SW to v0.4, timing only via watchdog, filled a little bit README.MD

README.md

@@ -14,7 +14,16 @@ FireFly Solar is a small outdoor LED blinker inspired by the idea of an LED thro
 During the day, the solar cell charges the energy storage.  
 At night, the circuit wakes up and sends a simple Morse-style light signal.
 
-The project is partly a small garden object, partly a low-power electronics experiment, and partly a design exercise for future DIY kits.
+## About this Project
+
+FireFly Solar is my **technology playground**. It is a small garden object, but its real purpose is to learn by building something complete. With it I learn about:
+
+- **Circuit design at the edge**: in this case, as low power as possible
+- **PCB design**
+- **Weatherproof casing**
+- **ATtiny programming**
+
+Possible next technology step: everything about DIY SMD design and soldering.
 
 ## Project Goals
 
@@ -24,6 +33,40 @@ The project is partly a small garden object, partly a low-power electronics expe
 - Test mechanical concepts for outdoor 3D-printed parts
 - Learn what is needed to turn a small electronics project into a possible DIY kit
 
+## Software
+
+The firmware runs on an **ATtiny85** at 1 MHz (internal clock, ATTinyCore: `clock=1internal`, `millis=disabled`). The LED itself is used as the light sensor. When it is dark, the firefly sends a short Morse text ("TGO 26") about once a minute.
+
+### Current Firmware version: v0.4 (2026-11-08)
+
+Goal: lowest possible average current.
+
+Changes vs v0.3:
+
+- No `delay()` / `millis()`; Timer0 and Timer1 are gated off in PRR.
+- The watchdog (interrupt mode) is the only timebase: Morse units (~96 ms), the sensing window and the 8 s sleeps. The CPU sleeps in power-down in between.
+- Darkness sensing: the CPU sleeps in 16 ms steps while the LED junction discharges, instead of a busy `digitalRead()` loop. Bright light exits after the first step. `darknessThreshold` is replaced by `darkSteps`.
+- The ADC is disabled before it is gated off in PRR; pins are set up before PRR.
+- After a power-on or external reset, no blinking for `RECOVER_CYCLES` (about 16 min), so the supercap can recharge.
+- `DEBUG_TEST` switch for bench testing: 8 s cycle, no recovery wait, short flash when the sketch decides "bright". Set it to 0 for the field.
+- Optional `BOD_FUSE_ENABLED` (BOD off during sleep); unused with the BOD fuse off.
+
+Tested: compiles with ATTinyCore and runs on hardware. Current draw is not yet measured.
+
+## PCB
+
+- Finished: a batch of 10 is assembled, tested and working.
+- Latest adjustment: fine-tuned the resistors for the LED, and the 3.9 V Zener diode is confirmed safe avoid overcharging 4V supercap.
+- Next version: the PCB should be a little shorter. The wiring space is a bit too tight now.
+
+## Casing
+
+Works basically as intended. Lessons for the next version:
+
+- Better locking of the solar modules.
+- The rope structure works, but building it is too complicated and takes a lot of nerves.
+- Using material tension to secure the modules via rope was basically a good idea. 
+
 ## Naming
 
 The English project name remains:
@@ -39,9 +82,12 @@ The name roughly means **sun-disc firefly**. It keeps the solar theme, adds a sl
 ---
 
 ## Contributing
-PRs and issues welcome. Keep it simple.
+
+PRs and issues welcome. Keep it simple.  
 Photos of your build you send me go in `Documentation/gallery/` with a short caption and license notice.
 
 ---
 
-## Default license**: [CC-BY-NC-4.0](https://creativecommons.org/licenses/by-nc/4.0/)
+## License
+
+Default license: [CC-BY-NC-4.0](https://creativecommons.org/licenses/by-nc/4.0/)

firmware/ATTINY85_2026_MorseThrowie/ATTINY85_2026_MorseThrowie.ino

@@ -6,19 +6,33 @@
 
  Project definitions, sources
  -----------------------------------------------------------------------------
- Version: 0.3 - ATTiny85, 1 MHz, BOD fuse disabled
+ Version: 0.4 - ATTiny85, 1 MHz, BOD fuse disabled
  gitea  : https://gitea.togo-lab.io/tgohle/0001-FireFly
- Date   : 2026-06-14
+ Date   : 2026-11-08
 
-Key changes Version 0.3:
+Key changes Version 0.4 (goal: lowest possible average current):
 
