DoorCounter/firmware/src/main.cpp

// firmware/src/main.cpp
#include <Arduino.h>
#include <WiFi.h>
#include <ArduinoOTA.h>
#include "config.h"
#include "provisioning.h"
#include "camera.h"
#include "cv.h"
#include "ble_scanner.h"
#include "reporter.h"
#include "event_log.h"
#include "net_guard.h"
#include <esp_system.h>
#include <esp_task_wdt.h>

// LED on GPIO2 (TimerCamera-F built-in LED) — verify against board schematic
// Factory reset: hold GPIO37 (BOOT button) for 5 seconds
#define LED_PIN       2
#define BUTTON_PIN   37
#define FACTORY_RESET_HOLD_MS 5000

// BLE scanning disabled in production until the NimBLE-Arduino 1.4.2 timer
// race is resolved. Symptom: FreeRTOS timer task dispatches an
// os_callout_timer_cb whose callback fn is NULL, causing PC=0 fetch and
// Historical note: NimBLE-Arduino 1.4.2 had an init/fire race in its FreeRTOS
// callout porting layer that caused a NULL-fn dispatch (PC=0,
// InstrFetchProhibited) within ~1s of boot when the camera task starved the
// timer service. Fixed by upgrading to 2.x (see platformio.ini).
#define BLE_SCANNING_ENABLED 1

#define CAM_FPS           5
#define CAM_INTERVAL_MS   (1000 / CAM_FPS)
#define REPORT_INTERVAL_S 3600
#define BOOT_REPORT_DELAY_S 60  // first report fires 60s after NTP sync

static DeviceConfig     g_cfg;
static CVState          g_cv;
static SemaphoreHandle_t s_cv_mutex = nullptr;

static void led_set(bool on) { digitalWrite(LED_PIN, on ? HIGH : LOW); }

// Non-blocking-ish detection blink. Saves and restores the current LED state
// so it doesn't clobber upload/no-wifi indicators. Total duration: ~60ms per
// pulse + 80ms gap between pulses.
static void led_blink_pattern(int pulses) {
    bool prev = digitalRead(LED_PIN);
    for (int i = 0; i < pulses; i++) {
        led_set(true);
        vTaskDelay(pdMS_TO_TICKS(60));
        led_set(false);
        if (i < pulses - 1) vTaskDelay(pdMS_TO_TICKS(80));
    }
    led_set(prev);
}

static void check_factory_reset() {
    if (digitalRead(BUTTON_PIN) != LOW) return;
    uint32_t held = millis();
    while (digitalRead(BUTTON_PIN) == LOW) {
        if (millis() - held >= FACTORY_RESET_HOLD_MS) {
            event_log_write(EVT_REBOOT, REBOOT_FACTORY_RESET, 0);
            config_clear_wifi();
            ESP.restart();
        }
        delay(50);
        esp_task_wdt_reset();
    }
}

// Camera + CV task — runs on core 1 at 5 fps
static void task_camera(void*) {
    static uint8_t frame[CV_PIXELS];  // static: avoids 9KB on task stack
    int last_logged_track_id = 0;     // diagnostic: log each new track once
    esp_task_wdt_add(nullptr);
    while (true) {
        if (camera_capture_96(frame)) {
            if (xSemaphoreTake(s_cv_mutex, pdMS_TO_TICKS(100)) == pdTRUE) {
                CVResult r = cv_process(g_cv, frame, g_cfg.line_offset);
                (void)last_logged_track_id;
                if (r.entries_delta) Serial.printf("[CV] entry +%d (total %d) first=%.1f min=%.1f max=%.1f last=%.1f dur=%d\n",
                    r.entries_delta, g_cv.entries,
                    r.fire_first_c, r.fire_min_c, r.fire_max_c, r.fire_last_c, r.fire_duration);
                if (r.exits_delta)   Serial.printf("[CV] exit  +%d (total %d) first=%.1f min=%.1f max=%.1f last=%.1f dur=%d\n",
                    r.exits_delta,  g_cv.exits,
                    r.fire_first_c, r.fire_min_c, r.fire_max_c, r.fire_last_c, r.fire_duration);
                xSemaphoreGive(s_cv_mutex);
                if (r.entries_delta) led_blink_pattern(1);
                if (r.exits_delta)   led_blink_pattern(2);
            }
        }
        vTaskDelay(pdMS_TO_TICKS(CAM_INTERVAL_MS));
        esp_task_wdt_reset();
    }
}

