esp32-Serial-Logger/sdcard_task.cpp

#include "sdcard_task.h"
#include "serial_task.h"
#include <time.h>

static SPIClass vspi(VSPI);
volatile bool sdLoggingActive = false;
volatile bool sdAutoStart = false;
char currentLogFileName[64] = "";
static File logFile;
static bool sdReady = false;
static SemaphoreHandle_t sdMutex = NULL;

// --- Persistent autostart flag ---
#define AUTOSTART_FLAG "/logs/.autostart"

// --- File rotation tracking ---
static int logStartDay = -1;      // Day-of-year when current log started
static size_t logFileSize = 0;    // Running byte count of current file

// Get current day-of-year (1~366)
static int getDayOfYear() {
  time_t now;
  time(&now);
  struct tm tm;
  localtime_r(&now, &tm);
  return tm.tm_yday;
}

// Check if file rotation is needed
static bool needsRotation() {
  // 1. Midnight check: day changed since file was created
  if (LOG_ROTATE_MIDNIGHT && logStartDay >= 0) {
    int today = getDayOfYear();
    if (today != logStartDay) {
      Serial.printf("[SD] Midnight rotation (day %d -> %d)\n", logStartDay, today);
      return true;
    }
  }
  // 2. Size check: file exceeds max size
  if (logFileSize >= LOG_MAX_FILE_SIZE) {
    Serial.printf("[SD] Size rotation (%.1fMB >= %.0fMB)\n",
      logFileSize / (1024.0 * 1024.0),
      LOG_MAX_FILE_SIZE / (1024.0 * 1024.0));
    return true;
  }
  return false;
}

// ============================================================
// Init
// ============================================================
void sdTaskInit() {
  sdMutex = xSemaphoreCreateMutex();

  vspi.begin(SD_VSPI_SCLK, SD_VSPI_MISO, SD_VSPI_MOSI, SD_VSPI_CS);

  if (!SD.begin(SD_VSPI_CS, vspi, 4000000)) {
    Serial.println("[SD] Card mount FAILED!");
    sdReady = false;
  } else {
    uint8_t cardType = SD.cardType();
    if (cardType == CARD_NONE) {
      Serial.println("[SD] No card detected!");
      sdReady = false;
    } else {
      sdReady = true;
      uint64_t cardSize = SD.cardSize() / (1024 * 1024);
      uint64_t usedSize = SD.usedBytes() / (1024 * 1024);
      Serial.printf("[SD] Card: %lluMB total, %lluMB used, %lluMB free\n",
        cardSize, usedSize, cardSize - usedSize);
      vspi.setFrequency(20000000);

      if (!SD.exists(LOG_DIR)) {
        SD.mkdir(LOG_DIR);
        Serial.println("[SD] Created /logs directory");
      }

      // Check persistent autostart flag
      sdAutoStart = SD.exists(AUTOSTART_FLAG);

      if (sdAutoStart) {
        // Auto-start logging immediately (field deployment mode)
        Serial.println("[SD] *** AUTOSTART MODE - starting logging immediately ***");
        // sdCreateNewLogFile takes mutex, so don't hold it here
        sdLoggingActive = false;  // Will be set true after file creation
      } else {
        sdLoggingActive = false;
        Serial.println("[SD] Ready (logging OFF - start via web UI)");
      }
      Serial.printf("[SD] Auto-rotate: midnight=%s, maxSize=%luMB\n",
        LOG_ROTATE_MIDNIGHT ? "ON" : "OFF",
        (unsigned long)(LOG_MAX_FILE_SIZE / (1024 * 1024)));
    }
  }

  xTaskCreatePinnedToCore(sdLoggingTask, "SDLog", TASK_STACK_SD_LOG,
    NULL, TASK_PRIORITY_SD_LOG, NULL, 0);

  // Deferred autostart (after task is running)
  if (sdReady && sdAutoStart) {
    sdCreateNewLogFile();
    sdLoggingActive = true;
    Serial.printf("[SD] Autostart logging: %s\n", currentLogFileName);
  }
}

// ============================================================
// Create new log file
// ============================================================
bool sdCreateNewLogFile() {
  if (!sdReady) return false;
  xSemaphoreTake(sdMutex, portMAX_DELAY);

  if (logFile) { logFile.flush(); logFile.close(); }

  struct tm timeinfo;
  time_t now;
  time(&now);
  localtime_r(&now, &timeinfo);

  snprintf(currentLogFileName, sizeof(currentLogFileName),
    "%s/LOG_%04d%02d%02d_%02d%02d%02d.csv",
    LOG_DIR,
    timeinfo.tm_year + 1900, timeinfo.tm_mon + 1, timeinfo.tm_mday,
    timeinfo.tm_hour, timeinfo.tm_min, timeinfo.tm_sec);

  logFile = SD.open(currentLogFileName, FILE_WRITE);
  if (!logFile) {
    Serial.printf("[SD] Failed to create: %s\n", currentLogFileName);
    xSemaphoreGive(sdMutex);
    return false;
  }
  logFile.print(CSV_HEADER);
  logFile.flush();

