cargo: increase STA WiFi connect window

docs/CHANGELOG.md

@@ -2,6 +2,18 @@
 
 ## Unreleased
 
+### Added
+- Cargo ESP local OTA firmware upload page at `/ota`.
+- Cargo ESP OTA API endpoint at `POST /api/v1/system/ota`.
+
+## Unreleased
+
+### Fixed
+- Cargo ESP starts AP and Web UI/API before attempting STA WiFi reconnects.
+- STA reconnect attempts now service the web server during short connection windows so AP mode remains usable when no saved WiFi is available.
+
+## Unreleased
+
 ### Changed
 - Reworked ESP32-S3 dashboard page navigation to use screen-wide LVGL swipe gestures.
 - Removed failed temporary double-tap and transparent hitbox navigation experiments.

docs/dashboard-esp32s3.md

@@ -311,3 +311,11 @@ The diagnostics overlay shows dashboard version, uptime, heap, WiFi RSSI/IP, Car
 - Swipe right from the main dashboard to open Battery Detail.
 - Swipe left from Battery Detail to return to the main dashboard.
 - Diagnostics remains hidden behind the multi-tap system-card gesture.
+
+
+## OBD-II Coolant Polling
+- Dashboard ESP32-S3 Touch LCD 5B uses onboard CAN/TWAI via GPIO15 CANTX and GPIO16 CANRX.
+- First implemented PID is Mode 01 PID 05 coolant temperature.
+- Sends standard 11-bit functional request ID `0x7DF` and accepts ECU responses from `0x7E8` through `0x7EF`.
+- Diagnostics page shows TWAI state, coolant value, TX/RX counts, and last OBD status.
+- Overview coolant gauge shows `--°` until a valid OBD response is received.

docs/roadmap.md

@@ -192,3 +192,24 @@ Next Dashboard Milestones:
 ## M9N GPS Module
 
 The dashboard enclosure will include an M9N GPS module connected to the ESP32-S3 dashboard over UART. It will provide GPS fix status, satellite count, position, speed, and UTC time. Future work will use GPS time/location for automatic timezone and DST handling.
+
+## Planned: WebSocket live dashboard updates
+
+Add a WebSocket push channel alongside the existing `/api/v1` REST API. The REST API remains the stable snapshot/debug/control contract, while WebSockets provide lower-latency live status updates for the dashboard.
+
+Planned behavior:
+
+- Cargo ESP continues to expose `/api/v1/status` and existing `/api/v1/...` endpoints.
+- Cargo ESP adds a WebSocket endpoint, likely `/ws`.
+- Dashboard ESP connects once to `/ws` and receives pushed status updates.
+- Relay commands may continue using REST initially, with pushed status updates confirming state changes.
+- Future high-rate data such as CAN/OBD, GPS, inclinometer, and temperature updates can use the WebSocket path.
+- If WebSocket disconnects, dashboard should fall back to the existing REST polling behavior.
+
+Rationale:
+
+- Keeps the current API architecture intact and easy to debug.
+- Avoids ESP-NOW channel-management complexity for now.
+- Improves perceived responsiveness without a major communication rewrite.
+- Supports future live gauges better than fixed-interval polling.
+

firmware/esp32-s3-dashboard/dashboard_config.h

@@ -1,20 +1,20 @@
 #pragma once
 
-static const char *DASHBOARD_VERSION = "0.1.114-websocket-roadmap";
+static const char *DASHBOARD_VERSION = "0.1.126-restore-boot-screen";
 
 // Update these if your Cargo ESP AP credentials are different.
-//static const char *CARGO_WIFI_SSID = "OverlandController";
+static const char *CARGO_WIFI_SSID = "OverlandController";
-//static const char *CARGO_WIFI_PASSWORD = "overland1234";
+static const char *CARGO_WIFI_PASSWORD = "overland1234";
 
