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Chapter 3 — Build & Configuration

Table of Contents

Repository Setup

Clone the repository and open it in VS Code with the PlatformIO extension installed:

git clone https://github.com/Andre1Becker/GalvOS.git
cd GalvOS
code .

PlatformIO detects platformio.ini automatically. On the first build it will download the ESP32-S3 platform toolchain (~500 MB) and all library dependencies. This happens once — subsequent builds are fast.

Library dependencies are declared in platformio.ini and managed automatically. You do not need to install anything manually:

Library Version Purpose
esp32async/AsyncTCP ^3.4.10 Async TCP for ESPAsyncWebServer
esp32async/ESPAsyncWebServer ^3.11.1 WebUI HTTP server + WebSocket
someweisguy/esp_dmx ^4.1.0 DMX-512 receive via UART
rstephan/ArtnetWifi git Art-Net UDP receiver
bblanchon/ArduinoJson ^7.0.4 JSON serialization (PSRAM allocator)
paulstoffregen/OneWire ^2.3.8 1-Wire bus
milesburton/DallasTemperature ^3.11.0 DS18B20 temperature sensor driver

PlatformIO Build

All build actions are run from the PlatformIO VS Code sidebar or the terminal:

# Build firmware (no flash)
pio run

# Flash firmware only (data/index.html not updated)
pio run --target upload

# Flash LittleFS only (updates WebUI, firmware not changed)
pio run --target uploadfs

# *** RECOMMENDED: build and flash everything in one step ***
pio run --target upload_all

# Open serial monitor (115200 baud)
pio device monitor

Important: Any change to files in the data/ directory (the WebUI) requires upload_all or uploadfs — a firmware-only flash will not update the WebUI. The same applies in reverse: changes to firmware source files do not require an uploadfs.

What upload_all Does

The scripts/upload_all.py pre-build script adds a custom target that:

  1. Builds the LittleFS image from data/
  2. Flashes the firmware
  3. Flashes the LittleFS

The scripts/gzip_assets.py pre-build hook automatically gzip-compresses index.html (and any other HTML/CSS/JS/SVG files in data/) before the LittleFS image is assembled. This reduces the on-flash size from ~440 KB to ~105 KB and eliminates a heap spike that occurred when serving the uncompressed file over Wi-Fi. The uncompressed originals remain in data/ as the editable source; only the .gz variants are served.

Flash Instructions

  1. Connect the ESP32-S3 DevKitC-1 to your PC via USB (the USB port labeled "UART", not "USB").
  2. On the first flash of a new board, or if the partition table has changed, hold the BOOT button while pressing EN, then release both. This puts the board in download mode.
  3. Run pio run --target upload_all.
  4. After flashing, the ESP32 restarts automatically.

Serial port selection: PlatformIO usually detects the correct port automatically. If you have multiple serial devices, set upload_port in platformio.ini:

upload_port = /dev/ttyUSB0   ; Linux
upload_port = COM5            ; Windows

Upload speed: Set to 921600 baud in platformio.ini. This is stable on most systems. If you see flash errors, reduce to 460800.

Wireless / OTA Update

Once a board has its first USB flash, every later update can go over Wi-Fi instead — no cable, no PlatformIO upload, just a browser. GalvOS exposes this at http://<hostname>.local/update (or the device's IP), protected by HTTP Basic Auth: user admin, password = the first 8 hex digits of the chip's MAC address (also shown as HTTP-OTA Pass on the Configuration tab — see Access Credentials).

Firmware Update page

The page has three parts:

Card Writes to Use it when…
Firmware whichever of app0/app1 isn't currently running (see Partition Table) anything under src/ or include/ changed
WebUI / Filesystem the spiffs partition (formatted LittleFS, holds data/) anything under data/ (index.html, assets) changed
Config Backup (download only) always — before flashing anything

Firmware and filesystem updates are independent uploads — a firmware-only change only needs the Firmware card, a WebUI-only change only needs the Filesystem one. Uploading a .bin that doesn't fit the target partition is rejected by Update.begin() rather than bricking the device.

