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ClearGrow Agent bcc25e8ae1

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fix: CG-51 add WiFi event handler stack monitoring and document coexistence

- Add stack high-water mark logging to WiFi/IP event handlers (DEBUG level)
- Document coexistence findings: BLE not used, Thread uses external RCP
- Document event handler stack safety: ~1200-1500 bytes worst case,
  3584 bytes available (>50% margin)
- Clarify wifi_manager uses event-driven pattern (no dedicated task)

Stack monitoring:
- log_event_handler_stack() called after disconnect and got_ip handling
- Rate-limited to avoid spam (30s interval)
- Warns if usage exceeds 70% of event loop stack

Analysis (CG-51):
- Coexistence NOT required: provisioning uses SoftAP, not BLE
- Event handler stack is safe with >50% margin
- Current event-driven architecture is appropriate

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

2025-12-11 09:48:53 -07:00

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ClearGrow Controller Firmware

ESP32-S3 gateway with 4.3" touchscreen, Thread Border Router, and WiFi.

Commands

# Setup
source ~/esp/esp-idf/export.sh
cd /opt/repos/controller

# Build and flash
idf.py build
idf.py -p /dev/ttyUSB0 flash monitor

# Production build (with security)
idf.py -D SDKCONFIG_DEFAULTS="sdkconfig.defaults;sdkconfig.defaults.prod" build

# Other
idf.py fullclean        # Clean build
idf.py menuconfig       # Configuration
idf.py size-components  # Size analysis

Code Style

C11 with snake_case functions, SCREAMING_SNAKE constants
Include guards (#ifndef), not #pragma once
Logging: ESP_LOGI(TAG, "msg"), ESP_LOGW(), ESP_LOGE()
Errors: Always check return values, use ESP_ERROR_CHECK() for fatal, ESP_RETURN_ON_ERROR() for recoverable

Critical Rules

NEVER call vTaskStartScheduler() - scheduler already running when app_main() is called

NEVER call lv_timer_handler() directly - handled by esp_lvgl_port

LVGL version is 8.x - NOT 9.x! APIs differ significantly

Memory allocation:

>4KB buffers → heap_caps_malloc(size, MALLOC_CAP_SPIRAM)
DMA buffers → heap_caps_malloc(size, MALLOC_CAP_DMA) (MUST be internal SRAM)
Performance-critical → heap_caps_malloc(size, MALLOC_CAP_INTERNAL)

Architecture

Core 0: WiFi, Thread BR, MQTT, REST API
Core 1: LVGL UI, Sensor Hub, Automation
Entry: app_main() in main/app_main.c

Key Components

Component	Purpose
`ui/`	LVGL screens (see `ui/CLAUDE.md`)
`display/`	LCD driver, GT911 touch
`sensor_hub/`	CoAP probe data aggregation
`thread_manager/`	OpenThread Border Router
`wifi_manager/`	WiFi state machine (event-driven, no dedicated task)
`settings/`	NVS configuration
`automation/`	Alert rules, webhooks
`network_api/`	REST API, MQTT
`ota_manager/`	Firmware updates

Thread/OpenThread Version Requirements

Component	Version	Notes
ESP-IDF	>=5.2.0	Required for Thread 1.3 support
OpenThread	Thread 1.3	Bundled with ESP-IDF component
RCP Firmware	>=1.3.0	nRF52840 probe firmware

The controller verifies RCP firmware version at initialization. Incompatible versions will prevent Thread network startup with ESP_ERR_NOT_SUPPORTED.

Version constants defined in components/thread_manager/include/thread_br.h:

THREAD_RCP_MIN_VERSION: Minimum version string ("1.3.0")
THREAD_RCP_MIN_VERSION_MAJOR/MINOR/PATCH: Numeric version components

Hardware

Display: 800x480 RGB LCD, 16bpp
Touch: GT911 capacitive (I2C)
Memory: 512KB SRAM, 8MB PSRAM, 16MB Flash
Pinout: See main/pin_config.h

Testing

# Unit tests (host-based)
cd test && idf.py build && ./build/test_app

# On device
idf.py flash monitor

Documentation

Full technical docs: /opt/repos/docs/reference/firmware/controller/

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