Add initial ESP32 controller firmware

firmware/esp32/xterra-controller/config.h

@@ -0,0 +1,18 @@
+#pragma once
+
+#define DEVICE_NAME "Xterra Controller"
+
+// Relay Outputs
+#define RELAY_STARLINK_PIN 16
+#define RELAY_FRIDGE_PIN   17
+
+// DS18B20 Bus
+#define ONEWIRE_PIN 4
+
+// Ignition Sense
+#define IGNITION_PIN 34
+
+// Future RS485
+#define RS485_TX_PIN 21
+#define RS485_RX_PIN 22
+#define RS485_DE_PIN 23

firmware/esp32/xterra-controller/protocol.h

@@ -0,0 +1,6 @@
+#pragma once
+
+#define MSG_STATUS_REQUEST       "status_request"
+#define MSG_STATUS_RESPONSE      "status_response"
+#define MSG_SET_RELAY            "set_relay"
+#define MSG_RELAY_RESPONSE       "relay_response"

firmware/esp32/xterra-controller/relays.cpp

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+#include <Arduino.h>
+#include "config.h"
+#include "relays.h"
+
+RelayState relays;
+
+void initRelays() {
+    pinMode(RELAY_STARLINK_PIN, OUTPUT);
+    pinMode(RELAY_FRIDGE_PIN, OUTPUT);
+
+    updateRelayOutputs();
+}
+
+void updateRelayOutputs() {
+    digitalWrite(RELAY_STARLINK_PIN, relays.starlink);
+    digitalWrite(RELAY_FRIDGE_PIN, relays.fridge);
+}

firmware/esp32/xterra-controller/relays.h

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+#pragma once
+
+struct RelayState {
+    bool starlink = false;
+    bool fridge = true;
+};
+
+extern RelayState relays;
+
+void initRelays();
+void updateRelayOutputs();

firmware/esp32/xterra-controller/sensors.cpp

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+#include "sensors.h"
+
+SensorData sensors;
+
+void initSensors() {
+}
+
+void updateSensors() {
+    // Placeholder until DS18B20 support is added
+}

firmware/esp32/xterra-controller/sensors.h

@@ -0,0 +1,13 @@
+#pragma once
+
+struct SensorData {
+    float fridgeZone1 = 36.0;
+    float fridgeZone2 = 12.0;
+    float rearSeat = 78.0;
+    float outsideAir = 88.0;
+};
+
+extern SensorData sensors;
+
+void initSensors();
+void updateSensors();

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

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+#include <WiFi.h>
+#include <WebServer.h>
+#include <ArduinoJson.h>
+
+#include "config.h"
+#include "relays.h"
+#include "sensors.h"
+
+WebServer server(80);
+
+float batterySOC = 82.0;
+float batteryVoltage = 13.2;
+float batteryCurrent = -6.4;
+float batteryRemainingAh = 82.0;
+float batteryRuntimeHours = 12.0;
+float batteryTemp = 76.0;
+
+void handleStatus() {
+
+    DynamicJsonDocument doc(2048);
+
+    doc["timestamp"] = millis();
+
+    JsonObject battery = doc.createNestedObject("battery");
+    battery["soc"] = batterySOC;
+    battery["voltage"] = batteryVoltage;
+    battery["current"] = batteryCurrent;
+    battery["remaining_ah"] = batteryRemainingAh;
+    battery["runtime_hours"] = batteryRuntimeHours;
+    battery["temperature_f"] = batteryTemp;
+
+    JsonObject temps = doc.createNestedObject("temps");
+    temps["fridge_zone_1"] = sensors.fridgeZone1;
+    temps["fridge_zone_2"] = sensors.fridgeZone2;
+    temps["rear_seat"] = sensors.rearSeat;
+    temps["outside"] = sensors.outsideAir;
+
+    JsonObject relayObj = doc.createNestedObject("relays");
+    relayObj["starlink"] = relays.starlink;
+    relayObj["fridge"] = relays.fridge;
+
+    JsonObject vehicle = doc.createNestedObject("vehicle");
+    vehicle["ignition_on"] = digitalRead(IGNITION_PIN);
+
+    JsonObject network = doc.createNestedObject("network");
+    network["wifi_enabled"] = true;
+    network["rs485_connected"] = true;
+
+    String output;
+    serializeJsonPretty(doc, output);
+
+    server.send(200, "application/json", output);
+}
+
+void handleStarlinkOn() {
+    relays.starlink = true;
+    updateRelayOutputs();
+    server.send(200, "text/plain", "OK");
+}
+
+void handleStarlinkOff() {
+    relays.starlink = false;
+    updateRelayOutputs();
+    server.send(200, "text/plain", "OK");
+}
+
+void handleFridgeOn() {
+    relays.fridge = true;
+    updateRelayOutputs();
+    server.send(200, "text/plain", "OK");
+}
+
+void handleFridgeOff() {
+    relays.fridge = false;
+    updateRelayOutputs();
+    server.send(200, "text/plain", "OK");
+}
+
+void setup() {
+
+    Serial.begin(115200);
+
+    Serial.println();
+    Serial.println("==================================");
+    Serial.println("Xterra Controller Booting");
+    Serial.println("==================================");
+
+    pinMode(IGNITION_PIN, INPUT);
+
+    initRelays();
+    initSensors();
+
+    WiFi.mode(WIFI_AP);
+
+    bool apResult = WiFi.softAP("XterraController");
+
+    if (apResult) {
+        Serial.println("AP Started");
+        Serial.print("IP: ");
+        Serial.println(WiFi.softAPIP());
+    }
+
+    server.on("/status", handleStatus);
+
+    server.on("/relay/starlink/on", handleStarlinkOn);
+    server.on("/relay/starlink/off", handleStarlinkOff);
+
+    server.on("/relay/fridge/on", handleFridgeOn);
+    server.on("/relay/fridge/off", handleFridgeOff);
+
+    server.begin();
+
+    Serial.println("Web Server Started");
+}
+
+void loop() {
+
+    server.handleClient();
+
+    static unsigned long lastSensorUpdate = 0;
+
+    if (millis() - lastSensorUpdate > 5000) {
+
+        updateSensors();
+
+        lastSensorUpdate = millis();
+
+        Serial.println("Sensor Update");
+    }
+}