-static const char *CARGO_WIFI_SSID = "WardAP";
+//static const char *CARGO_WIFI_SSID = "WardAP";
-static const char *CARGO_WIFI_PASSWORD = "Ward5213";
+//static const char *CARGO_WIFI_PASSWORD = "Ward5213";
 
-//static const char *CARGO_API_STATUS_URL = "http://192.168.4.1/api/v1/status";
+static const char *CARGO_API_STATUS_URL = "http://192.168.4.1/api/v1/status";
-//static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=battery,temps,relays";
+static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=battery,temps,relays";
-//static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=network,system,config";
+static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=network,system,config";
-//static const char *CARGO_API_RELAY_SET_URL = "http://192.168.4.1/api/v1/relay/set";
+static const char *CARGO_API_RELAY_SET_URL = "http://192.168.4.1/api/v1/relay/set";
 
-static const char *CARGO_API_STATUS_URL = "http://192.168.88.108/api/v1/status";
+//static const char *CARGO_API_STATUS_URL = "http://192.168.88.108/api/v1/status";
-static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.88.108/api/v1/status?fields=battery,temps,relays";
+//static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.88.108/api/v1/status?fields=battery,temps,relays";
-static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.88.108/api/v1/status?fields=network,system,config";
+//static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.88.108/api/v1/status?fields=network,system,config";
-static const char *CARGO_API_RELAY_SET_URL = "http://192.168.88.108/api/v1/relay/set";
+//static const char *CARGO_API_RELAY_SET_URL = "http://192.168.88.108/api/v1/relay/set";

firmware/esp32-s3-dashboard/esp32-s3-dashboard.ino

@@ -3,6 +3,7 @@
 #include <HTTPClient.h>
 #include <ArduinoJson.h>
 #include <esp_display_panel.hpp>
+#include <driver/twai.h>
 
 #include <lvgl.h>
 #include "lvgl_v8_port.h"
@@ -15,6 +16,24 @@ using namespace esp_panel::drivers;
 using namespace esp_panel::board;
 
 static DashboardStatus status_model;
+static constexpr gpio_num_t OBD_CAN_TX_PIN = GPIO_NUM_15;
+static constexpr gpio_num_t OBD_CAN_RX_PIN = GPIO_NUM_16;
+static constexpr uint32_t OBD_REQUEST_ID = 0x7DF;
+static constexpr uint32_t OBD_RESPONSE_ID_MIN = 0x7E8;
+static constexpr uint32_t OBD_RESPONSE_ID_MAX = 0x7EF;
+static constexpr uint8_t OBD_PID_COOLANT_TEMP = 0x05;
+
+static bool obd_can_ready = false;
+static bool obd_can_started = false;
+static unsigned long last_obd_poll_ms = 0;
+static unsigned long last_obd_rx_ms = 0;
+static unsigned long last_obd_tx_ms = 0;
+static uint32_t obd_tx_count = 0;
+static uint32_t obd_rx_count = 0;
+static int obd_coolant_temp_f = -999;
+static int last_rendered_obd_coolant_temp_f = -1000;
+static String obd_last_error = "not initialized";
+
 
 static lv_obj_t *battery_card_obj = nullptr;
 static lv_obj_t *battery_soc_arc = nullptr;
@@ -369,6 +388,149 @@ static String format_diag_uptime(unsigned long seconds)
     return out;
 }
 
