chore: bump version to 4.0.1

Fixed ESPHome 2024.6.0 breaking change where OTA requires platform

.github/FUNDING.yml

@@ -1 +1,2 @@
+github: tjhorner
 ko_fi: tjhorner

.github/ISSUE_TEMPLATE/bug_report.yml

@@ -0,0 +1,50 @@
+name: Bug Report
+description: File a bug report or get help with an issue.
+labels: ["bug"]
+assignees:
+  - tjhorner
+body:
+  - type: checkboxes
+    id: troubleshooting-followed
+    attributes:
+      label: Troubleshooting Guide
+      description: Please confirm you have followed the [troubleshooting guide](https://upsy-desky.tjhorner.dev/docs/troubleshooting).
+      options:
+        - label: I have followed the steps in the troubleshooting guide and my issue is either not listed or is not solved.
+          required: true
+  - type: textarea
+    id: description
+    attributes:
+      label: Description
+      description: Please describe the bug you encountered, and what you expected to happen instead.
+    validations:
+      required: true
+  - type: textarea
+    id: logs
+    attributes:
+      label: Logs
+      description: Please copy and paste any relevant log output. Learn how to obtain logs [here](https://upsy-desky.tjhorner.dev/docs/troubleshooting/#other-issues).
+      render: plain text
+  - type: input
+    id: config-version
+    attributes:
+      label: Which version of the Upsy Desky firmware config are you running?
+      placeholder: "1.1.1"
+  - type: dropdown
+    id: update-management
+    attributes:
+      label: How do you manage your Upsy Desky's updates?
+      options:
+        - OTA Updates
+        - ESPHome YAML Config
+  - type: input
+    id: esphome-version
+    attributes:
+      label: If you're using an ESPHome YAML config, which version of ESPHome are you running?
+      placeholder: "2023.5.4"
+  - type: textarea
+    id: esphome-config
+    attributes:
+      label: ESPHome Config
+      description: If you have your own ESPHome YAML configuration, please paste it here. Remember to redact any sensitive information like encryption keys or passwords.
+      render: YAML

.github/workflows/build.yaml

@@ -22,7 +22,7 @@ jobs:
         run: |
           esphome compile stock.yaml
           mkdir -p bin
-          cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware-factory.bin bin/firmware-factory.bin
+          cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware.factory.bin bin/firmware-factory.bin
           cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware.bin bin/firmware.bin
 
       - name: Compile Debug Firmware
@@ -31,7 +31,7 @@ jobs:
           rm -rf .esphome/build/upsy-desky
           esphome compile debug.yaml
           mkdir -p bin
-          cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware-factory.bin bin/debug-firmware-factory.bin
+          cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware.factory.bin bin/debug-firmware-factory.bin
           cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware.bin bin/debug-firmware.bin
 
       - name: Upload Firmware

.github/workflows/nightly-build.yaml

@@ -0,0 +1,40 @@
+name: Nightly Stock Firmware Build
+on:
+  schedule:
+    - cron: "0 0 * * *"
+
+jobs:
+  build:
+    name: Build Firmware
+    runs-on: ubuntu-latest
+    steps:
+      - uses: actions/checkout@v2
+
+      - uses: actions/setup-python@v2
+        with:
+          python-version: "3.9"
+
+      - name: Install ESPHome
+        run: pip install --pre --user esphome
+      
+      - name: Compile Release Firmware
+        working-directory: firmware
+        run: |
+          esphome compile stock.yaml
+          mkdir -p bin
+          cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware.factory.bin bin/firmware-factory.bin
+          cp .esphome/build/upsy-desky/.pioenvs/upsy-desky/firmware.bin bin/firmware.bin
+
+      - uses: actions/upload-artifact@v3
+        with:
+          name: firmware-bin
+          path: firmware/bin
+
+      - name: Send Discord failure notification
+        if: failure()
+        uses: appleboy/discord-action@master
+        with:
+          webhook_id: ${{ secrets.DISCORD_WEBHOOK_ID }}
+          webhook_token: ${{ secrets.DISCORD_WEBHOOK_TOKEN }}
+          color: "#FF6961"
+          message: "The latest nightly build failed: ${{ github.server_url }}/${{ github.repository }}/actions/runs/${{ github.run_id }}"

