Add ESC LED control and motor beep for arm/disarm

- Update SINE-ESC-CAN library to v0.0.4 (led-control branch) which adds
  SetLedControl (Data ID 218) and includes SetMotorSound (Data ID 214)
- Add setMotorSound() to SineEsc class to wire up motor beep protocol
- Add ESC LED aviation strobe pattern (red/green double pulse)
- Add motor beep on arm (ascending tone) and disarm (descending tone)
  matching the hand controller buzzer cadence
- Rename LED_RED/GREEN/YELLOW macros to NEOPIXEL_* to avoid collision
  with SineEsc::LedPattern enum

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

Author: PaulDWhite

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/esc.h

@@ -58,6 +58,15 @@ bool hasMotorIDet2Error(uint16_t errorCode);
 bool hasSwHwIncompatError(uint16_t errorCode);
 bool hasBootloaderBadError(uint16_t errorCode);
 
+// ESC LED control
+void setESCLedControl(const uint16_t *ledData, uint8_t ledNum);
+void startESCLedStrobeTest();
+
+// ESC motor beep
+void setESCMotorSound(const uint8_t *beepData, uint8_t beepDataLen, uint8_t beepNum);
+void escMotorBeepArm();
+void escMotorBeepDisarm();
+
 // for debugging
 void dumpThrottleResponse(const sine_esc_SetThrottleSettings2Response *res);
 void dumpESCMessages();  // dumps all messages to USBSerial

inc/sp140/utilities.h

@@ -1,22 +1,22 @@
-#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_
+
+#include <Arduino.h>
+
+// Function to get unique chip ID
+String chipId();
 
 // 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.
 
-#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
+#define NEOPIXEL_RED 0x00FF0000
+#define NEOPIXEL_ORANGE 0x00FF7F00
+#define NEOPIXEL_YELLOW 0x00FFFF00
+#define NEOPIXEL_GREEN 0x0000FF00
+#define NEOPIXEL_BLUE 0x000000FF
+#define NEOPIXEL_INDIGO 0x004B0082
+#define NEOPIXEL_VIOLET 0x008000FF
 
 #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
 
@@ -42,6 +43,7 @@ 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 +60,7 @@ 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#03045012a838c566b34bc0ae00cef457dd6d04d2
 	https://github.com/openppg/ANT-BMS-CAN#fd54852bc6f1c9608e37af9ca7c13ea4135c095b
 	lvgl/lvgl@^9.5.0
 	h2zero/NimBLE-Arduino@^2.3.9
@@ -105,9 +107,9 @@ 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/esc.cpp