+static void update_vehicle_coolant_widget()
+{
+    if (vehicle_coolant_value_label == nullptr || vehicle_coolant_meter == nullptr || vehicle_coolant_needle == nullptr) {
+        return;
+    }
+
+    if (obd_coolant_temp_f == last_rendered_obd_coolant_temp_f) {
+        return;
+    }
+
+    last_rendered_obd_coolant_temp_f = obd_coolant_temp_f;
+
+    lvgl_port_lock(-1);
+
+    if (obd_coolant_temp_f > -100) {
+        int bounded_temp = clamp_int(obd_coolant_temp_f, 100, 260);
+        lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, bounded_temp);
+        lv_label_set_text(vehicle_coolant_value_label, (String(obd_coolant_temp_f) + "°").c_str());
+    } else {
+        lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, 100);
+        lv_label_set_text(vehicle_coolant_value_label, "--°");
+    }
+
+    lvgl_port_unlock();
+}
+
+static bool init_obd_can()
+{
+    if (obd_can_ready && obd_can_started) {
+        return true;
+    }
+
+    twai_general_config_t general_config = TWAI_GENERAL_CONFIG_DEFAULT(OBD_CAN_TX_PIN, OBD_CAN_RX_PIN, TWAI_MODE_NORMAL);
+    general_config.tx_queue_len = 5;
+    general_config.rx_queue_len = 20;
+
+    twai_timing_config_t timing_config = TWAI_TIMING_CONFIG_500KBITS();
+    twai_filter_config_t filter_config = TWAI_FILTER_CONFIG_ACCEPT_ALL();
+
+    if (!obd_can_ready) {
+        esp_err_t install_result = twai_driver_install(&general_config, &timing_config, &filter_config);
+        if (install_result != ESP_OK && install_result != ESP_ERR_INVALID_STATE) {
+            obd_last_error = "driver install failed: " + String((int)install_result);
+            Serial.println("OBD CAN: " + obd_last_error);
+            return false;
+        }
+
+        obd_can_ready = true;
+    }
+
+    esp_err_t start_result = twai_start();
+    if (start_result != ESP_OK && start_result != ESP_ERR_INVALID_STATE) {
+        obd_last_error = "start failed: " + String((int)start_result);
+        Serial.println("OBD CAN: " + obd_last_error);
+        return false;
+    }
+
+    obd_can_started = true;
+    obd_last_error = "started";
+    Serial.println("OBD CAN: TWAI started on TX GPIO15 / RX GPIO16 at 500 kbps");
+    return true;
+}
+
+static void send_obd_coolant_request()
+{
+    twai_message_t message = {};
+    message.identifier = OBD_REQUEST_ID;
+    message.extd = 0;
+    message.rtr = 0;
+    message.data_length_code = 8;
+    message.data[0] = 0x02;
+    message.data[1] = 0x01;
+    message.data[2] = OBD_PID_COOLANT_TEMP;
+    message.data[3] = 0x55;
+    message.data[4] = 0x55;
+    message.data[5] = 0x55;
+    message.data[6] = 0x55;
+    message.data[7] = 0x55;
+
+    esp_err_t result = twai_transmit(&message, 0);
+    if (result == ESP_OK) {
+        obd_tx_count++;
+        last_obd_tx_ms = millis();
+        obd_last_error = "coolant request sent";
+    } else {
+        obd_last_error = "tx failed: " + String((int)result);
+    }
+}
+
+static void handle_obd_can_message(const twai_message_t &message)
+{
+    if (message.extd || message.rtr) {
+        return;
+    }
+
+    if (message.identifier < OBD_RESPONSE_ID_MIN || message.identifier > OBD_RESPONSE_ID_MAX) {
+        return;
+    }
+
+    if (message.data_length_code < 4) {
+        return;
+    }
+
+    // Single-frame OBD-II response:
+    // byte0 length, byte1 0x41 response mode, byte2 PID, byte3 value A.
+    if (message.data[1] == 0x41 && message.data[2] == OBD_PID_COOLANT_TEMP) {
+        int coolant_c = (int)message.data[3] - 40;
+        obd_coolant_temp_f = (int)roundf((coolant_c * 9.0f / 5.0f) + 32.0f);
+        obd_rx_count++;
+        last_obd_rx_ms = millis();
+        obd_last_error = "coolant response OK";
+
+        Serial.print("OBD CAN: coolant=");
+        Serial.print(obd_coolant_temp_f);
+        Serial.println(" F");
+
+        update_vehicle_coolant_widget();
+    }
+}
+
+static void process_obd_can()
+{
+    if (!init_obd_can()) {
+        return;
+    }
+
+    if (millis() - last_obd_poll_ms >= 1000) {
+        last_obd_poll_ms = millis();
+        send_obd_coolant_request();
+    }
+
+    twai_message_t message = {};
+    while (twai_receive(&message, 0) == ESP_OK) {
+        handle_obd_can_message(message);
+    }
+
+    if (millis() - last_obd_rx_ms > 5000 && obd_coolant_temp_f > -100) {
+        obd_coolant_temp_f = -999;
+        update_vehicle_coolant_widget();
+    }
+}
+
+
 static void update_diagnostics_overlay()
 {
     if (diagnostics_overlay == nullptr || diagnostics_label == nullptr) {
@@ -442,6 +604,21 @@ static void update_diagnostics_overlay()
     text += String(status_model.cell_delta_mv);
     text += " mV";
 
