VCU - Vehicle Control Unit with Web Interface

A professional FreeRTOS-based vehicle control unit for ESP32-S3 with a modern web interface for real-time monitoring and configuration.

Features

Core Functionality

• FreeRTOS Multi-tasking: Three dedicated tasks for CAN communication, control logic, and web server
• Advanced Pedal Control: Three-zone system (Regen/Coast/Accel) with smooth torque transitions
• CAN Bus Integration: Manages BMS, DMC, BSC, and NLG subsystems
• Persistent Configuration: JSON-based flash storage with validation
• Real-time Monitoring: Error logging, performance metrics, and system health checks

Web Interface

• Always-On Web Server: Configure and monitor from any device on the network
• Modern Dashboard: Real-time charts for speed and power, live vehicle status
• Tabbed Interface:
  • Dashboard: Live monitoring with gauges and graphs
  • Charging: Configure charging current and target SOC
  • Configuration: Driving modes, pedal zones, torque transitions
  • CAN Monitor: Live CAN bus message viewer
  • Task Monitor: FreeRTOS task statistics
  • System: WiFi settings, debug mode, firmware info
• WebSocket Updates: 10Hz real-time data streaming
• Dark Theme: Professional automotive UI with purple/blue accents

Hardware

Microcontroller

• ESP32-S3 DevKit C1
• Dual-core ARM @ 240 MHz
• 16 MB Flash, 8 MB SRAM

Communication

• MCP2515 CAN Controller (SPI)
• ADS1115 16-bit ADC (I2C)
• WiFi 802.11 b/g/n

I/O

• Dual throttle pedal inputs
• HV contactor control
• Cooling pump PWM
• Charger/inverter enable outputs
• Connector unlock interrupt

Quick Start

1. Build and Upload Firmware

# Install PlatformIO
pip install platformio

# Build project
pio run

# Upload firmware
pio run --target upload

# Upload filesystem (web interface)
pio run --target uploadfs

2. First-Time Setup

1. Power on the VCU
2. Look for WiFi network: VCU_XXXXX (XXXXX = chip ID)
3. Connect with password: vcu12345
4. Open browser to: http://192.168.4.1

3. Configure WiFi

1. Navigate to System tab
2. Enter your WiFi SSID and password
3. VCU will connect to your network
4. Note the new IP address displayed

Web Interface

Dashboard Tab

• Live Data (updates every 100ms):
  • Vehicle state, gear, speed, torque
  • Battery SOC, voltage, current
  • Motor/inverter/battery temperatures
  • Throttle, regen, brake inputs
• Real-time Charts:
  • Speed chart (last 100 samples)
  • Power chart (positive = discharge, negative = charge)

Charging Tab

• Set maximum charging current (6-32A)
• Configure target SOC (50-100%)
• Monitor charger state and current

Configuration Tab

Driving Mode

• Legacy: Traditional throttle response
• Regen: Regenerative braking enabled
• OPD: One Pedal Drive mode

Pedal Zones

• Regen Zone End: 10-50% (default 16%)
• Coast Zone End: 15-60% (default 17%)
• Regen Progression: 1.0-3.0 (curve aggressiveness)
• Accel Progression: 1.0-3.0 (curve aggressiveness)

Torque Transitions

• Regen Engage: Time for 0 → negative torque
• Regen Release: Time for negative → 0 torque
• Power Engage: Time for 0 → positive torque
• Power Release: Time for positive → 0 torque
• Crossover: Time for regen ↔ power transitions

CAN Monitor Tab

• Live view of CAN messages from:
  • BMS (0x0F1) - Battery data
  • DMC (0x280) - Motor controller
  • BSC (0x26A) - DC-DC converter
  • NLG (0x728) - Charger

Task Monitor Tab

• FreeRTOS task information
• Heap memory usage
• CPU frequency
• System performance metrics

System Tab

• WiFi Configuration: Change network settings
• Debug Mode: Enable/disable (prevents deep sleep)
• Firmware Info: Chip model, version, uptime
• Configuration Management:
  • Export configuration to JSON file
  • Import configuration from JSON file
  • Factory reset

REST API

All configuration is accessible via REST API:

Status Endpoints

GET /api/status              - System status
GET /api/status/live         - Real-time vehicle data
GET /api/status/errors       - Error log