Steps

  1. Build whichever artifact(s) you need — this only builds, it does not flash anything over USB:

    pio run                    # firmware.bin -> .pio/build/esp32-s3-devkitc-1/firmware.bin
pio run --target buildfs   # littlefs.bin -> .pio/build/esp32-s3-devkitc-1/littlefs.bin

    Both land in .pio/build/<environment>/ — esp32-s3-devkitc-1 for this board. The /update page doesn't care what you name the file you upload (it matches on the form field, not the filename), but renaming each to include the version you're about to ship — firmware_x.y.z.bin / littlefs_x.y.z.bin — keeps a folder of old builds sane to pick through later.

  2. Open http://<hostname>.local/update and sign in (admin / chip-ID password).

  3. Click Download Backup first — same JSON as the Configuration tab's Backup & Restore card, and cheap insurance against a bad flash.

  4. Pick the matching .bin under Firmware and/or WebUI / Filesystem and click its Upload button. A progress bar tracks the transfer; any Update.write()/Update.end() failure is shown inline (e.g. "not enough space", a truncated upload) instead of a bare "Update failed".

  5. Once every upload you started shows its success message, click Reboot Now.

The laser is force-disarmed the instant an upload starts, and OTA is refused outright while armed — same rule as POST /api/restore. Nothing reboots automatically on success, specifically so a multi-part update (say, firmware done but the filesystem upload still in progress) can't get rebooted into half-finished.

Note: ArduinoOTA (IDE/CLI push over port 3232, same chip-ID password) still runs in parallel with the /update page — use whichever is more convenient.

platformio.ini — Build Parameters

These are the parameters in platformio.ini that you may want to adjust. Everything else should be left at its default unless you have a specific reason to change it.

Parameters You Will Likely Touch

Parameter Default Description
LASER_FW_VERSION "6.36.0" Version string shown in the WebUI header and serial log. Increment this when you modify the firmware (see Version Bumps). Since v6.35.0 the WebUI additionally carries its own independent UI_VERSION (in data/index.html).
GALVO_SAMPLE_RATE_HZ 30000 The ISR tick rate — how many DAC samples are written per second. This is not the same as galvo_kpps in the WebUI (which controls how many of those ticks contain new pattern points). Default 30,000 Hz = 30 kpps effective output at full density.
DEFAULT_DMX_ADDRESS 1 Default DMX start address on first boot (before any NVS config).
DEFAULT_DMX_UNIVERSE 0 Default Art-Net universe on first boot.
upload_port (auto) Serial port for flashing. Set explicitly if auto-detect picks the wrong port.
upload_speed 921600 Baud rate for flashing. Reduce to 460800 if you see flash errors.

Parameters You Should Not Change (and Why)

Parameter Value Why Not
board_build.flash_size 16MB Must match the N16R8 physical flash. Wrong value = flash corruption.
board_build.psram_type octal Required for the N16R8 OPI PSRAM. Other values break PSRAM.
board_build.arduino.memory_type qio_opi Required for N16R8 octal PSRAM. Do not change.
board_build.partitions partitions.csv Custom partition table — the default ESP32-S3 table is too small for the LittleFS image.
BOARD_HAS_PSRAM defined Enables PSRAM in the Arduino core. Without this, ps_malloc() does not work.
ARDUINO_USB_MODE=1 defined Enables native USB CDC. Required for USB serial on the S3.
CONFIG_ASYNC_TCP_RUNNING_CORE=0 defined Pins AsyncTCP to Core 0, away from the galvo ISR on Core 1.

Version Bumps

Version strings follow Major.Minor.Patch:

  • Patch — single bug fix, one file changed
  • Minor — new feature or refactor touching multiple call sites
  • Major — broad architectural change

Update LASER_FW_VERSION in platformio.ini using Python string replacement (not sed — the escaped quotes make sed fragile):

# In a patch script:
content = content.replace('-D LASER_FW_VERSION=\\"6.36.0\\"',
                          '-D LASER_FW_VERSION=\\"6.36.1\\"', 1)

Partition Table

partitions.csv defines the flash memory layout:

Partition Type Size Purpose
otadata data/ota 8 KB OTA update bookkeeping
app0 app/ota_0 5 MB Active firmware image
app1 app/ota_1 5 MB OTA update staging slot
spiffs data/spiffs 5 MB LittleFS — WebUI (index.html.gz + assets)
coredump data/core dump 64 KB Core dump on crash (for post-mortem debugging)
nvs data/nvs 256 KB NVS key-value store — all runtime config

Total: ~15.32 MB of the 16 MB flash used. The LittleFS partition is labeled spiffs for historical PlatformIO compatibility — it is formatted as LittleFS, not SPIFFS.