+    text += "\n\nOBD-II / CAN\n";
+    text += "  TWAI: ";
+    text += obd_can_started ? "started" : "offline";
+    text += "\n  Pins: TX GPIO15 / RX GPIO16";
+    text += "\n  Coolant: ";
+    text += obd_coolant_temp_f > -100 ? String(obd_coolant_temp_f) + "°F" : String("--");
+    text += "\n  TX/RX: ";
+    text += String(obd_tx_count);
+    text += "/";
+    text += String(obd_rx_count);
+    text += "\n  Last RX age: ";
+    text += last_obd_rx_ms > 0 ? String((millis() - last_obd_rx_ms) / 1000) + "s" : String("--");
+    text += "\n  Last status: ";
+    text += obd_last_error;
+
     text += "\n\nControls\n";
     text += "  Relays visible: ";
     text += String(relay_count);
@@ -1288,14 +1465,10 @@ static void update_temp_tile_alert_style(int index, bool alert)
         return;
     }
 
-    if (last_temp_tile_alert[index] == alert) {
+    // Always apply the visual style. The cache can get out of sync when pages
-        return;
+    // are hidden/shown, so it must not prevent repainting the tile.
-    }
-
     last_temp_tile_alert[index] = alert;
 
-    lvgl_port_lock(-1);
-
     if (alert) {
         lv_obj_set_style_bg_color(temp_tile_objs[index], lv_color_hex(0x7A271A), 0);
         lv_obj_set_style_border_color(temp_tile_objs[index], lv_color_hex(0xF97066), 0);
@@ -1305,11 +1478,8 @@ static void update_temp_tile_alert_style(int index, bool alert)
         lv_obj_set_style_border_color(temp_tile_objs[index], lv_color_hex(0x2F3A46), 0);
         lv_obj_set_style_border_width(temp_tile_objs[index], 2, 0);
     }
-
-    lvgl_port_unlock();
 }
 
-
 static void update_battery_card_alert_style(bool alert)
 {
     if (battery_card_obj == nullptr) {
@@ -1465,7 +1635,6 @@ static void parse_status_json(const String &body)
 
             float temp_f = (float)(temp["temperature_f"] | 0.0);
             bool high_alert = temp["high_alert"] | false;
-
             if (weather) {
                 outside_status = "OUT ";
                 outside_status += String((int)round(temp_f));
@@ -1758,11 +1927,11 @@ current_dashboard_screen = SCREEN_OVERVIEW;
 lv_obj_t *system_card = create_card(screen, "", 960, 48, LV_ALIGN_TOP_MID, 0, 12);
     lv_obj_add_flag(system_card, LV_OBJ_FLAG_CLICKABLE);
     lv_obj_add_event_cb(system_card, system_card_event_cb, LV_EVENT_CLICKED, nullptr);
-    lv_obj_t *battery_card = create_card(screen, "", 380, 310, LV_ALIGN_TOP_LEFT, 32, 68);
+    lv_obj_t *battery_card = create_card(screen, "", 330, 310, LV_ALIGN_TOP_LEFT, 32, 68);
     battery_card_obj = battery_card;
     add_battery_card_tap_target(battery_card);
-    lv_obj_t *temp_card = create_card(screen, "", 260, 310, LV_ALIGN_TOP_LEFT, 426, 68);
+    lv_obj_t *temp_card = create_card(screen, "", 260, 310, LV_ALIGN_TOP_LEFT, 382, 68);
-    lv_obj_t *vehicle_card = create_card(screen, "", 292, 310, LV_ALIGN_TOP_RIGHT, -32, 68);
+    lv_obj_t *vehicle_card = create_card(screen, "", 330, 310, LV_ALIGN_TOP_RIGHT, -32, 68);
     lv_obj_t *relay_card = create_card(screen, "", 960, 205, LV_ALIGN_BOTTOM_MID, 0, -8);
 