-- Removed unnecessary ADC enable/disable from loop()
+- No delay(), no millis(): Timer0 and Timer1 are not needed any more and
-- Disabled ADC and analog comparator in setup()
+  are switched off in PRR. 
-- Added INPUT_PULLUP for unused Arduino pins 0, 1, 2 will save power
+- ALL timing (Morse units, sensing window, 8 s sleep) is done by the watchdog
-- Added safer watchdog setup with interrupt protection to save run near brownout
+  in interrupt mode while the CPU is in POWER-DOWN. The CPU runs only for a
-- Added wdt_reset() before sleep for cleaner 8 s timing
+  few microseconds per wake-up. LED pins keep their state in power-down.
-- Added lowercase-to-uppercase handling
+- Darkness sensing no longer polls digitalRead() in a busy loop (that was
-- Unsupported characters are now ignored without adding fake timing gaps
+  ~0.3-1 s awake per cycle). The LED junction is charged, then the CPU sleeps
+  in 16 ms steps and checks the pin: bright light exits after the first step.
+- ADC is disabled BEFORE it is gated off in PRR (order matters).
+- After a power-on / external reset the sketch waits RECOVER_CYCLES cycles
+  before it blinks again, so a nearly empty supercap can recharge first.
+  Default ~16 minutes, therefore added a debug option.
+- Optional: BOD disable during sleep (only useful if BOD fuse is enabled).
+  Not tested yet.
+- Field Test: After a sunny day in Winter, outdoor -1 ... 8°C, with a payload
+  of 10 signs) it blinks for >> 12h.
+
+Timing note: the watchdog oscillator is not precise (changes with Vcc and
+temperature). All Morse timing comes from the same clock, so dit/dah/gap
+ratios stay correct; only the absolute speed drifts a little.
+The HW actual allowes 5V and 3.3V, standard is 3.3V. So don't expec exact timing.
 
 -----------------------------------------------------------------------------
 
@@ -60,6 +74,12 @@ Inspired by Karl Lunt's FireFly project:
 #include <avr/interrupt.h>
 #include <string.h>
 
+// ---------------------------------------------------------------------------
+// DEBUG_TEST 1 = bench testing: no reset-recovery wait, a blink attempt every
+// 8 s, and a short flash when the sketch thinks it is BRIGHT.
+// SET TO 0 FOR THE FIELD (48 s cycle, 16 min recovery wait after a reset).
+#define DEBUG_TEST 0
+
 #ifndef cbi
 #define cbi(sfr, bit) (_SFR_BYTE(sfr) &= ~_BV(bit))
 #endif
@@ -68,16 +88,55 @@ Inspired by Karl Lunt's FireFly project:
 #endif
 
 // ---------------------------------------------------------------------------
-// Timing: unit length in ms.
+// Watchdog timeout codes (nominal, at ~5 V; real values vary with Vcc/temp):
-// At 1 MHz, delay() is accurate when F_CPU=1000000L is set in boards.txt.
+// actual HW uses 3.3 (standard) or 5V (for blue LED experimental setup)
-// 100 ms gives readable optical Morse; raise to 150 ms if readability is poor.
+// so don't expect exact timing)
-#define unitLength 100
+//   0=16ms  1=32ms  2=64ms  3=128ms  4=250ms  5=500ms
+//   6=1s    7=2s    8=4s    9=8s
+//
+// One Morse unit = UNIT_WDT_A + UNIT_WDT_B  ->  64 ms + 32 ms = ~96 ms
+//   A=3, B=0    -> ~144 ms (easier to read, more LED time)
+//   A=3, B=0xFF -> ~128 ms
+//   A=2, B=0xFF -> ~64 ms  (fast, less LED time, harder to read by eye)
+// Use 0xFF for B to skip the second sleep.
+#define UNIT_WDT_A 2
+#define UNIT_WDT_B 1
 
