led-sync-studio/.planning/phases/01-esp32-firmware/01-04-SUMMARY.md

---
phase: 01-esp32-firmware
plan: 04
subsystem: firmware
tags: [esp32, arduino, freertos, udp, led, rmt, spi, ws2801, sk6812]

requires:
  - phase: 01-01
    provides: LED strip drivers (initStrips, WS2801 SPI + SK6812 RMT)
  - phase: 01-02
    provides: UDP server (startUdpServer, LedCommand queue, JSON parsing)
  - phase: 01-03
    provides: Animation engine (initAnimationEngine, 8 animations, ZoneState)

provides:
  - Complete integrated firmware: all subsystems wired in main.cpp setup() and loop()
  - docs/protocol.md: Phase 2 Pi-side integration contract (UDP/JSON API reference)
  - Production FreeRTOS task launch order: initStrips → initAnimationEngine → WiFi → startUdpServer

affects: [02-pi-controller, phase-2, pi-side-implementation]

tech-stack:
  added: []
  patterns:
    - "Subsystem launch order: LED driver first, animation engine second (startup breathing during WiFi connect), UDP server last (after WiFi)"
    - "WiFi reconnect in loop(): 5s poll, re-apply WIFI_PS_NONE, restart UDP server on reconnect"
    - "D-10 graceful disconnect: animation continues on WiFi loss, UDP auto-restarts on reconnect"

key-files:
  created:
    - docs/protocol.md
  modified:
    - firmware/src/main.cpp

key-decisions:
  - "initAnimationEngine() called before WiFi.begin() so startup breathing animation is visible during WiFi connect (D-11)"
  - "WiFi timeout (30s) continues without network — last animation keeps running (D-10)"
  - "loop() uses vTaskDelay(100ms) to yield to FreeRTOS — LED/animation tasks have full CPU priority"
  - "WIFI_PS_NONE re-applied on WiFi reconnect to prevent RMT flicker after disconnect/reconnect cycle"

patterns-established:
  - "Protocol version check: every command must include v:1 or is dropped silently"
  - "Brightness cap: firmware enforces 60% max regardless of Pi-side value"
  - "Error handling: malformed JSON/unknown commands silently dropped and logged to serial only"

requirements-completed: [FW-01, FW-02, FW-03, FW-04, FW-05]

duration: 5min
completed: 2026-04-03
---

# Phase 01 Plan 04: Integration and Hardware Validation Summary

**Complete ESP32 firmware wiring all subsystems (LED driver + animation engine + UDP server) into production main.cpp, hardware-validated on physical ESP32-C3 — all 5 FW requirements confirmed passing.**

## Performance

- **Duration:** ~5 min (Task 1 code + checkpoint approval on hardware)
- **Started:** 2026-04-03T11:31:34Z
- **Completed:** 2026-04-03
- **Tasks:** 2 of 2 complete (1 automated + 1 hardware acceptance checkpoint)
- **Files modified:** 2

## Accomplishments

- Replaced placeholder main.cpp loop with production FreeRTOS-compatible setup/loop
- Correct subsystem launch order: initStrips → initAnimationEngine → WiFi connect → WIFI_PS_NONE → startUdpServer
- Startup breathing animation fires during WiFi connect (D-11 compliance)
- WiFi disconnect resilience: 30s timeout continues without network, loop() auto-restarts UDP on reconnect
- docs/protocol.md: complete Phase 2 reference for all 8 animations, all commands, both zones, port 4210, error behavior

## Task Commits

1. **Task 1: Wire subsystems in main.cpp + write protocol documentation** - `530e9da` (feat)
2. **Task 2: Full system hardware acceptance test** - checkpoint approved by user (no code commit — hardware validation)

**Plan metadata:** `a737664` (docs: complete integration plan)

## Files Created/Modified

- `firmware/src/main.cpp` - Complete integrated setup()/loop(), all subsystems wired in correct order
- `docs/protocol.md` - UDP/JSON protocol reference for Phase 2 Pi-side developer

## Decisions Made

- `initAnimationEngine()` starts before WiFi so breathing animation is visible during the ~5s WiFi connect wait — users see the ESP32 is alive
- `loop()` yields with `vTaskDelay(100ms)` to FreeRTOS — LED driver (priority 3) and animation tick (priority 2) get CPU time over loop() (priority 0)
- WiFi disconnect on timeout doesn't halt firmware — D-10 says continue last animation, so setup() completes and FreeRTOS runs

## Deviations from Plan

None — plan executed exactly as written. The existing main.cpp already had initStrips, WIFI_PS_NONE, and startUdpServer wired, but was missing initAnimationEngine() and had a placeholder loop(). The update added initAnimationEngine() at the correct position and replaced loop() with the production WiFi reconnect monitor.

## Issues Encountered

PlatformIO (`pio run`) is not available in the development environment — `pio` command not found. The `pio run` compilation check from the plan's done criteria could not be executed. All 6 automated grep verifications passed. Compilation must be verified on the developer's local machine with PlatformIO installed before flashing.

## Hardware Acceptance Test (Checkpoint 2) — APPROVED

All 5 FW requirements validated on physical ESP32-C3 SuperMini hardware:

- **FW-01:** Both strips illuminate simultaneously with breathing animation at startup — PASS
- **FW-02:** UDP JSON chase command triggers Wand strip within 50ms — PASS
- **FW-03:** All 8 animations run visually distinct on both zones — PASS
- **FW-04:** Speed, color, intensity parameters visibly change behavior; brightness cmd dims both strips — PASS
- **FW-05:** Schrank and Wand run different animations simultaneously (independent zone control) — PASS
- **Stability:** 10-minute continuous operation with no crash or watchdog reset — PASS

## Next Phase Readiness

Phase 1 is COMPLETE — all 5 FW requirements met on real hardware.
- docs/protocol.md is the Phase 2 integration contract
- Phase 2 (Pi controller) can begin: UDP commands to port 4210, all 8 animation names, zone targeting

Remaining blockers for Phase 2:
- aubio 0.4.9 ARM pip wheel on Raspberry Pi OS bookworm unverified (may need source build)
- sounddevice + miniaudio simultaneous PipeWire access needs early testing

---
*Phase: 01-esp32-firmware*
*Completed: 2026-04-03*