ci.yml

name: CI/CD

on:
  push:
    branches: [ phoenix, main ]
    tags:
      - 'v*.*.*'
    paths:
      - 'Controller/**'
      - 'mini/**'
      - 'app/**'
      - 'stewart-core'          # shared submodule gitlink — a bump must trigger firmware + SIL
      - '.github/workflows/ci.yml'
  pull_request:
    branches: [ phoenix, main ]
    paths:
      - 'Controller/**'
      - 'mini/**'
      - 'app/**'
      - 'stewart-core'          # shared submodule gitlink — a bump must trigger firmware + SIL
      - '.github/workflows/ci.yml'

jobs:
  version:
    name: Determine Version
    runs-on: ubuntu-latest
    outputs:
      version: ${{ steps.version.outputs.version }}
      is_release: ${{ steps.version.outputs.is_release }}
    
    steps:
      - name: Checkout repository
        uses: actions/checkout@v4
        with:
          fetch-depth: 0

      - name: Calculate version
        id: version
        run: |
          # Check if this is a tag push
          if [[ $GITHUB_REF == refs/tags/* ]]; then
            VERSION=${GITHUB_REF#refs/tags/}
            IS_RELEASE=true
          else
            # Auto-increment version based on commit count since last tag
            LAST_TAG=$(git describe --tags --abbrev=0 2>/dev/null || echo "")
            
            if [ -z "$LAST_TAG" ]; then
              # No tags exist yet, use total commit count
              COMMIT_COUNT=$(git rev-list --count HEAD)
              MAJOR=0
              MINOR=1
              PATCH=0
            else
              # Count commits since last tag
              COMMIT_COUNT=$(git rev-list --count ${LAST_TAG}..HEAD)
              
              # Parse last tag (expecting vMAJOR.MINOR.PATCH)
              if [[ $LAST_TAG =~ ^v([0-9]+)\.([0-9]+)\.([0-9]+) ]]; then
                MAJOR=${BASH_REMATCH[1]}
                MINOR=${BASH_REMATCH[2]}
                PATCH=${BASH_REMATCH[3]}
              else
                MAJOR=0
                MINOR=1
                PATCH=0
              fi
            fi
            
            # Auto-increment patch version
            NEW_PATCH=$((PATCH + 1))
            VERSION="v${MAJOR}.${MINOR}.${NEW_PATCH}-dev.${COMMIT_COUNT}+${GITHUB_SHA:0:7}"
            IS_RELEASE=false
          fi
          
          echo "version=$VERSION" >> $GITHUB_OUTPUT
          echo "is_release=$IS_RELEASE" >> $GITHUB_OUTPUT
          echo "Calculated version: $VERSION (Release: $IS_RELEASE)"

  firmware-build:
    name: Build ESP32-S3 Firmware (ESP-IDF)
    needs: version
    runs-on: ubuntu-latest

    steps:
      - name: Checkout repository
        uses: actions/checkout@v4
        with:
          submodules: 'recursive'

      - name: Install ESP-IDF prerequisites
        run: |
          sudo apt-get update
          sudo apt-get install -y git wget flex bison gperf python3 python3-pip python3-venv \
            cmake ninja-build ccache libffi-dev libssl-dev dfu-util libusb-1.0-0

      - name: Set up ESP-IDF and Build
        uses: espressif/esp-idf-ci-action@v1
        with:
          esp_idf_version: v5.5.2
          target: esp32s3
          path: 'Controller'
          command: idf.py build

      - name: Package firmware with version
        run: |
          VERSION="${{ needs.version.outputs.version }}"
          cp Controller/build/stewart_platform.bin "firmware-${VERSION}.bin"
          cp Controller/build/stewart_platform.elf "firmware-${VERSION}.elf"
          cp Controller/build/bootloader/bootloader.bin "bootloader-${VERSION}.bin"
          cp Controller/build/partition_table/partition-table.bin "partition-table-${VERSION}.bin"

      - name: Upload firmware artifacts
        uses: actions/upload-artifact@v4
        with:
          name: firmware-${{ needs.version.outputs.version }}
          path: |
            firmware-*.bin
            firmware-*.elf
            bootloader-*.bin
            partition-table-*.bin
          retention-days: 90

  mini-firmware-build:
    name: Build Mini Firmware (ESP-IDF)
    needs: version
    runs-on: ubuntu-latest

    steps:
      - name: Checkout repository
        uses: actions/checkout@v4
        with:
          submodules: 'recursive'   # root stewart-core supplies the shared math

      - name: Install ESP-IDF prerequisites
        run: |
          sudo apt-get update
          sudo apt-get install -y git wget flex bison gperf python3 python3-pip python3-venv \
            cmake ninja-build ccache libffi-dev libssl-dev dfu-util libusb-1.0-0

      - name: Set up ESP-IDF and Build
        uses: espressif/esp-idf-ci-action@v1
        with:
          esp_idf_version: v5.5.2
          target: esp32
          path: 'mini'
          command: idf.py build

      - name: Package mini firmware with version
        run: |
          VERSION="${{ needs.version.outputs.version }}"
          cp mini/build/mini_6dof.bin "mini-firmware-${VERSION}.bin"
          cp mini/build/mini_6dof.elf "mini-firmware-${VERSION}.elf"
          cp mini/build/bootloader/bootloader.bin "mini-bootloader-${VERSION}.bin"
          cp mini/build/partition_table/partition-table.bin "mini-partition-table-${VERSION}.bin"

