Lead with the separate-ground LED build

Keeps the shared-rail version documented as the alternative, since that is
what the current loom attempts, and links the new pinout reference.

.claude-context/00-overview.md

@@ -1,27 +0,0 @@
-# ps4-lego-bridge — Overview
-
-PS4 DualShock 4 controller driving a Johnny 5 (Short Circuit) LEGO MOC: seven
-motors across two LEGO Technic (Control+) hubs, plus two GPIO LED circuits.
-
-## Architecture in one paragraph
-Two ESP32 boards. **Board A** (`transmitter/`) runs Bluepad32 on the
-`esp32_bluepad32` 4.1.0 package, reads the pad over Bluetooth Classic, and
-streams checksummed ASCII frames over UART. **Board B** (`receiver/`) runs
-Legoino on plain `esp32` core 2.0.17 with NimBLE-Arduino 1.4.x, parses frames,
-and drives both hubs over BLE. Two boards because BTstack and NimBLE are both
-Bluetooth host stacks and cannot share one radio.
-
-## Branches
-- `main` — proven configuration: tank drive, power-controlled arms.
-- `johnny5-evolved` — current development: position-controlled arms on the
-  triggers, head on L1/R1 and d-pad, LED toggles, scan timeout.
-
-## Where to start
-- `README.md` — build guide, toolchain versions, wiring, power, gotchas.
-- `.claude-context/sessions/` — per-session notes.
-
-## Session Log
-- 2026-09-23 — PS4 Controller to Two LEGO Hubs — Johnny 5 Build — Pivoted from single to dual ESP32, got all seven motors working on main, then built position-controlled arms, LED toggles and scan retry on johnny5-evolved.
-
----
-Created by: Jess Rogerson (yelling commands at Claude.AI)