Note: The nvs partition grew from its original 20 KB in two steps (v6.00.0 → 64 KB, v6.00.2 → 256 KB) after calibration saves started failing with NOT_ENOUGH_SPACE as more tunable parameters (per-profile optimizer defaults, per-channel calibration, etc.) accumulated in NVS. Both resizes shifted every partition's offset — if you are updating from firmware older than v6.00.0, erase the entire flash before reflashing (pio run --target erase or esptool.py erase_flash), otherwise the ESP32-IDF partition table and the actual NVS contents on flash will disagree and NVS reads may return garbage or fail outright.

config.h — Compile-Time Constants

These constants are defined in include/config.h and require a firmware rebuild if changed. They are not adjustable at runtime.

Pattern Engine Limits

Constant Default Description
PATTERN_POINTS_MAX 2048 Maximum number of LaserPoint entries in the pattern buffer. Increasing this uses more PSRAM.
POINTS_MODE_MAX_DOTS 80 UI slider ceiling for the Points-Only mode dot count.
POINTS_MODE_MIN_DWELL 3 Minimum dwell ticks per dot in Points-Only mode. Below this, the dot is invisible.
POINTS_MODE_MAX_DWELL 30 Maximum dwell ticks per dot — prevents a small number of dots from consuming the whole frame budget.
RANDOM_PTS_MAX_COUNT 14 UI slider ceiling for the Random Points preset "Amount" parameter.
KALEIDO_SEGMENTS_MAX 16 UI slider ceiling for the Kaleidoscope effect segment count.

Content Limits

Constant Default Description
PLAYLIST_MAX_ENTRIES 32 Maximum entries in an ILDA playlist.
PAINT_STROKES_MAX 12 Maximum strokes/shapes on the Paint canvas.
PAINT_VERTS_PER_STROKE 96 Maximum vertices per stroke (simplified client-side before upload).
ZONE_POINTS_MAX 16 Maximum vertices in the projection zone polygon.
ILDA_MAX_FILES 40 Maximum .ild files indexed from the SD card.

RuntimeConfig — User Parameters

RuntimeConfig (defined in include/config.h, stored as gConfig) holds all parameters that can be changed at runtime via the WebUI or REST API. They are persisted to NVS and survive reboots.

Galvo Geometry

Field Default Range Description
galvo_x_offset 0 −32767..32767 DC offset applied to the X galvo output (DAC units). Use to center the image horizontally.
galvo_y_offset 0 −32767..32767 DC offset applied to the Y galvo output. Use to center the image vertically.
galvo_x_gain 32767 0..32767 Scaling factor for X. Full scale = 32767. Reduce to shrink the image horizontally.
galvo_y_gain 32767 0..32767 Scaling factor for Y. Reduce to shrink the image vertically.
swap_xy false bool Swap X and Y galvo channels. Use if your galvo wiring has X and Y reversed.
invert_x false bool Mirror the image horizontally.
invert_y false bool Mirror the image vertically.

DAC Output Limiting

Field Default Description
dac_limit_min 0x0666 Minimum DAC code (clips the lower end of travel). Default ≈ 2.5% from the bottom — keeps OPA4134 output within ±5.5V.
dac_limit_max 0xF999 Maximum DAC code (clips the upper end of travel). Default ≈ 2.5% from the top.

These limits protect the galvo driver from being fed voltages outside its rated ±5V input range. The OPA4134 has a gain of 2.2× (R2/R4 = 22 kΩ instead of the theoretical 10 kΩ), so the actual output can slightly exceed ±5V at full DAC swing. The limits compensate for this. Adjust cautiously — reducing dac_limit_min/increasing dac_limit_max expands the scan angle but may stress the galvo driver.