@@ -258,6 +258,93 @@ bool setupTWAI() {
   return true;
 }
 
+/**
+ * Send an LED control sequence to the ESC
+ * @param ledData Array of packed LED entries (use SineEsc::makeLedControlEntry)
+ * @param ledNum Number of entries (max 10)
+ */
+void setESCLedControl(const uint16_t *ledData, uint8_t ledNum) {
+  if (!escTwaiInitialized) return;
+  esc.setLedControl(ledData, ledNum);
+}
+
+/**
+ * Send a motor beep sequence to the ESC
+ * @param beepData Raw byte array of 3-byte entries (tone, duration_10ms, volume)
+ * @param beepDataLen Length of beepData in bytes (entries * 3)
+ * @param beepNum Number of beep entries
+ */
+void setESCMotorSound(const uint8_t *beepData, uint8_t beepDataLen, uint8_t beepNum) {
+  if (!escTwaiInitialized) return;
+  esc.setMotorSound(beepData, beepDataLen, beepNum);
+}
+
+// Helper to pack a beep entry into 3 bytes in a buffer
+// tone: 0-9, duration: in 10ms units, volume: 0-100
+static void packBeepEntry(uint8_t *buf, uint8_t tone, uint8_t duration10ms, uint8_t volume) {
+  buf[0] = tone;
+  buf[1] = duration10ms;
+  buf[2] = volume;
+}
+
+/**
+ * Play ascending arm beep on ESC motor (matches hand controller: C7 -> E7)
+ * Uses two tones at 100ms each, ascending pitch
+ */
+void escMotorBeepArm() {
+  uint8_t beepData[6];
+  packBeepEntry(&beepData[0], 3, 10, 50);  // lower tone, 100ms, 50% vol
+  packBeepEntry(&beepData[3], 6, 10, 50);  // higher tone, 100ms, 50% vol
+  setESCMotorSound(beepData, 6, 2);
+  USBSerial.println("ESC: arm beep sent");
+}
+
+/**
+ * Play descending disarm beep on ESC motor (matches hand controller: E7 -> C7)
+ * Uses two tones at 100ms each, descending pitch
+ */
+void escMotorBeepDisarm() {
+  uint8_t beepData[6];
+  packBeepEntry(&beepData[0], 6, 10, 50);  // higher tone, 100ms, 50% vol
+  packBeepEntry(&beepData[3], 3, 10, 50);  // lower tone, 100ms, 50% vol
+  setESCMotorSound(beepData, 6, 2);
+  USBSerial.println("ESC: disarm beep sent");
+}
+
+// FreeRTOS task: aviation strobe pattern
+// Quick red pulse, quick green pulse, then off for ~1.5s, repeat
+static void escLedStrobeTask(void *pvParameters) {
+  // Wait for ESC connection before starting
+  vTaskDelay(pdMS_TO_TICKS(3000));
+
+  const uint16_t pattern[] = {
+    SineEsc::makeLedControlEntry(SineEsc::LED_RED, 1),    // red flash 50ms
+    SineEsc::makeLedControlEntry(SineEsc::LED_OFF, 2),    // gap 100ms
+    SineEsc::makeLedControlEntry(SineEsc::LED_GREEN, 1),  // green flash 50ms
+    SineEsc::makeLedControlEntry(SineEsc::LED_OFF, 30),   // off 1500ms
+  };
+
+  USBSerial.println("ESC LED aviation strobe started");
+
+  for (;;) {
+    setESCLedControl(pattern, 4);
+    USBSerial.println("ESC LED: sent aviation strobe");
+    // Wait for full cycle (50 + 100 + 50 + 1500 = 1700ms) before resending
+    vTaskDelay(pdMS_TO_TICKS(1700));
+  }
+}
+
+static TaskHandle_t escLedStrobeTaskHandle = NULL;
+
+/**
+ * Start the ESC LED strobe test pattern
+ * Creates a FreeRTOS task that repeatedly sends the strobe sequence
+ */
+void startESCLedStrobeTest() {
+  if (escLedStrobeTaskHandle != NULL) return;  // already running
+  xTaskCreate(escLedStrobeTask, "ESCLedTest", 2048, NULL, 1, &escLedStrobeTaskHandle);
+}
+
 /**
  * Debug function to dump ESC throttle response data to serial
  * @param res Pointer to the throttle response structure from ESC

src/sp140/main.cpp

@@ -107,7 +107,7 @@ UnifiedBatteryData unifiedBatteryData = {0.0f, 0.0f, 0.0f, 0.0f};  // volts, amp
 // Throttle PWM smoothing buffer is managed in throttle.cpp
 
 Adafruit_NeoPixel pixels(1, 21, NEO_GRB + NEO_KHZ800);
-uint32_t led_color = LED_RED;  // current LED color
+uint32_t led_color = NEOPIXEL_RED;  // current LED color
 
 // Global variable for device state
 volatile DeviceState currentState = DISARMED;
@@ -735,7 +735,7 @@ void setup() {
     initVibeMotor();
   }
 
-  setLEDColor(LED_YELLOW);  // Indicate boot in progress
+  setLEDColor(NEOPIXEL_YELLOW);  // Indicate boot in progress
 
   // SPI bus (shared between display and BMS CAN)
   setupSPI(board_config);
@@ -766,7 +766,7 @@ void setup() {
     perfModeSwitch();
   }
 
-  setLEDColor(LED_GREEN);
+  setLEDColor(NEOPIXEL_GREEN);
 
   // Show splash screen (blocking)
   if (xSemaphoreTake(lvglMutex, portMAX_DELAY) == pdTRUE) {
@@ -815,6 +815,9 @@ void setup() {
   // =========================================================================
   setupTasks();
 
+  // Start ESC LED strobe test
+  startESCLedStrobeTest();
+
   // =========================================================================
   // PHASE 7: Start External Interfaces
   // =========================================================================
@@ -968,6 +971,7 @@ void resumeLEDTask() {
 void runDisarmAlert() {
   u_int16_t disarm_melody[] = {2637, 2093};
   playMelody(disarm_melody, 2);
+  escMotorBeepDisarm();
   pulseVibeMotor();
 }
 
@@ -1204,6 +1208,7 @@ bool armSystem() {
   vTaskSuspend(blinkLEDTaskHandle);
   setLEDs(HIGH);  // solid LED while armed
   playMelody(arm_melody, 2);
+  escMotorBeepArm();
   // runVibePattern(arm_vibes, 7);
   pulseVibeMotor();  // Ensure this is the active call
   return true;