power save - Reduce EMS-ESP energy consumption #3213

data/pre_load.json

@@ -129,6 +129,7 @@
         "eth_power": 15,
         "eth_phy_addr": 0,
         "eth_clock_mode": 1,
+        "eth_10mbit": false,
         "modbus_enabled": false,
         "modbus_port": 502,
         "modbus_max_clients": 10,

interface/src/app/main/types.ts

@@ -39,6 +39,7 @@ export interface Settings {
   eth_power: number;
   eth_phy_addr: number;
   eth_clock_mode: number;
+  eth_10mbit: boolean;
   platform: string;
   modbus_enabled: boolean;
   modbus_port: number;

interface/src/app/settings/ApplicationSettings.tsx

@@ -820,6 +820,18 @@ const ApplicationSettings = () => {
                 </Grid>
               </Grid>
             )}
+            {data.phy_type !== 0 && (
+              <BlockFormControlLabel
+                control={
+                  <Checkbox
+                    checked={data.eth_10mbit}
+                    onChange={updateFormValue}
+                    name="eth_10mbit"
+                  />
+                }
+                label="Force 10Mbit half-duplex"
+              />
+            )}
           </>
         )}
         <Grid container spacing={2} rowSpacing={0}>

mock-api/restServer.ts

@@ -58,6 +58,7 @@ let settings = {
   eth_power: 15,
   eth_phy_addr: 0,
   eth_clock_mode: 1,
+  eth_10mbit: false,
   led_type: 0,
   platform: 'ESP32',
   modbus_enabled: false,

project-words.txt

@@ -1345,4 +1345,6 @@ Sumr
 eraseap
 roomtempoffset
 dhcpc
-wifioff
+wifioff
+autonegotiation
+Mbit

src/core/main.cpp

@@ -28,4 +28,7 @@ void setup() {
 
 void loop() {
     application.loop();
+#ifndef EMSESP_STANDALONE
+    delay(1); // block for a tick so the idle task gets to run and the core can clock-gate
+#endif
 }

src/core/network.cpp

@@ -57,6 +57,7 @@ void Network::begin() {
         eth_power_      = settings.eth_power;
         eth_phy_addr_   = settings.eth_phy_addr;
         eth_clock_mode_ = settings.eth_clock_mode;
+        eth_10mbit_     = settings.eth_10mbit;
     });
 
     // get Access Point settings
@@ -78,39 +79,16 @@ void Network::begin() {
 
     phase_ = initialPhase();
 
-    // Initialise WiFi once when the Network service starts.
+    startWiFiRadio();
-    // persistent(false) keeps credentials in RAM so we don't auto-join leftover NVS config.
-    WiFi.persistent(false);
-    WiFi.setAutoReconnect(false);
-    WiFi.mode(WIFI_STA);
 
-    // Keep the radio up. disconnect(wifioff=true) maps to STA.end() -> esp_wifi_stop()
+#if CONFIG_IDF_TARGET_ESP32
-    if (WiFi.STA.started()) {
+    // Ethernet is switched off but the board still has a PHY wired up. Hold its power/oscillator
-        WiFi.disconnect(false, true); // drop leftover association, wipe RAM config
+    // enable low so an unused LAN8720 isn't left clocked and burning current for the whole uptime.
+    if (phy_type_ == PHY_type::PHY_TYPE_NONE && eth_power_ != -1) {
+        pinMode(eth_power_, OUTPUT);
+        digitalWrite(eth_power_, LOW);
     }
-
+#endif
-    WiFi.setScanMethod(WIFI_ALL_CHANNEL_SCAN);
-    WiFi.setHostname(hostname_.c_str());     // updates shared default_hostname buffer
-    WiFi.enableSTA(true);                    // no-op if already STA; recreates netif after a full off
-    WiFi.STA.setHostname(hostname_.c_str()); // pushes to esp_netif_set_hostname
-    WiFi.enableIPv6(true);
-    if (staticIPConfig_) {
-        WiFi.config(localIP_, gatewayIP_, subnetMask_, dnsIP1_, dnsIP2_); // configure for static IP
-    }
-
-    // www.esp32.com/viewtopic.php?t=12055
-    if (bandwidth20_) {
-        esp_wifi_set_bandwidth(static_cast<wifi_interface_t>(ESP_IF_WIFI_STA), WIFI_BW_HT20);
-    } else {
-        esp_wifi_set_bandwidth(static_cast<wifi_interface_t>(ESP_IF_WIFI_STA), WIFI_BW_HT40);
-    }
-    if (nosleep_) {
-        WiFi.setSleep(false); // turn off sleep - WIFI_PS_NONE
-    }
-
-    // scan settings give connect issues since arduino 2.0.14 and arduino 3.x.x with some wifi systems
-    // WiFi.setScanMethod(WIFI_ALL_CHANNEL_SCAN); // default is FAST_SCAN
-    // WiFi.setSortMethod(WIFI_CONNECT_AP_BY_SIGNAL); // is default, no need to set
 