     battery_charge_pulse_arc = lv_arc_create(battery_card);
@@ -1893,7 +2062,7 @@ lv_obj_t *system_card = create_card(screen, "", 960, 48, LV_ALIGN_TOP_MID, 0, 12
     lv_meter_set_indicator_end_value(vehicle_coolant_meter, hot_arc, 260);
 
     vehicle_coolant_needle = lv_meter_add_needle_line(vehicle_coolant_meter, coolant_scale, 4, lv_color_hex(0xFFFFFF), -14);
-    lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, 188);
+    lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, 100);
 
     lv_obj_t *vehicle_coolant_center_cap = lv_obj_create(vehicle_coolant_meter);
     lv_obj_set_size(vehicle_coolant_center_cap, 54, 54);
@@ -1905,7 +2074,7 @@ lv_obj_t *system_card = create_card(screen, "", 960, 48, LV_ALIGN_TOP_MID, 0, 12
 #endif
 
     vehicle_coolant_value_label = lv_label_create(vehicle_card);
-    lv_label_set_text(vehicle_coolant_value_label, "188°");
+    lv_label_set_text(vehicle_coolant_value_label, "--°");
     lv_obj_set_style_text_color(vehicle_coolant_value_label, lv_color_hex(0xFFFFFF), 0);
     lv_obj_set_style_text_font(vehicle_coolant_value_label, &lv_font_montserrat_40, 0);
     lv_obj_set_width(vehicle_coolant_value_label, 120);
@@ -2031,9 +2200,7 @@ void setup()
     lvgl_port_init(board->getLCD(), board->getTouch());
 
     lvgl_port_lock(-1);
-    // TEMP DEBUG: bypass blocking Cargo ESP WiFi screen while troubleshooting pages.
+    show_boot_screen();
-    create_overland_overview_screen();
-    overview_screen_created = true;
     lvgl_port_unlock();
 
     Serial.println("Dashboard boot screen ready");
@@ -2045,7 +2212,13 @@ void loop()
     update_system_status_label();
     process_pending_relay_command();
     poll_status_api();
+    process_obd_can();
     process_dashboard_page_switch();
 
-    delay(50);
+    
+
+    if (diagnostics_overlay != nullptr) {
+        update_diagnostics_overlay();
+    }
+delay(50);
 }

firmware/esp32/overland-controller/bms.cpp

@@ -26,6 +26,8 @@ static int bmsConnectFailCount = 0;
 static unsigned long bmsReconnectPausedUntil = 0;
 static bool bmsSetupMode = false;
 static const unsigned long READ_INTERVAL_MS = 5000;
+static const unsigned long BMS_CONNECT_BACKOFF_INITIAL_MS = 30000;
+static const unsigned long BMS_CONNECT_BACKOFF_MAX_MS = 300000;
 
 BmsData bmsData;
 
@@ -288,7 +290,34 @@ int scanBleDevices(uint32_t scanSeconds) {
     return bleScanResultCount;
 }
 