 // ---------------------------------------------------------------------------
-// Sleep interval.
+// Sleep interval between two sensing/blink attempts: sleepCycles x 8 s.
-// Watchdog setup uses 8 s. For final use, change sleepCycles from 4 to 6
+// 6 x 8 s = 48 s. Goal ~ 1 blink/min.
-// for about 32s - 48s between sensing/blinking activations. Goal ~ 1 blink/min
+#if DEBUG_TEST
-const uint8_t sleepCycles = 6;
+const uint8_t sleepCycles = 1;
+#else
+const uint8_t sleepCycles = 5;
+#endif
+
+// ---------------------------------------------------------------------------
+// Darkness window in 16 ms steps (nominal).
+// After charging the LED junction the CPU sleeps step by step. If the pin
+// reads LOW within the window the LED discharged quickly = bright = no blink.
+// Still HIGH after the full window = dark = blink.
+// Longer window = triggers in brighter conditions (like the old threshold).
+// The window costs almost no energy (CPU sleeps), so it is only a threshold.
+// Calibrate at real dusk. Old threshold 17000 loops: measure the old
+// sensDarkness() time with micros() at your dusk level and divide it by 16 ms.
+const uint8_t darkSteps = 40;     // ~640 ms
+
+// ---------------------------------------------------------------------------
+// After a power-on / external reset (e.g. supercap was empty, DC/DC restart)
+// do not blink for this many cycles (x ~48 s) so the supercap can recharge.
+// 20 -> ~16 min. Set to 0 while testing/uploading (upload = external reset).
+#if DEBUG_TEST
+#define RECOVER_CYCLES 0
+#else
+#define RECOVER_CYCLES 20
+#endif
+
+// ---------------------------------------------------------------------------
+// Set to 1 only if the BOD fuse is enabled (e.g. hfuse 0xDE = 1.8 V).
+// Then BOD is switched off during power-down to save its ~20 uA.
+// With BOD fuse disabled this has no effect, leave it 0.
+#define BOD_FUSE_ENABLED 0
 
 // ---------------------------------------------------------------------------
 // LED pin definitions (N-side = cathode, P-side = anode for sensing/driving).
@@ -95,28 +154,25 @@ const uint8_t sleepCycles = 6;
 // ATTiny85 has 512 bytes SRAM; this keeps the Morse text in flash.
 // Only uppercase letters, digits, spaces, and the special chars in the switch
 // below are emitted. Lowercase letters are converted to uppercase.
-// Test setup: 20 x "0" because 0 = "-----" gives maximum LED ON time for test.
+// Shorter text = less LED time = less energy.
-// shorter text will better, more text will cost more power.
+const char morseText[] PROGMEM = "TOGO-LAB.IO FIREFLY";
-const char morseText[] PROGMEM = "TGO 26";
+// Ruler:                        0....0....1....1....2
-// Ruler:                         0....0....1...1....2
+// Ruler:                        01...5....0....5....0
-// Ruler:                         0....5....0...5....0
-// ---------------------------------------------------------------------------
-// Darkness threshold.
-// Higher value = triggers in brighter conditions.
-// Best calibrated at actual dusk/dawn with the chosen LED type.
-const unsigned int darknessThreshold = 17000;
 
 // ---------------------------------------------------------------------------
-// Watchdog interrupt flag — volatile because it is written in an ISR.
+// Watchdog interrupt flag - volatile because it is written in an ISR.
-volatile bool f_wdt = true;
+volatile bool f_wdt = false;
+
+// Remaining cycles without blinking after a reset.
+static uint8_t recoverCycles = 0;
 
 // ---------------------------------------------------------------------------
 // Forward declarations.
-void setup_watchdog(uint8_t ii);
+static void sleepWdt(uint8_t ii);
-void system_sleep();
+static void waitUnits(uint8_t n);
 void configureUnusedPins();
 void releaseLedPins(int LED_N, int LED_P);
-unsigned int sensDarkness(int LED_N, int LED_P);
+bool isDark(int LED_N, int LED_P);
 void morse(int LED_N, int LED_P);
 void dit(int LED_P);
 void dah(int LED_P);
@@ -126,22 +182,28 @@ void dah(int LED_P);
 // ===========================================================================
 void setup()
 {
-  // Disable unused peripherals immediately to save power.
+  // Remember why we restarted, then clear the flags.
-  // PRTIM1, PRUSI: unused, safe to gate off.
+  uint8_t resetCause = MCUSR;
-  // PRADC: ADC is not used; LED sensing is done with digitalRead().
+  MCUSR = 0;
-  // PRTIM0: must stay ON while awake because delay() depends on Timer0.
+  if (resetCause & ((1 << PORF) | (1 << BORF) | (1 << EXTRF))) {
-  PRR = (1 << PRTIM1) | (1 << PRUSI) | (1 << PRADC);
+    recoverCycles = RECOVER_CYCLES;
-
+  }
-  // ADC off. It is not needed for digitalRead()-based LED sensing.
-  cbi(ADCSRA, ADEN);
-
-  // Analog comparator off. Saves a little sleep current.
-  ACSR |= (1 << ACD);
 
+  // Pins first (while the Arduino core can still reach all timer registers
+  // for its turnOffPWM() handling in digitalWrite()).
   configureUnusedPins();
   releaseLedPins(LED1_N_SIDE, LED1_P_SIDE);
 
