/{OTA_MANIFEST}?ref={REPO_BRANCH}"
+    )
+    try:
+        r = urequests.get(url, headers=_headers())
+        try:
+            if r.status_code == 200:
+                data = r.json()
+                if data.get("content"):
+                    import ubinascii
+
+                    content = ubinascii.a2b_base64(data["content"]).decode()
+                    patterns = [line.strip() for line in content.splitlines()]
+                    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}")
+    return None
+
+
+def _fetch_dir(path):
+    url = (
+        f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}"
+        f"/contents/{path}?ref={REPO_BRANCH}"
+    )
+    return _api_get(url)
+
+
+def _api_get(url):
+    """GET a URL and return parsed JSON, or None on failure."""
+    try:
+        r = urequests.get(url, headers=_headers())
+        if r.status_code == 200:
+            data = r.json()
+            r.close()
+            return data
+        warn(f"HTTP {r.status_code} for {url}")
+        r.close()
+    except Exception as e:
+        log_err(f"GET {url} failed: {e}")
+    return None
+
+
+def _download(url, dest_path):
+    """Download url to dest_path. Returns True on success."""
+    tmp = dest_path + ".tmp"
+    try:
+        r = urequests.get(url, headers=_headers())
+        if r.status_code != 200:
+            warn(f"Download failed HTTP {r.status_code}: {url}")
+            r.close()
+            return False
+        with open(tmp, "wb") as f:
+            f.write(r.content)
+        r.close()
+        # Rename into place
+        try:
+            os.remove(dest_path)
+        except OSError:
+            pass
+        os.rename(tmp, dest_path)
+        return True
+    except Exception as e:
+        log_err(f"Download error {url}: {e}")
+        try:
+            os.remove(tmp)
+        except OSError:
+            pass
+        return False
+
+
+def _load_manifest():
+    try:
+        with open(MANIFEST_FILE) as f:
+            return ujson.load(f)
+    except Exception:
+        return {}
+
+
+def _save_manifest(manifest, commit_sha=None):
+    try:
+        with open(MANIFEST_FILE, "w") as f:
+            if commit_sha:
+                manifest["_commit"] = commit_sha
+            ujson.dump(manifest, f)
+    except Exception as e:
+        warn(f"Could not save manifest: {e}")
+
+
+
+def _ok_flag_exists():
+    try:
+        os.stat(OK_FLAG_FILE)
+        return True
+    except OSError:
+        return False
+
+
+def _clear_ok_flag():
+    try:
+        os.remove(OK_FLAG_FILE)
+    except OSError:
+        pass
+
+
+def mark_ok():
+    """
+    Call this from main.py after successful startup.
+    Signals to the OTA updater that the last update was good.
+    """
+    try:
+        with open(OK_FLAG_FILE, "w") as f:
+            f.write("ok")
+    except Exception as e:
+        warn(f"Could not write OK flag: {e}")
+
+
+# ---------------------------------------------------------------------------
+# Core update logic
+# ---------------------------------------------------------------------------
+
+
+def _fetch_file_list():
+    """
+    Returns list of {name, sha, download_url} dicts based on the
+    ota_manifest.txt patterns in the repo folder, or None on failure.
+    """
+    manifest_patterns = _fetch_manifest()
+    if manifest_patterns is None:
+        log_err("No manifest — cannot determine what to fetch")
+        return None
+
+    info(f"Manifest patterns: {manifest_patterns}")
+    files = []
+    visited = set()
+
+    def fetch_matching(entries, patterns):
+        for entry in entries:
+            if entry.get("type") == "dir":
+                for p in patterns:
+                    if p.endswith("/") and entry["name"].startswith(p.rstrip("/")):
+                        sub = _fetch_dir(entry["path"])
+                        if sub:
+                            fetch_matching(sub, patterns)
+                        break
+            else:
+                name = entry["name"]
+                for p in patterns:
+                    p = p.rstrip("/")
+                    if _match_pattern(name, p) or _match_pattern(entry["path"], p):
