ESC lights/beeps, baro cache, and UI sync

Introduce ESC status light modes and motor beep queuing, add cached barometer/altitude/vertical-speed getters, and reduce cross-task I2C/CAN contention. Key changes:

- esc.h / esc.cpp: add EscStatusLightMode enum and APIs to request status lights and queue motor beeps; implement LED patterns, motor-tone building, and sync logic to send outputs only when ESC is connected.
- altimeter.h / altimeter.cpp: add cached getters (altitude, baro temp, vertical speed), compute vertical speed from buffer, seed and retry BMP3xx init to avoid transient I2C failures, and update cache on reads to allow safe cross-task access.
- alert_display.h / alert_display.cpp: track ESC/BMS-specific active alert counts and expose getEscBmsAlertCounts() used to influence ESC lights.
- main.cpp: prefer cached getters in non-I2C tasks, restructure changeDeviceState to minimize mutex hold time and side effects outside critical section, use status LED constants, queue ESC beeps on arm/disarm, avoid direct CAN throttle writes from disarm, and use non-blocking queue overwrite for throttle/cruise updates.
- utilities.h: rename LED macros to STATUS_LED_* for controller status semantics.
- buzzer.cpp / audioTask: increase default melody duration and add short silence between notes for separation.
- system_monitors.cpp: re-enable Baro_Temp monitor using cached getter to avoid I2C access from monitors.
- platformio.ini / extra_script.py / .claude/settings.local.json: adjust project src_dir and build flags, update a lib dep commit hash, clean up extra_script usage, and add a couple shell checks for CI.

Overall these changes improve robustness against I2C/CAN races, provide cross-task-safe sensor values, and add ESC visual/audio feedback tied to alert state.

Author: PaulDWhite

.claude/settings.local.json

@@ -6,7 +6,9 @@
       "Bash(cpplint:*)",
       "Bash(grep:*)",
       "Bash(pio test:*)",
-      "Bash(pio run:*)"
+      "Bash(pio run:*)",
+      "Bash(pio --version)",
+      "Bash(python -c \"import platformio; print\\(platformio.__file__\\)\")"
     ],
     "deny": []
   }

extra_script.py

@@ -2,12 +2,6 @@
 import subprocess
 
 Import("env")
-folder = env.GetProjectOption("custom_src_folder")
-
-# Generic
-env.Replace(
-    PROJECT_SRC_DIR="$PROJECT_DIR/src/" + folder
-)
 
 def get_git_revision_short_hash():
     try:

inc/sp140/alert_display.h

@@ -73,6 +73,9 @@ void updateAlertCounterDisplay(const AlertCounts& counts);
 // Helper for monitors/UI logger to push alert events
 void sendAlertEvent(SensorID id, AlertLevel level);
 
+// Current active alert counts limited to ESC and BMS categories.
+AlertCounts getEscBmsAlertCounts();
+
 // ILogger sink that pushes events to the alert queue (for UI)
 struct AlertUILogger : ILogger {
   void log(SensorID id, AlertLevel lvl, float v) override {

inc/sp140/altimeter.h

@@ -29,4 +29,10 @@ float getBaroTemperature();
 // Get the pressure in hPa
 float getBaroPressure();
 
+// Cached getters — safe to call from any task (atomic float reads on Xtensa).
+// Populated by the designated I2C reader (uiTask via getAltitude()).
+float getCachedAltitude();
+float getCachedBaroTemperature();
+float getCachedVerticalSpeed();
+
 #endif  // INC_SP140_ALTIMETER_H_

inc/sp140/esc.h

@@ -15,6 +15,16 @@ inline bool isMotorTempValidC(float tempC) {
 #include <SineEsc.h>
 #include <CanardAdapter.h>
 
