Update roadmap networking and dashboard architecture

2026-06-04 12:46:35 -06:00
parent d8f756ee53
commit e3efdc581f
3 changed files with 355 additions and 0 deletions
@@ -292,3 +292,107 @@ Target use cases:
 - RV electrical systems
 - Mobile command systems
 - Off-grid battery monitoring
+
+---
+
+## Current Direction Update
+
+The project direction is now:
+
+ESP32:
+
+    Controller
+    Source of truth
+    BMS telemetry
+    Temperature sensors
+    Relay control
+    Configuration storage
+    HTTP API
+    Lightweight embedded web dashboard
+    WiFi AP recovery network
+
+Pico 2 W:
+
+    Instant-on physical dashboard
+    UART client
+    Touchscreen UI
+    Local control surface
+
+Optional future Pi Zero 2 W:
+
+    Advanced web app
+    Historical logging
+    Graphs
+    MQTT/Home Assistant bridge
+    Advanced integrations
+
+The base system should remain ESP32 + Pico.
+
+A Pi Zero may be added later as an optional expansion module, not a required component.
+
+---
+
+## Networking Direction
+
+Current:
+
+    ESP32 AP mode
+    http://192.168.4.1
+
+Planned:
+
+    ESP32 AP + STA mode
+
+Expected future behavior:
+
+    AP always remains enabled
+    ESP32 attempts to join configured WiFi networks
+    Multiple saved networks are tried in priority order
+
+Example network priority:
+
+    1. Starlink
+    2. Home WiFi
+    3. Shop WiFi
+
+This allows:
+
+- Direct connection when camping without Starlink
+- Phone access over Starlink at camp
+- Phone/laptop access over home WiFi in the driveway
+- Recovery access even when STA setup fails
+
+---
+
+## Recent Design Decisions
+
+The onboard ESP32 relays may be acceptable for low-current loads such as:
+
+    Starlink Mini
+    12V fridge
+    small accessories
+
+Reason:
+
+- Starlink Mini current draw is modest
+- Typical 12V fridge current is modest
+- Smaller enclosure is a priority
+
+External automotive relays remain recommended for higher-current loads or future expansion.
+
+The current enclosure concept includes:
+
+- ESP32 relay board
+- Small fuse block
+- Ground bus
+- CAT6 keystone
+- CAT5/CAT6 run to dash
+- 12V feed to dash
+- Buck converter in dash enclosure
+
+The dash power plan is:
+
+    Rear fused 12V
+      -> CAT5/CAT6 blue pair
+      -> dash buck converter
+      -> Pico VSYS
@@ -251,3 +251,156 @@ Potential future features:
 - Bluetooth sensor support
 - Mobile web dashboard
 - Plugin-style integrations
+
+---
+
+## Networking Roadmap
+
+### Current
+
+The ESP32 currently operates as a local access point.
+
+Default local access:
+
+    http://192.168.4.1
+
+This provides a reliable recovery/setup path even when no other WiFi network is available.
+
+### Planned: AP + STA Mode
+
+The ESP32 should support AP and STA mode at the same time.
+
+Access Point mode:
+
+    Overland-Controller
+    192.168.4.1
+
+Station mode:
+
+    Connects to a configured WiFi network such as Starlink, home WiFi, or shop WiFi.
+
+The AP should remain enabled even when STA mode is connected.
+
+Reason:
+
+- Always available recovery path
+- Easier setup
+- Less risk of locking yourself out
+- Useful when Starlink/home WiFi is unavailable
+
+### Planned: Multiple Saved WiFi Networks
+
+The controller should eventually support multiple saved WiFi profiles.
+
+Example priority order:
+
+    1. Starlink
+    2. Home WiFi
+    3. Shop WiFi
+
+Expected boot behavior:
+
+    Start AP
+    Try Starlink
+    If Starlink fails, try Home WiFi
+    If Home WiFi fails, try Shop WiFi
+    If all fail, remain AP-only
+
+The ESP32 only connects to one STA network at a time, but it can remember and try multiple networks.
+
+### Planned WiFi Configuration
+
+Future configuration should include:
+
+    ap_enabled
+    sta_enabled
+    hostname
+    saved networks
+    priority order
+
+Future setup options:
+
+- Serial console
+- HTTP API
+- Pico dashboard UI
+- Embedded web dashboard
+
+### Planned mDNS
+
+The controller should eventually support mDNS.