-  setup_watchdog(9);      // 8-second watchdog interval.
+  // ADC off FIRST, then gate its clock. With PRADC set, ADC register
+  // writes are ignored, so the order matters.
+  cbi(ADCSRA, ADEN);
+
+  // Analog comparator off.
+  ACSR |= (1 << ACD);
+
+  // Power reduction: ADC, USI, Timer0, Timer1 all off.
+  // Nothing in this sketch uses them: no delay(), no millis(), no analogWrite().
+  PRR = (1 << PRADC) | (1 << PRUSI) | (1 << PRTIM0) | (1 << PRTIM1);
 }
 
 // ===========================================================================
@@ -149,22 +211,29 @@ void setup()
 // ===========================================================================
 void loop()
 {
-  if (f_wdt) {
+  if (recoverCycles > 0) {
-    f_wdt = false;
+    recoverCycles--;
-
+  } else if (isDark(LED1_N_SIDE, LED1_P_SIDE)) {
-    if (sensDarkness(LED1_N_SIDE, LED1_P_SIDE) > darknessThreshold) {
+    morse(LED1_N_SIDE, LED1_P_SIDE);
-      morse(LED1_N_SIDE, LED1_P_SIDE);
-    }
-
-    // Return LED pins to high-Z before sleeping.
-    // Internal pullups stay disabled for the LED pins.
-    releaseLedPins(LED1_N_SIDE, LED1_P_SIDE);
   }
+#if DEBUG_TEST
+  else {
+    // Sketch decided "bright": one short ~128 ms flash so you can see it.
+    pinMode(LED1_N_SIDE, OUTPUT);
+    pinMode(LED1_P_SIDE, OUTPUT);
+    digitalWrite(LED1_N_SIDE, LOW);
+    digitalWrite(LED1_P_SIDE, HIGH);
+    sleepWdt(3);
+    digitalWrite(LED1_P_SIDE, LOW);
+  }
+#endif
+
+  // Return LED pins to high-Z before sleeping.
+  // Internal pullups stay disabled for the LED pins.
+  releaseLedPins(LED1_N_SIDE, LED1_P_SIDE);
 
-  // Test setup: 1 x 8 s sleep.
-  // Final setup: set sleepCycles = 4 for about 32 s.
   for (uint8_t i = 0; i < sleepCycles; i++) {
-    system_sleep();
+    sleepWdt(9);                      // 8 s each
   }
 }
 
@@ -188,87 +257,102 @@ void releaseLedPins(int LED_N, int LED_P)
 }
 
 // ===========================================================================
-// Sleep helpers
+// Sleep helpers (watchdog = only timebase)
 // ===========================================================================
-void system_sleep()
+ISR(WDT_vect)
 {
-  // Reset watchdog counter so each sleep cycle starts with a fresh interval.
+  f_wdt = true;
-  wdt_reset();
-
-  set_sleep_mode(SLEEP_MODE_PWR_DOWN);
-
-  // Atomic sleep entry pattern.
-  // After sei(), AVR executes the next instruction before servicing interrupts,
-  // so sleep_cpu() is not skipped by a just-pending interrupt.
-  cli();
-  sleep_enable();
-  sei();
-  sleep_cpu();
-
-  // WDT interrupt wakes the CPU here.
-  sleep_disable();
 }
 
-// Watchdog setup - ii selects timeout:
+// Sleep in POWER-DOWN until the watchdog interrupt fires after timeout code ii
-//   0=16ms  1=32ms  2=64ms  3=128ms  4=250ms  5=500ms
+// (0=16 ms ... 9=8 s). Reconfigures the watchdog on every call, so the full
-//   6=1s    7=2s    8=4s    9=8s
+// interval always starts fresh.
-void setup_watchdog(uint8_t ii)
+static void sleepWdt(uint8_t ii)
 {
   if (ii > 9) ii = 9;
 
   uint8_t bb = ii & 7;
   if (ii > 7) bb |= (1 << WDP3);
 
-  uint8_t oldSREG = SREG;
+  // Interrupt-only mode (WDE = 0). WDIF written as 1 clears a stale flag.
-  cli();
+  const uint8_t cfg = bb | (1 << WDIE) | (1 << WDIF);
 
+  f_wdt = false;
+  cli();
   wdt_reset();
   MCUSR &= ~(1 << WDRF);
 
-  // Timed sequence: enable configuration change, then set interrupt-only WDT.
+  // Timed sequence: the two writes must follow each other within 4 cycles.
-  WDTCR |= (1 << WDCE) | (1 << WDE);
+  WDTCR = (1 << WDCE) | (1 << WDE);
-  WDTCR = bb | (1 << WDIE);
+  WDTCR = cfg;
 