.claude-context/sessions/2026-09-23-johnny5-ps4-control.md

@@ -1,151 +0,0 @@
-# PS4 Controller to Two LEGO Hubs — Johnny 5 Build
-
-**Date:** 2026-09-23
-**Project:** ps4-lego-bridge (also ps4-lego-onebrain)
-**Status:** ongoing
-**Tags:** esp32, bluepad32, legoino, nimble, btstack, lwp3, lego-powered-up, ps4, arduino
-
-## Context
-Goal was to drive a Johnny 5 (Short Circuit) LEGO MOC — seven motors across two
-Technic (Control+) hubs — from a PS4 DualShock 4 via ESP32. The starting sketch
-combined Bluepad32 and Legoino on one ESP32 and failed to compile
-(`Bluepad32.h: No such file or directory`). The session went through a
-single-board attempt, then settled on two boards, then iterated the control
-scheme on a separate branch.
-
-## Key Decisions
-- **Two ESP32 boards, not one.** Bluepad32 uses BTstack (needed for BR/EDR —
-  the DS4 is Bluetooth Classic); Legoino uses NimBLE. Two host stacks cannot
-  share one radio/VHCI. Board A runs Bluepad32 only, board B runs Legoino only,
-  linked by UART.
-  - *Rejected:* single-board via hand-rolled LWP3 GATT client on BTstack
-    (`ps4-lego-onebrain`). It compiled and connected, but was far more code, an
-    unresolved routing fault appeared, and the pivot made that moot. Kept as a
-    separate repo, not maintained.
-  - *Rejected:* PS4-esp32 (Bluedroid) + BLE on one board — PS4-esp32 depends
-    on internal Bluedroid symbols and is broken on modern cores.
-- **ASCII UART protocol with XOR checksum** over binary — debuggable with any
-  USB-serial adapter. Receiver drops bad frames and stops all motors after
-  400ms of silence.
-- **Tank drive, one input per motor.** Arcade drive was tried first and
-  rejected: mixing put one stick on both track motors.
-- **Direction via `DIR_*` constants** rather than editing signs inline —
-  mirrored mountings are normal and flips should be one-line changes.
-- **Board B pinned to arduino-esp32 core 2.0.17.** Core 3.x breaks Legoino.
-  Downgrading chosen over patching the library (patch is the first of several
-  layers and gets reverted by Library Manager updates).
-- **Arms moved to position control** on the evolved branch: trigger position =
-  arm angle, via `setAbsoluteMotorPosition` with `BrakingStyle::HOLD`.
-  *Rejected:* power-based arm control with separate lower buttons — works, but
-  the user wanted angle-proportional behaviour.
-- **Arm encoders zeroed once per boot, not per reconnect.** The hub retains its
-  encoder preset; re-zeroing mid-session would redefine zero wherever the arms
-  happened to be.
-- **Separate branch `johnny5-evolved`** for the new control scheme so `main`
-  keeps the proven configuration.
-
-## Technical Details
-**Toolchain**
-| Board | Package / library | Version |
-| --- | --- | --- |
-| A | esp32_bluepad32 | 4.1.0 |
-| B | esp32 (Espressif) | 2.0.17 |
-| B | NimBLE-Arduino | 1.4.x |
-| B | Legoino | latest |
-
-- Bluepad32 board manager URL:
-  `https://raw.githubusercontent.com/ricardoquesada/esp32-arduino-lib-builder/master/bluepad32_files/package_esp32_bluepad32_index.json`
-- Selecting the `esp32_bluepad32` package starts BTstack **before `setup()`**.
-  Any NimBLE sketch compiled under it aborts with `ESP_ERR_INVALID_STATE` at
-  `esp_bt_controller_init`. Board B must use the plain `esp32` package.
-- Core 3.x Legoino errors: `'string' in namespace 'std' does not name a type`
-  and `no declaration matches ... ReadUInt32LE`. Cause: ESP-IDF 5 made
-  `uint32_t` `unsigned long`.
-
-**Wiring:** A GPIO17 TX → B GPIO16 RX; A GPIO16 RX ← B GPIO17 TX; common GND
-(mandatory). Optional 5V→5V daisy-chain for single supply — never with both USB
-cables connected. LEDs on board B: GPIO25 and GPIO26, each via resistor to
-board B GND (not tapped off the UART ground wire).
-
-**Link frame:** `G,<lx>,<ly>,<rx>,<ry>,<buttons>,<dpad>,<l2>,<r2>*<XX>\n`,
-115200 8N1. Axes −512..511, triggers 0..1023, XX = XOR of payload.
-
-**Port map (verified on hardware)**
-- hub0 `90:84:2b:61:f2:d7` — A right track, B left track, C free, D body lift
-- hub1 `90:84:2b:61:e6:8c` — A left arm, B head tilt, C head turn, D right arm
-- Note: the two addresses were originally the wrong way round, and hub1 A/C and
-  B/C were both mislabelled at points. All found by observation, not code.
-
-**Arm calibration:** travel ≈ +280 (left) / −275 (right) motor degrees — under
-one revolution, so the single-turn absolute encoder is unambiguous. Spans set
-to ±250 to keep backlash clear of the end stop.
-
-**Rate limits:** `MOTOR_MIN_GAP_MS` 100 (per port), `HUB_MIN_GAP_MS` 25 (per
-hub, ~40 cmd/s), `ARM_MIN_GAP_MS` 60. Hub1 carries four motors, hence the
-per-hub cap.
-
-**Arduino gotchas hit this session**
-- The IDE injects generated prototypes before the *first function definition*.
-  Types used in signatures (`HubLink`, `PortState`, `ArmState`, `Frame`) must
-  be declared above it — broke the build twice.
-- `Lpf2Hub::init()` starts an **asynchronous** scan. Guarding it on
-  `!isConnected() && !isConnecting()` re-enters `NimBLEDevice::init()`
-  continuously and crashes. Use a one-shot `initialised` flag.
-- A scan that finds nothing ends silently; without a timeout the hub sits dead
-  until power cycle. Fixed with `scanExpiresAt` / `SCAN_TIMEOUT_MS` (12s).
-- Bluepad32 keeps pairing keys in NVS; reflashing doesn't clear them.
-  `BP32.forgetBluetoothKeys()` must be commented out after first pairing.
-
-**Startup order:** wake both hubs (green button, blinking) → arms physically
-down → power board B. hub1 is only serviced after hub0 connects.
-
-## Code Changes
-- `transmitter/transmitter.ino` — frame extended with d-pad and analog
-  triggers; `DEBUG_FRAMES` flag.
-- `receiver/receiver.ino` (main) — seven motors, tank drive, `DIR_*`
-  constants, swapped hub addresses, right-arm button swap, types hoisted,
-  core 2.0.17 noted in header.
-- `receiver/receiver.ino` (johnny5-evolved) — evolved scheme, position-
-  controlled arms, GPIO LED toggles, head tilt/turn port swap, once-per-boot
-  arm zeroing, scan timeout.
-- `tools/arm_calibrate/arm_calibrate.ino` — measures arm span in motor degrees
-  (delivered as a file; Gitea push timed out — verify it's on the branch).
-- `README.md` (main) — build guide, toolchain table, power section,
-  power-loss test, gotchas.
-
-**Evolved control scheme (johnny5-evolved)**
-| Input | Action |
-| --- | --- |
-| Left / right stick Y | Left / right track |
-| L2 / R2 analog | Left / right arm angle |
-| L1 / R1 | Head turn left / right |
-| D-pad ↑/↓ | Body lift |
-| D-pad ←/→ | Head tilt |
-| Square | All stop (arms go limp) |
-| Cross | Toggle 50/100% track speed |
-| Circle / Triangle | Toggle LED pair 1 / 2 |
-
-## Open Questions / Next Steps
-- **Head direction untested.** `DIR_HEAD_TURN` and `DIR_HEAD_TILT` are +1 by
-  default; flip if L1/R1 or d-pad ←/→ run backwards.
-- **Scan timeout tuning.** 12s is a guess; don't go below ~6s.
-- **Power-loss test not yet run.** The 400ms failsafe only fires if board B is
-  alive. Cut board B's power with a track running and confirm whether the hub
-  stops on BLE disconnect.
-- **Heavy-load test.** Both arms held mid-travel plus head swinging is the peak
-  hub1 command load — check it doesn't drop.
-- **Arm calibrate sketch** — confirm it landed on `johnny5-evolved`.
-- **Merge decision** — `johnny5-evolved` into `main` once verified.
-- **Boot track speed** defaults to 50%; user may want 100%.
-
-## Artifacts
-- Repo: https://gitea.hideawaygaming.com.au/jessikitty/ps4-lego-bridge
-  (branches `main`, `johnny5-evolved`)
-- Single-board attempt: https://gitea.hideawaygaming.com.au/jessikitty/ps4-lego-onebrain
-- Bluepad32 docs: https://bluepad32.readthedocs.io/
-- LEGO Wireless Protocol 3.0: https://lego.github.io/lego-ble-wireless-protocol-docs/
-- Device type IDs: https://github.com/pybricks/technical-info/blob/master/assigned-numbers.md
-- Legoino: https://github.com/corneliusmunz/legoino
-
----
-Created by: Jess Rogerson (yelling commands at Claude.AI)

