v1.11.3: Increase watchdog timeout to 256ms and optimize USB chunking

- Increased watchdog timeout from 128ms to 256ms for better stability
- Reduced USB chunk timeout from 10ms to 3ms to prevent blocking
- Prevents watchdog timeouts during USB reconnection on app restart
- Total USB blocking time now ~30ms (well within 256ms watchdog limit)

Author: eldinmiller

CHANGELOG.md

@@ -2,6 +2,30 @@
 
 All notable changes to the Pressboi firmware will be documented in this file.
 
+## [1.11.3] - 2025-11-26
+
+### Changed
+- **Watchdog timeout increased to 256ms**: Doubled from 128ms to provide better stability during USB reconnection
+- **USB chunking timeout reduced**: Lowered per-chunk timeout from 10ms to 3ms to prevent blocking (total ~30ms vs previous ~100ms)
+
+### Fixed
+- **Watchdog timeout on app restart**: Prevents main loop blocking during USB reconnection when TX queue processes large messages
+
+## [1.11.2] - 2025-11-24
+
+### Changed
+- **NVM dump output**: Added polarity information to `dump_nvm` command summary
+
+## [1.11.1] - 2025-11-24
+
+### Changed
+- Updated compiled binaries with latest source changes
+
+## [1.11.0] - 2025-11-24
+
+### Added
+- **`set_polarity` command**: Allows flipping coordinate system between 'normal' and 'inverted' modes, saved to NVM
+
 ## [1.10.5] - 2025-11-21
 
 ### Fixed

Debug/pressboi.bin

@@ -46,7 +46,7 @@
  * @name General System Behavior
  * @{
  */
-#define FIRMWARE_VERSION                "1.11.2"   ///< Pressboi firmware version
+#define FIRMWARE_VERSION                "1.11.3"   ///< Pressboi firmware version
 #define STATUS_MESSAGE_BUFFER_SIZE      256       ///< Standard buffer size for composing status and error messages.
 /** @} */
 
@@ -173,7 +173,7 @@
  * @{
  */
 #define WATCHDOG_ENABLED                    true      ///< Enable/disable watchdog timer. When enabled, system must call safety check regularly or motors will be disabled.
-#define WATCHDOG_TIMEOUT_MS                 100       ///< Watchdog timeout period in milliseconds. System will reset if not fed within this time.
+#define WATCHDOG_TIMEOUT_MS                 256       ///< Watchdog timeout period in milliseconds. System will reset if not fed within this time.
 #define WATCHDOG_RECOVERY_FLAG              0xDEADBEEF ///< Magic number written to backup register to indicate watchdog recovery.
 
 // Breadcrumb codes to identify where the watchdog timeout occurred

Debug/pressboi.elf

@@ -138,7 +138,7 @@ void CommsController::processUsbSerial() {
 	static int usbBufferIndex = 0;
 	static bool usbFirstData = false;  // Track if we've seen first data
 
-	// Limit characters processed per call to prevent watchdog timeout (128ms)
+	// Limit characters processed per call to prevent watchdog timeout (256ms)
 	int charsProcessed = 0;
 	const int MAX_CHARS_PER_CALL = 32;
 
@@ -355,6 +355,13 @@ void CommsController::processTxQueue() {
 			// Large message - send in chunks with continuation markers
 			// Format: "MSG_PART_1/3: first_50_chars"
 			int totalChunks = (msgLen + CHUNK_SIZE - 1) / CHUNK_SIZE;
+			
+			// Reduce timeout during USB reconnection to prevent watchdog timeout
+			// During reconnection, USB buffer is often small (e.g. 63 bytes)
+			// Limit total blocking time to ~30ms max (3ms per chunk × 10 chunks worst case)
+			// With 256ms watchdog, this provides ample safety margin (30ms << 256ms)
+			const uint32_t CHUNK_TIMEOUT_MS = 3;  // Reduced from 10ms to 3ms
+			
 			for (int chunk = 0; chunk < totalChunks; chunk++) {
 				int offset = chunk * CHUNK_SIZE;
 				int chunkLen = (msgLen - offset > CHUNK_SIZE) ? CHUNK_SIZE : (msgLen - offset);
@@ -367,10 +374,10 @@ void CommsController::processTxQueue() {
 				strncat(chunkMsg, msg.buffer + offset, chunkLen);
 				chunkMsg[headerLen + chunkLen] = '\0';
 
-				// Wait for buffer space (with timeout to prevent watchdog)
+				// Wait for buffer space (with shorter timeout to prevent watchdog)
 				uint32_t startWait = Milliseconds();
 				while (ConnectorUsb.AvailableForWrite() < (int)strlen(chunkMsg) + 1) {
-					if (Milliseconds() - startWait > 10) {
+					if (Milliseconds() - startWait > CHUNK_TIMEOUT_MS) {
 						// Timeout - skip this chunk to prevent blocking
 						break;
 					}

Debug/pressboi.uf2

@@ -254,7 +254,7 @@ void Pressboi::loop() {
             case WD_BREADCRUMB_LWIP_INPUT: breadcrumb_name = "LWIP_INPUT"; break;
             case WD_BREADCRUMB_LWIP_TIMEOUT: breadcrumb_name = "LWIP_TIMEOUT"; break;
         }
-        snprintf(recoveryMsg, sizeof(recoveryMsg), "Watchdog timeout in %s - main loop blocked >128ms. Motors disabled. Send RESET to clear.", breadcrumb_name);
+        snprintf(recoveryMsg, sizeof(recoveryMsg), "Watchdog timeout in %s - main loop blocked >256ms. Motors disabled. Send RESET to clear.", breadcrumb_name);
         reportEvent(STATUS_PREFIX_RECOVERY, recoveryMsg);
     }
 
@@ -1009,7 +1009,7 @@ void Pressboi::handleWatchdogRecovery() {
             case WD_BREADCRUMB_LWIP_INPUT: breadcrumb_name = "LWIP_INPUT"; break;
             case WD_BREADCRUMB_LWIP_TIMEOUT: breadcrumb_name = "LWIP_TIMEOUT"; break;
         }
-        snprintf(recoveryMsg, sizeof(recoveryMsg), "Watchdog timeout in %s - main loop blocked >128ms. Motors disabled. Send RESET to clear.", breadcrumb_name);
+        snprintf(recoveryMsg, sizeof(recoveryMsg), "Watchdog timeout in %s - main loop blocked >256ms. Motors disabled. Send RESET to clear.", breadcrumb_name);
         m_comms.reportEvent(STATUS_PREFIX_RECOVERY, recoveryMsg);
 
         // Keep LED on solid to indicate recovered state
@@ -1042,8 +1042,8 @@ void Pressboi::initializeWatchdog() {
     // Configure watchdog:
     // - For timeout at 1kHz WDT clock
     // - Period values: 0x3 = 64 cycles (~64ms), 0x4 = 128 cycles (~128ms), 0x5 = 256 cycles (~256ms)
-    // - Use 0x4 for ~128ms - aggressive timeout to catch real hangs quickly
-    uint8_t per_value = 0x4;  // 128 cycles ≈ 128ms at 1kHz
+    // - Use 0x5 for ~256ms - provides margin for USB reconnection without being too lenient
+    uint8_t per_value = 0x5;  // 256 cycles ≈ 256ms at 1kHz
 
     // Configure watchdog with early warning interrupt
     WDT->CONFIG.reg = WDT_CONFIG_PER(per_value);