remote-rig/firmware/src/esp32-mqtt-bridge.cpp

/**
 * RemoteRig — ESP32 MQTT Bridge Firmware
 * ======================================
 * Dedicated board per camera node. Connects the ESP8266 camera bridge
 * to the RemoteRig MQTT hub.
 *
 * ONE JOB: relay between UART (ESP8266) and MQTT (Pi hub).
 *   - Connects to travel router Wi-Fi
 *   - Reads status JSON from ESP8266 over UART → publishes via MQTT
 *   - Receives commands via MQTT from hub → forwards to ESP8266 over UART
 *   - Handles auto-registration (announce on first boot)
 *   - Heartbeat publishing
 *   - Zero camera communication, zero network switching
 *
 * UART Protocol: JSON-per-line at 115200 8N1
 *   ESP8266 → ESP32:  {"type":"status","battery_raw":217,...}\n
 *   ESP8266 → ESP32:  {"type":"ack","cmd":"start_recording"}\n
 *   ESP32 → ESP8266:  {"type":"cmd","command":"start_recording"}\n
 *   ESP32 → ESP8266:  {"type":"cmd","command":"ping"}\n
 *
 * Hardware:
 *   - ESP32 Dev Board (or D1 Mini ESP32)
 *   - UART2: RX=GPIO16, TX=GPIO17 (connected to ESP8266)
 *   - Shared GND between boards
 *   - LiPo → 3.3V buck → VIN on both boards
 */

#include <Arduino.h>
#include <WiFi.h>
#include <WiFiClient.h>
#include <PubSubClient.h>
#include <ArduinoJson.h>
#include <SPIFFS.h>

// ────────────────────────────────────────────
// Configuration (SPIFFS)
// ────────────────────────────────────────────

struct Config {
  String wifi_ssid       = "RemoteRig";
  String wifi_password   = "";
  String mqtt_broker     = "192.168.4.10";
  int    mqtt_port       = 1883;
  String camera_id       = "";   // assigned by hub
  int    heartbeat_sec   = 60;
} cfg;

bool loadConfig() {
  if (!SPIFFS.begin(true)) { Serial.println("[CFG] SPIFFS mount failed"); return false; }
  File f = SPIFFS.open("/config.json", "r");
  if (!f) { Serial.println("[CFG] No config — using defaults"); return false; }

  JsonDocument doc;
  DeserializationError err = deserializeJson(doc, f);
  f.close();
  if (err) { Serial.printf("[CFG] Parse error: %s\n", err.c_str()); return false; }

  cfg.wifi_ssid       = doc["wifi_ssid"]     | cfg.wifi_ssid;
  cfg.wifi_password   = doc["wifi_password"] | cfg.wifi_password;
  cfg.mqtt_broker     = doc["mqtt_broker"]   | cfg.mqtt_broker;
  cfg.mqtt_port       = doc["mqtt_port"]     | cfg.mqtt_port;
  cfg.camera_id       = doc["camera_id"]     | cfg.camera_id;
  cfg.heartbeat_sec   = doc["heartbeat_interval_sec"] | cfg.heartbeat_sec;
  return true;
}

bool saveConfig() {
  File f = SPIFFS.open("/config.json", "w");
  if (!f) return false;
  JsonDocument doc;
  doc["wifi_ssid"]     = cfg.wifi_ssid;
  doc["wifi_password"] = cfg.wifi_password;
  doc["mqtt_broker"]   = cfg.mqtt_broker;
  doc["mqtt_port"]     = cfg.mqtt_port;
  doc["camera_id"]     = cfg.camera_id;
  doc["heartbeat_interval_sec"] = cfg.heartbeat_sec;
  serializeJson(doc, f);
  f.close();
  return true;
}

// ────────────────────────────────────────────
// UART to ESP8266 (HardwareSerial2)
// ────────────────────────────────────────────
// ESP32 UART2: RX=GPIO16, TX=GPIO17
// Connect: ESP32 RX(16) ← ESP8266 TX
//          ESP32 TX(17) → ESP8266 RX