firmware/addons/bluetooth-proxy.yaml

@@ -1,4 +1,7 @@
+substitutions:
+  bluetooth_proxy_active_connections: "true"
+
 esp32_ble_tracker:
 
 bluetooth_proxy:
-  active: true
+  active: ${bluetooth_proxy_active_connections}

firmware/addons/presets.yaml

@@ -2,22 +2,28 @@ output:
   - platform: gpio
     inverted: true
     id: button_bit1
-    pin: ${button_bit1_pin}
+    pin:
+      number: ${button_bit1_pin}
+      allow_other_uses: true
 
   - platform: gpio
     inverted: true
     id: button_bit2
-    pin: ${button_bit2_pin}
+    pin:
+      number: ${button_bit2_pin}
+      allow_other_uses: true
 
   - platform: gpio
     inverted: true
     id: button_bit4
-    pin: ${button_bit4_pin}
+    pin:
+      number: ${button_bit4_pin}
 
   - platform: gpio
     inverted: true
     id: button_m
-    pin: ${button_m_pin}
+    pin:
+      number: ${button_m_pin}
 
 button:
   # Recall Presets

firmware/base.yaml

@@ -3,7 +3,7 @@ esphome:
   name: "${name}"
   friendly_name: "${friendly_name}"
   name_add_mac_suffix: true
-  min_version: "2023.5.1"
+  min_version: "2024.6.0"
   on_boot:
     then:
       # Wakes up the desk and reports height
@@ -12,7 +12,7 @@ esphome:
           data: [ 0x0 ]
   project:
     name: tj_horner.upsy_desky
-    version: "1.0.4"
+    version: "4.0.1"
 
 uart:
   id: handset_tx
@@ -21,6 +21,8 @@ uart:
 
 esp32:
   board: esp32dev
+  framework:
+    type: esp-idf
 
 # Configurable options
 substitutions:
@@ -50,7 +52,6 @@ packages:
   addon_presets: !include addons/presets.yaml
   addon_stable_ids: !include addons/stable-ids.yaml
   addon_runtime_config: !include addons/runtime-config.yaml
-  addon_bluetooth_proxy: !include addons/bluetooth-proxy.yaml
 
 button:
   - platform: restart

firmware/stock.yaml

@@ -1,6 +1,15 @@
 packages:
   base: !include base.yaml
 
+external_components:
+  - source: github://tjhorner/esphome-custom-components
+    components: [ project_version ]
+
+text_sensor:
+  - platform: project_version
+    name: "Upsy Desky Firmware Version"
+    internal: true
+
 logger:
   level: INFO
 
@@ -12,14 +21,20 @@ captive_portal:
 
 improv_serial:
 
+esp32_improv:
+  authorizer: false
+
 api:
   reboot_timeout: 0s
 
 web_server:
   port: 80
+  version: 2
+  js_url: "https://upsy-desky.tjhorner.dev/esphome-webserver/www.js"
 
 ota:
-  password: ""
+  - platform: esphome
+    password: ""
 
 dashboard_import:
-  package_import_url: github://tjhorner/upsy-desky/firmware/stock.yaml@v1.0.4
+  package_import_url: github://tjhorner/upsy-desky/firmware/stock.yaml@v4.0.1