-static bool connectBms() {
+static void scheduleBmsReconnectBackoff();
+static void clearBmsReconnectBackoff();
+
+static void scheduleBmsReconnectBackoff() {
+    bmsConnectFailCount++;
+
+    if (bmsConnectBackoffMs == 0) {
+        bmsConnectBackoffMs = BMS_CONNECT_BACKOFF_INITIAL_MS;
+    } else {
+        bmsConnectBackoffMs = min(bmsConnectBackoffMs * 2, BMS_CONNECT_BACKOFF_MAX_MS);
+    }
+
+    bmsReconnectPausedUntil = millis() + bmsConnectBackoffMs;
+
+    Serial.print("BMS: reconnect backoff ");
+    Serial.print(bmsConnectBackoffMs / 1000);
+    Serial.print("s after ");
+    Serial.print(bmsConnectFailCount);
+    Serial.println(" failed attempt(s)");
+}
+
+static void clearBmsReconnectBackoff() {
+    bmsConnectFailCount = 0;
+    bmsConnectBackoffMs = 0;
+    bmsReconnectPausedUntil = 0;
+}
+
+bool connectBms() {
     if (client && client->isConnected()) {
         bmsData.connected = true;
         return true;
@@ -307,6 +336,7 @@ static bool connectBms() {
 
     if (!appConfig.bms.enabled || appConfig.bms.address.length() == 0) {
         bmsData.connected = false;
+        clearBmsReconnectBackoff();
         return false;
     }
 
@@ -322,6 +352,9 @@ static bool connectBms() {
         bmsData.connected = false;
         NimBLEDevice::deleteClient(client);
         client = nullptr;
+        notifyChar = nullptr;
+        writeChar = nullptr;
+        scheduleBmsReconnectBackoff();
         return false;
     }
 
@@ -352,6 +385,7 @@ static bool connectBms() {
 
     Serial.println("BMS: Connected");
     bmsData.connected = true;
+    clearBmsReconnectBackoff();
     return true;
 }
 

firmware/esp32/overland-controller/overland-controller.ino

@@ -3,6 +3,7 @@
 #include <Preferences.h>
 #include <esp_wifi.h>
 #include <esp_system.h>
+#include <Update.h>
 
 #define OLED_ENABLED 0
 
@@ -1648,6 +1649,98 @@ void sendSimpleJsonError(int status, const char* error, const char* detail) {
 }
 