docs/ESP32-PINOUT.md

@@ -0,0 +1,75 @@
+# ESP32 pinout reference
+
+For the original **ESP32-WROOM-32 / WROVER** devkit, which is what both boards
+in this project are. S3, C3, C6 and H2 have different maps entirely — and no
+Bluetooth Classic, so they cannot run board A at all.
+
+## Already in use
+
+| Pin | Board | Used for |
+| --- | --- | --- |
+| GPIO2 | A and B | onboard status LED |
+| GPIO16 | A and B | UART2 RX (link) |
+| GPIO17 | A and B | UART2 TX (link) |
+| GPIO25 | B | LED circuit 1 (Circle) |
+| GPIO26 | B | LED circuit 2 (Triangle) |
+
+## Free and safe for output
+
+Use these first. No strapping duties, no boot-time side effects.
+
+```
+4   13   14   18   19   21   22   23   27   32   33
+```
+
+That is eleven spare pins, which is plenty for more LEDs, a buzzer, servos or
+switches. GPIO21 and GPIO22 are the default I2C pins and GPIO18/19/23 the
+default SPI pins, but nothing in this project uses either bus, so they are free
+here.
+
+## Never use
+
+| Pin | Why |
+| --- | --- |
+| GPIO6–11 | wired to the on-board SPI flash chip. Touching these bricks the running firmware. |
+| GPIO12 | strapping pin (MTDI). Pulled high at boot it sets the flash voltage to 1.8V and the board will not boot. |
+| GPIO1, GPIO3 | UART0, the USB serial console. Using them breaks uploads and the serial monitor. |
+
+## Usable, with a catch
+
+| Pin | Catch |
+| --- | --- |
+| GPIO0 | strapping. Must be high at boot or the board enters flash-download mode. Has a button on most devkits. |
+| GPIO2 | strapping, and the onboard LED. Must be low or floating at boot. Fine as an output once running — this project uses it. |
+| GPIO5 | strapping. Outputs a PWM burst during boot, so anything attached will twitch at power-on. |
+| GPIO15 | strapping. Emits boot log noise unless pulled low. |
+
+## Input only — cannot drive an LED
+
+```
+34   35   36   39
+```
+
+These have no output drivers and no internal pull-ups. Fine for buttons with an
+external pull-up, or for analog input. Connect an LED and nothing happens.
+
+## Current limits
+
+A single pin is comfortable at about **12mA** and hard-limited near **40mA**.
+The whole chip should stay under roughly 200mA across all pins at once.
+
+Two or three small LEDs per pin is fine. Anything beyond about 20mA per circuit
+— which pre-wired "3V" LEDs sized for a coin cell often draw — wants a small
+NPN transistor or a logic-level MOSFET, with the pin driving the base or gate
+rather than the LED directly.
+
+## ADC note
+
+ADC2 pins (0, 2, 4, 12–15, 25–27) cannot be read with `analogRead()` while
+WiFi is active. Irrelevant to this project, which uses no WiFi and no analog
+input, but worth knowing before adding a potentiometer. ADC1 pins (32–39) work
+regardless.
+
+---
+
+Created by: Jess Rogerson (yelling commands at Claude.AI)

docs/WIRING.md

@@ -0,0 +1,88 @@
+# Wiring
+
+![Wiring pinout](wiring.svg)
+
+Pin availability and limits: [ESP32-PINOUT.md](ESP32-PINOUT.md).
+
+## Board to board
+
+| Board A (esp32_bluepad32) | | Board B (esp32 2.0.17) |
+| --- | --- | --- |
+| GPIO17 TX | → | GPIO16 RX |
+| GPIO16 RX | ← | GPIO17 TX |
+| GND | — | GND |
+| 5V | — | 5V (model setup only, see README) |
+
+TX goes to RX, not TX to TX. The ground is a shared voltage reference so the
+two boards agree on what a logic 1 is — without it you get garbage or silence.
+It is not a return path for anything else, so do not hang LED current off it.
+
+## LED circuits — recommended build
+
+Each LED gets its own wire out and its own wire back to its own GND pin. Four
+wires, no shared junction anywhere.
+
+![LED wiring with separate grounds](wiring-leds-separate.svg)
+
+```
+GPIO25 ──[220Ω]──▶|── RED pair ──── GND (a)
+GPIO26 ──[100Ω]──▶|── GREEN pair ── GND (b)
+```
+
+GND (a) and GND (b) are different physical pins but the same net inside the
+board. That is fine, and it is exactly what makes this safe: there is no shared
+connection point to wire incorrectly.
+
+Both circuits live entirely on **board B**. LED long leg (anode) faces the
+resistor and GPIO side. A reversed LED simply stays dark, so it looks like a
+dead circuit rather than a wiring error.
+
+Resistor values are a starting point: roughly 220Ω for red, 100Ω for blue or
+white. A pin is comfortable at about 12mA and hard-limited near 40mA. If a pair
+draws more than ~20mA — which pre-wired "3V" LEDs sized for a coin cell often
+do — drive it through a small NPN transistor or MOSFET instead of off the pin.
+
+## Shared ground rail — the other way
+
+Also valid, one wire fewer, but it has a junction that can be wired wrong:
+
+```
+GPIO25 ──[220Ω]──▶|── RED pair ────┐
+                                   ├── ground rail ── board B GND
+GPIO26 ──[100Ω]──▶|── GREEN pair ──┘
+```
+
+The two returns must meet **only at the ground rail**, and the rail goes
+straight to a GND pin. See the failure mode below for what happens when that
+junction lands in the wrong place.
+
+## Known failure mode: LEDs wired in series
+
+Symptom seen on this build — green only lights when red is already on, and
+green never lights alone:
+
+| Software state | Observed |
+| --- | --- |
+| red on, green off | red on ✓ |
+| red off, green on | **both off** ✗ |
+| red on, green on | both on ✓ |
+| red off, green off | both off ✓ |
+
+Cause: the green return lands on the *anode* side of the red LED rather than on
+the ground rail, putting the two LEDs in series. Green alone then has to push
+through both — roughly 2.1V plus 1.9V — and a 3.3V pin cannot do it, so neither
+lights. With GPIO25 also high, the junction is lifted and both conduct.
+
+Two rows of that table are impossible from a software fault, which is what
+identifies it as wiring.
+
+**Test:** with both LEDs off, meter from the shared return wire to a GND pin.
+It must read 0V. Press Circle and measure again — if it rises above 0V, that
+wire is not ground.
+
+**Fix:** switch to the separate-ground build above. It removes the junction
+entirely, so this cannot recur.
+
+---
+
+Created by: Jess Rogerson (yelling commands at Claude.AI)

docs/wiring-leds-separate.svg

@@ -0,0 +1,56 @@
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+<title id="t2">LED wiring with separate ground pins - recommended</title>
+<desc id="d2">Board B GPIO25 goes through a 220 ohm resistor to the red LED pair and returns to its own GND pin. Board B GPIO26 goes through a 100 ohm resistor to the green LED pair and returns to a different GND pin. Four wires total and the two circuits never touch each other, so neither can end up in series with the other.</desc>
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+
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+<text class="h" x="42" y="373">Why this version cannot fail the same way</text>
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+<text class="s" x="42" y="413">neither can end up in series with the other. GND (a) and GND (b) are different physical pins</text>
+<text class="s" x="42" y="431">but the same net inside the board - that is fine, and it is what makes this safe to do.</text>
+</svg>

