feat: diagnostic telemetry system (Plan 06)#84
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basmeerman merged 6 commits intomasterfrom Mar 19, 2026
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Add a built-in diagnostic telemetry system that captures 64-byte state snapshots into a RAM ring buffer (8 KB, 128 slots). Supports multiple capture profiles (GENERAL, SOLAR, LOADBAL, MODBUS, FAST) and exposes REST endpoints for status, start/stop, and binary download. New modules: - diag_telemetry.h/c: Pure C ring buffer with CRC32 serialization - diag_sampler.h/cpp: Firmware bridge sampling globals every 1s - test_diag_telemetry.c: 29 native tests with SbE annotations - tools/diag_decode.py: Python script to decode .diag binary to JSON REST API: /diag/status, /diag/start, /diag/stop, /diag/download Verified: native tests (39 suites), sanitizers, cppcheck, ESP32 + CH32 builds. RAM impact: +8.2 KB (23.7% total). Flash: 85.7%. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
…48) Add diagnostic telemetry persistence and auto-trigger capabilities: - diag_storage.h/cpp: LittleFS dump/load with 4-file retention policy, extended data capture (per-node LB state), auto-delete oldest on overflow - Auto-dump triggers: error onset, unexpected C→A disconnect, solar timer max, meter timeout — fires automatically when capture is active - REST endpoints: POST /diag/dump, GET /diag/files, GET /diag/file/*, DELETE /diag/file/* for file management - MQTT Set/DiagProfile command: accepts off/general/solar/loadbal/modbus/fast (string or numeric 0-5) to start/stop capture remotely - 5 new MQTT parser tests for DiagProfile command validation Verified: 39 test suites, sanitizers, cppcheck, ESP32 (85.9%) + CH32 builds. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add real-time diagnostic streaming and Modbus communication monitoring: - diag_modbus.h/c: Pure C ring buffer for Modbus frame timing events (32 entries x 8 bytes = 256 bytes RAM). Records sent/received/error events with timestamps from ModbusSend8, MBhandleData, MBhandleError. - WebSocket /diag/stream endpoint in network_common.cpp: pushes 64-byte binary snapshots to connected clients on each sample tick, following the existing wsLcdConnections pattern. - Modbus event ring auto-enables for MODBUS and FAST capture profiles. - tools/diag_viewer.html: standalone browser diagnostic viewer with live WebSocket table, profile control, and .diag download button. - 8 new native tests for Modbus event ring (test_diag_modbus.c). Verified: 40 test suites, sanitizers, cppcheck, ESP32 (85.9%) + CH32 builds. RAM impact: +264 bytes (23.8% total). Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add a .diag file loader and replay test framework for the native test harness, enabling developers to replay captured diagnostic data: - diag_loader.h/c: Pure C loader for .diag binary files. Supports loading from file, in-memory buffer, and synthetic generation. Validates magic, version, CRC32, and handles truncated files. - test_diag_replay.c: 9 native tests covering loader functionality, field mapping to evse_ctx_t, state transition tracking, solar oscillation detection, and full serialize/load round-trip. The replay framework operates in advisory mode — snapshots are mapped to evse_ctx_t fields for analysis rather than strict assertion, since the 1 Hz sample rate cannot capture all sub-second transients. Verified: 41 test suites, sanitizers, ESP32 + CH32 builds. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
CI enforces -Wstack-usage=1024 (GCC). diag_capture_t contains a 256-entry snapshot array (16 KB) which exceeded the limit when declared as a local variable. Move to file-scope static instance shared across all test functions. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Two more test functions (test_push_and_read_single, test_frozen_allows_read) exceeded the 1024-byte stack limit with buf[8] + out[8] arrays. Use file-scope static buffers instead. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
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Mar 19, 2026
- Add Plan 06 (Diagnostic Telemetry) features section with PR #84 - Add Plan 07 (Web UI Modernization) features with PR #85 - Add Plan 09 (Power Input Methods) features: API staleness detection, HomeWizard P1 energy data, manual IP fallback, metering diagnostics - Add per-phase energy MQTT and metering diagnostic counters to MQTT section - Update Testing & Quality metrics (43 suites, 870+ scenarios) - Update Roadmap: all 9 plans marked Done with PR links - Add PR references throughout for traceability Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
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Summary
diag_telemetry.h/c): Pure C circular buffer with 64-byte packed snapshots (128 slots = 8 KB RAM), CRC32 serialization, configurable capture profiles (OFF/GENERAL/SOLAR/LOADBAL/MODBUS/FAST)diag_sampler.h/cpp): Bridges 50+ firmware globals into snapshots every 1s, with REST endpoints for status/start/stop/downloaddiag_storage.h/cpp): On-demand dump to flash with 4-file retention, auto-dump on error transitions (error onset, unexpected C→A, solar timer max, meter timeout)Set/DiagProfilecommand to start/stop capture remotely/diag/stream): Real-time binary snapshot push to browser clientsdiag_modbus.h/c): 32-entry timing ring (256 bytes) instrumented in ModbusSend8/MBhandleData/MBhandleErrordiag_loader.h/c): Load .diag files in native tests, advisory replay with field mapping to evse_ctx_tdiag_decode.py(binary→JSON),diag_viewer.html(live browser dashboard)Verification
Issues closed
Closes #47, closes #48, closes #49, closes #50
Test plan
cd SmartEVSE-3/test/native && make clean testmake clean test CFLAGS_EXTRA="-fsanitize=address,undefined -fno-omit-frame-pointer"pio run -e release -d SmartEVSE-3/pio run -e ch32 -d SmartEVSE-3//diag/status,/diag/start?profile=general,/diag/download)Set/DiagProfilecommanddiag_viewer.htmldiag_decode.pydecodes downloaded .diag files🤖 Generated with Claude Code