 
+
+const char OTA_HTML[] PROGMEM = R"rawliteral(
+<!doctype html>
+<html>
+<head>
+<meta name="viewport" content="width=device-width,initial-scale=1">
+<title>Cargo ESP OTA</title>
+<style>
+body{background:#0b0f14;color:#eef4ff;font-family:-apple-system,BlinkMacSystemFont,Segoe UI,Roboto,Arial,sans-serif;margin:0}
+.wrap{max-width:620px;margin:0 auto;padding:22px}
+.card{background:#141b24;border:1px solid #223044;border-radius:18px;padding:18px}
+h1{margin-top:0}
+input,button{width:100%;box-sizing:border-box;margin-top:12px}
+input{border:1px solid #223044;border-radius:12px;padding:12px;background:#0f151d;color:#eef4ff}
+button{border:0;border-radius:12px;padding:13px;background:#1d324f;color:#eef4ff;font-weight:800}
+.warn{color:#ffd166;font-size:14px;line-height:1.4}
+.small{color:#7f8da3;font-size:13px}
+</style>
+</head>
+<body>
+<div class="wrap">
+  <div class="card">
+    <h1>Cargo ESP OTA</h1>
+    <p class="warn">Upload only firmware built for the Cargo ESP. The controller will reboot after a successful update.</p>
+    <form method="POST" action="/api/v1/system/ota" enctype="multipart/form-data">
+      <input type="file" name="firmware" accept=".bin" required>
+      <button type="submit">Upload Firmware</button>
+    </form>
+    <p class="small">Tip: Arduino IDE can create this with Sketch → Export Compiled Binary.</p>
+  </div>
+</div>
+</body>
+</html>
+)rawliteral";
+
+static bool otaUploadHadError = false;
+
+void handleOtaPage() {
+    server.send_P(200, "text/html", OTA_HTML);
+}
+
+void handleOtaUploadDone() {
+    DynamicJsonDocument doc(512);
+    doc["ok"] = !otaUploadHadError && !Update.hasError();
+    doc["firmware_name"] = FIRMWARE_NAME;
+    doc["message"] = doc["ok"].as<bool>() ? "OTA update complete. Rebooting." : "OTA update failed.";
+
+    String output;
+    serializeJson(doc, output);
+
+    if (doc["ok"].as<bool>()) {
+        server.send(200, "application/json", output);
+        delay(500);
+        ESP.restart();
+    } else {
+        server.send(500, "application/json", output);
+    }
+}
+
+void handleOtaUploadStream() {
+    HTTPUpload& upload = server.upload();
+
+    if (upload.status == UPLOAD_FILE_START) {
+        otaUploadHadError = false;
+        Serial.print("OTA: upload start: ");
+        Serial.println(upload.filename);
+
+        if (!Update.begin(UPDATE_SIZE_UNKNOWN)) {
+            otaUploadHadError = true;
+            Update.printError(Serial);
+        }
+    } else if (upload.status == UPLOAD_FILE_WRITE) {
+        if (!otaUploadHadError && Update.write(upload.buf, upload.currentSize) != upload.currentSize) {
+            otaUploadHadError = true;
+            Update.printError(Serial);
+        }
+    } else if (upload.status == UPLOAD_FILE_END) {
+        if (!otaUploadHadError && Update.end(true)) {
+            Serial.print("OTA: success, bytes=");
+            Serial.println(upload.totalSize);
+        } else {
+            otaUploadHadError = true;
+            Update.printError(Serial);
+        }
+    } else if (upload.status == UPLOAD_FILE_ABORTED) {
+        otaUploadHadError = true;
+        Update.abort();
+        Serial.println("OTA: upload aborted");
+    }
+}
+
+
 void handleResetApConfig() {
     resetApConfigToDefaults();
     restartAccessPoint();
@@ -1998,8 +2091,10 @@ void connectStaWifi() {
         WiFi.begin(staSsids[i].c_str(), staPasswords[i].c_str());
 
         unsigned long start = millis();
-        while (WiFi.status() != WL_CONNECTED && millis() - start < 10000) {
+        while (WiFi.status() != WL_CONNECTED && millis() - start < 8000) {
-            delay(500);
+            server.handleClient();
+            oledLoop();
+            delay(100);
             Serial.print(".");
         }
 
@@ -3404,6 +3499,7 @@ void handleCapabilities() {
     endpoints.add("POST /api/v1/bms/setup/exit");
     endpoints.add("POST /api/v1/bms/scan");
     endpoints.add("POST /api/v1/bms/select");
+    endpoints.add("POST /api/v1/system/ota");
 
     JsonObject limits = doc.createNestedObject("limits");
     limits["relay_count"] = MAX_RELAYS;
@@ -4007,11 +4103,15 @@ void setup() {
     startAccessPoint();
     oledShowSetupPage();
 
-    connectStaWifi();
+    // Do not block setup on STA WiFi. Start the AP and web server first so the
+    // local Web UI/API remains available even when no saved WiFi networks exist.
+    lastStaReconnectAttempt = millis() - STA_RECONNECT_INTERVAL_MS;
 
     server.on("/", HTTP_GET, []() {
         server.send_P(200, "text/html", INDEX_HTML);
     });
+    server.on("/ota", HTTP_GET, handleOtaPage);
+    server.on(API_V1("/system/ota"), HTTP_POST, handleOtaUploadDone, handleOtaUploadStream);
 
     server.on(API_V1("/status"), handleStatus);
     server.on(API_V1("/health"), HTTP_GET, handleHealth);

firmware/esp32/overland-controller/system_status.h

@@ -1,4 +1,4 @@
 #pragma once
 
-#define FIRMWARE_VERSION "0.5.0"
+#define FIRMWARE_VERSION "0.5.5-wifi-connect-window-8s"
 #define FIRMWARE_NAME "overland-controller"