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@tipih tipih released this 09 Jan 08:01
· 73 commits to main since this release
v1.0.0
d4f72a4

Changelog

All notable changes to the 12V Battery Monitor project.

[v1.0.0] - 2026-01-09

Added

  • OTA support (ArduinoOTA) and a PlatformIO OTA environment (firebeatleV2_ota) for in-network firmware uploads.
  • BLE textual commands SET_CAP and SET_BASE with a read/notify chCapacity characteristic and queued, safe processing.
  • MQTT telemetry improvements: ah_left field, Home Assistant discovery payloads (retained), and retained device IP publish to simplify OTA targeting.
  • Runtime persistence for battery capacity and Rint baseline via NVS (battery_capacity_Ah, rintBase_mR).
  • Rint learner improvements and SOC blending (OCV + coulomb) for more accurate ah_left and SOH estimation.

Fixed

  • Resolved KEY_TOO_LONG NVS failures by shortening keys and centralizing persistence.
  • Prevented NimBLE blocking by moving heavy NVS and restart operations out of BLE callbacks.
  • Various build and stability fixes across BLE, telemetry, and learner code.

Notes

  • See the detailed Unreleased entries below for file-level changes and technical details.

[2026-01-08] - 2026-01-08

Added

  • BLE textual commands SET_CAP and SET_BASE (queued, processed in main loop) to set runtime battery capacity (Ah) and Rint baseline (mΩ); NVS_TEST probe command for verifying NVS writes.
  • BLE characteristics: chCapacity (battery capacity), chStatus (headless status notifications), and chAhLeft (remaining Ah) with read/notify support.
  • BatteryConfig helper and short NVS keys (bat_cap, bat_cap2) to robustly persist battery capacity and avoid KEY_TOO_LONG errors.
  • Ah-left telemetry field (ah_left) included in telemetry JSON, exposed over BLE and published via MQTT; Home Assistant discovery config for Battery Ah Left (two-decimal formatting, unit Ah).
  • Adaptive complementary SOC filter that blends coulomb-counted SOC and OCV-derived SOC based on rest time; blended SOC used for Ah-left calculation and persisted when corrected.
  • Advertising watchdog and BLE stability improvements (move heavy NVS/restart ops out of NimBLE callbacks, queue commands).

Changed

  • Telemetry now includes ah_left and uses blended SOC for publish and snapshot paths.
  • MQTT Home Assistant discovery refreshed on reconnect and now includes the Ah_left sensor discovery payload.

Fixed

  • Fixed KEY_TOO_LONG NVS failures by shortening keys and centralizing persistence.
  • Prevented NimBLE blocking by enqueuing writes and processing heavy commands from the main loop.

Files touched (high level)

  • src/main.cpp, src/comms/ble_mgr.*, src/telemetry_payload.*, src/app_config.*, src/learner/*, CHANGELOG.md, platformio.ini

[2026-01-07] - 2026-01-07

Added

  • Home Assistant MQTT Discovery: publish retained discovery payloads so Home Assistant auto-discovers sensors (Toyota_batt_sensor discovery id).
  • BLE commands SET_CAP and SET_BASE to set runtime battery capacity (Ah) and Rint baseline (mΩ) and persist to NVS.
  • BLE characteristic exposing runtime battery capacity (read/notify).

Changed

  • Queued BLE command processing: BLE writes now enqueue commands; heavy ops (NVM writes, restart) are processed from main loop to avoid blocking NimBLE.
  • Rint learner ingestion guarded: skip ingestion when |I| > RINT_INGEST_MAX_I_A and filter extreme Rint values > RINT_MAX_VALID_MOHM in telemetry.
  • Rest accumulator robustness: added REST_RESET_GRACE_SEC so brief current spikes don't immediately clear rest accumulation.
  • Home Assistant discovery unique_id base set to Toyota_batt_sensor (while preserving MQTT_CLIENT_ID in device identifiers).

Fixed

  • Removed invalid telemetry initializer causing a compile error (hasRintBaseline).

  • Fixed compile errors by forward-declaring extern MqttMgr mqtt for discovery publisher and other small fixes.

  • NVS / BLE fixes: Resolved KEY_TOO_LONG NVS failures for battery capacity by shortening keys and centralizing persistence in BatteryConfig; SET_CAP now persists. Moved heavy NVS work out of NimBLE callbacks, added chCapacity and chStatus BLE characteristics, a NVS_TEST probe, an advertising watchdog, and wrapped recent debug prints behind ENABLE_DEBUG_SERIAL.

Docs / Tools

  • Added ArduinoOTA integration and PlatformIO OTA environment; publish retained device IP to <MQTT_TOPIC>/ip to simplify OTA targeting.
  • Updated README and added secrets.example.h and CHANGELOG updates.

Notes

  • Key files changed: src/main.cpp, src/app_config.h, src/telemetry_payload.*, src/comms/ble_mgr.*, src/learner/rint_learner.h, platformio.ini, secrets.example.h, README and CHANGELOG.