Color & Brightness

Field Default Range Description
gain_r 115 0..255 White balance gain for the red channel. Calibrated for R=1W, 638 nm (V(λ)=0.235).
gain_g 43 0..255 White balance gain for the green channel. Calibrated for G=1W, 520 nm (V(λ)=0.710).
gain_b 255 0..255 White balance gain for the blue channel. Calibrated for B=3W, 445 nm (V(λ)=0.040).
gamma_enable true bool Enable CIE 1931 perceptual brightness correction. When enabled, the 0–255 PWM range follows human perception rather than linear power. Strongly recommended — linear laser output looks "blown out" at mid-brightness.
thresh_r 143 0..255 Visibility threshold for red: the minimum PWM duty at which the red laser diode actually emits visible light. Below this value the beam is physically dark. Calibrated via the Calibration tab.
thresh_g 144 0..255 Same for green.
thresh_b 169 0..255 Same for blue. The blue channel typically has the highest threshold.

How thresholds work: The mapVisibleRange() function remaps the logical 0–255 color range onto [thresh_x .. 255], so "0% brightness" in patterns always means the laser is off, and "100% brightness" always means full output — regardless of the threshold. Without calibrated thresholds, the bottom portion of the brightness range does nothing visible, making the projector appear to have lower dynamic range than it actually has.

Network

Field Default Description
wifi_ssid "" Wi-Fi network name. Empty = start in AP mode (SSID: "galvOS", open).
wifi_pass "" Wi-Fi password.
hostname "galvOS" mDNS hostname. Accessible as http://galvOS.local on networks with mDNS support. Auto-generated from MAC if empty.
wifi_static false Use static IP instead of DHCP.
wifi_ip / wifi_gw / wifi_mask / wifi_dns "" Static IP configuration. Only used when wifi_static = true.
ntp_server "pool.ntp.org" NTP server for time synchronization.
ntp_tz "UTC0" POSIX time zone string. Example for Central European Time: "CET-1CEST,M3.5.0,M10.5.0/3".

DMX / Art-Net

Field Default Range Description

| dmx_address | 1 | 1..512 | DMX start channel. CH1 = Master Dimmer, CH2–25 as per the channel map in config.h. | | artnet_universe | 0 | 0..32767 | Art-Net universe number. |

Safety & Diagnostics

Field Default Description
scanfail_timeout_ms 50 How long the NE555 scan-fail timer runs before declaring a fault (firmware side, for display only — the hardware NE555 has its own RC time constant).
watchdog_period_ms 500 Hardware watchdog heartbeat interval. Firmware pulses GPIO14 at this rate; the NE555 watchdog must be retriggered within this window or it cuts the laser rail.
heap_critical_bytes 6144 Minimum free internal DRAM block. If internal heap fragmentation causes the largest free block to fall below this, the firmware triggers esp_restart(). Calibrated to 6 KB — approximately 2× margin below the measured peak load.
safety_override false Bypass software safety checks. Use only for development. Never enable in production.
auth_hash "" SHA-256 hex of the WebUI password. Empty = default password "laser". Set via the Settings tab.
dac_debug_log false Log DAC8562 writes (hex) to serial and WebUI log, rate-limited. Useful for debugging DAC output; not for production use.

ProjectionConfig — Galvo & Laser Parameters

ProjectionConfig (stored as gProjection, NVS namespace "projection") holds parameters related to the physical galvo and laser hardware.

Field Default Description
galvo_kpps 20 The most important runtime parameter. Output rate in kilo-points-per-second. This directly controls the ISR period and how fast the galvo mirrors move. Range: 12–60 kpps. The Jolooyo JY-15K-BL is rated at 15 kpps — running above this causes missed steps and visible distortion. Start at 15 and only increase if your specific hardware handles it.
galvo_rated_kpps 15 The galvo's rated speed from its datasheet. Used as the basis for PPS scaling in the optimizer — do not confuse with galvo_kpps. If you use a different galvo set, set this to its rated speed.
scan_angle_mech_deg 25.0° Galvo mechanical half-angle (±25° = 50° full sweep). Used for display and safety zone calculations.
exit_angle_deg 20.0° Housing aperture half-angle — often smaller than the mechanical limit.
ilda_test_angle_deg 8.0° ILDA standard rating angle (±8° optical). Used for PPS scaling calculations.
power_r_mw 1000.0 Red channel laser power in mW. Used for white balance auto-calculation and laser hazard display.
power_g_mw 1000.0 Green channel laser power in mW.
power_b_mw 3000.0 Blue channel laser power in mW. The blue diode in the Mikoy 5W is 3W — be aware that 445 nm carries an elevated photochemical retinal hazard (B(λ) = 0.22).
distance_m 3.0 Throw distance to the projection surface in meters. Used for spot size and safety calculations in the UI.