+                        if entry["path"] not in visited:
+                            visited.add(entry["path"])
+                            files.append(
+                                {
+                                    "name": entry["path"],
+                                    "sha": entry["sha"],
+                                    "download_url": entry["download_url"],
+                                }
+                            )
+                        break
+
+    root = _fetch_dir(REPO_FOLDER)
+    if root is None:
+        return None
+
+    fetch_matching(root, manifest_patterns)
+    return files
+
+
+def _do_update(commit_sha=None):
+    """
+    Fetch file list, download changed files, update manifest.
+    Returns True if all succeeded (or nothing needed updating).
+    """
+    info(
+        f"Checking {GITEA_BASE}/{REPO_OWNER}/{REPO_NAME}/{REPO_FOLDER} @ {REPO_BRANCH}"
+    )
+    file_list = _fetch_file_list()
+    if file_list is None:
+        log_err("Could not fetch file list — skipping update")
+        return False
+
+    info(f"Found {len(file_list)} file(s) to sync")
+    manifest = _load_manifest()
+    updated = []
+    failed = []
+
+    for entry in file_list:
+        name = entry["name"]
+        sha = entry["sha"]
+
+        if manifest.get(name) == sha:
+            info(f"  {name}  up to date")
+            continue
+
+        info(f"  {name}  updating (sha={sha[:8]}...)")
+        gc.collect()
+        ok = _download(entry["download_url"], f"/{name}")
+        if ok:
+            manifest[name] = sha
+            updated.append(name)
+            info(f"  {name}  OK")
+        else:
+            failed.append(name)
+            log_err(f"  {name}  FAILED")
+
+    if failed:
+        log_err(f"Update incomplete — {len(failed)} file(s) failed: {failed}")
+        _save_manifest(manifest, commit_sha)
+        return False
+
+    _save_manifest(manifest, commit_sha)
+
+    if updated:
+        info(f"Update complete — {len(updated)} file(s) updated: {updated}")
+    else:
+        info("All files up to date — nothing to do")
+
+    return True
+
+
+# ---------------------------------------------------------------------------
+# Public entry point
+# ---------------------------------------------------------------------------
+
+
+def update():
+    """
+    Main entry point. Call from boot.py before importing application code.
+
+    - If the OK flag is missing, the previous boot is assumed to have
+      failed — wipes the manifest so everything is re-fetched cleanly.
+    - If the commit hash hasn't changed and last boot was good, skip
+      file comparison entirely.
+    - Runs the update.
+    - Clears the OK flag so main.py must re-assert it on successful start.
+    """
+    info("=" * 40)
+    info("OTA updater starting")
+    info("=" * 40)
+
+    load_config()
+
+    ok_flag = _ok_flag_exists()
+    manifest = _load_manifest()
+
+    if not ok_flag:
+        warn("OK flag missing — last boot may have failed")
+        warn("Re-checking all files, will only download changed ones")
+    else:
+        info("OK flag present — last boot was good")
+
+    commit_sha = _fetch_commit_sha()
+
+    if ok_flag and commit_sha and manifest.get("_commit") == commit_sha:
+        info(f"Commit unchanged ({commit_sha[:8]}) — skipping file check")
+        info("-" * 40)
+        return
+
+    if commit_sha:
+        info(f"Remote commit: {commit_sha[:8]}")
+    else:
+        warn("Could not fetch remote commit — proceeding with file check")
+
+    # Clear the flag now; main.py must call ota.mark_ok() to re-set it
+    _clear_ok_flag()
+
+    success = _do_update(commit_sha)
+
+    if success:
+        info("OTA check complete — booting application")
+    else:
+        warn("OTA check had errors — booting with current files")
+
+    info("-" * 40)
+    gc.collect()

ota_config.example.json

@@ -0,0 +1,9 @@
+{
+    "gitea_base": "http://git.baumann.gr",
+    "repo_owner": "adebaumann",
+    "repo_name": "Selsyn_inspired_gauge",
+    "repo_folder": "",
+    "repo_branch": "main",
+    "wifi_ssid": "YourNetwork",
+    "wifi_password": "YourPassword"
+}

ota_manifest.txt

@@ -0,0 +1 @@
+*.py