#define UART_ESP8266 Serial2

void sendCmdToESP8266(const String& command) {
  JsonDocument doc;
  doc["type"]    = "cmd";
  doc["command"] = command;
  String line;
  serializeJson(doc, line);
  UART_ESP8266.println(line);
  UART_ESP8266.flush();
}

String uartLine;
bool readFromESP8266(String& line) {
  while (UART_ESP8266.available()) {
    char c = UART_ESP8266.read();
    if (c == '\n') {
      line = uartLine;
      uartLine = "";
      return true;
    }
    if (c != '\r') uartLine += c;
  }
  return false;
}

// ────────────────────────────────────────────
// MQTT
// ────────────────────────────────────────────

WiFiClient   routerClient;
PubSubClient mqtt(routerClient);

unsigned long bootMs = 0;
bool cameraOnline    = false;
unsigned long lastStatusMs = 0;

String clientID() {
  uint8_t mac[6];
  WiFi.macAddress(mac);
  char buf[32];
  snprintf(buf, sizeof(buf), "rig-%02x%02x%02x", mac[3], mac[4], mac[5]);
  return String(buf);
}

String mqttTopic(const char* t) {
  return "remoterig/cameras/" + cfg.camera_id + "/" + t;
}

void mqttCallback(char* topic, byte* payload, unsigned int len) {
  char buf[256];
  unsigned int n = len < 255 ? len : 255;
  memcpy(buf, payload, n); buf[n] = 0;

  JsonDocument doc;
  if (deserializeJson(doc, buf)) return;

  String cmd = doc["command"] | "";
  if (cmd == "start_recording" || cmd == "stop_recording") {
    Serial.printf("[MQTT] Forwarding command: %s → ESP8266\n", cmd.c_str());
    sendCmdToESP8266(cmd);
  } else if (cmd == "reboot") {
    ESP.restart();
  } else if (cmd == "registered") {
    String id = doc["camera_id"] | "";
    if (id.length() > 0 && id != cfg.camera_id) {
      cfg.camera_id = id;
      saveConfig();
      mqtt.unsubscribe(mqttTopic("command").c_str());
      mqtt.subscribe(mqttTopic("command").c_str(), 2);
      Serial.printf("[MQTT] Registered as %s\n", id.c_str());
    }
  }
}

bool connectMQTT() {
  mqtt.setServer(cfg.mqtt_broker.c_str(), cfg.mqtt_port);
  mqtt.setCallback(mqttCallback);
  mqtt.setKeepAlive(60);

  if (!mqtt.connect(clientID().c_str())) {
    Serial.printf("[MQTT] Connect fail (state=%d)\n", mqtt.state());
    return false;
  }

  Serial.println("[MQTT] Connected");

  // Subscribe to commands (if registered)
  if (cfg.camera_id.length() > 0) {
    mqtt.subscribe(mqttTopic("command").c_str(), 2);
  }

  // Announce if new
  if (cfg.camera_id.length() == 0) {
    JsonDocument doc;
    doc["mac_address"]      = WiFi.macAddress();
    doc["firmware_version"] = "0.3.0-esp32-mqtt-bridge";
    doc["friendly_name"]    = "Cam-" + clientID();
    JsonArray caps = doc["capabilities"].to<JsonArray>();
    caps.add("start_stop"); caps.add("status");
    String payload; serializeJson(doc, payload);
    mqtt.publish("remoterig/cameras/announce-" + clientID(), payload.c_str(), true);
    Serial.println("[MQTT] Announced for registration");
  }

  return true;
}

// ────────────────────────────────────────────
// Setup
// ────────────────────────────────────────────

void setup() {
  Serial.begin(115200);
  delay(500);
  Serial.println("\n[BRIDGE] ESP32 MQTT Bridge v1.0");

  bootMs = millis();
  pinMode(2, OUTPUT); // built-in LED
  digitalWrite(2, LOW);

  loadConfig();

  // UART to ESP8266
  UART_ESP8266.begin(115200, SERIAL_8N1, 16, 17); // RX=16, TX=17
  Serial.println("[UART] ESP8266 link on RX16/TX17 @ 115200");