+enum class EscStatusLightMode : uint8_t {
+  OFF = 0,
+  DISARMED_NOMINAL,
+  DISARMED_WARNING,
+  DISARMED_CRITICAL,
+  FLIGHT_NOMINAL,
+  FLIGHT_WARNING,
+  FLIGHT_CRITICAL,
+};
+
 void initESC();
 void setESCThrottle(int throttlePWM);
 void readESCTelemetry();
@@ -58,6 +68,13 @@ bool hasMotorIDet2Error(uint16_t errorCode);
 bool hasSwHwIncompatError(uint16_t errorCode);
 bool hasBootloaderBadError(uint16_t errorCode);
 
+// ESC LED control
+void requestEscStatusLightMode(EscStatusLightMode mode);
+
+// ESC motor beep
+void queueEscMotorBeepArm();
+void queueEscMotorBeepDisarm();
+
 // for debugging
 void dumpThrottleResponse(const sine_esc_SetThrottleSettings2Response *res);
 void dumpESCMessages();  // dumps all messages to USBSerial

inc/sp140/utilities.h

@@ -1,22 +1,14 @@
-#ifndef INC_SP140_UTILITIES_H_
-#define INC_SP140_UTILITIES_H_
-
-#include <Arduino.h>
-
-// Function to get unique chip ID
-String chipId();
+#ifndef INC_SP140_UTILITIES_H_
+#define INC_SP140_UTILITIES_H_
 
-// Definitions for main rainbow colors in WRGB format for NeoPixel.
-// The 32-bit color value is WRGB. W (White) is ignored for RGB pixels.
-// The next bytes are R (Red), G (Green), and B (Blue).
-// For example, YELLOW is 0x00FFFF00, with FF for Red and Green, and 00 for Blue.
+#include <Arduino.h>
 
-#define LED_RED 0x00FF0000
-#define LED_ORANGE 0x00FF7F00
-#define LED_YELLOW 0x00FFFF00
-#define LED_GREEN 0x0000FF00
-#define LED_BLUE 0x000000FF
-#define LED_INDIGO 0x004B0082
-#define LED_VIOLET 0x008000FF
+// Function to get unique chip ID
+String chipId();
+
+// Controller status LED colors in WRGB format for NeoPixel.
+#define STATUS_LED_RED 0x00FF0000
+#define STATUS_LED_YELLOW 0x00FFFF00
+#define STATUS_LED_GREEN 0x0000FF00
 
 #endif  // INC_SP140_UTILITIES_H_

platformio.ini

@@ -11,6 +11,7 @@
 [platformio]
 lib_dir = libraries
 include_dir = inc
+src_dir = src/sp140
 default_envs =
 	OpenPPG-CESP32S3-CAN-SP140
 
@@ -27,7 +28,6 @@ framework = arduino, espidf
 board_build.f_cpu = 240000000L
 board_build.flash_mode = qio
 board_build.partitions = default_8MB.csv
-custom_src_folder = sp140 ; Used by extra_script.py to rewrite PROJECT_SRC_DIR
 ; If esptool.py complains about missing intelhex, install into the tool package:
 ;   ~/.platformio/penv/bin/python -m pip install intelhex -t ~/.platformio/packages/tool-esptoolpy
 extra_scripts =
@@ -42,6 +42,7 @@ build_flags =
 	-D CORE_DEBUG_LEVEL=2
 	-D CONFIG_ARDUINO_LOOP_STACK_SIZE=8192
 	-Wno-error=format
+	-Wno-error=int-in-bool-context
 	;-D BLE_PAIR_ON_BOOT
 build_type = debug
 debug_speed = 12000
@@ -58,7 +59,7 @@ lib_deps =
 	adafruit/Adafruit CAN@0.2.3
 	adafruit/Adafruit MCP2515@0.2.1
 	https://github.com/rlogiacco/CircularBuffer@1.4.0
-	https://github.com/openppg/SINE-ESC-CAN#8caa93996b5d000fe10ca5265bd1c472dfdf885b
+	https://github.com/openppg/SINE-ESC-CAN#2ab56a4e5b52e4456317c8ee3e3d802b232c6148
 	https://github.com/openppg/ANT-BMS-CAN#fd54852bc6f1c9608e37af9ca7c13ea4135c095b
 	lvgl/lvgl@^9.5.0
 	h2zero/NimBLE-Arduino@^2.3.9
@@ -105,9 +106,9 @@ build_flags =
   -std=c++17
 build_src_filter =
   -<*>
-  +<sp140/lvgl/lvgl_main_screen.cpp>
-  +<sp140/lvgl/lvgl_updates.cpp>
-  +<sp140/lvgl/lvgl_alerts.cpp>
+  +<lvgl/lvgl_main_screen.cpp>
+  +<lvgl/lvgl_updates.cpp>
+  +<lvgl/lvgl_alerts.cpp>
 test_filter = test_screenshots
 lib_deps =
   lvgl/lvgl@^9.5.0