     // avoid duplicate registration, so register the lambdas only once across the lifetime of this Network instance
     if (!wifi_events_registered_) {
@@ -326,6 +304,10 @@ void Network::checkConnection() {
         network_iface_            = NetIface::NONE;
         if (lost_iface == NetIface::ETHERNET) {
             LOG_WARNING("Ethernet connection lost");
+            // restore the radio now so the WiFi and AP fallbacks have something to work with
+            if (wifi_radio_off_) {
+                startWiFiRadio();
+            }
             return;
         }
         begin();
@@ -502,6 +484,59 @@ const char * Network::disconnectReason([[maybe_unused]] uint8_t code) {
     return "";
 }
 
+// Bring up the STA interface and apply all the radio-level settings to it
+// Safe to call repeatedly - enableSTA() is a no-op when the STA is already running, and recreates the netif after stopWiFiRadio() has torn it down
+void Network::startWiFiRadio() {
+#ifndef EMSESP_STANDALONE
+    WiFi.persistent(false); // keep credentials in RAM so we don't auto-join leftover NVS config
+    WiFi.setAutoReconnect(false);
+    WiFi.mode(WIFI_STA);
+
+    // Keep the radio up. disconnect(wifioff=true) maps to STA.end() -> esp_wifi_stop()
+    if (WiFi.STA.started()) {
+        WiFi.disconnect(false, true); // drop leftover association, wipe RAM config
+    }
+
+    // scan settings give connect issues since arduino 2.0.14 and arduino 3.x.x with some wifi systems
+    WiFi.setScanMethod(WIFI_ALL_CHANNEL_SCAN); // default is FAST_SCAN
+    WiFi.setHostname(hostname_.c_str());       // updates shared default_hostname buffer
+    WiFi.enableSTA(true);                    // no-op if already STA; recreates netif after a full off
+    WiFi.STA.setHostname(hostname_.c_str()); // pushes to esp_netif_set_hostname
+    WiFi.enableIPv6(true);
+    if (staticIPConfig_) {
+        WiFi.config(localIP_, gatewayIP_, subnetMask_, dnsIP1_, dnsIP2_); // configure for static IP
+    }
+
+    // www.esp32.com/viewtopic.php?t=12055
+    if (bandwidth20_) {
+        esp_wifi_set_bandwidth(static_cast<wifi_interface_t>(ESP_IF_WIFI_STA), WIFI_BW_HT20);
+    } else {
+        esp_wifi_set_bandwidth(static_cast<wifi_interface_t>(ESP_IF_WIFI_STA), WIFI_BW_HT40);
+    }
+    if (nosleep_) {
+        WiFi.setSleep(false); // turn off sleep - WIFI_PS_NONE
+    } else {
+        WiFi.setSleep(true); // WIFI_PS_MIN_MODEM
+    }
+
+    wifi_radio_off_ = false;
+#endif
+}
+
+// Power down the WiFi radio completely (esp_wifi_stop), used when Ethernet is carrying the traffic.
+// An idle STA still keeps the receiver powered, which on an Ethernet gateway is a pure waste of heat.
+void Network::stopWiFiRadio() {
+#ifndef EMSESP_STANDALONE
+    if (wifi_radio_off_) {
+        return;
+    }
+    WiFi.mode(WIFI_OFF);
+    wifi_radio_off_       = true;
+    wifi_connect_pending_ = false;
+    LOG_INFO("Powering down WiFi radio, Ethernet is active");
+#endif
+}
+
 // WiFi management
 void Network::startWIFI() {
 #ifndef EMSESP_STANDALONE
@@ -510,6 +545,11 @@ void Network::startWIFI() {
         return;
     }
 
+    // the radio was powered down while Ethernet was up, so bring it back before trying to associate
+    if (wifi_radio_off_) {
+        startWiFiRadio();
+    }
+
     // exit if WiFi or Ethernet is already connected, or if we have no SSID or another Wifi.begin() is already in progress
     if (WiFi.isConnected() || ssid_.isEmpty() || ethernet_connected() || wifi_connect_pending_) {
         return;
@@ -610,6 +650,17 @@ void Network::startEthernet() {
         eth_hostname_handler_registered_ = true;
     }
 