docs/wiring.svg

@@ -0,0 +1,90 @@
+<svg xmlns="http://www.w3.org/2000/svg" viewBox="0 0 760 740" width="760" height="740" role="img" aria-labelledby="t d">
+<title id="t">Johnny 5 wiring pinout - both ESP32 boards and both LED circuits</title>
+<desc id="d">Board A runs Bluepad32 and pairs with the PS4 controller. Board A GPIO17 goes to Board B GPIO16; Board A GPIO16 goes to Board B GPIO17; the grounds are joined as a shared reference. Board B runs Legoino, connects to two LEGO hubs over BLE, and drives two independent LED circuits: GPIO25 through a 220 ohm resistor to the red LED pair and back to a ground rail, and GPIO26 through a 100 ohm resistor to the green LED pair and back to the same ground rail. Each LED has its own complete path; they are never in series.</desc>
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+
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+<text class="xs" x="145" y="156" text-anchor="middle">transmitter.ino</text>
+<rect class="box p" x="170" y="170" width="84" height="24" rx="4"/><text class="s" x="212" y="187" text-anchor="middle">TX 17</text>
+<rect class="box p" x="170" y="200" width="84" height="24" rx="4"/><text class="s" x="212" y="217" text-anchor="middle">RX 16</text>
+<rect class="box n" x="170" y="230" width="84" height="24" rx="4"/><text class="s" x="212" y="247" text-anchor="middle">GND</text>
+
+<rect class="box t" x="440" y="98" width="230" height="182" rx="12"/>
+<text class="h" x="555" y="124" text-anchor="middle">BOARD B</text>
+<text class="xs" x="555" y="141" text-anchor="middle">esp32 core 2.0.17</text>
+<text class="xs" x="555" y="156" text-anchor="middle">receiver.ino</text>
+<rect class="box t" x="446" y="170" width="84" height="24" rx="4"/><text class="s" x="488" y="187" text-anchor="middle">RX 16</text>
+<rect class="box t" x="446" y="200" width="84" height="24" rx="4"/><text class="s" x="488" y="217" text-anchor="middle">TX 17</text>
+<rect class="box n" x="446" y="230" width="84" height="24" rx="4"/><text class="s" x="488" y="247" text-anchor="middle">GND</text>
+<rect class="box r" x="576" y="170" width="88" height="24" rx="4"/><text class="s" x="620" y="187" text-anchor="middle">GPIO 25</text>
+<rect class="box g" x="576" y="200" width="88" height="24" rx="4"/><text class="s" x="620" y="217" text-anchor="middle">GPIO 26</text>
+<rect class="box n" x="576" y="230" width="88" height="24" rx="4"/><text class="s" x="620" y="247" text-anchor="middle">GND 2</text>
+
+<line class="w" x1="256" y1="182" x2="442" y2="182" stroke="#D85A30" marker-end="url(#ar)"/>
+<line class="w" x1="444" y1="212" x2="258" y2="212" stroke="#7F77DD" marker-end="url(#ar)"/>
+<line class="w" x1="256" y1="242" x2="444" y2="242" stroke="#888780"/>
+<text class="xs" x="350" y="166" text-anchor="middle">UART link 115200 8N1</text>
+<text class="xs" x="350" y="262" text-anchor="middle">shared voltage reference only - do NOT hang LED current off this</text>
+
+<rect class="box b" x="440" y="300" width="108" height="40" rx="8"/>
+<text class="s" x="494" y="318" text-anchor="middle">Hub 0 (BLE)</text><text class="xs" x="494" y="333" text-anchor="middle">A B D</text>
+<rect class="box b" x="558" y="300" width="108" height="40" rx="8"/>
+<text class="s" x="612" y="318" text-anchor="middle">Hub 1 (BLE)</text><text class="xs" x="612" y="333" text-anchor="middle">A B C D</text>
+<line class="w" x1="555" y1="282" x2="555" y2="296" stroke="#888780" marker-end="url(#ar)"/>
+
+<line x1="30" y1="380" x2="730" y2="380" stroke="#c9c8c3" stroke-width="1" stroke-dasharray="4 4"/>
+<text class="h" x="30" y="408">LED circuits - two separate loops, board B only</text>
+
+<rect class="box r" x="30" y="430" width="88" height="26" rx="4"/><text class="s" x="74" y="448" text-anchor="middle">GPIO 25</text>
+<line class="w" x1="120" y1="443" x2="164" y2="443" stroke="#D85A30"/>
+<rect class="box r" x="166" y="430" width="96" height="26" rx="4"/><text class="s" x="214" y="448" text-anchor="middle">220&#937;</text>
+<line class="w" x1="264" y1="443" x2="308" y2="443" stroke="#D85A30"/>
+<rect class="box r" x="310" y="424" width="150" height="38" rx="6"/>
+<text class="s" x="385" y="441" text-anchor="middle">RED pair</text>
+<text class="xs" x="385" y="456" text-anchor="middle">long leg faces this side</text>
+<line class="w" x1="462" y1="443" x2="596" y2="443" stroke="#D85A30"/>
+
+<rect class="box g" x="30" y="510" width="88" height="26" rx="4"/><text class="s" x="74" y="528" text-anchor="middle">GPIO 26</text>
+<line class="w" x1="120" y1="523" x2="164" y2="523" stroke="#3D9A50"/>
+<rect class="box g" x="166" y="510" width="96" height="26" rx="4"/><text class="s" x="214" y="528" text-anchor="middle">100&#937;</text>
+<line class="w" x1="264" y1="523" x2="308" y2="523" stroke="#3D9A50"/>
+<rect class="box g" x="310" y="504" width="150" height="38" rx="6"/>
+<text class="s" x="385" y="521" text-anchor="middle">GREEN pair</text>
+<text class="xs" x="385" y="536" text-anchor="middle">long leg faces this side</text>
+<line class="w" x1="462" y1="523" x2="596" y2="523" stroke="#3D9A50"/>
+
+<line class="w" x1="598" y1="443" x2="598" y2="523" stroke="#888780"/>
+<line class="w" x1="598" y1="483" x2="658" y2="483" stroke="#888780" marker-end="url(#ar)"/>
+<rect class="box n" x="662" y="470" width="68" height="26" rx="4"/><text class="s" x="696" y="488" text-anchor="middle">GND 2</text>
+<text class="xs" x="598" y="562" text-anchor="middle">ground rail - the two returns join ONLY here</text>
+
+<rect class="box r" x="30" y="596" width="700" height="112" rx="8"/>
+<text class="h" x="48" y="622">The fault to look for</text>
+<text class="s" x="48" y="645">The green return is reaching the RED side of the red LED instead of the ground rail, putting</text>
+<text class="s" x="48" y="663">the two LEDs in series. Green alone then needs about 4V through both, and 3.3V cannot supply it.</text>
+<text class="s" x="48" y="686">TEST: with both LEDs off, meter from the shared return wire to GND. It must read 0V. Press</text>
+<text class="s" x="48" y="704">Circle and measure again - if it rises above 0V that wire is not ground, and that is the fault.</text>
+</svg>