[Unreleased] - 2025-12-14

Added

  • BLE Command Interface: Added command characteristic for remote device control via Bluetooth
    • CLEAR_NVM command: Clears all non-volatile memory (battmon and hall namespaces)
    • RESET command: Restarts the device
    • CLEAR_RESET command: Clears NVM then restarts (factory reset)
    • Command characteristic UUID: a94f0006-12d3-11ee-be56-0242ac120002
    • Command callbacks with response notifications (NVM_CLEARED, RESETTING, etc.)
    • Serial logging for all command operations

Changed

  • Deep Sleep Timing - Optimized for production use:

    • PARKED_WAKE_INTERVAL_US: Changed from 3 minutes to 5 minutes (300 seconds)
    • PARKED_IDLE_MAX_MS: Changed from 60 minutes to 20 minutes before deep sleep
    • PARKED_IDLE_ENTRY_DWELL_SEC: Changed from 5 minutes to 2 minutes to enter idle state

  • Battery Configuration - LTX9-4 Motorcycle Support:

    • BATTERY_CAPACITY_AH: Changed from 70.0Ah to 8.0Ah (later adjusted to 9.0Ah)
    • INITIAL_BASELINE_mOHM: Changed from 10.0mΩ to 35.0mΩ (correct baseline for LTX9-4)

  • Rint Learner Improvements - Enhanced step detection reliability:

    • STEP_WINDOW_MS: Increased from 120ms to 1000ms (2x sampling interval for better detection)
    • SCAN_BACK_MS: Increased from 800ms to 2000ms (extended lookback window)
    • Minimum sample requirement: Reduced from 4 to 3 samples per window (line 222)
    • Better accommodates 500ms sampling rate in active mode

Fixed

  • SOH Calculation: Corrected unrealistic State of Health readings

    • Previous: 21-31% (due to incorrect 10mΩ baseline for 8Ah battery)
    • Current: 75-100% (with proper 35mΩ baseline for LTX9-4)

  • Rint Step Detection: Resolved "step_rejected: few_samples" issues

    • Widened detection window to match actual sampling rate
    • Reduced minimum sample requirements for faster detection
    • Improved stability with load step transitions

Technical Details

  • Files Modified:
    • src/app_config.h: Battery capacity and baseline configuration
    • src/learner/rint_learner.h: Step detection timing parameters
    • src/comms/ble_mgr.h: Added command characteristic handle
    • src/comms/ble_mgr.cpp: Implemented CommandCallbacks class with NVM clear and reset functionality
    • src/main.cpp: Added debug output for Rint calculations (lines 312-318)

Notes

  • BLE commands can be sent via nRF Connect or LightBlue apps
  • HEX format commands:
    • CLEAR_NVM: 434C4541525F4E564D
    • RESET: 5245534554
    • CLEAR_RESET: 434C4541525F5245534554
  • Factory reset clears learned Rint baseline and Hall sensor calibration
  • New baseline will be established after 10+ minutes of load step observations

[Unreleased] - 2026-01-02

Added

  • SET_CAP / SET_BASE BLE commands: Added textual BLE commands to set runtime configuration:
    • SET_CAP:12.5, SET_CAP 12.5, SET_CAP=12.5 — set runtime battery capacity (Ah) and persist to NVS (battery_capacity_Ah).
    • SET_BASE:35.0, SET_BASELINE=35.0 — set Rint baseline (mΩ) and persist (rintBase_mR).
  • Battery capacity BLE characteristic: Added chCapacity read/notify characteristic exposing the runtime batteryCapacityAh value (UUID: a94f0009-12d3-11ee-be56-0242ac120002).
  • Runtime persistence API: loadBatteryCapacityFromPrefs() and setBatteryCapacityAh() added to src/app_config.* to load and persist capacity.
  • Rint learner API: Added RintLearner::setBaseline(float mOhm) and an extern RintLearner learner to allow BLE-initiated baseline changes.

Changed

  • Queued BLE command processing: BLE write callbacks now enqueue commands only; heavy operations (Preferences clear, restart, NVM writes) are executed in BleMgr::process() called from the main loop to avoid blocking NimBLE.
  • Case-insensitive BLE parsing: Command parsing made case-insensitive so variants like set_cap or Set_Base are accepted.
  • NVS safety: Preference reads now check isKey() before getFloat() to suppress noisy NOT_FOUND logs when keys are absent.
  • MQTT notifications: When capacity or baseline are changed via BLE, the firmware publishes retained JSON messages to the configured MQTT_TOPIC so remote listeners receive the latest values immediately.
  • Main loop integration: loadBatteryCapacityFromPrefs() is called from setup() and main.cpp now calls ble.process() after BLE updates so queued commands are executed.

Fixed

  • NimBLE blocking & stability: Removed blocking NVM and restart operations from NimBLE callbacks to prevent BLE stack issues.
  • Build errors: Fixed callback construction compile errors by passing BleMgr* into CommandCallbacks and updating callback code accordingly.