-  SREG = oldSREG;
+  set_sleep_mode(SLEEP_MODE_PWR_DOWN);
+
+  // Atomic sleep entry: after sei() the next instruction (sleep_cpu) still
+  // executes before any interrupt is serviced, so the wake-up cannot be missed.
+  // Loop again if something else woke the CPU.
+  while (!f_wdt) {
+    sleep_enable();
+#if BOD_FUSE_ENABLED
+    sleep_bod_disable();
+#endif
+    sei();
+    sleep_cpu();
+    sleep_disable();
+    cli();
+  }
+  sei();
 }
 
-ISR(WDT_vect)
+// Wait n Morse units in power-down.
+static void waitUnits(uint8_t n)
 {
-  f_wdt = true;
+  while (n--) {
+    sleepWdt(UNIT_WDT_A);
+#if UNIT_WDT_B != 0xFF
+    sleepWdt(UNIT_WDT_B);
+#endif
+  }
 }
 
 // ===========================================================================
 // Light sensor
 // ===========================================================================
-// Returns a "darkness level": higher = darker.
+// Returns true if it is dark.
-// Charges the LED junction capacitance, then times how long it takes to bleed
+// Charges the LED junction capacitance, then lets it bleed through the
-// back through the reverse-biased LED until the input reads LOW.
+// reverse-biased LED while the CPU sleeps. Checks the pin every ~16 ms.
-//   ~30000 = pitch black,  ~0 = bright light
+//   LOW within the window  -> bright (discharged fast)
-unsigned int sensDarkness(int LED_N, int LED_P)
+//   still HIGH at the end  -> dark
+// In power-down the input buffer of the floating pin is disabled by hardware,
+// so the slowly falling voltage causes no shoot-through current.
+bool isDark(int LED_N, int LED_P)
 {
-  unsigned int i;
-
   // Charge the LED junction capacitance.
   pinMode(LED_N, OUTPUT);
   pinMode(LED_P, OUTPUT);
   digitalWrite(LED_N, HIGH);
   digitalWrite(LED_P, LOW);
 
-  // Let the N-side float and measure bleed-down time.
+  // Let the N-side float (no pullup) and measure bleed-down time.
   pinMode(LED_N, INPUT);
-  digitalWrite(LED_N, LOW);   // disable internal pullup
+  digitalWrite(LED_N, LOW);
 
-  for (i = 0; i < 30000; i++) {
+  bool dark = true;
-    if (digitalRead(LED_N) == LOW) break;
+  for (uint8_t k = 0; k < darkSteps; k++) {
+    sleepWdt(0);                              // ~16 ms
+    if (digitalRead(LED_N) == LOW) {
+      dark = false;                           // bright: stop early
+      break;
+    }
   }
 
-  // Clean up after sensing: both LED pins low, then caller releases them.
+  // Clean up after sensing: both LED pins low, caller releases them.
   pinMode(LED_N, OUTPUT);
   digitalWrite(LED_N, LOW);
   pinMode(LED_P, OUTPUT);
   digitalWrite(LED_P, LOW);
 
-  return i;
+  return dark;
 }
 
 // ===========================================================================
@@ -277,17 +361,17 @@ unsigned int sensDarkness(int LED_N, int LED_P)
 void dit(int LED_P)
 {
   digitalWrite(LED_P, HIGH);
-  delay(unitLength);
+  waitUnits(1);
   digitalWrite(LED_P, LOW);
-  delay(unitLength);
+  waitUnits(1);
 }
 
 void dah(int LED_P)
 {
   digitalWrite(LED_P, HIGH);
-  delay(unitLength * 3);
+  waitUnits(3);
   digitalWrite(LED_P, LOW);
-  delay(unitLength);
+  waitUnits(1);
 }
 
 // ===========================================================================
@@ -371,7 +455,7 @@ void morse(int LED_N, int LED_P)
     // Previous symbol already ended with 1 unit OFF and then received the
     // normal 2 unit character gap. Add 4 units here -> total word gap 7 units.
     case ' ':
-      delay(unitLength * 4);
+      waitUnits(4);
       break;
 
     // Unsupported chars are ignored without adding an artificial gap.
@@ -382,10 +466,10 @@ void morse(int LED_N, int LED_P)
     // Inter-character gap: 3 units total.
     // dit()/dah() already trail 1 unit OFF, so add the remaining 2 units.
     if (symbolSent) {
-      delay(unitLength * 2);
+      waitUnits(2);
     }
   }
 
   digitalWrite(LED_P, LOW);
   digitalWrite(LED_N, LOW);
-}
+}