+    // Forcing 10BASE-T roughly halves the PHY's power draw, which on these boards is usually the
+    // hottest component. All three must be set before ETH.begin(), and in this order - the speed
+    // and duplex setters are ignored while autonegotiation is still on. Half duplex is deliberate:
+    // a switch port that can't negotiate falls back to parallel detection, which is always half,
+    // so forcing full here would be a duplex mismatch. Opt-in only for that reason.
+    if (eth_10mbit_) {
+        ETH.setAutoNegotiation(false);
+        ETH.setLinkSpeed(10);
+        ETH.setFullDuplex(false);
+    }
+
     if (ETH.begin(type, eth_phy_addr_, 23, 18, eth_power_, (eth_clock_mode_t)eth_clock_mode_)) {
         // LOG_DEBUG("Ethernet module found - initialising");
         ethernet_started_         = true;
@@ -739,6 +790,14 @@ void Network::findNetworks() {
             stopAP();
         }
 
+        // Ethernet is carrying the traffic so the STA is dead weight - shut the radio down.
+        // It is brought back by checkConnection() when the link drops, or by startWIFI() if we
+        // fall through to the WiFi phase. Do this before startmDNS() so we don't register on a
+        // netif we are about to destroy.
+        if (network_iface_ == NetIface::ETHERNET) {
+            stopWiFiRadio();
+        }
+
         // count the number of restarts (for Wifi and Eth)
         if (juststopped_) {
             juststopped_ = false;
@@ -823,6 +882,11 @@ void Network::startAP() {
         return;
     }
 
+    // the AP needs the radio, which may have been powered down while Ethernet was up
+    if (wifi_radio_off_) {
+        startWiFiRadio();
+    }
+
     if (!WiFi.softAPConfig(ap_localIP_, ap_gatewayIP_, ap_subnetMask_)) {
         LOG_DEBUG("softAPConfig failed");
         return;

src/core/network.h

@@ -186,6 +186,8 @@ class Network {
     void         startAP();
     void         startWIFI();
     void         startEthernet();
+    void         startWiFiRadio();
+    void         stopWiFiRadio();
     void         setWiFiPower(uint8_t tx_power);
     const char * disconnectReason(uint8_t code);
     void         stopAP();
@@ -216,6 +218,7 @@ class Network {
     bool ethernet_started_                = false; // ETH.begin() succeeded; the driver runs for the lifetime of the boot
     bool wifi_ever_connected_             = false; // set true once we've successfully obtained an IP
     bool ethernet_ever_connected_         = false; // set true once we've successfully obtained an IP
+    bool wifi_radio_off_                  = false; // STA powered down because Ethernet is carrying the traffic
 
     // Network and AP settings
     bool      enableMDNS_;
@@ -236,6 +239,7 @@ class Network {
     int8_t    eth_power_;
     uint8_t   eth_phy_addr_;
     uint8_t   eth_clock_mode_;
+    bool      eth_10mbit_;
 
     // AP settings
     uint8_t   ap_provisionMode_;

src/web/WebSettingsService.cpp

@@ -79,6 +79,7 @@ void WebSettings::read(WebSettings & settings, JsonObject root) {
     root["eth_power"]             = settings.eth_power;
     root["eth_phy_addr"]          = settings.eth_phy_addr;
     root["eth_clock_mode"]        = settings.eth_clock_mode;
+    root["eth_10mbit"]            = settings.eth_10mbit;
     root["modbus_enabled"]        = settings.modbus_enabled;
     root["modbus_port"]           = settings.modbus_port;
     root["modbus_max_clients"]    = settings.modbus_max_clients;
@@ -120,6 +121,7 @@ StateUpdateResult WebSettings::update(JsonObject root, WebSettings & settings) {
     settings.eth_power      = root["eth_power"];
     settings.eth_phy_addr   = root["eth_phy_addr"];
     settings.eth_clock_mode = root["eth_clock_mode"];
+    settings.eth_10mbit     = root["eth_10mbit"];
     settings.led_type       = root["led_type"]; // 1 = RGB-LED
 
     reset_flags();
@@ -145,6 +147,7 @@ StateUpdateResult WebSettings::update(JsonObject root, WebSettings & settings) {
     if (settings.phy_type != PHY_type::PHY_TYPE_NONE) {
         check_flag(original_settings.eth_power, settings.eth_power, ChangeFlags::RESTART);
         check_flag(original_settings.eth_clock_mode, settings.eth_clock_mode, ChangeFlags::RESTART);
+        check_flag(original_settings.eth_10mbit, settings.eth_10mbit, ChangeFlags::RESTART);
         if (settings.eth_power != -1) { // Ethernet Power -1 means disabled
             EMSESP::system_.remove_gpio(settings.eth_power, true);
         }

src/web/WebSettingsService.h

@@ -119,6 +119,7 @@ class WebSettings {
     int8_t  eth_power; // -1 means disabled
     uint8_t eth_phy_addr;
     uint8_t eth_clock_mode;
+    bool    eth_10mbit; // force 10BASE-T half-duplex, no auto-negotiation
 
     bool developer_mode; // developer mode
     bool disable_reset;  // disable reset