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Peter Woolery 9d5b588231 feat: production-ready firmware with BLE memory management, device_id fixes, and docs

- 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>

2026-04-16 11:13:50 -07:00

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DoorCounter

Retail door traffic counter using M5Stack TimerCamera-F (ESP32 + OV3660). Counts entries/exits via overhead camera CV, passively scans BLE foot traffic, and reports hourly to logs.research.bike.

Hardware

Device: M5Stack TimerCamera-F (ESP32-S, OV3660, PSRAM, WiFi/BLE)
Mount: Overhead, camera pointing straight down, centered above doorway
Power: USB (any phone charger)

Firmware

Built with PlatformIO. Target: timercam.

cd firmware
pio run -t upload --upload-port /dev/ttyUSB0

What it does

Module	Behavior
CV pipeline	5 fps, 96×96 grayscale, blob tracking, line-crossing count
BLE scanner	Continuous passive scan; deinits during hourly upload to free heap
Reporter	Hourly HMAC-signed POST; 60s boot report for fast connectivity check
Provisioning	Captive portal AP on first boot for WiFi setup
OTA	Arduino OTA; operator push via `ota_push.py`

Reporting intervals

First report: 60 seconds after NTP sync (connectivity check)
Subsequent reports: every 3600 seconds

Operator Setup

1. Flash firmware

cd firmware
pio run -t upload --upload-port /dev/ttyUSB0

2. Provision device identity

python tools/flash_device.py \
  --port /dev/ttyUSB0 \
  --device-id dc-0042 \
  --location-id retailer-123 \
  --hmac-secret <32-byte-hex> \
  --wifi-ssid "StoreWiFi" \
  --wifi-password "secret"

WiFi credentials are optional — if omitted, device starts captive portal on boot.

3. OTA updates

python tools/ota_push.py \
  --host dc-0042.local \
  --firmware firmware/.pio/build/timercam/firmware.bin

End User Setup

Mount device overhead, camera pointing straight down
Plug into USB power
Connect phone to DoorCounter-Setup WiFi
Browser opens automatically → enter store WiFi password → done

LED indicators: Red = no WiFi · Blue = counting · Yellow = uploading

API

Endpoint: http://logs.research.bike

Endpoint	Data
`POST /api/v1/camera/events/batch`	Hourly entry/exit counts
`POST /api/v1/events/batch`	Hourly BLE proximity records
`POST /api/v1/heartbeat`	Device health (uptime, RSSI, pending records)

All requests are HMAC-SHA256 signed. See design spec for full API shapes and auth scheme.

Project Structure

DoorCounter/
├── firmware/
│   ├── platformio.ini
│   ├── lib/hmac/          — HMAC-SHA256 signing library
│   └── src/
│       ├── main.cpp       — FreeRTOS tasks, boot sequence
│       ├── config.*       — NVS read/write
│       ├── provisioning.* — captive portal
│       ├── camera.*       — frame capture + CV pipeline
│       ├── ble_scanner.*  — BLE passive scan
│       └── reporter.*     — hourly batch POST + local buffer
├── tools/
│   ├── flash_device.py    — NVS provisioning script
│   └── ota_push.py        — OTA push script
├── docs/superpowers/specs/
│   └── 2026-04-13-door-counter-design.md
└── server/                — API server (separate deployment)

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