Add ESP32 alarms system status and debug commands

firmware/esp32/xterra-controller/alarms.cpp

@@ -0,0 +1,13 @@
+#include "alarms.h"
+#include "bms.h"
+
+AlarmState alarms;
+
+void updateAlarms() {
+    alarms.lowSoc = bmsData.valid && bmsData.soc < 20;
+    alarms.criticalSoc = bmsData.valid && bmsData.soc < 10;
+    alarms.lowVoltage = bmsData.valid && bmsData.voltage < 12.0;
+    alarms.highBatteryTemp = bmsData.valid && bmsData.temperatureF > 120.0;
+    alarms.cellImbalance = bmsData.cellsValid && bmsData.cellDeltaMv > 20;
+    alarms.bmsDisconnected = !bmsData.connected;
+}

firmware/esp32/xterra-controller/alarms.h

@@ -0,0 +1,14 @@
+#pragma once
+
+struct AlarmState {
+    bool lowSoc = false;
+    bool criticalSoc = false;
+    bool lowVoltage = false;
+    bool highBatteryTemp = false;
+    bool cellImbalance = false;
+    bool bmsDisconnected = false;
+};
+
+extern AlarmState alarms;
+
+void updateAlarms();

firmware/esp32/xterra-controller/bms.cpp

@@ -64,9 +64,19 @@ static void handleNotify(
 
 static bool connectBms() {
     if (client && client->isConnected()) {
+        bmsData.connected = true;
         return true;
     }
 
+    if (client && !client->isConnected()) {
+        Serial.println("BMS: Disconnected, resetting client");
+        NimBLEDevice::deleteClient(client);
+        client = nullptr;
+        notifyChar = nullptr;
+        writeChar = nullptr;
+        bmsData.connected = false;
+    }
+
     Serial.println("BMS: Connecting...");
 
     NimBLEAddress address(std::string(BMS_ADDRESS), BLE_ADDR_PUBLIC);
@@ -76,6 +86,8 @@ static bool connectBms() {
     if (!client->connect(address)) {
         Serial.println("BMS: Connect failed");
         bmsData.connected = false;
+        NimBLEDevice::deleteClient(client);
+        client = nullptr;
         return false;
     }
 
@@ -116,6 +128,9 @@ static bool requestPacket(uint8_t* command, size_t commandLength) {
     if (!ok) {
         Serial.println("BMS: Write failed");
         bmsData.connected = false;
+        if (client) {
+            client->disconnect();
+        }
         return false;
     }
 

firmware/esp32/xterra-controller/system_status.h

@@ -0,0 +1,4 @@
+#pragma once
+
+#define FIRMWARE_VERSION "0.3.0"
+#define FIRMWARE_NAME "xterra-controller"

firmware/esp32/xterra-controller/xterra-controller.ino

@@ -7,6 +7,8 @@
 #include "relays.h"
 #include "sensors.h"
 #include "bms.h"
+#include "alarms.h"
+#include "system_status.h"
 
 WebServer server(80);
 HardwareSerial DashboardSerial(2);
@@ -56,6 +58,7 @@ void buildStatusDocument(JsonDocument& doc) {
         battery["cell_min_voltage"] = bmsData.cellMinVoltage;
         battery["cell_max_voltage"] = bmsData.cellMaxVoltage;
         battery["cell_delta_mv"] = bmsData.cellDeltaMv;
+        battery["cells_valid"] = bmsData.cellsValid;
     } else {
         battery["source"] = "placeholder";
         battery["connected"] = false;
@@ -113,6 +116,21 @@ void buildStatusDocument(JsonDocument& doc) {
     JsonObject network = doc.createNestedObject("network");
     network["wifi_enabled"] = true;
     network["uart_connected"] = true;
+
+    JsonObject alarmObj = doc.createNestedObject("alarms");
+    alarmObj["low_soc"] = alarms.lowSoc;
+    alarmObj["critical_soc"] = alarms.criticalSoc;
+    alarmObj["low_voltage"] = alarms.lowVoltage;
+    alarmObj["high_battery_temp"] = alarms.highBatteryTemp;
+    alarmObj["cell_imbalance"] = alarms.cellImbalance;
+    alarmObj["bms_disconnected"] = alarms.bmsDisconnected;
+
+    JsonObject system = doc.createNestedObject("system");
+    system["firmware_name"] = FIRMWARE_NAME;
+    system["firmware_version"] = FIRMWARE_VERSION;
+    system["build_date"] = __DATE__;
+    system["build_time"] = __TIME__;
+    system["uptime_seconds"] = millis() / 1000;
 }
 
 void sendStatus(Stream& output, bool pretty = false) {
@@ -214,6 +232,51 @@ void pollDashboardUart() {
     }
 }
 
+
+void handleDebugSerial() {
+    if (!Serial.available()) {
+        return;
+    }
+
+    String command = Serial.readStringUntil('\n');
+    command.trim();
+
+    if (command == "status") {
+        sendStatus(Serial, true);
+        return;
+    }
+
+    if (command == "relay starlink on") {
+        setRelayByName("starlink", true);
+        Serial.println("OK starlink on");
+        return;
+    }
+
+    if (command == "relay starlink off") {
+        setRelayByName("starlink", false);
+        Serial.println("OK starlink off");
+        return;
+    }
+
+    if (command == "relay fridge on") {
+        setRelayByName("fridge", true);
+        Serial.println("OK fridge on");
+        return;
+    }
+
+    if (command == "relay fridge off") {
+        setRelayByName("fridge", false);
+        Serial.println("OK fridge off");
+        return;
+    }
+
+    if (command.length() > 0) {
+        Serial.print("Unknown command: ");
+        Serial.println(command);
+        Serial.println("Commands: status, relay starlink on/off, relay fridge on/off");
+    }
+}
+
 void handleStatus() {
     DynamicJsonDocument doc(2048);
     buildStatusDocument(doc);
@@ -305,7 +368,9 @@ void setup() {
 
 void loop() {
     server.handleClient();
+    handleDebugSerial();
     updateBms();
+    updateAlarms();
     pollDashboardUart();
 
     static unsigned long lastSensorUpdate = 0;