Technical Details / Files Modified

  • src/comms/ble_mgr.h — added PendingCommand entries, enqueueCommand(), process() and chCapacity handle.
  • src/comms/ble_mgr.cpp — parsing for SET_CAP / SET_BASE, case-insensitive parsing, CommandCallbacks now enqueues commands, added chCapacity characteristic and notify support, publishes retained MQTT messages on config changes.
  • src/app_config.h / src/app_config.cpp — added batteryCapacityAh, loadBatteryCapacityFromPrefs(), setBatteryCapacityAh() and guarded NVS reads.
  • src/learner/rint_learner.h — added setBaseline() and extern learner for external baseline control.
  • src/main.cpp — call loadBatteryCapacityFromPrefs() in setup() and ble.process() in the main update loop; use runtime batteryCapacityAh where applicable.

[Unreleased] - 2026-01-03

Added

  • OTA (ArduinoOTA) support: Added ArduinoOTA initialization and handlers; OTA is initialized when Wi‑Fi connects and on reconnects. Optional password support via OTA_PASSWORD is supported.
  • PlatformIO OTA environment: Added firebeatleV2_ota env to platformio.ini for espota uploads; includes instructions in README for CLI and VS Code uploads.
  • Retained MQTT IP publish: Device now publishes its IPv4 address as a retained message to <MQTT_TOPIC>/ip on connect/reconnect to help locate OTA target.

Changed

  • Documentation: Updated README.md and src/README.md with OTA usage instructions and power/prototyping guidance; added secrets.example.h with OTA password examples.

Files Modified / Added

  • src/main.cpp — added ArduinoOTA setup (handlers, begin) and ArduinoOTA.handle() in loop(); initialize OTA on reconnect and publish retained IP on connect.
  • platformio.ini — added env:firebeatleV2_ota configured for espota uploads.
  • secrets.example.h — added OTA password examples and guidance.
  • README.md / src/README.md — added OTA instructions and prototyping power notes.

Changelog

All notable changes to the 12V Battery Monitor project.

[Unreleased] - 2025-12-14

Added

  • BLE Command Interface: Added command characteristic for remote device control via Bluetooth
    • CLEAR_NVM command: Clears all non-volatile memory (battmon and hall namespaces)
    • RESET command: Restarts the device
    • CLEAR_RESET command: Clears NVM then restarts (factory reset)
    • Command characteristic UUID: a94f0006-12d3-11ee-be56-0242ac120002
    • Command callbacks with response notifications (NVM_CLEARED, RESETTING, etc.)
    • Serial logging for all command operations

Changed

  • Deep Sleep Timing - Optimized for production use:

    • PARKED_WAKE_INTERVAL_US: Changed from 3 minutes to 5 minutes (300 seconds)
    • PARKED_IDLE_MAX_MS: Changed from 60 minutes to 20 minutes before deep sleep
    • PARKED_IDLE_ENTRY_DWELL_SEC: Changed from 5 minutes to 2 minutes to enter idle state

  • Battery Configuration - LTX9-4 Motorcycle Battery Support:

    • BATTERY_CAPACITY_AH: Changed from 70.0Ah to 8.0Ah (later adjusted to 9.0Ah)
    • INITIAL_BASELINE_mOHM: Changed from 10.0mΩ to 35.0mΩ (correct baseline for LTX9-4)

  • Rint Learner Improvements - Enhanced step detection reliability:

    • STEP_WINDOW_MS: Increased from 120ms to 1000ms (2x sampling interval for better detection)
    • SCAN_BACK_MS: Increased from 800ms to 2000ms (extended lookback window)
    • Minimum sample requirement: Reduced from 4 to 3 samples per window (line 222)
    • Better accommodates 500ms sampling rate in active mode

Fixed

  • SOH Calculation: Corrected unrealistic State of Health readings

    • Previous: 21-31% (due to incorrect 10mΩ baseline for 8Ah battery)
    • Current: 75-100% (with proper 35mΩ baseline for LTX9-4)

  • Rint Step Detection: Resolved "step_rejected: few_samples" issues

    • Widened detection window to match actual sampling rate
    • Reduced minimum sample requirements for faster detection
    • Improved stability with load step transitions

Technical Details

  • Files Modified:
    • src/app_config.h: Battery capacity and baseline configuration
    • src/learner/rint_learner.h: Step detection timing parameters
    • src/comms/ble_mgr.h: Added command characteristic handle
    • src/comms/ble_mgr.cpp: Implemented CommandCallbacks class with NVM clear and reset functionality
    • src/main.cpp: Added debug output for Rint calculations (lines 312-318)

Notes

  • BLE commands can be sent via nRF Connect or LightBlue apps
  • HEX format commands:
    • CLEAR_NVM: 434C4541525F4E564D
    • RESET: 5245534554
    • CLEAR_RESET: 434C4541525F5245534554
  • Factory reset clears learned Rint baseline and Hall sensor calibration
  • New baseline will be established after 10+ minutes of load step observations
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