pcb/upsy-desky.kicad_pro

@@ -67,20 +67,26 @@
       "rule_severities": {
         "annular_width": "error",
         "clearance": "error",
+        "connection_width": "warning",
         "copper_edge_clearance": "error",
+        "copper_sliver": "warning",
         "courtyards_overlap": "error",
         "diff_pair_gap_out_of_range": "error",
         "diff_pair_uncoupled_length_too_long": "error",
         "drill_out_of_range": "error",
         "duplicate_footprints": "warning",
         "extra_footprint": "warning",
+        "footprint": "error",
         "footprint_type_mismatch": "error",
         "hole_clearance": "error",
         "hole_near_hole": "error",
         "invalid_outline": "error",
+        "isolated_copper": "warning",
         "item_on_disabled_layer": "error",
         "items_not_allowed": "error",
         "length_out_of_range": "error",
+        "lib_footprint_issues": "warning",
+        "lib_footprint_mismatch": "warning",
         "malformed_courtyard": "error",
         "microvia_drill_out_of_range": "error",
         "missing_courtyard": "ignore",
@@ -90,9 +96,14 @@
         "padstack": "error",
         "pth_inside_courtyard": "ignore",
         "shorting_items": "error",
+        "silk_edge_clearance": "warning",
         "silk_over_copper": "ignore",
         "silk_overlap": "warning",
         "skew_out_of_range": "error",
+        "solder_mask_bridge": "error",
+        "starved_thermal": "error",
+        "text_height": "warning",
+        "text_thickness": "warning",
         "through_hole_pad_without_hole": "error",
         "too_many_vias": "error",
         "track_dangling": "warning",
@@ -101,7 +112,6 @@
         "unconnected_items": "error",
         "unresolved_variable": "error",
         "via_dangling": "warning",
-        "zone_has_empty_net": "error",
         "zones_intersect": "error"
       },
       "rules": {
@@ -109,20 +119,65 @@
         "allow_microvias": false,
         "max_error": 0.005,
         "min_clearance": 0.0,
+        "min_connection": 0.0,
         "min_copper_edge_clearance": 0.0,
         "min_hole_clearance": 0.25,
         "min_hole_to_hole": 0.25,
         "min_microvia_diameter": 0.19999999999999998,
         "min_microvia_drill": 0.09999999999999999,
+        "min_resolved_spokes": 2,
         "min_silk_clearance": 0.0,
+        "min_text_height": 0.7999999999999999,
+        "min_text_thickness": 0.08,
         "min_through_hole_diameter": 0.3,
         "min_track_width": 0.19999999999999998,
         "min_via_annular_width": 0.049999999999999996,
         "min_via_diameter": 0.39999999999999997,
         "solder_mask_clearance": 0.0,
         "solder_mask_min_width": 0.0,
+        "solder_mask_to_copper_clearance": 0.0,
         "use_height_for_length_calcs": true
       },
+      "teardrop_options": [
+        {
+          "td_allow_use_two_tracks": true,
+          "td_curve_segcount": 5,
+          "td_on_pad_in_zone": false,
+          "td_onpadsmd": true,
+          "td_onroundshapesonly": false,
+          "td_ontrackend": false,
+          "td_onviapad": true
+        }
+      ],
+      "teardrop_parameters": [
+        {
+          "td_curve_segcount": 0,
+          "td_height_ratio": 1.0,
+          "td_length_ratio": 0.5,
+          "td_maxheight": 2.0,
+          "td_maxlen": 1.0,
+          "td_target_name": "td_round_shape",
+          "td_width_to_size_filter_ratio": 0.9
+        },
+        {
+          "td_curve_segcount": 0,
+          "td_height_ratio": 1.0,
+          "td_length_ratio": 0.5,
+          "td_maxheight": 2.0,
+          "td_maxlen": 1.0,
+          "td_target_name": "td_rect_shape",
+          "td_width_to_size_filter_ratio": 0.9
+        },
+        {
+          "td_curve_segcount": 0,
+          "td_height_ratio": 1.0,
+          "td_length_ratio": 0.5,
+          "td_maxheight": 2.0,
+          "td_maxlen": 1.0,
+          "td_target_name": "td_track_end",
+          "td_width_to_size_filter_ratio": 0.9
+        }
+      ],
       "track_widths": [
         0.0,
         0.2,

