Add software LiPo UV protection with energy-save boot.

Detect under-voltage on GPIO1/11, persist UV state in NVS, enter a minimal power mode without ESP-NOW, and recover after charge; expose LED mode 6 battery-low for host testing via goTool. Co-authored-by: Cursor <cursoragent@cursor.com>
2026-06-23 18:22:52 +02:00
parent be18b758ed
commit f006f8b912
26 changed files with 418 additions and 37 deletions
@@ -0,0 +1,130 @@
+#include "battery_uv.h"
+
+#if POWERPOD_BATTERY_UV_ENABLE
+
+#include "led_ring.h"
+#include "pod_reboot.h"
+#include "pod_settings.h"
+#include "esp_log.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+
+static const char *TAG = "[BATTERY_UV]";
+
+#define UV_DEBOUNCE_SAMPLES 2u
+#define UV_POLL_INTERVAL_MS 30000u
+
+static uint8_t s_uv_streak;
+static uint8_t s_charge_streak;
+
+bool battery_uv_is_latched(void) { return pod_settings_is_uv_latched(); }
+
+bool battery_uv_reading_is_under(const board_lipo_reading_t *reading) {
+  if (reading == NULL) {
+    return false;
+  }
+
+  if (reading->lipo1_valid && reading->lipo1_mv < BATTERY_UV_ADC_MV) {
+    return true;
+  }
+  if (reading->lipo2_valid && reading->lipo2_mv < BATTERY_UV_ADC_MV) {
+    return true;
+  }
+  return false;
+}
+
+bool battery_uv_reading_is_charged(const board_lipo_reading_t *reading) {
+  if (reading == NULL) {
+    return false;
+  }
+
+  bool any_valid = false;
+  if (reading->lipo1_valid) {
+    any_valid = true;
+    if (reading->lipo1_mv < BATTERY_CHARGE_ADC_MV) {
+      return false;
+    }
+  }
+  if (reading->lipo2_valid) {
+    any_valid = true;
+    if (reading->lipo2_mv < BATTERY_CHARGE_ADC_MV) {
+      return false;
+    }
+  }
+  return any_valid;
+}
+
+bool battery_uv_evaluate_boot(void) {
+  board_lipo_reading_t reading;
+  board_input_read_lipo(&reading);
+
+  if (pod_settings_is_uv_latched() && battery_uv_reading_is_charged(&reading)) {
+    ESP_LOGI(TAG, "charged — clearing UV latch");
+    pod_settings_clear_uv_latched();
+    return false;
+  }
+
+  if (pod_settings_is_uv_latched() || battery_uv_reading_is_under(&reading)) {
+    if (!pod_settings_is_uv_latched()) {
+      ESP_LOGW(TAG, "under-voltage at boot — latching UV");
+    } else {
+      ESP_LOGW(TAG, "UV latched — energy-save boot");
+    }
+    pod_settings_set_uv_latched(true);
+    return true;
+  }
+
+  return false;
+}
+
+void battery_uv_poll(const board_lipo_reading_t *reading) {
+  if (reading == NULL || pod_settings_is_uv_latched()) {
+    return;
+  }
+
+  if (battery_uv_reading_is_under(reading)) {
+    s_uv_streak++;
+    ESP_LOGW(TAG, "under-voltage sample %u/%u", (unsigned)s_uv_streak,
+             (unsigned)UV_DEBOUNCE_SAMPLES);
+    if (s_uv_streak >= UV_DEBOUNCE_SAMPLES) {
+      ESP_LOGW(TAG, "UV confirmed — latching and restarting");
+      pod_settings_set_uv_latched(true);
+      pod_schedule_restart();
+    }
+    return;
+  }
+
+  s_uv_streak = 0;
+}
+
+void battery_uv_run_mode(void) {
+  s_charge_streak = 0;
+  s_uv_streak = 0;
+
+  led_ring_init();
+  led_ring_show_battery_low();
+
+  ESP_LOGW(TAG, "energy-save mode — ADC poll every %u ms", UV_POLL_INTERVAL_MS);
+
+  while (1) {
+    board_lipo_reading_t reading;
+    board_input_read_lipo(&reading);
+
+    if (battery_uv_reading_is_charged(&reading)) {
+      s_charge_streak++;
+      ESP_LOGI(TAG, "charge sample %u/%u", (unsigned)s_charge_streak,
+               (unsigned)UV_DEBOUNCE_SAMPLES);
+      if (s_charge_streak >= UV_DEBOUNCE_SAMPLES) {
+        ESP_LOGI(TAG, "charged — clearing UV latch and restarting");
+        pod_settings_clear_uv_latched();
+        pod_schedule_restart();
+      }
+    } else {
+      s_charge_streak = 0;
+    }
+
+    vTaskDelay(pdMS_TO_TICKS(UV_POLL_INTERVAL_MS));
+  }
+}
+
+#endif