Archive stale documentation
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# Hardware Status
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Last Updated: 2026-06-03
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This document is stale and records earlier hardware ordering/status notes. Current hardware direction is documented in `docs/HARDWARE.md` and `docs/dashboard-esp32s3.md`.
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The current dashboard target is the Waveshare ESP32-S3-Touch-LCD-5 over WiFi/HTTP. No Pico dashboard is planned.
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--------------------------------------------------
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## Dashboard Hardware
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### Raspberry Pi Pico 2 W
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Status:
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- Ordered
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Purpose:
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- Dashboard controller
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- Touchscreen UI
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- Audible alarms
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- UART communications
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Notes:
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- Waiting for delivery
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--------------------------------------------------
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### 3.5 Inch Touchscreen
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Display Controller:
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- ST7796S
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Touch Controller:
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- FT6336U
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Status:
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- Ordered
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Purpose:
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- Main dashboard display
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Testing Required:
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- Display initialization
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- Touch functionality
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- Performance testing
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--------------------------------------------------
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### Active 5V Buzzer
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Status:
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- Ordered
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Purpose:
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- Audible alarms
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Testing Required:
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- Alarm volume
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- Dashboard mounting location
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--------------------------------------------------
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## Controller Hardware
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### ESP32 2-Channel Relay Board
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Status:
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- On Hand
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Purpose:
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- Relay control
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- Sensor collection
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- Communications
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Known Information:
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GPIO16 = Relay Output 1
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GPIO17 = Relay Output 2
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Relay ON = HIGH
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Relay OFF = LOW
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Testing Required:
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- Verify relay operation
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- Verify startup behavior
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--------------------------------------------------
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## Communications Hardware
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### CAT5 Cable
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Status:
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- On Hand
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Purpose:
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- Dashboard power
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- UART communications
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- Ignition sense
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--------------------------------------------------
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### RS485 Modules
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Status:
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- Ordered
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Purpose:
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- Future fallback communication
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Current Plan:
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- Not used initially
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Testing Required:
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- Only if UART proves unreliable
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--------------------------------------------------
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## Sensor Hardware
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### DS18B20 Waterproof Sensors
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Quantity:
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- 4
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Status:
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- Ordered
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Assignments:
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Sensor 1
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- Fridge Zone 1
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Sensor 2
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- Fridge Zone 2
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Sensor 3
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- Rear Seat Area
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Sensor 4
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- Outside Air
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Testing Required:
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- Address discovery
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- Temperature validation
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--------------------------------------------------
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## Power Hardware
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### 12V To 5V Buck Converter
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Status:
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- Planned
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Purpose:
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- Dashboard power
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Requirements:
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Input:
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- Vehicle 12V
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Output:
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- 5V
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Recommended:
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- 3A minimum
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--------------------------------------------------
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### Bosch Relays
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Status:
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- Planned
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Purpose:
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- Starlink power
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- Fridge power
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Future:
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- Inverter
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- Camp lights
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Requirements:
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- 30A or 40A automotive relays
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--------------------------------------------------
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### Fuse Block
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Status:
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- Planned
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Purpose:
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- Circuit protection
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--------------------------------------------------
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## Future Hardware
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### JBD / Xiaoxiang BMS
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Status:
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- Existing battery system
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Purpose:
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- Battery monitoring
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Future Integration:
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- BLE communications
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--------------------------------------------------
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### ELM327
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Status:
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- Future
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Purpose:
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- OBD-II integration
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--------------------------------------------------
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### GPS Module
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Status:
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- Future
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Purpose:
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- Vehicle tracking
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- Trip logging
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--------------------------------------------------
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## Bring-Up Checklist
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ESP32
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[ ] Verify relay outputs
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[ ] Verify WiFi AP
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[ ] Verify HTTP status endpoint
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[ ] Verify DS18B20 support
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Pico
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[ ] Display test
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[ ] Touch test
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[ ] Buzzer test
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[ ] UART communications
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Vehicle
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[ ] Install CAT5 run
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[ ] Install buck converter