src/sp140/alert_display.cpp

@@ -18,6 +18,7 @@ static std::map<SensorID, AlertLevel> g_currentLevels;
 static AlertCounts g_currentCounts = {0, 0};
 static AlertCounts g_previousCounts = {0, 0};  // Track previous counts for transitions
 static uint32_t g_epoch = 0;
+static AlertCounts g_escBmsCounts = {0, 0};
 
 // Rotation state for display - separate lists for warnings and criticals
 static std::vector<SensorID> g_critList;
@@ -31,6 +32,12 @@ static void alertAggregationTask(void* parameter);
 static void recalcCountsAndPublish();
 static void handleAlertVibration(const AlertCounts& newCounts, const AlertCounts& previousCounts);
 
+static bool isEscOrBmsSensor(SensorID id) {
+  return id >= SensorID::ESC_MOS_Temp && id <= SensorID::BMS_CAN_Init_Failure;
+}
+
+AlertCounts getEscBmsAlertCounts() { return g_escBmsCounts; }
+
 // ------------ Public helpers -------------
 void initAlertDisplay() {
   // Create queues – small, non-blocking
@@ -131,25 +138,33 @@ static void alertAggregationTask(void* parameter) {
 static void recalcCountsAndPublish() {
   AlertCounts counts{0, 0};
   std::vector<SensorID> newCritList;
+  AlertCounts escBmsCounts{0, 0};
   std::vector<SensorID> newWarnList;
   for (const auto& kv : g_currentLevels) {
     switch (kv.second) {
       case AlertLevel::WARN_LOW:
       case AlertLevel::WARN_HIGH:
         newWarnList.push_back(kv.first);
         counts.warningCount++;
+        if (isEscOrBmsSensor(kv.first)) {
+          escBmsCounts.warningCount++;
+        }
         break;
       case AlertLevel::CRIT_LOW:
       case AlertLevel::CRIT_HIGH:
         newCritList.push_back(kv.first);
         counts.criticalCount++;
+        if (isEscOrBmsSensor(kv.first)) {
+          escBmsCounts.criticalCount++;
+        }
         break;
       default:
         break;
     }
   }
 
   // Handle vibration alerts based on count changes
+  g_escBmsCounts = escBmsCounts;
   handleAlertVibration(counts, g_previousCounts);
   g_previousCounts = counts;
 

src/sp140/altimeter.cpp

@@ -16,6 +16,28 @@ struct AltitudeReading {
 // Buffer to store altitude readings with timestamps
 CircularBuffer<AltitudeReading, VARIO_BUFFER_SIZE> altitudeBuffer;
 
+// Cached values — written by the designated I2C reader (uiTask via getAltitude),
+// safe to read from any task (32-bit float reads are atomic on Xtensa).
+static float cachedAltitude = 0.0f;
+static float cachedBaroTemperature = __FLT_MIN__;
+static float cachedVerticalSpeed = 0.0f;
+
+// Recompute vertical speed from the altitude buffer. Must be called from the
+// same task that pushes to altitudeBuffer (uiTask) to avoid CircularBuffer races.
+static float computeVerticalSpeed() {
+  if (altitudeBuffer.size() < 2) {
+    return 0.0f;
+  }
+  const AltitudeReading& oldest = altitudeBuffer.first();
+  const AltitudeReading& newest = altitudeBuffer.last();
+  float timeDiff = (newest.timestamp - oldest.timestamp) / 1000.0f;
+  if (timeDiff <= 0) {
+    return 0.0f;
+  }
+  float verticalSpeed = (newest.altitude - oldest.altitude) / timeDiff;
+  return constrain(verticalSpeed, -MAX_VERTICAL_SPEED, MAX_VERTICAL_SPEED);
+}
+
 float getAltitude(const STR_DEVICE_DATA_140_V1& deviceData) {
   if (bmpPresent && i2cMutex != nullptr) {
     if (xSemaphoreTake(i2cMutex, pdMS_TO_TICKS(20)) == pdTRUE) {
@@ -27,6 +49,10 @@ float getAltitude(const STR_DEVICE_DATA_140_V1& deviceData) {
       AltitudeReading reading = {relativeAltitude, millis()};
       altitudeBuffer.push(reading);
 