pcb/upsy-desky.kicad_sch

@@ -4340,7 +4340,7 @@
     (property "Checked" "Y" (at 78.74 114.3 0)
       (effects (font (size 1.27 1.27)) hide)
     )
-    (property "MPN" "CP2102N-A02-GQFN24" (at 78.74 114.3 0)
+    (property "MPN" "CP2102N-Axx-xQFN28" (at 78.74 114.3 0)
       (effects (font (size 1.27 1.27)) hide)
     )
     (pin "1" (uuid bde9cef2-abc7-4dd2-a325-cb48af34c27d))
@@ -4766,7 +4766,7 @@
     (property "Reference" "D1" (at 56.1975 16.51 0)
       (effects (font (size 1.27 1.27)))
     )
-    (property "Value" "1N5817" (at 56.1975 19.05 0)
+    (property "Value" "1N5819WS" (at 56.1975 19.05 0)
       (effects (font (size 1.27 1.27)))
     )
     (property "Footprint" "Diode_SMD:D_SOD-323" (at 55.88 18.415 0)
@@ -4781,7 +4781,7 @@
     (property "Checked" "Y" (at 55.88 22.86 0)
       (effects (font (size 1.27 1.27)) hide)
     )
-    (property "MPN" "1N5817" (at 55.88 22.86 0)
+    (property "MPN" "1N5819WS" (at 55.88 22.86 0)
       (effects (font (size 1.27 1.27)) hide)
     )
     (property "Package" "SOD-323" (at 55.88 22.86 0)

test-firmware/src/main.cpp

@@ -26,7 +26,7 @@ void setup() {
 
   digitalWrite(LED_BUILTIN, HIGH);
 
-  delay(100);
+  delay(200);
 
   for (int &pin : pins_to_test) {
     Serial.print("Waiting for pin ");
@@ -41,6 +41,8 @@ void setup() {
     delay(100);
     digitalWrite(LED_BUILTIN, HIGH);
   }
+
+  digitalWrite(LED_BUILTIN, LOW);
 #else
   digitalWrite(LED_BUILTIN, HIGH);
 
@@ -61,7 +63,7 @@ void loop() {
     Serial.println();
 
     digitalWrite(pin, HIGH);
-    delay(1000);
+    delay(300);
     digitalWrite(pin, LOW);
   }
 #endif

tools/tindie/split-csv.sh

@@ -1,18 +1,20 @@
 #!/bin/bash
 
-rm -f first_class_and_intl.csv priority.csv priority_express.csv pickup.csv
+rm -f ud_orders.csv ground_advantage_and_intl.csv priority.csv priority_express.csv pickup.csv
 
-csvq -o first_class_and_intl.csv "SELECT * FROM all_orders WHERE \`Shipping Method\` LIKE \"%First-Class%\" OR \`Shipping Method\` LIKE \"%Simple Export Rate%\";"
-csvq -o priority.csv "SELECT * FROM all_orders WHERE \`Shipping Method\` LIKE \"%Priority Mail%\" AND \`Shipping Method\` NOT LIKE \"%Priority Mail Express%\";"
-csvq -o priority_express.csv "SELECT * FROM all_orders WHERE \`Shipping Method\` LIKE \"%Priority Mail Express%\";"
-csvq -o pickup.csv "SELECT * FROM all_orders WHERE \`Shipping Method\` LIKE \"%Pickup%\";"
+csvq -o ud_orders.csv "SELECT * FROM all_orders WHERE \`Model Number\` LIKE \"%UPSY%\";"
+
+csvq -o ground_advantage_and_intl.csv "SELECT * FROM ud_orders WHERE \`Shipping Method\` LIKE \"%Ground Advantage%\" OR \`Shipping Method\` LIKE \"%Simple Export Rate%\" OR \`Shipping Method\` LIKE \"%First-Class Package International%\";"
+csvq -o priority.csv "SELECT * FROM ud_orders WHERE \`Shipping Method\` LIKE \"%Priority Mail%\" AND \`Shipping Method\` NOT LIKE \"%Priority Mail Express%\";"
+csvq -o priority_express.csv "SELECT * FROM ud_orders WHERE \`Shipping Method\` LIKE \"%Priority Mail Express%\";"
+csvq -o pickup.csv "SELECT * FROM ud_orders WHERE \`Shipping Method\` LIKE \"%Pickup%\";"
 
 SANITY_CHECK_QUERY=$(cat <<-END
   SELECT
-    (SELECT count(*) from all_orders)
+    (SELECT count(*) from ud_orders)
       =
     (
-      (SELECT count(*) from first_class_and_intl) +
+      (SELECT count(*) from ground_advantage_and_intl) +
       (SELECT count(*) from priority) +
       (SELECT count(*) from priority_express) +
       (SELECT count(*) from pickup)