SafetyConfig — Temperature Thresholds

SafetyConfig (stored as gSafety, in the "laser" NVS namespace) controls the temperature-based safety responses.

Field Default Description
temp_warn_c 45°C Temperature at which fans switch to 100% duty. Normal operation: fans run at fan_min_pct.
temp_reduce_c 55°C Temperature at which laser power is reduced to 50% (via thermal_power_scale).
temp_shutdown_c 70°C Temperature at which an immediate shutdown is triggered.
fan_min_pct 15% Minimum fan PWM percentage. Below ~15%, most 12V fans fail to start reliably.
fan_auto true Automatic fan speed based on temperature. If false, fans run at fan_min_pct always.

Optimizer Defaults

All optimizer defaults are defined as OPT_DEFAULT_* macros in config.h. These set the initial values for all six optimizer profiles on first boot (before NVS). Changing them requires a rebuild and an NVS reset to take effect (existing NVS values take priority over compile-time defaults).

For a full explanation of what each parameter does, see Chapter 5 — The Optimizer.

Macro Default Description
OPT_DEFAULT_CORNER_ANGLE_DEG 25.0° Minimum angle (at a vertex) that triggers corner dwell extra points.
OPT_DEFAULT_MIN_CORNER_PTS 2 Minimum extra points added at a corner.
OPT_DEFAULT_MAX_CORNER_PTS 8 Maximum extra points added at a corner.
OPT_DEFAULT_PTS_PER_1000_UNITS 6.0 Interior point density — points added per 1000 DAC units of segment length.
OPT_DEFAULT_MIN_SEGMENT_PTS 2 Minimum points per segment (excluding endpoints).
OPT_DEFAULT_BLANK_SAMPLES 16 Default blank jump sample count (without distance scaling).
OPT_DEFAULT_MAX_PTS_PER_FRAME 1010 Point budget per frame. Known effective limit: 1300 — no optical improvement is observed above this value on the JY-15K-BL hardware.
OPT_DEFAULT_MIN_BLANK_SAMPLES 6 Minimum blank samples (floor for distance-scaled blanking).
OPT_DEFAULT_BLANK_PTS_PER_1000_UNITS 8.0 Blank sample count scales with jump distance at this rate.
OPT_DEFAULT_MIN_INTERIOR_PTS_PER_SEG 8 Minimum interior points for longer segments.
OPT_DEFAULT_STAGE1_BLANK_TARGET 16 Stage 1 blank target point count.
OPT_DEFAULT_RESAMPLE_ENABLED false Constant-spacing resample stage. Disabled by default — output is identical to pre-resample when off.
OPT_DEFAULT_RESAMPLE_SPACING_UNITS 160.0 Spacing between resampled points in DAC units.
OPT_DEFAULT_RINGING_COMP_ENABLED false ZV input-shaping ringing compensation. Must be measured on your hardware before enabling — wrong values make ringing worse.
OPT_DEFAULT_RING_FREQ_HZ 200.0 Resonant frequency of the galvo (Hz). Measure via scope step-response capture.
OPT_DEFAULT_RING_DAMPING_RATIO 0.15 Damping ratio of the galvo. Measure via scope.
OPT_DEFAULT_VEL_CLAMP_ENABLED false Velocity clamp. Disabled by default — tune max_step_units for your hardware first.
OPT_DEFAULT_MAX_STEP_UNITS 200.0 Maximum per-tick position change (DAC units/sample). Long lit moves above this are subdivided.
OPT_DEFAULT_ACCEL_CLAMP_ENABLED false Acceleration clamp. Disabled by default.
OPT_DEFAULT_MAX_ACCEL_UNITS 800.0 Maximum per-tick change in step magnitude (DAC units/sample²).

pinmap.h — GPIO Assignments

All GPIO assignments are defined in include/pinmap.h. The following table summarizes the assignments. Pins marked Do Not Use are reserved by hardware and cannot be reassigned.