+      // Update caches (atomic 32-bit float writes on Xtensa)
+      cachedAltitude = relativeAltitude;
+      cachedVerticalSpeed = computeVerticalSpeed();
+
       return relativeAltitude;
     }
   }
@@ -72,12 +98,18 @@ float getBaroTemperature() {
     if (xSemaphoreTake(i2cMutex, pdMS_TO_TICKS(20)) == pdTRUE) {
       float temp = bmp.readTemperature();
       xSemaphoreGive(i2cMutex);
+      cachedBaroTemperature = temp;  // Update cache for cross-task reads
       return temp;
     }
   }
   return __FLT_MIN__;
 }
 
+// Cached getters — safe to call from any task (atomic float reads on Xtensa).
+float getCachedAltitude() { return cachedAltitude; }
+float getCachedBaroTemperature() { return cachedBaroTemperature; }
+float getCachedVerticalSpeed() { return cachedVerticalSpeed; }
+
 // Get the pressure in hPa
 float getBaroPressure() {
   if (bmpPresent && i2cMutex != nullptr) {
@@ -97,13 +129,37 @@ bool setupAltimeter() {
   // pull down pin 40 to high to set the address
   pinMode(40, OUTPUT);
   digitalWrite(40, HIGH);
-  if (!bmp.begin_I2C(BMP3XX_DEFAULT_ADDRESS, &Wire)) return false;
+
+  // Give the BMP3xx time to finish powering up after cold boot.
+  // Without this, the first begin_I2C() occasionally fails before the
+  // sensor is ready, leaving bmpPresent=false for the whole session and
+  // tripping the Baro_Init_Failure alert.
+  delay(20);
+
+  // Retry a few times — most failures here are transient I2C timing races.
+  const int kInitAttempts = 4;
+  bool ok = false;
+  for (int i = 1; i <= kInitAttempts; i++) {
+    if (bmp.begin_I2C(BMP3XX_DEFAULT_ADDRESS, &Wire)) {
+      ok = true;
+      if (i > 1) {
+        USBSerial.printf("BMP3xx initialized on attempt %d\n", i);
+      }
+      break;
+    }
+    USBSerial.printf("BMP3xx init attempt %d/%d failed\n", i, kInitAttempts);
+    delay(50);
+  }
+  if (!ok) return false;
 
   bmp.setOutputDataRate(BMP3_ODR_25_HZ);
   bmp.setTemperatureOversampling(BMP3_OVERSAMPLING_2X);
   bmp.setPressureOversampling(BMP3_OVERSAMPLING_4X);
   bmp.setIIRFilterCoeff(BMP3_IIR_FILTER_COEFF_15);
   bmp.readPressure();  // throw away first reading
+  // Seed the temperature cache so monitors and telemetry don't see __FLT_MIN__
+  // until the first periodic read populates it.
+  cachedBaroTemperature = bmp.readTemperature();
   bmpPresent = true;
   return true;
 }

src/sp140/buzzer.cpp

@@ -79,7 +79,7 @@ bool playMelody(uint16_t melody[], int siz) {
   MelodyRequest request = {
     .notes = melodyBuffer,
     .size = (uint8_t)std::min(siz, 32),
-    .duration = 100  // Default duration
+    .duration = 200  // Default duration
   };
 
   // Send to queue with timeout