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[ ] Install relays
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[ ] Install sensors
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[ ] Install dashboard enclosure
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--------------------------------------------------
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## Notes
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Current Communication Plan:
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Primary:
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- UART over CAT5
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Backup:
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- WiFi HTTP API
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Fallback:
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- RS485
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Current UI Plan:
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- Touchscreen only
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- No physical buttons required
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Current Logging Plan:
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- No persistent logging planned
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- Focus on live monitoring and alarms
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## ESP32 Cargo Controller Bring-Up Results
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### Date
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2026-06-04
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### Hardware
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- ESP32 2-channel relay board
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- ESP32-WROOM-32
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- Integrated dual relay module
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### Firmware Status
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- Firmware compiles successfully
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- Firmware uploads successfully
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- Board boots reliably
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- No watchdog resets observed
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### WiFi Access Point
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Status: PASS
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Verified:
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- AP starts correctly
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- SSID visible
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- Client devices can connect
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- HTTP API accessible
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### Status Endpoint
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Status: PASS
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Endpoint:
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/status
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Issue Found:
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- Original streaming JSON implementation produced malformed responses
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- Browser reported "cannot parse response"
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Resolution:
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- Replaced streamed response with serialized JSON string response
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Result:
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- Valid JSON returned successfully
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### Relay Control
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Status: PASS
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Verified:
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/relay/starlink/on
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/relay/starlink/off
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/relay/fridge/on
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/relay/fridge/off
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Results:
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- Relay 1 responds correctly
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- Relay 2 responds correctly
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- Relay state updates correctly
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- Relay state reflected correctly in status API
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### Relay Default State
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Issue Found:
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- Fridge relay defaulted to ON
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Root Cause:
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bool fridge = true;
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Resolution:
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bool fridge = false;
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Result:
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- Both relays now default OFF at boot
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### DS18B20 Testing
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Status: BLOCKED
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Hardware:
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- Waterproof DS18B20 sensors
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- 5 meter leads
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Current Result:
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- Sensors not detected
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Likely Cause:
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- Missing 4.7kΩ pull-up resistor on 1-Wire bus
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Planned Fix:
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- Install 4.7kΩ resistor between GPIO4 and 3.3V
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- Retest sensor detection
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### Overall Milestone Status
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ESP32 Hardware Bring-Up
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Status: COMPLETE
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Completed:
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- Boot validation
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- WiFi validation
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- HTTP API validation
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- Relay validation
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Remaining:
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- DS18B20 validation after resistor installation
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## JBD/Xiaoxiang BMS Bring-Up Results
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### Date
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2026-06-04
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### Hardware
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- DGJBD / Xiaoxiang-compatible BMS
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- Bluetooth name: Greta
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- ESP32 BLE address: a5:c2:37:2c:05:dc
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- Battery capacity: 150Ah
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- Chemistry: 4S LiFePO4
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### BLE Discovery
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Status: PASS
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Verified BLE service and characteristics:
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- Service: 0xff00
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- Notify characteristic: 0xff01
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- Write characteristic: 0xff02
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- Write mode: write without response
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### BMS Read Test
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Status: PASS
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Verified JBD basic status command:
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DD A5 03 00 FF FD 77
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Confirmed live values:
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- SOC: 70%
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- Pack voltage: 13.34V
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- Current: 0.00A
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- Remaining capacity: 104.88Ah
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- Nominal capacity: 150.00Ah
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- Cycle count: 3
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- Cell count: 4
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- Temperature: approximately 67.6°F
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### ESP32 Firmware Integration
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Status: PASS
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Verified:
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- Main firmware connects to BMS
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- BMS data is read repeatedly
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- BMS data is parsed correctly
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- Serial monitor reports live SOC, voltage, current, and remaining Ah
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### Notes
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- First BMS read after boot may time out.
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- Subsequent reads succeed consistently.
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- Current implementation reads basic pack telemetry only.
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- Cell voltage and cell delta support will require an additional JBD command.
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## JBD Cell Voltage Bring-Up Results
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### Date
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2026-06-04
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### Status
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PASS
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### Verified
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- JBD cell voltage command works
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- ESP32 receives cell voltage packet
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- Firmware parses 4 cell voltages
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- Firmware calculates min cell voltage
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- Firmware calculates max cell voltage
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- Firmware calculates cell delta
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### Observed Values
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- Cell count: 4
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- Minimum cell voltage: 3.336V
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- Maximum cell voltage: 3.337V
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- Cell delta: 1mV
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### Notes
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- Pack appears well balanced.
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- First BMS status read after boot may timeout, but subsequent reads succeed.
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- This behavior is acceptable for current bring-up.
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