Changed timing to timer interrupts - scoping data showed inconsistencies

- Replace gauge.py (MicroPython) references with gaugecontroller.yaml (ESPHome)
- Update CLAUDE.md and README.md to document ESPHome-native API integration
- Update LED wiring docs for separate main/indicator strips (D22/D36)
- Refactor Arduino firmware to drive two WS2812 strips independently
- Add per-gauge physical offset caching for main and indicator LEDs
- Frame-limit breathe effect (16ms) to reduce unnecessary strip refreshes

.gitignore

@@ -32,3 +32,4 @@
 *.out
 *.app
 
+.codex

CLAUDE.md

@@ -6,6 +6,8 @@ This file provides guidance to Claude Code (claude.ai/code) when working with co
 
 Main firmware lives in `Gaugecontroller/Gaugecontroller.ino`. Requires the **FastLED** library (`arduino-cli lib install FastLED`). Use the Arduino IDE or `arduino-cli`:
 
+The ESP32 bridge runs ESPHome; the config is in `gaugecontroller.yaml`.
+
 ```bash
 # Compile (replace board/port as needed)
 arduino-cli compile --fqbn arduino:avr:mega Gaugecontroller
@@ -58,7 +60,7 @@ The sketch controls `GAUGE_COUNT` stepper-motor gauges using a trapezoidal veloc
 
 ### 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.
+- `GaugePins` — hardware pin mapping per gauge (dir, step, enable, active-high/low polarity flags, `ledOrder` string). 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`)
@@ -76,7 +78,7 @@ When `sweepEnabled`, `updateSweepTarget` bounces `targetPos` between `minPos` an
 
 ### LED strip
 
-One shared WS2812B strip is driven from `LED_DATA_PIN` (currently 22). 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[]`. LED commands and effects mark the strip dirty, and `FastLED.show()` is called once per main-loop iteration if anything changed.
+Two LED strips are driven: main backlight/status LEDs on `LED_DATA_PIN` (currently 22) and dial indicator LEDs on `INDICATOR_LED_DATA_PIN` (currently 36). The serial protocol still exposes one logical per-gauge LED segment: `0-2` backlight, `3-4` indicators, `5-6` status. `gaugePins[i].ledOrder` is a per-LED type string (one char per LED, `'G'` = GRB-ordered, `'R'` = RGB-ordered) and its length defines the logical LED count. `TOTAL_LEDS`, `TOTAL_MAIN_LEDS`, and `TOTAL_INDICATOR_LEDS` are computed at compile time. Per-gauge logical and physical offsets are cached in `setup()`. LED writes dirty only their physical strip, and the loop flushes each FastLED controller independently with `showLeds()`.
 
 ### Serial command protocol
 
@@ -104,6 +106,6 @@ 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`).
+2. Add a `constexpr GaugePins` entry to `gaugePins[]` (including the `ledOrder` string — one char per LED, `'G'` for GRB or `'R'` for RGB).
 3. Tune `maxPos` and `homingBackoffSteps` in the corresponding `Gauge` default or at runtime.
-4. `TOTAL_LEDS` and `gaugeLedOffset[]` update automatically — no manual changes needed.
+4. `TOTAL_LEDS`, `gaugeLedOffset[]`, and `gaugeLedCount[]` update automatically — no manual changes needed.

README.md

@@ -7,7 +7,7 @@ A dedicated gauge controller for Arduinos.
 This repository contains:
 
 - `Gaugecontroller/Gaugecontroller.ino`: the Arduino Mega firmware for the stepper gauges, LEDs, and integrated HV5812-based VFD
-- `gauge.py`: the ESP32 / MicroPython MQTT bridge that exposes the controller to Home Assistant
+- `gaugecontroller.yaml`: the ESPHome-based ESP32 firmware that exposes the gauges and VFD to Home Assistant via the native API
 
 ## VFD Support
 
@@ -48,16 +48,19 @@ Rules:
 - shorter values are right-aligned
 - leading zeroes are preserved if they are part of the input
 
-## Home Assistant Entities
+## Home Assistant Integration
 
-The MQTT bridge publishes Home Assistant discovery entities for the VFD:
