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Fix reconnect bugs, add watchdog & HTTP push OTA #1

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e297dba
Fix reconnect bugs, add watchdog, clean dead code
nuketownada Feb 17, 2026
ad223f8
HTTP push OTA via mDNS
nuketownada Feb 18, 2026
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8 changes: 5 additions & 3 deletions include/config.h
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Original file line number Diff line number Diff line change
Expand Up @@ -38,13 +38,13 @@
// ============================================================================
#define CLIENT_ID "tanksensor"
#define DEVICE_VERSION "v1.0.0"
#define MDNS_HOSTNAME "dusa"
#define OTA_PORT 80

// ============================================================================
// ADC Configuration
// ============================================================================
#define ADC_RESOLUTION 12 // 12-bit ADC (0-4095)
#define ADC_MAX 4095
#define ADC_VREF 3.3f

// ADC reading parameters
#define ADC_SAMPLES 64 // Number of samples to average
Expand All @@ -63,7 +63,6 @@
// ============================================================================
#define READ_INTERVAL_MS 5000 // Read ADC every 5 seconds
#define PUBLISH_INTERVAL_MS 30000 // Publish to MQTT every 30 seconds
#define HEARTBEAT_INTERVAL_MS 60000 // Keepalive every 60 seconds

// Connection timeouts
#define WIFI_CONNECT_TIMEOUT_MS 30000 // WiFi connection timeout
Expand All @@ -74,6 +73,9 @@
#define WIFI_RECONNECT_DELAY_MS 5000 // Delay between WiFi reconnect attempts
#define MQTT_RECONNECT_DELAY_MS 2000 // Delay between MQTT reconnect attempts

// Watchdog
#define WDT_TIMEOUT_S 30 // Hardware watchdog timeout (seconds)

// ============================================================================
// Pin Assignments (XIAO ESP32-S3)
// ============================================================================
Expand Down
76 changes: 67 additions & 9 deletions src/main.cpp
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Original file line number Diff line number Diff line change
Expand Up @@ -15,6 +15,9 @@
#include <WiFiClientSecure.h>
#endif
#include <ESPmDNS.h>
#include <WebServer.h>
#include <Update.h>
#include <esp_task_wdt.h>
#include <PubSubClient.h>
#include <ArduinoJson.h>

Expand All @@ -34,7 +37,6 @@ struct TankConfig {
struct TankState {
int rawADC; // Raw ADC reading
int level; // Level percentage (0-100)
int lastPublishedLevel;
bool registered;
char topicPath[64]; // W/portalId/tank/N path from registration
int deviceInstance;
Expand Down Expand Up @@ -77,6 +79,8 @@ PubSubClient mqttClient(wifiClient);

TankState tankStates[TANK_COUNT];
DeviceState deviceState = STATE_INIT;
WebServer otaServer(OTA_PORT);
bool otaInitialized = false;

char portalId[32] = "";
bool allTanksRegistered = false;
Expand All @@ -86,7 +90,6 @@ IPAddress mqttServerIP;
// Timing
unsigned long lastReadTime = 0;
unsigned long lastPublishTime = 0;
unsigned long lastHeartbeatTime = 0;
unsigned long stateEnteredTime = 0;
unsigned long lastWiFiAttempt = 0;
unsigned long lastMQTTAttempt = 0;
Expand Down Expand Up @@ -278,6 +281,49 @@ bool resolveMqttServer() {
return false;
}

// ============================================================================
// OTA Functions
// ============================================================================

void otaSetup() {
if (otaInitialized) return;

MDNS.begin(MDNS_HOSTNAME);

otaServer.on("/update", HTTP_POST, []() {
bool ok = !Update.hasError();
otaServer.sendHeader("Connection", "close");
otaServer.send(ok ? 200 : 500, "text/plain", ok ? "OK\n" : "FAIL\n");
if (ok) {
delay(500);
ESP.restart();
}
}, []() {
HTTPUpload& upload = otaServer.upload();
if (upload.status == UPLOAD_FILE_START) {
DEBUG_PRINTF("OTA update: %s\n", upload.filename.c_str());
if (!Update.begin(UPDATE_SIZE_UNKNOWN)) {
DEBUG_PRINTF("OTA begin failed: %s\n", Update.errorString());
}
} else if (upload.status == UPLOAD_FILE_WRITE) {
esp_task_wdt_reset();
if (Update.write(upload.buf, upload.currentSize) != upload.currentSize) {
DEBUG_PRINTF("OTA write failed: %s\n", Update.errorString());
}
} else if (upload.status == UPLOAD_FILE_END) {
if (Update.end(true)) {
DEBUG_PRINTF("OTA complete: %u bytes\n", upload.totalSize);
} else {
DEBUG_PRINTF("OTA end failed: %s\n", Update.errorString());
}
}
});

otaServer.begin();
otaInitialized = true;
DEBUG_PRINTF("OTA ready: http://%s.local/update\n", MDNS_HOSTNAME);
}

// ============================================================================
// MQTT Functions
// ============================================================================
Expand Down Expand Up @@ -472,8 +518,6 @@ void publishTankViaProxy(int tankIndex) {

DEBUG_PRINTF("Publishing %s: %s\n", topic, payload);
mqttClient.publish(topic, payload);

state.lastPublishedLevel = state.level;
}

void publishAllTanks() {
Expand Down Expand Up @@ -507,7 +551,8 @@ void runStateMachine() {
case STATE_WIFI_CONNECT:
if (wifiIsConnected()) {
DEBUG_PRINTF("WiFi connected, IP: %s\n", WiFi.localIP().toString().c_str());

otaSetup();

// Resolve MQTT server hostname (supports mDNS .local names)
if (resolveMqttServer()) {
mqttClient.setServer(mqttServerIP, MQTT_PORT);
Expand Down Expand Up @@ -570,12 +615,15 @@ void runStateMachine() {

case STATE_RUNNING:
if (!wifiIsConnected()) {
clearRegistration();
changeState(STATE_WIFI_CONNECT);
break;
}

if (!mqttClient.connected()) {
clearRegistration();
resolveMqttServer();
mqttClient.setServer(mqttServerIP, MQTT_PORT);
changeState(STATE_MQTT_CONNECT);
break;
}
Expand Down Expand Up @@ -679,7 +727,6 @@ void setup() {
for (int i = 0; i < TANK_COUNT; i++) {
tankStates[i].rawADC = 0;
tankStates[i].level = 0;
tankStates[i].lastPublishedLevel = -1;
tankStates[i].registered = false;
tankStates[i].topicPath[0] = '\0';
tankStates[i].deviceInstance = 0;
Expand All @@ -689,13 +736,24 @@ void setup() {
adcSetup();
wifiSetup();
mqttSetup();


// Hardware watchdog — resets device if loop() stalls
esp_task_wdt_config_t wdtConfig = {
.timeout_ms = WDT_TIMEOUT_S * 1000,
.idle_core_mask = 0,
.trigger_panic = true,
};
esp_task_wdt_reconfigure(&wdtConfig);
esp_task_wdt_add(NULL);

DEBUG_PRINTLN("Setup complete, starting state machine");
}

void loop() {
unsigned long now = millis();

esp_task_wdt_reset();
otaServer.handleClient();

// Always process MQTT messages
if (mqttClient.connected()) {
mqttClient.loop();
Expand Down