      - name: Upload mini firmware artifacts
        uses: actions/upload-artifact@v4
        with:
          name: mini-firmware-${{ needs.version.outputs.version }}
          path: |
            mini-firmware-*.bin
            mini-firmware-*.elf
            mini-bootloader-*.bin
            mini-partition-table-*.bin
          retention-days: 90

  desktop-app-build:
    name: Build Desktop App (CMake)
    needs: version
    runs-on: windows-latest

    steps:
      - name: Checkout repository
        uses: actions/checkout@v4
        with:
          submodules: 'recursive'

      - name: Configure CMake
        run: cmake -S app -B app/build -DCMAKE_BUILD_TYPE=Release

      - name: Build
        run: cmake --build app/build --config Release

      - name: Upload desktop app artifact
        uses: actions/upload-artifact@v4
        with:
          name: desktop-app-windows-${{ needs.version.outputs.version }}
          path: app/build/Release/stewart-platform.exe
          retention-days: 90

  create-release:
    name: Create GitHub Release
    needs: [version, firmware-build, desktop-app-build]
    runs-on: ubuntu-latest
    if: startsWith(github.ref, 'refs/tags/')
    permissions:
      contents: write
    
    steps:
      - name: Checkout repository
        uses: actions/checkout@v4
        with:
          fetch-depth: 0

      - name: Download firmware artifacts
        uses: actions/download-artifact@v4
        with:
          name: firmware-${{ needs.version.outputs.version }}

      - name: Download desktop app artifact
        uses: actions/download-artifact@v4
        with:
          name: desktop-app-windows-${{ needs.version.outputs.version }}
        continue-on-error: true

      - name: Generate changelog
        id: changelog
        run: |
          VERSION="${{ needs.version.outputs.version }}"
          IS_RELEASE="${{ needs.version.outputs.is_release }}"
          LAST_TAG=$(git describe --tags --abbrev=0 HEAD^ 2>/dev/null || echo "")
          
          if [ -n "$LAST_TAG" ]; then
            CHANGELOG=$(git log ${LAST_TAG}..HEAD --pretty=format:"- %s (%h)" --no-merges)
          else
            CHANGELOG=$(git log --pretty=format:"- %s (%h)" --no-merges -n 20)
          fi
          
          # Determine release type messaging
          if [ "$IS_RELEASE" = "true" ]; then
            RELEASE_TYPE="## 🎯 Official Release"
            RELEASE_WARNING=""
          else
            RELEASE_TYPE="## 🚧 Development Build (Pre-Release)"
            RELEASE_WARNING="
          **⚠️ NOT AN OFFICIAL RELEASE**
          This is an automated development build from commit ${GITHUB_SHA:0:7}.
          - Use for testing and development only
          - May contain unstable or incomplete features
          - Official releases use version tags without '-dev' suffix
          "
          fi
          
          # Write changelog to file
          cat > CHANGELOG.txt <<EOF
          # $VERSION
          
          $RELEASE_TYPE
          $RELEASE_WARNING
          
          ## Changes
          $CHANGELOG
          
          ## Firmware Files
          - \`firmware-${VERSION}.bin\`: Main application binary
          - \`bootloader-${VERSION}.bin\`: ESP32-S3 bootloader
          - \`partition-table-${VERSION}.bin\`: Partition table
          - \`firmware-${VERSION}.elf\`: Debug symbols for GDB
          
          ## Installation
          Flash all components to ESP32-S3:
          \`\`\`bash
          esptool.py --chip esp32s3 --port COM3 --baud 460800 \\
            --before default_reset --after hard_reset write_flash \\
            --flash_mode dio --flash_freq 80m --flash_size 8MB \\
            0x0 bootloader-${VERSION}.bin \\
            0x8000 partition-table-${VERSION}.bin \\
            0x10000 firmware-${VERSION}.bin
          \`\`\`
          
          Or use ESP-IDF tooling:
          \`\`\`bash
          idf.py -p COM3 flash monitor
          \`\`\`
          
          ## Safety Notice
          ⚠️ This firmware controls a motion platform capable of causing serious injury. Verify E-stop functionality before energizing actuators. See docs/hardware/servo_driver_interface.md for safety checklist.
          EOF
          
          echo "changelog<<EOF" >> $GITHUB_OUTPUT
          cat CHANGELOG.txt >> $GITHUB_OUTPUT
          echo "EOF" >> $GITHUB_OUTPUT

      - name: Create Release
        uses: softprops/action-gh-release@v2
        with:
          tag_name: ${{ needs.version.outputs.version }}
          name: ${{ needs.version.outputs.is_release == 'true' && format('Release {0}', needs.version.outputs.version) || format('Development Build {0}', needs.version.outputs.version) }}
          body: ${{ steps.changelog.outputs.changelog }}
          draft: false
          prerelease: ${{ needs.version.outputs.is_release != 'true' }}
          files: |
            firmware-*.bin
            firmware-*.elf
            bootloader-*.bin
            partition-table-*.bin
            stewart-platform.exe
        env:
          GITHUB_TOKEN: ${{ secrets.GITHUB_TOKEN }}