+The ESPHome firmware in `gaugecontroller.yaml` exposes entities to Home Assistant via the native API:
 
-- `VFD Display`
+### Gauge Controls
-  text entity for the displayed value
+- Number entities for each gauge's target value (with unit conversion)
-- `VFD Decimal Point`
+- Number entities for speed and acceleration (diagnostic)
-  switch entity
+- Rezero buttons for each gauge and all gauges
-- `VFD Alarm`
+
-  switch entity
+### VFD Display
+- `VFD Display`: text entity for the displayed value
+- `VFD Decimal Point`: switch entity
+- `VFD Alarm`: switch entity
 
 The display is intentionally exposed as a text entity rather than a numeric entity so that:
 
@@ -65,27 +68,12 @@ The display is intentionally exposed as a text entity rather than a numeric enti
 - hexadecimal values like `DEAD` or `BEEF` work
 - clearing the display is possible with an empty value
 
-## MQTT Topics
+### LED Controls
+- RGB light entity for each gauge's backlight with effects (Blink, Breathe, Double Flash)
+- Binary light entities for each gauge's red/green indicators and status lights
 
-Using the configured `mqtt_prefix` from `config.json`, the VFD topics are:
+### Diagnostics
-
+- WiFi signal sensor
-- `<prefix>/vfd/set`
+- Uptime sensor
-- `<prefix>/vfd/state`
+- IP address and SSID text sensors
-- `<prefix>/vfd/decimal_point/set`
+- Arduino Last Message sensor
-- `<prefix>/vfd/decimal_point/state`
-- `<prefix>/vfd/alarm/set`
-- `<prefix>/vfd/alarm/state`
-
-Example with the default prefix `gauges`:
-
-- `gauges/vfd/set`
-- `gauges/vfd/decimal_point/set`
-- `gauges/vfd/alarm/set`
-
-Example payloads:
-
-- publish `0123` to `gauges/vfd/set`
-- publish `ON` to `gauges/vfd/decimal_point/set`
-- publish `OFF` to `gauges/vfd/alarm/set`
-
-The MQTT bridge then converts that into the correct Arduino serial command such as `VFD 0123.`.

Rewire_checklist.md

@@ -183,13 +183,14 @@ Then connect the motor side of that driver to:
 
 according to the driver board you are using.
 
-## 14. Wire The WS2812B LEDs
+## 14. Wire The WS2812 LEDs
 
 Connect:
 
-- `Mega D22` -> `WS2812B DIN`
+- `Mega D22` -> main backlight/status strip `DIN`
-- `5V LED supply` -> `WS2812B 5V`
+- `Mega D36` -> indicator strip `DIN`
-- `WS2812B GND` -> common ground rail
+- `5V LED supply` -> both strip `5V` inputs
+- both strip `GND` inputs -> common ground rail
 
 If the LED chain is long or bright:
 

Stripboard_layout.md

@@ -205,9 +205,10 @@ If `D8` and `D9` come from separate fly wires to the stripboard, keep them in th
 
 Route:
 
-- `D22` -> `WS2812 DIN`
+- `D22` -> main backlight/status strip `DIN`
-- `5V` -> `WS2812 5V`
+- `D36` -> indicator strip `DIN`
-- `GND` -> `WS2812 GND`
+- `5V` -> both strip `5V` inputs
+- `GND` -> both strip `GND` inputs
 
 Keep the LED connector in the low-voltage area.
 

archive/gauge.py

@@ -28,6 +28,16 @@ import gc
 from umqtt.robust import MQTTClient
 from machine import UART
 
+# Activate WiFi driver before any heavy heap allocation so it can claim its
+# contiguous DRAM block before the Python heap fragments the address space.
+# Only activate if not already running (e.g. boot.py may have started it).
+gc.collect()
+_early_wlan = network.WLAN(network.STA_IF)
+if not _early_wlan.active():
+    _early_wlan.active(True)
+del _early_wlan
+gc.collect()
+
 # ---------------------------------------------------------------------------
 # Logging
 # ---------------------------------------------------------------------------
@@ -151,27 +161,19 @@ 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 = 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."""
-    _ensure_arduino().write((cmd + "\n").encode())
+    _arduino.write((cmd + "\n").encode())
