BMW_E8x_EPS/gateway/dio_monitor.py

"""Standalone digital-IO monitor/logger for the CAN-IO board.

Deliberately separate from the CAN path: it talks to the board over the
USB '!'/'@' channel (see can-io/firmware/src/usb_bridge.h), which keeps
working when the CAN bus has no other powered node - the situation you're
in before the EPS gets its 12V enable, and exactly when the CAN status
frame goes missing because the shared TX queue backs up behind
100ms-timing-out transmits.

Logs each direction as its own signal:
  IN1  = the car's 12V ignition/enable signal arriving at this board
  OUT1 = the 12V signal this board repeats onward to the EPS

CSV columns: t, uptime_s, in1..in4, out1, out2, event
  event is "change" for a real transition, "sample" for periodic polls.
"""
from __future__ import annotations

import csv
import threading
import time
from pathlib import Path
from typing import Optional


class DioLogger:
    """Appends IO states to a CSV, noting which rows were real transitions."""

    def __init__(self, path: Path):
        self._file = open(path, "w", newline="")
        self._writer = csv.writer(self._file)
        self._writer.writerow(
            ["t", "wall", "uptime_s", "in1", "in2", "in3", "in4", "out1", "out2", "event"]
        )
        self._lock = threading.Lock()
        self._t0 = time.time()
        self._prev: Optional[tuple[int, int]] = None

    def record(self, inputs: int, outputs: int, uptime_s: int) -> bool:
        """Returns True if this was a change (not just a periodic sample)."""
        with self._lock:
            changed = self._prev is not None and (inputs, outputs) != self._prev
            first = self._prev is None
            self._prev = (inputs, outputs)
            now = time.time()
            self._writer.writerow(
                [
                    round(now - self._t0, 4),
                    round(now, 4),
                    uptime_s,
                    *[(inputs >> i) & 1 for i in range(4)],
                    outputs & 1,
                    (outputs >> 1) & 1,
                    "change" if changed else ("boot" if first else "sample"),
                ]
            )
            self._file.flush()  # keep the log usable while a session is still running
            return changed

    def close(self) -> None:
        self._file.close()


class DioMonitor:
    """Polls the board's IO channel on its own thread, independent of any
    CAN relay/replay activity, optionally logging every update.

    `owns_reads` must be False whenever something else (the Gateway's relay
    thread, the replay loop) is already calling read_frame() on the same
    adapter: two threads reading one serial port interleave partial lines
    and corrupt both streams. In that case this only writes '@G' requests
    and samples the io_state the other reader populates. Set it True when
    this monitor is the sole user of the port.
    """

    def __init__(self, adapter, logger: Optional[DioLogger] = None,
                 poll_interval: float = 0.25, owns_reads: bool = False):
        self.adapter = adapter
        self.logger = logger
        self.poll_interval = poll_interval
        self.owns_reads = owns_reads
        self.inputs = 0
        self.outputs = 0
        self.uptime_s = 0
        self.last_update: Optional[float] = None
        self.updates = 0
        self.changes = 0
        self._stop = threading.Event()
        self._thread: Optional[threading.Thread] = None

    def is_running(self) -> bool:
        return bool(self._thread and self._thread.is_alive())

    def start(self) -> None:
        if self.is_running():
            return
        self._stop.clear()
        self._thread = threading.Thread(target=self._run, daemon=True)
        self._thread.start()

    def stop(self) -> None:
        self._stop.set()
        if self._thread:
            self._thread.join(timeout=2)
        if self.logger is not None:
            self.logger.close()

    def set_output(self, index: int, on: bool) -> None:
        self.adapter.set_output(index, on)

    def set_output_verified(self, index: int, on: bool, attempts: int = 4, timeout: float = 0.6) -> bool:
        """Command an output and confirm the board actually reports it, retrying.

        A single '@S' write can be lost (USB CDC hiccup, or the line arriving
        while the board is mid-parse), which shows up as an output that
        occasionally just doesn't switch. Re-asserting until the reported
        state matches makes that self-healing - the command is idempotent,
        so a duplicate is harmless.
        """
        want = 1 if on else 0
        for _ in range(attempts):
            self.adapter.set_output(index, on)
            deadline = time.monotonic() + timeout
            while time.monotonic() < deadline:
                self.adapter.request_io()
                time.sleep(0.08)
                state = self.adapter.io_state
                if state is not None and ((state.outputs >> index) & 1) == want:
                    self.outputs = state.outputs
                    return True
        return False

    def _run(self) -> None:
        while not self._stop.is_set():
            self.adapter.request_io()
            if self.owns_reads:
                deadline = time.monotonic() + self.poll_interval
                while time.monotonic() < deadline:
                    self.adapter.read_frame(timeout=0.05)
            else:
                time.sleep(self.poll_interval)

            state = self.adapter.io_state
            if state is None:
                continue
            self.inputs = state.inputs
            self.outputs = state.outputs
            self.uptime_s = state.uptime_s
            self.last_update = state.recv_time
            self.updates += 1
            if self.logger is not None and self.logger.record(state.inputs, state.outputs, state.uptime_s):
                self.changes += 1