feat(firmware): show amber on a watchdog trip or heater fault

CHANGELOG.md

@@ -59,6 +59,17 @@ This project did not use formal release tags through most of its history, so thi
 
 ### Changed
 
+- **The status LED shows amber on a firmware hold** (gen2). While a
+  command-watchdog trip or a latched heater fault holds the heaters off, the
+  LED is amber (red 50, green 16) instead of green; red still wins while the
+  e-stop is held, and the LED returns to green once the trip and faults are
+  cleared. It takes the colour from `bsc::StatusLed::stateFor()`. Requires
+  bread-slice-core `^0.2.0` (`firmware/platformio.ini` and `slice.yaml`).
+  The e-stop input keeps the internal pull-up.
+  Host-tested only: the amber value is worked from the WS2812B datasheet and
+  has not been seen on a board. Gen2 flash grows by 40 B and RAM by 1 B;
+  gen1, which has no LED, by 2 B of flash and 1 B of RAM from the core's
+  e-stop input.
 - **The firmware README says which env fits a board** (#32). It links
   the generation-to-env map in `docs/hardware-revisions.md` and says to
   name the env when flashing, since a bare `pio run` builds `gen2_nano`.

firmware/platformio.ini

@@ -15,7 +15,7 @@ lib_deps =
     cameronbrooks11/bread-crumbs-contracts @ ^0.11.1
     br3ttb/PID @ ^1.2.1
     https://github.com/adafruit/MAX6675-library.git
-    cameronbrooks11/bread-slice-core @ ^0.1.0
+    cameronbrooks11/bread-slice-core @ ^0.2.0
 build_flags =
     -DCRUMBS_MAX_HANDLERS=12
     ; override for flashed board address:

firmware/src/main.cpp

@@ -471,14 +471,16 @@ void setupRLHT()
     timing.relay2Start = millis();
 }
 
-// Red while the e-stop is held, green otherwise; StatusLed writes only on a
-// change. Called from loop() only. The boot wait in setup() polls the e-stop
-// too, and when that wrote the LED, its first pass replaced the boot blue
-// within microseconds.
+// Red while the e-stop is held, amber while a command-watchdog trip or a
+// latched heater fault holds the heaters off (the hold relayControlLogic and
+// checkHeaterFaults apply), green otherwise; red wins over amber. StatusLed
+// writes only on a change. Called from loop() only. The boot wait in setup()
+// polls the e-stop too, and when that wrote the LED, its first pass replaced
+// the boot blue within microseconds.
 void updateStatusLed()
 {
 #if RLHT_HAS_STATUS_LED
-    statusLed.set(estopInput.asserted() ? bsc::StatusLed::EStop : bsc::StatusLed::Running);
+    statusLed.set(bsc::StatusLed::stateFor(estopInput.asserted(), commandWatchdog.tripped() || heaterFaults != 0));
 #endif
 }
 

firmware/test/host/Makefile

@@ -36,7 +36,7 @@ FW_SRC   := $(wildcard $(FW)/src/*.cpp) $(PIDLIB)/PID_v1.cpp $(wildcard $(CORE)/
 CRUMBS_OBJ := $(OUT)/crumbs_core.o $(OUT)/crumbs_crc.o $(OUT)/crc8_nibble.o
 # test_status_led runs once per e-stop case (the test target); the others
 # run once.
-SINGLE   := test_dispatch test_estop_hold test_watchdog_trip test_serial_burst test_serial_numbers test_set_pid_length test_setpoint_limits test_heater_faults test_watchdog_lease test_pid_sample test_tc_select
+SINGLE   := test_dispatch test_estop_hold test_watchdog_trip test_serial_burst test_serial_numbers test_set_pid_length test_setpoint_limits test_heater_faults test_watchdog_lease test_pid_sample test_tc_select test_status_led_hold
 TESTS    := $(SINGLE) test_status_led
 
 .PHONY: all test clean check-libdeps FORCE

firmware/test/host/README.md

@@ -47,6 +47,7 @@ the board. `make` exits non-zero if any check fails.
 | `test_tc_select.cpp` | A heater's thermocouple select can't change while it heats in closed loop: SET_TC_SELECT is refused `WRONG_MODE` for that channel and applies the other, resending the select in force is applied, serial `R1TC=` is ignored; with the setpoint at 0 it changes, and the heater restarts on the new sensor with no derivative kick and no P term carried over (#54). The serial status line shows the selected reading in open loop (#28) |
 | `test_set_pid_length.cpp` | SET_PID takes 6 bytes (u8 x10) and 12 bytes (u16 x1000, up to 65.535, `RLHT_CAP_PID_X1000`); 5, 7, 11 and 13 bytes are refused `MALFORMED` and change no gain (#50, bread-crumbs-contracts#64) |
 | `test_status_led.cpp` | Blue through the boot wait, then green or red on the first `loop()` pass, with the e-stop released or held from power-up; no LED driven on gen1 (#46) |
+| `test_status_led_hold.cpp` | Amber while a command-watchdog trip or a latched heater fault holds the heaters off, red over amber while the e-stop is held, amber again on the release while the hold stays latched, and green once it is cleared; no LED driven on gen1 |
 