     info(f"Arduino → {cmd}")
 
 
 def arduino_recv():
     """Print any lines waiting in the Arduino RX buffer."""
-    uart = _ensure_arduino()
+    while _arduino.any():
-    while uart.any():
+        line = _arduino.readline()
-        line = uart.readline()
         if line:
             print(f"[{_ts()}] ARDU   {line.decode().strip()}")
 
@@ -538,14 +540,11 @@ _WIFI_CONNECT_ATTEMPTS = 3
 def _reset_wifi_interface():
     global _wifi_sta
     _wifi_sta = network.WLAN(network.STA_IF)
-    if not _wifi_sta.active():
+    if _wifi_sta.active():
+        _wifi_sta.active(False)
+        utime.sleep_ms(200)
     _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):
@@ -562,7 +561,6 @@ def connect_wifi(ssid, password, timeout_s=15, force_reconnect=False):
     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)
@@ -578,7 +576,7 @@ def connect_wifi(ssid, password, timeout_s=15, force_reconnect=False):
             info(f"  SSID    : {ssid}")
             info(f"  MAC     : {mac}")
             info(f"  IP      : {ip}  mask:{mask}  gw:{gw}  dns:{dns}")
-            utime.sleep_ms(2000)
+            utime.sleep_ms(500)
             return ip
         except Exception as e:
             last_error = e
@@ -603,7 +601,7 @@ def check_wifi():
 
     log_err("WiFi lost connection — attempting reconnect...")
     try:
-        ip = connect_wifi(WIFI_SSID, WIFI_PASSWORD, timeout_s=15)
+        ip = connect_wifi(WIFI_SSID, WIFI_PASSWORD, timeout_s=15, force_reconnect=True)
         info(f"WiFi reconnected! IP:{ip}")
     except Exception as e:
         log_err(f"WiFi reconnect failed: {e}")
@@ -913,6 +911,10 @@ def connect_mqtt():
         except Exception as e:
             last_error = e
             log_err(f"MQTT connect attempt {attempt + 1} failed: {type(e).__name__}: {e}")
+            try:
+                client.sock.close()
+            except Exception:
+                pass
             gc.collect()
             utime.sleep_ms(1000)
 
@@ -920,6 +922,27 @@ def connect_mqtt():
     raise last_error
 
 
+_mqtt_check_interval_ms = 30000
+_last_mqtt_check = 0
+_discovery_queue = []
+_discovery_idx = 0
+_last_discovery_ms = 0
+_DISCOVERY_INTERVAL_MS = 350
+
+
+def _compact_discovery_payload(payload):
+    """Trim optional HA discovery fields when RAM is tight."""
+    compact = dict(payload)
+
+    # Light entities are the largest payloads because they repeat effect metadata.
+    # Keep core functionality, but omit optional effect declarations to reduce heap use.
+    if compact.get("schema") == "json":
+        compact.pop("effect", None)
+        compact.pop("effect_list", None)
+
+    return compact
+
+
 def check_mqtt():
     global client_ref, _mqtt_connected, _last_mqtt_check
     now = utime.ticks_ms()
@@ -961,6 +984,10 @@ def check_mqtt():
             return True
         except Exception as e2:
             log_err(f"MQTT reconnect attempt {attempt + 1} failed: {e2}")
+            try:
+                client_ref.sock.close()
+            except Exception:
+                pass
             gc.collect()
             utime.sleep_ms(2000)
 
@@ -968,17 +995,9 @@ def check_mqtt():
     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)
+    client.publish(topic, ujson.dumps(_compact_discovery_payload(payload)), retain=True)
     info(log_msg)
 
 
@@ -1286,42 +1305,12 @@ 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")
@@ -1329,7 +1318,7 @@ def main():
     info("=" * 48)
 
     gc.collect()
-    connect_wifi(WIFI_SSID, WIFI_PASSWORD)
+    connect_wifi(WIFI_SSID, WIFI_PASSWORD, force_reconnect=True)
 
     mqtt_attempts = 0
     while True:
@@ -1342,14 +1331,13 @@ def main():
             if mqtt_attempts % 3 == 0:
                 log_err("WiFi may be stale — forcing reconnect...")
                 try:
-                    connect_wifi(WIFI_SSID, WIFI_PASSWORD)
+                    connect_wifi(WIFI_SSID, WIFI_PASSWORD, force_reconnect=True)
                 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):
@@ -1362,10 +1350,6 @@ 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)

boot.py

@@ -1,62 +0,0 @@
-"""
-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
-
-

changes.md

@@ -0,0 +1,46 @@
+# Changes
+
+## 2026-04-27 — Arduino firmware refactor (`Gaugecontroller/Gaugecontroller.ino`)
+
+### Non-blocking VFD multiplexer
+`vfd::refresh()` previously held each digit for 2000 µs via `delayMicroseconds`,
+which capped the effective stepper pulse rate at roughly 500 Hz regardless of
+`maxSpeed`. It now tracks `phaseStartMicros`/`phaseActive` and returns
+immediately while the digit is still being held; the main loop runs at
+microsecond cadence again and the configured `maxSpeed = 4000.0f` steps/s is
+actually achievable.
+
+### Fixed-buffer command parser (no more `String` heap churn)
+Replaced `String rxLine` with `char rxBuf[128]` and converted the entire
+command pipeline to take `const char*`:
+
+- `processLine`, `sendReply`, `vfd::parseCommand`
+- All `parse*` functions: `parseSet`, `parseSpeed`, `parseAccel`, `parseEnable`,
+  `parseZero`, `parseHome`, `parseSweep`, `parsePosQuery`, `parseCfgQuery`,
+  `parseLedQuery`, `parseLed`, `parseBlink`, `parseBreathe`, `parseDflash`,
+  `parseVfd`, `parsePing`.
+
+`parseSpeed` / `parseAccel` / `parseSweep` use `strncmp` + `atof` because the
+default AVR-libc `sscanf` doesn't support `%f`. No allocations on the command
+path; the Mega's heap no longer fragments over time.
+
+### Cached `ledNeedsSwap[TOTAL_LEDS]`
+Per-LED RGB-vs-GRB swap flag is now precomputed once in `setup()` from
+`gaugePins[].ledOrder`. `encodeForStrip` is a single array index instead of
+walking the gauge table on every LED read/write.
+
+### Cached step direction per gauge
+Added `Gauge.lastDir`. `setDir()` skips the DIR-pin `digitalWrite` when the
+direction hasn't flipped (the common case during a step run) and adds a 1 µs
+DIR-to-STEP setup delay only when it actually flips.
+
+### Cleanups
+- Removed the `absf` helper; use `fabsf` consistently.
+- Removed the `+ 0.0001f` epsilon in the trapezoidal braking-distance divisor.
+  `parseAccel` already rejects `accel <= 0`, so the divisor is always positive.
+- Fixed the `<r> <ig> <b>` typo to `<r> <g> <b>` in the protocol comment for
+  `DFLASH`.
+
+### Build verification
+`arduino-cli compile --fqbn arduino:avr:mega Gaugecontroller`:
+17758 B flash (6%), 1845 B SRAM (22%).

wiring.md

@@ -163,19 +163,22 @@ Also connect:
 
 If your driver boards need separate motor power, supply that from the proper motor supply. Do not power motors from the Mega `5V` pin.
 
-## WS2812B LED Strip
+## WS2812 LED Strips
 
-The current sketch expects one shared WS2812B chain.
+The current sketch expects two LED data chains. Backlight and status LEDs stay
+on the main strip; the red/green dial indicator LEDs are on their own strip.
 
-| Mega Pin | WS2812B |
+| Mega Pin | LED Strip |
 |---|---|
-| `D22` | `DIN` |
+| `D22` | main backlight/status `DIN` |
-| `5V` | `5V` |
+| `D36` | indicator `DIN` |
-| `GND` | `GND` |
+| `5V` | both strips `5V` |
+| `GND` | both strips `GND` |
 
 Notes:
 
-- the code expects `7 LEDs per gauge`, so `21 LEDs total`
+- the command protocol still exposes `7 LEDs per gauge`
+- logical indices `0-2` are backlight, `3-4` are indicators, and `5-6` are status
 - use a proper 5V supply sized for the LED current
 - keep LED ground common with the Mega