  // Connect to travel router — the ONLY network we touch
  Serial.printf("[WIFI] Connecting to: %s\n", cfg.wifi_ssid.c_str());
  WiFi.mode(WIFI_STA);
  WiFi.begin(cfg.wifi_ssid.c_str(), cfg.wifi_password.c_str());

  int attempts = 0;
  while (WiFi.status() != WL_CONNECTED && attempts < 40) {
    delay(500); Serial.print("."); attempts++;
  }

  if (WiFi.status() == WL_CONNECTED) {
    Serial.printf("\n[WIFI] Connected. IP: %s\n", WiFi.localIP().toString().c_str());
  } else {
    Serial.println("\n[WIFI] FAILED — will retry");
  }

  // MQTT
  if (WiFi.status() == WL_CONNECTED) {
    connectMQTT();
  }
}

// ────────────────────────────────────────────
// Main Loop
// ────────────────────────────────────────────

void loop() {
  unsigned long now = millis();
  static unsigned long lastBeat = 0, lastRecon = 0;
  static int reconDelay = 1;

  // ── Wi-Fi watchdog ──
  if (WiFi.status() != WL_CONNECTED) {
    if (now - lastRecon > 5000) { lastRecon = now; WiFi.reconnect(); }
    delay(100); return;
  }

  // ── MQTT watchdog ──
  if (!mqtt.connected()) {
    if (now - lastRecon > (unsigned long)(reconDelay * 1000)) {
      lastRecon = now;
      if (connectMQTT()) reconDelay = 1;
      else reconDelay = min(reconDelay * 2, 30);
    }
    mqtt.loop(); delay(100); return;
  }

  mqtt.loop();

  // ── Read status from ESP8266 over UART → publish via MQTT ──
  String line;
  while (readFromESP8266(line)) {
    JsonDocument doc;
    DeserializationError err = deserializeJson(doc, line);
    if (err) { Serial.printf("[UART] Bad JSON: %s\n", line.c_str()); continue; }

    String type = doc["type"] | "";
    
    if (type == "status") {
      // Relay camera status to MQTT hub
      lastStatusMs = now;
      bool online = doc["online"] | false;
      
      if (online != cameraOnline) {
        cameraOnline = online;
        digitalWrite(2, online ? HIGH : LOW);
      }

      if (cfg.camera_id.length() > 0) {
        // Build the MQTT status payload per contract
        JsonDocument mqttDoc;
        mqttDoc["camera_id"]  = cfg.camera_id;
        mqttDoc["timestamp"]  = millis();
        mqttDoc["battery_raw"] = doc["battery_raw"] | 0;
        mqttDoc["video_remaining_sec"] = doc["video_remaining_sec"] | 0;
        mqttDoc["recording"]  = doc["recording"] | false;
        mqttDoc["online"]     = online;
        
        String payload;
        serializeJson(mqttDoc, payload);
        mqtt.publish(mqttTopic("status").c_str(), payload.c_str(), true);
      }
    }
    else if (type == "ack") {
      Serial.printf("[UART] ESP8266 ack: %s\n", (doc["cmd"] | "?").c_str());
    }
    else if (type == "pong") {
      Serial.printf("[UART] ESP8266 pong (uptime=%d)\n", doc["uptime_ms"] | 0);
    }
    else if (type == "error") {
      Serial.printf("[UART] ESP8266 error: %s\n", (doc["msg"] | "?").c_str());
    }
  }

  // ── Heartbeat to hub (every heartbeat_sec) ──
  if (cfg.camera_id.length() > 0 &&
      now - lastBeat > (unsigned long)(cfg.heartbeat_sec * 1000)) {
    lastBeat = now;
    JsonDocument doc;
    doc["camera_id"]  = cfg.camera_id;
    doc["timestamp"]  = millis();
    doc["uptime_sec"] = (now - bootMs) / 1000;
    doc["free_heap"]  = ESP.getFreeHeap();
    doc["status_age_ms"] = now - lastStatusMs;
    String payload; serializeJson(doc, payload);
    mqtt.publish(mqttTopic("heartbeat").c_str(), payload.c_str(), false);
  }

  // ── Periodic ping to ESP8266 to verify UART link ──
  static unsigned long lastPing = 0;
  if (now - lastPing > 30000) {
    lastPing = now;
    sendCmdToESP8266("ping");
  }

  delay(50);
}