// Hourly reporter task — runs on core 0
static void task_reporter(void*) {
    uint32_t last_report_ts = 0; // 0 = not initialized yet
    esp_task_wdt_add(nullptr);

    while (true) {
        vTaskDelay(pdMS_TO_TICKS(10000)); // check every 10s
        esp_task_wdt_reset();

        uint32_t now = (uint32_t)(time(nullptr));
        if (now < 1700000000UL) continue; // NTP not synced

        // First valid timestamp — schedule boot report 60s from now
        if (last_report_ts == 0) {
            event_log_write(EVT_NTP_SYNC, (uint16_t)(millis() / 1000), 0);
            last_report_ts = now - (REPORT_INTERVAL_S - BOOT_REPORT_DELAY_S);
            continue;
        }

        if ((now - last_report_ts) < REPORT_INTERVAL_S) continue;

        uint32_t period_start = last_report_ts;
        uint32_t period_end   = now;
        last_report_ts = now;

        // Deinit BLE to free ~25KB heap for SSL handshakes
#if BLE_SCANNING_ENABLED
        ble_scanner_deinit();
#endif
        led_set(true); // on = uploading

        CameraHourlyRecord cam_rec;
        if (xSemaphoreTake(s_cv_mutex, pdMS_TO_TICKS(500)) == pdTRUE) {
            cam_rec = {period_start, period_end, g_cv.entries, g_cv.exits};
            cv_reset_counts(g_cv);
            xSemaphoreGive(s_cv_mutex);
        } else {
            // Failed to acquire — skip this cycle, will report next hour
#if BLE_SCANNING_ENABLED
            ble_scanner_reinit();
#endif
            led_set(false);
            continue;
        }

#if !BLE_SCANNING_ENABLED
        BLEHourlyRecord ble_rec = {period_start, period_end, 0, 0};
#else
        BLEHourlyRecord ble_rec = ble_scanner_collect(period_start, period_end);
#endif

        reporter_submit_camera(g_cfg, cam_rec);
        reporter_submit_ble(g_cfg, ble_rec);
        bool hb_ok = reporter_heartbeat(g_cfg, millis() / 1000, WiFi.RSSI());

#if BLE_SCANNING_ENABLED
        ble_scanner_reinit();
#endif
        led_set(false);

        static uint8_t consecutive_misses = 0;
        if (hb_ok) {
            consecutive_misses = 0;
        } else {
            consecutive_misses++;
            event_log_write(EVT_HEARTBEAT_MISS, consecutive_misses, 0);
            Serial.printf("[WDG] heartbeat miss %u/6\n", consecutive_misses);
            if (consecutive_misses >= 6) {
                event_log_write(EVT_REBOOT, REBOOT_HEARTBEAT_MISS, 0);
                delay(200); // let NVS commit before reboot
                ESP.restart();
            }
        }
    }
}

void setup() {
    Serial.begin(115200);
    pinMode(LED_PIN, OUTPUT);
    pinMode(BUTTON_PIN, INPUT_PULLUP);
    led_set(true); // on = booting

    event_log_init();
    event_log_write(EVT_BOOT, (uint16_t)esp_reset_reason(), 0);

    if (!config_load(g_cfg)) {
        Serial.println("FATAL: device_id/location_id/hmac_secret not provisioned");
        event_log_write(EVT_REBOOT, REBOOT_FATAL_CONFIG, 0);
        // Blink fast for 3s so a physically-present operator can see it,
        // then reboot so EVT_BOOT history on the next heartbeat surfaces
        // the failure — though in this case the device can't heartbeat
        // without config, so the real signal is the fast-blink-then-reboot
        // cycle visible on the LED.
        uint32_t t0 = millis();
        while (millis() - t0 < 3000) { led_set(!digitalRead(LED_PIN)); delay(100); }
        ESP.restart();
    }