receiver/receiver.ino

@@ -1,32 +1,49 @@
 /*
  * receiver.ino  --  UART -> two LEGO Powered Up hubs (ESP32 "B")
  *
- * Model: Johnny 5 (Short Circuit) MOC, 7 motors across 2 Technic hubs.
+ * Model: Johnny 5 (Short Circuit) MOC - "Evolved" control scheme.
+ *        7 motors across 2 Technic hubs, plus 2 GPIO-driven LED circuits.
  *
  * Board package: esp32 (the normal Espressif one), core 2.0.17
  * Libraries:     Legoino  +  NimBLE-Arduino 1.4.x  (both via Library Manager)
  *
  * Core 3.x will not build Legoino - you get 'std::string does not name a type'
  * and a ReadUInt32LE declaration mismatch. Stay on 2.0.17 for this board.
- *
- * Listens for gamepad frames from the Bluepad32 board on Serial2 and drives
- * both hubs over BLE using Legoino. This board must NOT have the Bluepad32
- * board package selected - keeping BTstack and NimBLE on separate chips is
- * the entire reason there are two boards.
+ * Do NOT select the esp32_bluepad32 package here either: it starts BTstack
+ * before setup() runs and NimBLE aborts with ESP_ERR_INVALID_STATE.
  *
  * Wiring to the transmitter board:
  *   RX GPIO16  <-  TX GPIO17 on transmitter
  *   TX GPIO17  ->  RX GPIO16 on transmitter
  *   GND        ->  GND                       (mandatory - common ground)
  *
- * Control scheme is tank drive: every input drives exactly one motor.
+ * LED circuits - both on THIS board, returning to THIS board's GND:
+ *   GPIO25 -> resistor -> LED pair -> GND
+ *   GPIO26 -> resistor -> LED pair -> GND
+ *   Pins output 3.3V, not 3V. ~12mA per pin is comfortable, 40mA is the hard
+ *   limit. Anything drawing more than ~20mA per circuit needs a transistor.
+ *   Do not tap the LED return off the UART ground wire to the other board -
+ *   that reference needs to stay clean.
+ *
+ * STARTUP ORDER:
+ *   Wake BOTH hubs with their green buttons and check both are blinking,
+ *   THEN power this board. hub1 is only serviced once hub0 is connected, so a
+ *   sleeping hub0 blocks the whole sequence. Hubs stop advertising after a
+ *   couple of minutes idle.
+ *
+ * ARMS ARE POSITION CONTROLLED:
+ *   The triggers set an ANGLE, not a power level. Trigger released holds the
+ *   arm at 0, fully depressed holds it at ARM_SPAN_*. The encoders are zeroed
+ *   once, on the first hub1 connect after boot, so BOTH ARMS MUST BE DOWN at
+ *   that moment. They are deliberately NOT re-zeroed on a reconnect - the hub
+ *   keeps its encoder preset, and re-zeroing mid-session would redefine zero
+ *   at whatever position the arms happened to be in.
  *
  * FILE ORDER MATTERS:
  *   The Arduino IDE injects generated function prototypes immediately before
  *   the FIRST function definition in the file. Any type used in a function
  *   signature must be declared above that point - which is why HubLink,
- *   PortState and Frame all live in the types block. Move a function above
- *   them and you get "'Frame' has not been declared".
+ *   PortState, ArmState and Frame all live in the types block.
  *
  * Created by: Jess Rogerson (yelling commands at Claude.AI)
  */
@@ -38,55 +55,64 @@
 // Hub BLE addresses. Run tools/hub_scanner to find them - do not guess.
 //
 //   hub 0 - lower body        hub 1 - upper body
-//     A  right track            A  head tilt
-//     B  left track             B  head turn
-//     D  body lift              C  left arm
-//                               D  right arm
+//     A  right track            A  left arm
+//     B  left track             B  head tilt
+//     C  (free)                 C  head turn
+//     D  body lift              D  right arm
 static const char *HUB0_ADDR = "90:84:2b:61:f2:d7";
 static const char *HUB1_ADDR = "90:84:2b:61:e6:8c";
 
-// Port numbers are just bytes in the LEGO protocol, same on every hub type.
 static const byte PORT_A = 0x00;
 static const byte PORT_B = 0x01;
 static const byte PORT_C = 0x02;
 static const byte PORT_D = 0x03;
 
-// Technic / Control+ motors are tacho motors -> leave this at 1.
-// Plain train motors and the simple Powered Up motors -> set it to 0.
+// LED circuits. Safe GPIOs - no boot strapping or flash duties, unlike 0, 2,
+// 12 and 15.
+static const int LED_1_PIN = 25;    // Circle toggles this pair
+static const int LED_2_PIN = 26;    // Triangle toggles this pair
+
 #define USE_TACHO_MOTORS 1
 
-// Set to 1 to log every motor command that goes out. Useful for proving which
-// port a command actually lands on. Noisy - turn it back off afterwards.
+// Set to 1 to log every command that goes out. Noisy - turn it back off.
 #define DEBUG_MOTORS 0
 
 static const int DEADZONE = 40;     // raw stick counts ignored around centre
 
-// Motor directions. Flip to -1 if an axis runs backwards - mirrored mountings
-// are normal on a symmetric model, and this is cheaper than editing signs
-// scattered through applyFrame().
+// Motor directions. Flip to -1 if an axis runs backwards.
 static const int DIR_LEFT_TRACK  =  1;
 static const int DIR_RIGHT_TRACK = -1;
 static const int DIR_BODY_LIFT   =  1;
 static const int DIR_HEAD_TILT   =  1;
 static const int DIR_HEAD_TURN   =  1;
-static const int DIR_LEFT_ARM    =  1;
-static const int DIR_RIGHT_ARM   =  1;
 