 ## Writing a test
 

firmware/test/host/test_status_led_hold.cpp

@@ -0,0 +1,108 @@
+// The status LED through a firmware hold: amber while a command-watchdog trip
+// or a latched heater fault holds the heaters off, red over amber while the
+// e-stop is held, amber again on the release while the hold stays latched,
+// and green once it is cleared. Gen1 boards have no LED, and their firmware
+// must never drive one.
+#include "host.h"
+#include "globals.h"
+#include <bread/rlht_ops.h>
+#include <bsc_status_led.h>
+
+void setup();
+void loop();
+
+// The last frame the core's StatusLed sent, in GRB order (BSC_HOST_TEST
+// records it instead of sending it).
+static bool shown(uint8_t g, uint8_t r, uint8_t b)
+{
+    return bsc_host_led_writes > 0 && bsc_host_led_frame[0] == g && bsc_host_led_frame[1] == r &&
+           bsc_host_led_frame[2] == b;
+}
+
+static bool green() { return shown(25, 0, 0); }
+static bool red() { return shown(0, 50, 0); }
+static bool amber() { return shown(16, 50, 0); }
+
+static void arm(uint16_t ms)
+{
+    const uint8_t d[2] = {(uint8_t)(ms & 0xFF), (uint8_t)(ms >> 8)};
+    host_send(RLHT_TYPE_ID, BREAD_OP_SET_WATCHDOG, d, 2);
+    (void)host_read_ack();
+}
+
+static void press()
+{
+    host_estop_level = LOW;
+    loop();
+}
+
+// Past the core's 25 ms release debounce.
+static void release()
+{
+    host_estop_level = HIGH;
+    loop();
+    host_now += 30;
+    loop();
+    loop();
+}
+
+static void check(const char *what, bool led_ok)
+{
+#if RLHT_HAS_STATUS_LED
+    host_check(what, led_ok);
+#else
+    (void)what;
+    (void)led_ok;
+#endif
+}
+
+int main()
+{
+    host_estop_level = HIGH;
+    host_tc1_celsius = 25.0f;
+    host_tc2_celsius = 25.0f;
+    setup();
+    loop();
+    check("running shows green", green());
+
+    // ---- A command-watchdog trip.
+    arm(100);
+    host_now += 100;
+    loop(); // trips
+    loop(); // shows it
+    check("a watchdog trip shows amber", commandWatchdog.tripped() && amber());
+    press();
+    check("an e-stop over a watchdog trip shows red", red());
+    release();
+    check("the release with the trip latched shows amber", commandWatchdog.tripped() && amber());
+    arm(0);
+    host_send(RLHT_TYPE_ID, BREAD_OP_CLEAR_WATCHDOG_TRIP, nullptr, 0);
+    (void)host_read_ack();
+    loop();
+    check("clearing the trip shows green", !commandWatchdog.tripped() && green());
+
+    // ---- A latched heater fault (an over-temperature, which latches in
+    // either mode).
+    host_tc1_celsius = RLHT_OVERTEMP_C + 5.0f;
+    for (int i = 0; i < RLHT_OVERTEMP_READS; i++)
+    {
+        host_now += THERMO_UPDATE_TIME_MS;
+        loop();
+    }
+    loop();
+    check("a latched heater fault shows amber", heaterFaults != 0 && amber());
+    press();
+    check("an e-stop over a latched fault shows red", red());
+    release();
+    check("the release with the fault latched shows amber", heaterFaults != 0 && amber());
+    host_tc1_celsius = 25.0f;
+    host_send(RLHT_TYPE_ID, BREAD_OP_CLEAR_FAULTS, nullptr, 0);
+    (void)host_read_ack();
+    loop();
+    check("clearing the fault shows green", heaterFaults == 0 && green());
+
+#if !RLHT_HAS_STATUS_LED
+    host_check("no LED is driven on a board without one", bsc_host_led_writes == 0);
+#endif
+    return host_finish();
+}

slice.yaml

@@ -107,7 +107,7 @@ firmware:
     - "gen1_nanoevery"
     - "gen2_nanoevery"
   lib_deps:
-    - "cameronbrooks11/bread-slice-core @ ^0.1.0"
+    - "cameronbrooks11/bread-slice-core @ ^0.2.0"
     - "cameronbrooks11/CRUMBS @ ^0.17.0"
     - "cameronbrooks11/bread-crumbs-contracts @ ^0.11.1"
     - "br3ttb/PID @ ^1.2.1"