    // Connect to WiFi
    if (!config_has_wifi()) {
        provisioning_run();
        event_log_write(EVT_REBOOT, REBOOT_WIFI_REPROV, 0);
        ESP.restart();
    }

    WiFi.begin(g_cfg.wifi_ssid.c_str(), g_cfg.wifi_pass.c_str());
    uint32_t wifi_start = millis();
    while (WiFi.status() != WL_CONNECTED && millis() - wifi_start < 15000) {
        check_factory_reset();
        delay(200);
    }

    if (WiFi.status() != WL_CONNECTED) {
        // Saved creds failed — re-provision
        provisioning_run();
        event_log_write(EVT_REBOOT, REBOOT_WIFI_REPROV, 0);
        ESP.restart();
    }

    // Boot connect happens before net_guard registers its WiFi event handler,
    // so the GOT_IP-driven DNS override there won't fire for this association.
    // Pin DNS now; net_guard re-applies it on every subsequent reconnect.
    net_guard_pin_dns();

    net_guard_start(g_cfg);
    led_set(false); // off = connected

    // NTP sync (UTC)
    configTime(0, 0, "pool.ntp.org", "time.nist.gov");

    cv_init(g_cv);

    if (!camera_init()) {
        Serial.println("FATAL: camera init failed");
        event_log_write(EVT_REBOOT, REBOOT_FATAL_CAMERA, 0);
        uint32_t t0 = millis();
        while (millis() - t0 < 3000) { led_set(!digitalRead(LED_PIN)); delay(100); }
        ESP.restart();
    }

    reporter_init();

#if BLE_SCANNING_ENABLED
    ble_scanner_start();
#endif

    // OTA update support
    ArduinoOTA.setHostname(g_cfg.device_id.c_str());
#if !BLE_SCANNING_ENABLED
    ArduinoOTA.onStart([]() { });
#else
    ArduinoOTA.onStart([]() { ble_scanner_pause(); });
#endif
    ArduinoOTA.onEnd([]()   {
#if BLE_SCANNING_ENABLED
        ble_scanner_resume();
#endif
        event_log_write(EVT_REBOOT, REBOOT_OTA, 0);
        ESP.restart();
    });
#if !BLE_SCANNING_ENABLED
    ArduinoOTA.onError([](ota_error_t e) { });
#else
    ArduinoOTA.onError([](ota_error_t e) { ble_scanner_resume(); });
#endif
    ArduinoOTA.begin();

    s_cv_mutex = xSemaphoreCreateMutex();

    // Task watchdog: 30s timeout, panic on trigger so we reboot and log
    // via esp_reset_reason() in EVT_BOOT on the next boot.
    esp_task_wdt_init(30, /*panic=*/true);
    esp_task_wdt_add(nullptr); // subscribe the Arduino loopTask

    xTaskCreatePinnedToCore(task_camera,   "cam",  8192, nullptr, 2, nullptr, 1);
    xTaskCreatePinnedToCore(task_reporter, "rep",  8192, nullptr, 1, nullptr, 0);
}

void loop() {
    esp_task_wdt_reset();
    ArduinoOTA.handle();
    check_factory_reset();
    net_guard_tick();

    static bool s_was_up = true;
    bool up = net_guard_is_up();
    if (up != s_was_up) {
        led_set(!up); // LED on when NOT up
        if (up) reporter_flush(g_cfg);
        s_was_up = up;
    }
    delay(200);
}