+
+Example:
+
+    http://overland-controller.local
+
+This would avoid needing to look up the controller IP when connected through Starlink or home WiFi.
+
+---
+
+## Embedded Web Dashboard
+
+### Current Direction
+
+The ESP32 should serve a lightweight mobile-friendly dashboard.
+
+Purpose:
+
+- Check battery status from a phone
+- Check fridge/temp status from camp
+- Toggle relays if needed
+- View alarms
+- Provide fallback UI without the Pico display
+
+Design limits:
+
+- No React
+- No external libraries
+- No images
+- Small inline HTML/CSS/JS
+- Poll /status every few seconds
+- Use existing relay endpoints
+
+This dashboard is not intended to replace the physical Pico dashboard.
+
+---
+
+## Optional Future Pi Zero Module
+
+The base system should not require a Pi Zero.
+
+Base system:
+
+    ESP32 controller
+    Pico 2 W dashboard
+
+Optional future advanced module:
+
+    Pi Zero 2 W
+
+Possible Pi Zero functions:
+
+- Rich web dashboard
+- Historical logging
+- Graphs
+- SQLite database
+- MQTT bridge
+- Home Assistant bridge
+- Advanced configuration UI
+
+The core controller should remain functional without the Pi Zero.
+
+---
+
+## Configuration Backup and Restore
+
+Planned future feature.
+
+Goals:
+
+- Export configuration JSON
+- Import configuration JSON
+- Backup install-specific setup
+- Restore after factory reset
+- Make support easier for future users
+
+This is important if the project becomes shareable or sellable.
@@ -449,3 +449,101 @@ Current required physical wiring:
 - Do not connect 12V directly to any ESP32 or Pico GPIO.
 - Do not power high-current loads directly through the ESP32 relay board.
 - Test relay behavior with a multimeter before connecting expensive loads.
+
+---
+
+## Dash Power Revision
+
+The current preferred dashboard power plan is to send fused 12V over the CAT5/CAT6 run and regulate it in the dash enclosure.
+
+Rear compartment:
+
+    House battery +
+          |
+          +-- 1A or 2A fuse
+          |
+          +---> CAT5/CAT6 blue pair
+
+    House battery -
+          |
+          +---> CAT5/CAT6 green pair
+
+Dash enclosure:
+
+    CAT5/CAT6 blue pair
+          |
+          +---> Buck converter IN+
+
+    CAT5/CAT6 green pair
+          |
+          +---> Buck converter IN-
+
+    Buck converter OUT+ 5V
+          |
+          +---> Pico VSYS
+
+    Buck converter OUT- GND
+          |
+          +---> Pico GND
+
+Reason:
+
+- Less voltage drop concern than sending 5V over the full cable run
+- Clean local 5V regulation at the dashboard
+- Pico/display power stays independent from the ESP32 board regulator
+
+Important:
+
+- Do not connect 12V directly to Pico.
+- Do not connect 5V to Pico 3V3.
+- Use Pico VSYS for 5V input.
+
+---
+
+## CAT5/CAT6 Updated Plan
+
+Recommended cable assignment:
+
+    Orange/White  ESP32 TX  ---> Pico GP1 RX
+    Orange        ESP32 RX  <--- Pico GP0 TX
+
+    Green/White   Ground
+    Green         Ground
+
+    Blue/White    +12V fused dash feed
+    Blue          +12V fused dash feed
+
+    Brown/White   Spare
+    Brown         Spare
+
+Notes:
+
+- Blue pair carries fused 12V to the dash buck converter.
+- Green pair carries ground.
+- Orange pair carries UART.
+- Brown pair remains spare.
+
+---
+
+## Compact Enclosure Direction
+
+Current rear enclosure target:
+
+    ESP32 relay board
+    compact fuse block
+    ground bus
+    CAT6 keystone
+    wiring exits
+
+Because the Starlink Mini and typical 12V fridge are modest loads, the onboard relays may be acceptable for the initial build if properly fused.
+
+Suggested fuse allocation:
+
+    ESP32 controller     2A
+    Pico dashboard       1A or 2A
+    Starlink Mini        7.5A
+    Fridge               10A
+    Spare                optional
+    Spare                optional
+
+External automotive relays remain a good upgrade path for higher-current loads.