-// Per-axis power caps. Everything except the tracks runs into a mechanical end
-// stop and there is no position feedback, so holding a direction at a stop
-// stalls the motor. Lower these if an axis feels forceful.
+// Arm travel in MOTOR degrees, measured with tools/arm_calibrate.
+// Raw measurements were roughly +280 (left) and -275 (right). These are set
+// slightly short so backlash cannot stall the motor against the top stop.
+// The sign carries the direction - there is no DIR_ constant for the arms.
+static const int32_t ARM_SPAN_LEFT  =  250;
+static const int32_t ARM_SPAN_RIGHT = -250;
+
+static const int  ARM_SPEED     = 60;   // how fast it travels to the target
+static const byte ARM_MAX_POWER = 40;   // torque cap - keeps a jam survivable
+static const int  ARM_STEP_DEG  = 3;    // ignore target changes smaller than this
+
+// Arms get their own command interval. They are position controlled, so the
+// target moves continuously with the trigger and needs updating more often
+// than a velocity axis does - at the per-port 100ms the arm sprints to each
+// target then sits idle, which feels like stepping.
+static const unsigned long ARM_MIN_GAP_MS = 60;
+
+// Per-axis power caps for the velocity-controlled axes.
 static const int TRACK_MAX = 100;   // LEGO speed range is -100..100
 static const int HEAD_MAX  = 45;
 static const int LIFT_MAX  = 60;
-static const int ARM_MAX   = 45;
 
-// Track scaling: normal, L1 held (precision), R1 held (full).
-static const int SCALE_NORMAL    = 75;
-static const int SCALE_PRECISION = 40;
-static const int SCALE_FULL      = 100;
+// Track speed, toggled by Cross.
+static const int SPEED_SLOW = 50;
+static const int SPEED_FAST = 100;
 
-// Bluepad32 button masks. Verify against your own pad with DEBUG_BUTTONS in
-// the transmitter sketch if any of these seem wrong.
+// Bluepad32 button masks. Verify with DEBUG_BUTTONS in the transmitter.
 static const unsigned BTN_A  = 0x0001;   // Cross
 static const unsigned BTN_B  = 0x0002;   // Circle
 static const unsigned BTN_X  = 0x0004;   // Square
@@ -99,11 +125,18 @@ static const unsigned DPAD_D = 0x02;
 static const unsigned DPAD_R = 0x04;
 static const unsigned DPAD_L = 0x08;
 
+// Triggers rest at 0 and are noisy near the bottom of their travel.
+static const int TRIGGER_DEADZONE = 60;
+
 static const unsigned long MOTOR_MIN_GAP_MS = 100;  // per port
 static const unsigned long HUB_MIN_GAP_MS   = 25;   // per hub, ~40 cmd/sec
 static const unsigned long LINK_TIMEOUT_MS  = 400;  // failsafe
 static const unsigned long RECONNECT_GAP_MS = 2000;
 
+// A Legoino scan that never finds its hub expires silently, leaving the hub
+// stuck waiting forever. This is how long we give it before starting over.
+static const unsigned long SCAN_TIMEOUT_MS = 12000;
+
 static const int  LINK_RX_PIN = 16;
 static const int  LINK_TX_PIN = 17;
 static const long LINK_BAUD   = 115200;
@@ -118,7 +151,8 @@ struct HubLink {
     const char *label;
     bool initialised;
     unsigned long retryAt;
-    unsigned long lastCmdAt;   // per-hub rate limit, shared across its ports
+    unsigned long lastCmdAt;       // per-hub rate limit, shared across ports
+    unsigned long scanExpiresAt;   // when to give up on the current scan
 };
 
 struct PortState {
@@ -126,6 +160,11 @@ struct PortState {
     unsigned long lastSentAt;
 };
 
+struct ArmState {
+    int32_t lastTarget;
+    unsigned long lastSentAt;
+};
+
 struct Frame {
     int lx, ly, rx, ry;
     unsigned buttons, dpad;
@@ -135,18 +174,28 @@ struct Frame {
 // ================================================================= globals
 
 static HubLink gHubs[2] = {
-    {Lpf2Hub(), HUB0_ADDR, "hub0", false, 0, 0},
-    {Lpf2Hub(), HUB1_ADDR, "hub1", false, 0, 0},
+    {Lpf2Hub(), HUB0_ADDR, "hub0", false, 0, 0, 0},
+    {Lpf2Hub(), HUB1_ADDR, "hub1", false, 0, 0, 0},
 };
 
-// Indexes: 0 rightTrack, 1 leftTrack, 2 bodyLift,
-//          3 headTilt,   4 headTurn,  5 leftArm, 6 rightArm
-static PortState gPort[7] = {{999, 0}, {999, 0}, {999, 0}, {999, 0},
-                             {999, 0}, {999, 0}, {999, 0}};
+// Indexes follow physical ports, not functions:
+//   0 hub0/A  1 hub0/B  2 hub0/D  3 hub1/B  4 hub1/C
+static PortState gPort[5] = {{999, 0}, {999, 0}, {999, 0}, {999, 0}, {999, 0}};
+
+// Arms are position controlled, so they get their own state.
+static ArmState gArmLeft  = {INT32_MIN, 0};
+static ArmState gArmRight = {INT32_MIN, 0};
+static bool gArmsZeroed = false;
 
 static unsigned long lastFrameAt = 0;
 static bool failsafeEngaged = true;
 
+// Latched state, changed on button press rather than while held.
+static int  gTrackSpeed = SPEED_SLOW;
+static bool gLed1On = false;
+static bool gLed2On = false;
+static unsigned gPrevButtons = 0;
+
 // ================================================================= helpers
 
 // Deadzone, then rescale so the remaining travel still reaches full speed.
@@ -159,6 +208,15 @@ static int stickToSpeed(int raw, int maxSpeed) {
     return sign * (int)scaled;
 }
 
+// Analog trigger, 0..1023, to a target angle between 0 and span.
+static int32_t triggerToAngle(int raw, int32_t span) {
+    if (raw <= TRIGGER_DEADZONE) return 0;
+    long travel = (long)raw - TRIGGER_DEADZONE;
+    long full = 1023L - TRIGGER_DEADZONE;
+    if (travel > full) travel = full;
+    return (int32_t)((travel * span) / full);
+}
+
 static void driveMotor(HubLink &hl, byte port, int speed, PortState &st) {
     if (!hl.hub.isConnected()) return;
 
