NimBLE-Arduino 1.4.2 had an init/fire race in its FreeRTOS callout porting
layer where os_callout_timer_cb dispatched a queued TimerHandle expiry
against a not-yet-initialized event (NULL fn pointer), causing PC=0
InstrFetchProhibited within ~1s of boot when the camera task starved the
timer service. Confirmed by ets_printf instrumentation. Upgrading to
^2.0.0 rewrites the porting layer and eliminates the race; verified clean
on the customer network for 1+ hour.
Also rolls in DNS-resilience work that surfaced the BLE crash during
provisioning: pin lwIP/esp-netif resolvers to 1.1.1.1/8.8.8.8 across DHCP
renewals, add three-tier resolver fallback in reporter with a hardcoded
IP of last resort, and switch to raw WiFiClient with manual Host header
to bypass HTTPClient's brittle DNS path.
Migration touches for NimBLE 2.x:
- NimBLEAdvertisedDeviceCallbacks -> NimBLEScanCallbacks
- onResult signature now takes const NimBLEAdvertisedDevice*
- setAdvertisedDeviceCallbacks -> setScanCallbacks
- start(0, nullptr, false) -> start(0, false, false)
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
- Config-load and camera-init FATAL branches now reboot (3s LED signal
before restart) instead of hanging forever. Matches the enum name
REBOOT_FATAL_* and makes camera-init failures diagnosable via the
next boot's heartbeat recent_events. Config failures produce a
visible reboot loop rather than a silent hang.
- Emit EVT_NTP_SYNC(seconds_since_boot) on the first NTP-synced
reporter iteration so slow / failed NTP sync is a visible signal in
the heartbeat's recent_events window.
- README "Deploying firmware 1.1" now opens with a "Before you flash"
warning directing the operator to land server-side heartbeat
schema changes first (migration 005 + stub integration) to avoid a
strict-schema 4xx reboot loop after deployment.
Two FATAL while(true) hangs in main.cpp (config load fail, camera init
fail) previously relied on the hardware watchdog to reboot the device,
leaving the cause invisible beyond a generic TWDT reset reason. Now
each path logs EVT_REBOOT with REBOOT_FATAL_CONFIG or REBOOT_FATAL_CAMERA
before hanging, so the next heartbeat's recent_events surfaces which
branch hung. Server-side decoder updated for the two new enum values.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Reporter task counts consecutive heartbeat failures from the bool
returned by reporter_heartbeat (Task 5). After 6 consecutive misses
(~6 hours at the hourly cadence) the device logs EVT_HEARTBEAT_MISS
then EVT_REBOOT(REBOOT_HEARTBEAT_MISS) and restarts, giving the whole
network stack a clean reinitialization. The 200ms delay before the
restart lets NVS commit the REBOOT entry so the next boot can report
it via EVT_BOOT + esp_reset_reason().
30s TWDT subscribes all three long-running tasks and panics on hang.
The reporter task's retry loop explicitly feeds between attempts so
the 3-try sequence (worst case 52s) does not itself trip the dog.
Reset reason on next boot is visible via esp_reset_reason() which
EVT_BOOT already logs.
loop() no longer blocks for 5s after a disconnect; reconnect is
scheduled from the WiFi event handler with exponential backoff.
Buffered reports flush on every clean UP transition.
Every boot logs EVT_BOOT with esp_reset_reason(); every deliberate
ESP.restart() is preceded by EVT_REBOOT with a reason code. This
gives us a persistent answer to 'why did the device just reboot?'.
Replace per-track line-crossing counter with a single event state machine
gated by foreground pixel count (ENTER=250, EXIT=150) and finalized by
quiet-exit or timeout. Direction inferred from centroid excursion
(up_score vs down_score) on quiet-exit fires, and from net displacement
(last_c vs first_c) on timeout fires.
Tuning reflects bench data at the intended 7' overhead mount: walkers
produce smaller centroid excursions than originally modelled, so
EXTENT gates, MIN_TRAJ, MAX_FRAMES and REFRACTORY were all relaxed from
their initial guesses. Constants and rationale live in firmware/lib/cv/cv.h.
Bench results (8 isolated walks, 4 entries + 4 exits):
* Event detection: 8/8 (100%)
* Aggregate entries+exits split: 4+4 (matches)
* Per-walk direction labelling: 4/8 (~50%)
Document explicitly that per-walk direction is unreliable at this mount
and that downstream analytics should trust only gross traffic
(entries + exits). Recovering direction would require a physical mount
change or a richer signal; both are out of scope for v1.
Tooling:
* tools/replay_logs.py — replay event state machine against captured
[F] diagnostic lines, for offline tuning without flash-test loops.
* firmware/src/main_capture.cpp + tools/capture_frames.py +
tools/replay_frames.py — raw-frame capture firmware and Python port
of the detector, kept in tree for future iteration even though the
TimerCamera-F serial driver stripped specific byte ranges in testing
and log-based replay became the working path.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
A single person walking under the overhead camera was generating both an
entry and an exit within a few seconds — the line-crossing logic treated
a blob's traversal into one side of the frame and out the other as two
separate events whenever the track spawned near the line, oscillated
against shadows, or churned at creation.
Replaced line-crossing semantics with directional traversal:
- Each track records spawn_y at creation and a counted flag.
- An event fires only if the track is not yet counted, spawned firm on
one side of the line (|spawn_y - line_y| > CV_TRAVERSAL_MARGIN_PX),
and is now firm on the opposite side. Direction of travel determines
entry vs exit. The track is then flagged counted — one trip, one count.
- Cooldown remains as a secondary safety net.
main.cpp: single/double LED pulse on entry/exit detections. Saves and
restores the current LED state so upload (yellow-on) and no-WiFi
indicators aren't clobbered.
Tests updated to walk blobs beyond the margin and register two new
cases: wobble-at-line doesn't count, and a reversed full traversal
doesn't double-count on the same track.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
- Reduce debug level to 1 (errors only) for production builds
- Replace BLE pause/resume with full deinit/reinit during HTTP uploads (~25KB freed)
- Add 60s boot report delay for fast post-deploy connectivity verification
- Add device_id to BLE batch and heartbeat request bodies
- Correct API host to http:// (plain HTTP, not HTTPS)
- Add HTTP response logging and CV entry/exit serial logging
- Create root README.md with operator setup and architecture overview
- Update design spec: HMAC format, BLE memory approach, request body shapes, reporting intervals
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
loopTask: cv_init() created a CVState{} temporary (9KB background
array) on the stack — fixed by initializing members directly.
cam task: cv_process() had uint8_t fg[CV_PIXELS] (9KB) as a local
variable — made static, matching the existing fg_copy fix.
cam task stack bumped from 4096 to 8192 for headroom.
Also: switch to 4MB OTA partition table (TimerCamera-F has 4MB flash,
not 8MB), add CONFIG_ARDUINO_LOOP_STACK_SIZE=16384 build flag,
upload_speed=115200 and --no-stub for reliable CH340 flashing.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Replaces empty stub with full application: camera+CV task on core 1 at
5 fps, hourly reporter task on core 0, WiFi reconnect loop, 5-second
factory reset via BOOT button (GPIO37), LED on GPIO2 for status.
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