Configuration Endpoints

GET  /api/config/driving     - Get driving config
POST /api/config/driving     - Set driving config
GET  /api/config/charging    - Get charging config
POST /api/config/charging    - Set charging config
GET  /api/config/pedal       - Get pedal zones
POST /api/config/pedal       - Set pedal zones
GET  /api/config/transition  - Get torque transitions
POST /api/config/transition  - Set torque transitions
GET  /api/config/limits      - Get speed/power limits
POST /api/config/limits      - Set limits

System Endpoints

POST /api/system/save        - Save config to flash
POST /api/system/reset       - Factory reset
GET  /api/system/export      - Download config JSON
POST /api/system/import      - Upload config JSON
GET  /api/system/info        - System information
POST /api/system/debug       - Enable/disable debug mode

CAN Monitor

GET /api/can/messages        - Get CAN message data

WebSocket

ws://[IP_ADDRESS]/ws         - Real-time data stream (10Hz)

Debug Mode

Debug mode prevents the VCU from entering deep sleep, useful for:

• Development and testing
• Keeping WiFi active during extended stops
• Debugging CAN communication issues

Enable via:

• Web interface: System tab → Enable Debug Mode
• API: POST /api/system/debug {"enabled": true}

FreeRTOS Task Structure

Core 0 (CAN Communication)

• CAN Task (Priority 1, 12KB stack)
  • CAN message RX/TX
  • Motor speed updates
  • Torque calculation
  • Temperature monitoring
  • 1ms cycle time

Core 1 (Control & Web)

• Control Task (Priority 1, 24KB stack)

  • State machine updates
  • Interrupt handling
  • Performance monitoring
  • 50ms cycle time

• Web Server Task (Priority 1, 16KB stack)

  • WiFi management
  • HTTP request handling
  • WebSocket broadcasts
  • 10ms cycle time

Safety Features

• Input validation on all configuration changes
• Automatic fallback to safe defaults
• Error monitoring with severity levels
• System health checks
• CAN timeout detection
• Temperature monitoring
• Voltage/current limits
• Emergency stop capability

Configuration Backup

Export Configuration

1. Open web interface
2. Navigate to System tab
3. Click "Export Configuration"
4. Save vcu_config.json file

Import Configuration

1. Open web interface
2. Navigate to System tab
3. Click "Import Configuration"
4. Select previously saved JSON file

Network Configuration

Access Point Mode (Default)

• SSID: VCU_XXXXX (XXXXX = chip ID)
• Password: vcu12345
• IP Address: 192.168.4.1

Station Mode

• Configure via web interface System tab
• Automatically falls back to AP if connection fails
• Reconnects automatically if WiFi drops

Troubleshooting

Can't Connect to WiFi

1. Check that AP mode is active (look for VCU_ network)
2. Default password is vcu12345
3. Try factory reset if needed

Web Interface Not Loading

1. Check IP address in serial monitor
2. Ensure device is on same network
3. Try clearing browser cache
4. Use incognito/private browsing mode

Configuration Not Saving

1. Click "Save Configuration" button after changes
2. Check API response in browser console
3. Verify flash storage isn't full

Real-time Data Not Updating

1. Check WebSocket connection status (indicator in header)
2. Refresh page to reconnect
3. Ensure CAN bus is connected and operational

Development

File Structure

VCU/
├── src/
│   ├── main.cpp                  - Main application
│   ├── state_manager.cpp         - State machine
│   ├── vehicle_control.cpp       - Pedal control
│   ├── can_manager.cpp           - CAN communication
│   ├── configuration.cpp         - Config management
│   ├── wifi_manager.cpp          - WiFi management
│   └── web_server.cpp            - Web server
├── include/
│   └── [corresponding headers]
├── data/
│   ├── index.html                - Main web page
│   ├── styles.css                - Styling
│   ├── app.js                    - API/config logic
│   └── dashboard.js              - Charts/live data
├── platformio.ini                - Build configuration
└── min_spiffs.csv                - Partition table

Building from Source

# Clone repository
git clone [your-repo-url]
cd VCU

# Install dependencies (automatic via PlatformIO)
pio lib install

# Build
pio run

# Upload firmware
pio run --target upload

# Upload web interface
pio run --target uploadfs

# Monitor serial output
pio device monitor

License

[Your License Here]

Credits

Built with:

• PlatformIO
• ESP32 Arduino Framework
• ESPAsyncWebServer
• ArduinoJson
• FreeRTOS

Support

For issues, questions, or contributions, please open an issue on GitHub.