@@ -166,8 +224,8 @@ static void driveMotor(HubLink &hl, byte port, int speed, PortState &st) {
     bool stopping = (speed == 0 && st.lastSpeed != 0);
 
     // Stops always go out immediately. Everything else is rate limited twice:
-    // per port, and per hub - hub 1 has four motors on it, and the per-port
-    // limit alone lets through more than the hub will swallow.
+    // per port, and per hub - the per-port limit alone lets through more than
+    // a hub with several motors on it will swallow.
     if (!stopping) {
         if (speed == st.lastSpeed) return;
         if ((now - st.lastSentAt) < MOTOR_MIN_GAP_MS) return;
@@ -189,18 +247,56 @@ static void driveMotor(HubLink &hl, byte port, int speed, PortState &st) {
     hl.lastCmdAt = now;
 }
 
+// Position control. HOLD keeps the motor actively at the target rather than
+// letting gravity drag the arm back down.
+static void driveArm(HubLink &hl, byte port, int32_t target, ArmState &st) {
+    if (!hl.hub.isConnected() || !gArmsZeroed) return;
+
+    unsigned long now = millis();
+    if (labs((long)target - (long)st.lastTarget) < ARM_STEP_DEG) return;
+    if ((now - st.lastSentAt) < ARM_MIN_GAP_MS) return;
+    if ((now - hl.lastCmdAt) < HUB_MIN_GAP_MS) return;
+
+#if DEBUG_MOTORS
+    Serial.printf("TX %s port %u angle %ld\n", hl.label, port, (long)target);
+#endif
+
+    hl.hub.setAbsoluteMotorPosition(port, ARM_SPEED, target, ARM_MAX_POWER,
+                                    BrakingStyle::HOLD);
+
+    st.lastTarget = target;
+    st.lastSentAt = now;
+    hl.lastCmdAt = now;
+}
+
 static void stopEverything() {
     driveMotor(gHubs[0], PORT_A, 0, gPort[0]);
     driveMotor(gHubs[0], PORT_B, 0, gPort[1]);
     driveMotor(gHubs[0], PORT_D, 0, gPort[2]);
-    driveMotor(gHubs[1], PORT_A, 0, gPort[3]);
-    driveMotor(gHubs[1], PORT_B, 0, gPort[4]);
-    driveMotor(gHubs[1], PORT_C, 0, gPort[5]);
-    driveMotor(gHubs[1], PORT_D, 0, gPort[6]);
+    driveMotor(gHubs[1], PORT_B, 0, gPort[3]);
+    driveMotor(gHubs[1], PORT_C, 0, gPort[4]);
+
+    // Arms: a plain speed command overrides the position hold and goes limp.
+    // Reset the cached targets so the next trigger movement re-commands.
+    if (gHubs[1].hub.isConnected()) {
+        gHubs[1].hub.setTachoMotorSpeed(PORT_A, 0);
+        gHubs[1].hub.setTachoMotorSpeed(PORT_D, 0);
+    }
+    gArmLeft.lastTarget = INT32_MIN;
+    gArmRight.lastTarget = INT32_MIN;
 }
 
 // Connect the hubs one at a time. Kicking off two scans at once upsets the
 // shared NimBLE scanner and you end up with one hub connected and one sulking.
+//
+// Note the 'initialised' one-shot. init() starts an ASYNCHRONOUS scan, so
+// immediately afterwards isConnected() and isConnecting() are both still
+// false. Guarding on those alone re-enters NimBLEDevice::init() thousands of
+// times a second and the Bluetooth controller aborts.
+//
+// The scanExpiresAt deadline exists because a scan that finds nothing just
+// ends quietly - isConnecting() never goes true, so without a timeout the hub
+// sits on a dead scan until the board is power cycled.
 static void serviceHub(HubLink &hl) {
     if (hl.hub.isConnected()) return;
 
@@ -217,13 +313,40 @@ static void serviceHub(HubLink &hl) {
         return;
     }
 
+    if (hl.initialised && millis() >= hl.scanExpiresAt) {
+        Serial.printf("[%s] scan timed out, restarting\n", hl.label);
+        hl.initialised = false;
+        hl.retryAt = millis() + RECONNECT_GAP_MS;
+        return;
+    }
+
     if (!hl.initialised && millis() >= hl.retryAt) {
         Serial.printf("[%s] scanning for %s\n", hl.label, hl.addr);
         hl.hub.init(std::string(hl.addr));
         hl.initialised = true;
+        hl.scanExpiresAt = millis() + SCAN_TIMEOUT_MS;
     }
 }
 
+// Define "arms down" as angle zero. Runs once per boot, after hub1 connects,
+// with the arms physically at the bottom of their travel. Not repeated on a
+// reconnect: the hub keeps its encoder preset, and re-zeroing mid-session
+// would redefine zero wherever the arms happened to be sitting.
+static void zeroArms() {
+    if (gArmsZeroed || !gHubs[1].hub.isConnected()) return;
+
+    delay(500);   // let the hub finish reporting its ports
+    gHubs[1].hub.setAbsoluteMotorEncoderPosition(PORT_A, 0);
+    delay(200);
+    gHubs[1].hub.setAbsoluteMotorEncoderPosition(PORT_D, 0);
+    delay(200);
+
+    gArmsZeroed = true;
+    gArmLeft.lastTarget = INT32_MIN;
+    gArmRight.lastTarget = INT32_MIN;
+    Serial.println("Arms zeroed at current position");
+}
+
 static uint8_t xorChecksum(const char *s, size_t len) {
     uint8_t c = 0;
     for (size_t i = 0; i < len; i++) c ^= (uint8_t)s[i];
@@ -244,44 +367,68 @@ static bool parseFrame(char *line, Frame &f) {
                   &f.buttons, &f.dpad, &f.l2, &f.r2) == 8;
 }
 
