Reverted a lot of cruft

.gitignore

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

CLAUDE.md

@@ -6,8 +6,6 @@ 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
@@ -60,7 +58,7 @@ 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, `ledOrder` string). 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, `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`)
@@ -78,7 +76,7 @@ When `sweepEnabled`, `updateSweepTarget` bounces `targetPos` between `minPos` an
 
 ### LED strip
 
-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()`.
+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.
 
 ### Serial command protocol
 
@@ -106,6 +104,6 @@ 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 the `ledOrder` string — one char per LED, `'G'` for GRB or `'R'` for RGB).
+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`, `gaugeLedOffset[]`, and `gaugeLedCount[]` update automatically — no manual changes needed.
+4. `TOTAL_LEDS` and `gaugeLedOffset[]` 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
-- `gaugecontroller.yaml`: the ESPHome-based ESP32 firmware that exposes the gauges and VFD to Home Assistant via the native API
+- `gauge.py`: the ESP32 / MicroPython MQTT bridge that exposes the controller to Home Assistant
 
 ## VFD Support
 
@@ -48,19 +48,16 @@ Rules:
 - shorter values are right-aligned
 - leading zeroes are preserved if they are part of the input
 
-## Home Assistant Integration
+## Home Assistant Entities
 
-The ESPHome firmware in `gaugecontroller.yaml` exposes entities to Home Assistant via the native API:
+The MQTT bridge publishes Home Assistant discovery entities for the VFD:
 
-### Gauge Controls
-- Number entities for each gauge's target value (with unit conversion)
-- Number entities for speed and acceleration (diagnostic)
-- Rezero buttons for each gauge and all gauges
-
-### VFD Display
-- `VFD Display`: text entity for the displayed value
-- `VFD Decimal Point`: switch entity
-- `VFD Alarm`: switch entity
+- `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:
 
@@ -68,12 +65,27 @@ 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
 
-### 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
+## MQTT Topics
 
-### Diagnostics
-- WiFi signal sensor
-- Uptime sensor
-- IP address and SSID text sensors
-- Arduino Last Message sensor
+Using the configured `mqtt_prefix` from `config.json`, the VFD topics are:
+
+- `<prefix>/vfd/set`
+- `<prefix>/vfd/state`
+- `<prefix>/vfd/decimal_point/set`
+- `<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

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

Stripboard_layout.md

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

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
+
+

changes.md

@@ -1,46 +0,0 @@
-# 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%).

gauge.py

@@ -28,16 +28,6 @@ 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
 # ---------------------------------------------------------------------------
@@ -161,19 +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()}")
 
@@ -540,11 +538,14 @@ _WIFI_CONNECT_ATTEMPTS = 3
 def _reset_wifi_interface():
     global _wifi_sta
     _wifi_sta = network.WLAN(network.STA_IF)
-    if _wifi_sta.active():
-        _wifi_sta.active(False)
-        utime.sleep_ms(200)
+    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):
@@ -561,6 +562,7 @@ 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)
@@ -576,7 +578,7 @@ 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(500)
+            utime.sleep_ms(2000)
             return ip
         except Exception as e:
             last_error = e
@@ -601,7 +603,7 @@ def check_wifi():
 
     log_err("WiFi lost connection — attempting reconnect...")
     try:
-        ip = connect_wifi(WIFI_SSID, WIFI_PASSWORD, timeout_s=15, force_reconnect=True)
+        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}")
@@ -911,10 +913,6 @@ 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)
 
@@ -922,27 +920,6 @@ 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()
@@ -984,10 +961,6 @@ 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)
 
@@ -995,9 +968,17 @@ 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(_compact_discovery_payload(payload)), retain=True)
+    client.publish(topic, ujson.dumps(payload), retain=True)
     info(log_msg)
 
 
@@ -1305,12 +1286,42 @@ 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")
@@ -1318,7 +1329,7 @@ def main():
     info("=" * 48)
 
     gc.collect()
-    connect_wifi(WIFI_SSID, WIFI_PASSWORD, force_reconnect=True)
+    connect_wifi(WIFI_SSID, WIFI_PASSWORD)
 
     mqtt_attempts = 0
     while True:
@@ -1331,13 +1342,14 @@ def main():
             if mqtt_attempts % 3 == 0:
                 log_err("WiFi may be stale — forcing reconnect...")
                 try:
-                    connect_wifi(WIFI_SSID, WIFI_PASSWORD, force_reconnect=True)
+                    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):
@@ -1350,6 +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)

wiring.md

@@ -163,22 +163,19 @@ 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.
 
-## WS2812 LED Strips
+## WS2812B LED Strip
 
-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.
+The current sketch expects one shared WS2812B chain.
 
-| Mega Pin | LED Strip |
+| Mega Pin | WS2812B |
 |---|---|
-| `D22` | main backlight/status `DIN` |
-| `D36` | indicator `DIN` |
-| `5V` | both strips `5V` |
-| `GND` | both strips `GND` |
+| `D22` | `DIN` |
+| `5V` | `5V` |
+| `GND` | `GND` |
 
 Notes:
 
-- the command protocol still exposes `7 LEDs per gauge`
-- logical indices `0-2` are backlight, `3-4` are indicators, and `5-6` are status
+- the code expects `7 LEDs per gauge`, so `21 LEDs total`
 - use a proper 5V supply sized for the LED current
 - keep LED ground common with the Mega