  // Reset rotation tracking
  logStartDay = timeinfo.tm_yday;
  logFileSize = strlen(CSV_HEADER);

  Serial.printf("[SD] New log: %s (day=%d)\n", currentLogFileName, logStartDay);
  xSemaphoreGive(sdMutex);
  return true;
}

// ============================================================
// Auto-rotate: close current, open new (called inside mutex)
// ============================================================
static void rotateLogFile() {
  // Close current
  if (logFile) {
    logFile.flush();
    logFile.close();
    Serial.printf("[SD] Rotated: %s (%.1fMB)\n",
      currentLogFileName, logFileSize / (1024.0 * 1024.0));
  }

  // Create new file (releases and re-takes mutex internally)
  // We need to release mutex first since sdCreateNewLogFile takes it
  xSemaphoreGive(sdMutex);
  sdCreateNewLogFile();
  xSemaphoreTake(sdMutex, portMAX_DELAY);
}

// ============================================================
// SD Logging Task
// ============================================================
void sdLoggingTask(void *param) {
  Serial.println("[Task] SDLog started on core " + String(xPortGetCoreID()));

  TickType_t lastFlush = xTaskGetTickCount();
  TickType_t lastRotateCheck = xTaskGetTickCount();
  int pendingWrites = 0;
  char csvLine[LOG_LINE_MAX_LEN + 64];

  while (true) {
    LogEntry *entry;
    if (xQueueReceive(queueSD, &entry, pdMS_TO_TICKS(100)) == pdTRUE) {
      if (sdLoggingActive && sdReady && logFile) {
        xSemaphoreTake(sdMutex, portMAX_DELAY);

        // Check rotation before writing
        if (needsRotation()) {
          rotateLogFile();
        }

        int len = snprintf(csvLine, sizeof(csvLine),
          "\"%s\",\"%c\",\"", entry->timestamp,
          entry->direction == 'T' ? 'T' : 'R');

        for (int i = 0; i < entry->dataLen && len < (int)sizeof(csvLine) - 4; i++) {
          char c = entry->data[i];
          if (c == '"') { csvLine[len++] = '"'; csvLine[len++] = '"'; }
          else if (c >= 0x20) { csvLine[len++] = c; }
        }
        len += snprintf(csvLine + len, sizeof(csvLine) - len, "\"\r\n");

        if (logFile) {
          logFile.write((uint8_t*)csvLine, len);
          logFileSize += len;
          pendingWrites++;
        }

        xSemaphoreGive(sdMutex);
      }
      vPortFree(entry);
    }

    // Periodic flush
    if (pendingWrites > 0 &&
        (xTaskGetTickCount() - lastFlush) > pdMS_TO_TICKS(SD_WRITE_INTERVAL)) {
      if (logFile) {
        xSemaphoreTake(sdMutex, portMAX_DELAY);
        logFile.flush();
        xSemaphoreGive(sdMutex);
      }
      pendingWrites = 0;
      lastFlush = xTaskGetTickCount();
    }

    // Batch flush
    if (pendingWrites >= 50) {
      if (logFile) {
        xSemaphoreTake(sdMutex, portMAX_DELAY);
        logFile.flush();
        xSemaphoreGive(sdMutex);
      }
      pendingWrites = 0;
      lastFlush = xTaskGetTickCount();
    }

    // Periodic midnight check even when idle (every 30s)
    if (sdLoggingActive && logFile &&
        (xTaskGetTickCount() - lastRotateCheck) > pdMS_TO_TICKS(30000)) {
      lastRotateCheck = xTaskGetTickCount();
      if (needsRotation()) {
        xSemaphoreTake(sdMutex, portMAX_DELAY);
        rotateLogFile();
        xSemaphoreGive(sdMutex);
      }
    }
  }
}

// ============================================================
// Stop / Start Logging
// ============================================================
void sdStopLogging() {
  sdLoggingActive = false;
  if (logFile) {
    xSemaphoreTake(sdMutex, portMAX_DELAY);
    logFile.flush();
    logFile.close();
    xSemaphoreGive(sdMutex);
  }
  logStartDay = -1;
  logFileSize = 0;
  Serial.println("[SD] Logging stopped");
}

void sdStartLogging() {
  if (!sdReady) { Serial.println("[SD] Card not ready!"); return; }
  if (!logFile || !sdLoggingActive) sdCreateNewLogFile();
  sdLoggingActive = true;
  Serial.println("[SD] Logging started");
}

// ============================================================
// Comments - stored in /logs/.comments (filename|comment per line)
// ============================================================
#define COMMENTS_FILE "/logs/.comments"

// Read all comments into a temp map, find one for given filename
String sdGetComment(const char *filename) {
  if (!sdReady) return "";
  // Note: caller should NOT hold sdMutex (or use recursive mutex)
  File f = SD.open(COMMENTS_FILE, FILE_READ);
  if (!f) return "";

  String target = String(filename) + "|";
  String line;
  String result = "";
  while (f.available()) {
    line = f.readStringUntil('\n');
    line.trim();
    if (line.startsWith(target)) {
      result = line.substring(target.length());
      break;
    }
  }
  f.close();
  return result;
}

bool sdSetComment(const char *filename, const char *comment) {
  if (!sdReady) return false;