GPIO Assignment Direction Notes
1 PIN_SD_MISO Input SD card MISO on SPI3 (independent from DAC's SPI2). Pull-up recommended.
4 PIN_DMX_RX Input DMX-512 receive from MAX485 RO
5 PIN_SD_SCK Output SD card SCK on SPI3 (independent from DAC's SPI2)
6 PIN_SD_MOSI Output SD card MOSI on SPI3 (independent from DAC's SPI2)
7 PIN_LASER_R Output Red laser TTL (via 6N137). Fail-safe pull-up R_FSR 10kΩ → +3.3V
8 PIN_LASER_G Output Green laser TTL (via 6N137). Fail-safe pull-up R_FSG 10kΩ → +3.3V
10 PIN_GALVO_CS Output DAC8562 /SYNC (chip select) on SPI2
11 PIN_GALVO_MOSI Output SPI2 MOSI — DAC8562 only, no longer shared
12 PIN_GALVO_SCK Output SPI2 SCLK — DAC8562 only, no longer shared
13 PIN_DAC_CLR_N Output DAC8562 /CLR — pulsed LOW at init, then HIGH
14 PIN_WATCHDOG_OUT Output Hardware watchdog heartbeat to NE555 (U12)
16 PIN_FAN1_PWM Output Fan 1 PWM (25 kHz, 8-bit)
17 PIN_FAN2_PWM Output Fan 2 PWM (25 kHz, 8-bit)
18 PIN_ONEWIRE Bidirectional DS18B20 1-Wire data. 4.7 kΩ pull-up to +3.3V required.
21 PIN_LASER_B Output Blue laser TTL (via 6N137). Fail-safe pull-up R_FSB 10kΩ → +3.3V
38 PIN_LASER_ENABLE Output Central laser enable → SSR1. HIGH only when all safety checks pass.
39 PIN_SCAN_FAIL_IN Input NE555 scan-fail output (U11)
42 PIN_SD_CS Output SD card chip select on SPI3 (independent from DAC's SPI2)
43 PIN_DEBUG_TX Output UART0 TX / USB CDC TX
44 PIN_DEBUG_RX Input UART0 RX / USB CDC RX
47 PIN_ESTOP Input Emergency stop (active = pin HIGH via pull-up = E-stop not pressed)
48 PIN_STATUS_LED Output Onboard RGB LED

Reserved — Do Not Use:

GPIO Reason
0, 3, 45, 46 Strapping pins — state at boot determines boot mode
19, 20 USB D−/D+ — native USB CDC
35, 36, 37 OPI PSRAM internal connections on N16R8 — not accessible

Currently unassigned (free for expansion):

GPIO 5, 6, 15, 40, 41, 42 are free. GPIO 15, 40, 41 were previously used for an encoder (removed in v3.2).

NVS — Parameter Persistence

GalvOS uses the ESP32 NVS (Non-Volatile Storage) to persist configuration across reboots. Parameters are stored in two NVS namespaces:

Namespace Contents
"laser" RuntimeConfig fields, optimizer profiles, safety config, Wi-Fi credentials
"projection" ProjectionConfig fields (galvo_kpps, laser power, angles, distance)

NVS values take priority over compile-time defaults on every boot. This means:

  • Changing an OPT_DEFAULT_* macro in config.h has no effect if that parameter is already stored in NVS.
  • To apply new compile-time defaults, you must reset NVS (see below).

Optimizer profile parameters are keyed with a per-profile suffix (_s, _c, _w, _3, _sol, _sc) pinned to the profile index — not the profile name. This means profile parameters survive renames without resetting to defaults.

Resetting to Defaults

Via WebUI: Settings tab → "Reset NVS" button. This clears all NVS keys in the "laser" and "projection" namespaces and restarts the ESP32. On reboot, all compile-time defaults are applied and a new Wi-Fi AP is started.

Via serial monitor: Send nvs_reset over the serial console (if implemented), or trigger a factory reset by holding a specific GPIO low during boot (check the current firmware for the exact method).

Via esptool (nuclear option): Erase the entire NVS partition:

esptool.py --port /dev/ttyUSB0 erase_region 0x9000 0x5000

This clears NVS completely. The firmware will apply all compile-time defaults on next boot.

Note: Wi-Fi credentials are stored in NVS. After a reset, the ESP32 will return to AP mode (SSID: "galvOS") with no password until you reconfigure it via the WebUI Settings tab.