+// Latching controls fire once per press, not continuously while held. Frames
+// arrive at ~50 Hz, so without edge detection a single press would toggle
+// twenty times.
+static void handleLatchingButtons(unsigned buttons) {
+    unsigned pressed = buttons & ~gPrevButtons;
+    gPrevButtons = buttons;
+
+    if (pressed & BTN_A) {          // Cross - alternate track speed
+        gTrackSpeed = (gTrackSpeed == SPEED_FAST) ? SPEED_SLOW : SPEED_FAST;
+        Serial.printf("track speed %d%%\n", gTrackSpeed);
+    }
+    if (pressed & BTN_B) {          // Circle - LED pair 1
+        gLed1On = !gLed1On;
+        digitalWrite(LED_1_PIN, gLed1On ? HIGH : LOW);
+    }
+    if (pressed & BTN_Y) {          // Triangle - LED pair 2
+        gLed2On = !gLed2On;
+        digitalWrite(LED_2_PIN, gLed2On ? HIGH : LOW);
+    }
+}
+
 // Tank drive. One input per motor - nothing is mixed.
 static void applyFrame(const Frame &f) {
-    // Both shoulders together is the panic stop.
-    if ((f.buttons & BTN_L1) && (f.buttons & BTN_R1)) {
+    handleLatchingButtons(f.buttons);
+
+    // Square is the panic stop. LEDs are left alone - they are not motion.
+    if (f.buttons & BTN_X) {
         stopEverything();
         return;
     }
 
-    int scale = SCALE_NORMAL;
-    if (f.buttons & BTN_L1) scale = SCALE_PRECISION;
-    if (f.buttons & BTN_R1) scale = SCALE_FULL;
+    int leftTrack  = stickToSpeed(-f.ly, TRACK_MAX) * gTrackSpeed / 100
+                     * DIR_LEFT_TRACK;
+    int rightTrack = stickToSpeed(-f.ry, TRACK_MAX) * gTrackSpeed / 100
+                     * DIR_RIGHT_TRACK;
 
-    int leftTrack  = stickToSpeed(-f.ly, TRACK_MAX) * scale / 100 * DIR_LEFT_TRACK;
-    int rightTrack = stickToSpeed(-f.ry, TRACK_MAX) * scale / 100 * DIR_RIGHT_TRACK;
+    // L1 / R1 turn the head while held.
+    int headTurn = ((f.buttons & BTN_R1) ? HEAD_MAX
+                 :  (f.buttons & BTN_L1) ? -HEAD_MAX : 0) * DIR_HEAD_TURN;
 
-    int headTilt = ((f.dpad & DPAD_U) ? HEAD_MAX
-                 :  (f.dpad & DPAD_D) ? -HEAD_MAX : 0) * DIR_HEAD_TILT;
-    int headTurn = ((f.dpad & DPAD_R) ? HEAD_MAX
-                 :  (f.dpad & DPAD_L) ? -HEAD_MAX : 0) * DIR_HEAD_TURN;
+    // D-pad: up/down lifts the body, left/right tilts the head.
+    int bodyLift = ((f.dpad & DPAD_U) ? LIFT_MAX
+                 :  (f.dpad & DPAD_D) ? -LIFT_MAX : 0) * DIR_BODY_LIFT;
+    int headTilt = ((f.dpad & DPAD_R) ? HEAD_MAX
+                 :  (f.dpad & DPAD_L) ? -HEAD_MAX : 0) * DIR_HEAD_TILT;
 
-    // R2 raises, L2 lowers. Both analog 0..1023, so the lift stays proportional.
-    int bodyLift = constrain((f.r2 - f.l2) * LIFT_MAX / 1023,
-                             -LIFT_MAX, LIFT_MAX) * DIR_BODY_LIFT;
-
-    // Square raises the left arm, Circle lowers it.
-    int leftArm  = ((f.buttons & BTN_X) ? ARM_MAX
-                 :  (f.buttons & BTN_B) ? -ARM_MAX : 0) * DIR_LEFT_ARM;
-    // Cross raises the right arm, Triangle lowers it.
-    int rightArm = ((f.buttons & BTN_A) ? ARM_MAX
-                 :  (f.buttons & BTN_Y) ? -ARM_MAX : 0) * DIR_RIGHT_ARM;
+    // Arms: trigger position IS arm angle. Released means "go to zero", which
+    // gravity is already doing, so the motor mostly just catches it.
+    int32_t leftTarget  = triggerToAngle(f.l2, ARM_SPAN_LEFT);
+    int32_t rightTarget = triggerToAngle(f.r2, ARM_SPAN_RIGHT);
 
     driveMotor(gHubs[0], PORT_A, rightTrack, gPort[0]);
     driveMotor(gHubs[0], PORT_B, leftTrack,  gPort[1]);
     driveMotor(gHubs[0], PORT_D, bodyLift,   gPort[2]);
-    driveMotor(gHubs[1], PORT_A, headTilt,   gPort[3]);
-    driveMotor(gHubs[1], PORT_B, headTurn,   gPort[4]);
-    driveMotor(gHubs[1], PORT_C, leftArm,    gPort[5]);
-    driveMotor(gHubs[1], PORT_D, rightArm,   gPort[6]);
+
+    // hub1 B is the tilt motor and C is the turn motor - the reverse of what
+    // the first build assumed.
+    driveMotor(gHubs[1], PORT_B, headTilt,   gPort[3]);
+    driveMotor(gHubs[1], PORT_C, headTurn,   gPort[4]);
+
+    driveArm(gHubs[1], PORT_A, leftTarget,  gArmLeft);
+    driveArm(gHubs[1], PORT_D, rightTarget, gArmRight);
 }
 
 // ==================================================================== main
@@ -293,7 +440,13 @@ void setup() {
     pinMode(STATUS_LED_PIN, OUTPUT);
     digitalWrite(STATUS_LED_PIN, LOW);
 
-    Serial.println("LEGO hub receiver starting");
+    pinMode(LED_1_PIN, OUTPUT);
+    pinMode(LED_2_PIN, OUTPUT);
+    digitalWrite(LED_1_PIN, LOW);
+    digitalWrite(LED_2_PIN, LOW);
+
+    Serial.println("LEGO hub receiver starting (Johnny 5 Evolved)");
+    Serial.println("Wake both hubs first. Both arms must be DOWN.");
 }
 
 void loop() {
@@ -301,6 +454,9 @@ void loop() {
     serviceHub(gHubs[0]);
     if (gHubs[0].hub.isConnected()) serviceHub(gHubs[1]);
 
+    // Zeroes once per boot. Deliberately not reset when the hub drops.
+    if (gHubs[1].hub.isConnected()) zeroArms();
+
     bool ready = gHubs[0].hub.isConnected() && gHubs[1].hub.isConnected();
     digitalWrite(STATUS_LED_PIN, ready ? HIGH : LOW);