  // Read existing comments (skip target file)
  String allLines = "";
  File f = SD.open(COMMENTS_FILE, FILE_READ);
  String target = String(filename) + "|";
  if (f) {
    while (f.available()) {
      String line = f.readStringUntil('\n');
      line.trim();
      if (line.length() == 0) continue;
      if (line.startsWith(target)) continue;  // Skip old comment for this file
      allLines += line + "\n";
    }
    f.close();
  }

  // Append new comment (if not empty)
  if (comment && strlen(comment) > 0) {
    allLines += String(filename) + "|" + String(comment) + "\n";
  }

  // Rewrite file
  f = SD.open(COMMENTS_FILE, FILE_WRITE);
  if (!f) return false;
  f.print(allLines);
  f.close();
  return true;
}

// Remove comment when file is deleted
static void sdRemoveComment(const char *filename) {
  sdSetComment(filename, "");  // Empty = remove
}

// ============================================================
// File List (includes comments)
// ============================================================
String sdGetFileList() {
  if (!sdReady) return "{\"files\":[]}";
  xSemaphoreTake(sdMutex, portMAX_DELAY);

  // Pre-load all comments
  String commentsRaw = "";
  File cf = SD.open(COMMENTS_FILE, FILE_READ);
  if (cf) {
    commentsRaw = cf.readString();
    cf.close();
  }

  String json = "{\"files\":[";
  File dir = SD.open(LOG_DIR);
  bool first = true;

  if (dir && dir.isDirectory()) {
    File file = dir.openNextFile();
    while (file) {
      if (!file.isDirectory()) {
        String fname = file.name();
        // Skip the .comments metadata file
        if (fname == ".comments") { file = dir.openNextFile(); continue; }

        if (!first) json += ",";
        first = false;
        json += "{\"name\":\"";
        json += fname;
        json += "\",\"size\":";
        json += String(file.size());
        time_t t = file.getLastWrite();
        struct tm *tm = localtime(&t);
        char timeBuf[32];
        strftime(timeBuf, sizeof(timeBuf), "%Y-%m-%d %H:%M:%S", tm);
        json += ",\"modified\":\"";
        json += timeBuf;
        json += "\"";

        // Find comment for this file
        String key = fname + "|";
        int idx = commentsRaw.indexOf(key);
        if (idx >= 0) {
          int start = idx + key.length();
          int end = commentsRaw.indexOf('\n', start);
          if (end < 0) end = commentsRaw.length();
          String cmt = commentsRaw.substring(start, end);
          cmt.trim();
          // Escape quotes in comment for JSON
          cmt.replace("\\", "\\\\");
          cmt.replace("\"", "\\\"");
          json += ",\"comment\":\"";
          json += cmt;
          json += "\"";
        }

        json += "}";
      }
      file = dir.openNextFile();
    }
    dir.close();
  }

  uint64_t totalMB = SD.totalBytes() / (1024 * 1024);
  uint64_t usedMB = SD.usedBytes() / (1024 * 1024);
  json += "],\"totalMB\":";
  json += String((uint32_t)totalMB);
  json += ",\"usedMB\":";
  json += String((uint32_t)usedMB);
  json += "}";

  xSemaphoreGive(sdMutex);
  return json;
}

// ============================================================
// Delete File (also removes comment)
// ============================================================
bool sdDeleteFile(const char *filename) {
  if (!sdReady) return false;
  xSemaphoreTake(sdMutex, portMAX_DELAY);

  char path[128];
  snprintf(path, sizeof(path), "%s/%s", LOG_DIR, filename);
  if (sdLoggingActive && strcmp(path, currentLogFileName) == 0) {
    xSemaphoreGive(sdMutex);
    return false;
  }
  bool result = SD.remove(path);
  if (result) sdRemoveComment(filename);
  Serial.printf("[SD] Delete %s: %s\n", path, result ? "OK" : "FAIL");
  xSemaphoreGive(sdMutex);
  return result;
}

bool sdCardPresent() { return sdReady; }

// ============================================================
// Autostart - persistent flag on SD card
// ============================================================
bool sdGetAutoStart() {
  if (!sdReady) return false;
  return SD.exists(AUTOSTART_FLAG);
}

void sdSetAutoStart(bool enable) {
  if (!sdReady) return;
  xSemaphoreTake(sdMutex, portMAX_DELAY);

  if (enable) {
    // Create flag file
    File f = SD.open(AUTOSTART_FLAG, FILE_WRITE);
    if (f) {
      f.println("autostart=1");
      f.close();
    }
    sdAutoStart = true;
    Serial.println("[SD] Autostart ENABLED (will log on next boot)");
  } else {
    // Remove flag file
    if (SD.exists(AUTOSTART_FLAG)) {
      SD.remove(AUTOSTART_FLAG);
    }
    sdAutoStart = false;
    Serial.println("[SD] Autostart DISABLED");
  }

  xSemaphoreGive(sdMutex);
}