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nk25719 merged 1 commit into from
Feb 7, 2026
Merged

Fix DFPlayer test to fail cleanly when hardware is missing #355

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168 changes: 38 additions & 130 deletions Firmware/factoryTest/FactoryTest_wMenu/FactoryTest_wMenu.ino
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Original file line number Diff line number Diff line change
@@ -1,4 +1,4 @@
#define FIRMWARE_VERSION "v0.4.2.5"
#define FIRMWARE_VERSION "v0.4.2.6"
/*
------------------------------------------------------------------------------
File: FactoryTest_wMenu.ino
Expand All @@ -24,9 +24,11 @@ Revision History:
| v0.4.2 | 2026-1-1 | N. Kheir | SPI backloop working and final. DFP debug |
|v0.4.2.1 | 2026-1-1 | N. Kheir | DFplayer cleanup test. |
|v0.4.2.2 | 2026-1-1 | N. Kheir | SPI cleanup test. |
|v0.4.2.3 | 2026-1-5 | L. Erickson | Make menu two colums. |
|v0.4.2.3 | 2026-1-5 | L. Erickson | Make menu two columns. |
|v0.4.2.4 | 2026-1-6 | L. Erickson | Make volume full, 30. |
|v0.4.2.5 | 2026-1-7 | L. Erickson | Use myDFPlayer.getVersion() |
|v0.4.2.5 | 2026-1-7 | L. Erickson | Use dfPlayer.getVersion() |
|v0.4.2.6 | 2026-1-8 | Yukti | Fix DFPlayer test to fail cleanly when hardware |
| | | | is missing; improve error handling |
----------------------------------------------------------------------------------------|
Overview:
- Repeatable factory test sequence for ESP32-WROOM-32D Krake/GPAD v2 boards.
Expand All @@ -36,10 +38,12 @@ Overview:
(marks FAIL) and the command runs next.
- WiFi SSID/PASS input does NOT abort just because SSID starts with A/B/C/D.
It aborts only when the entire line is exactly one menu key (e.g., "C"+Enter).
- DFPlayer test now fails cleanly when hardware is missing or unresponsive.
------------------------------------------------------------------------------
Build notes:
- Adjust pin mapping to match your PCB (especially UART1 pins).
- If LAMP2 shares DFPlayer BUSY, we skip driving LAMP2 in the LED test.
- Ensure DF_RXD2 and DF_TXD2 are correctly wired to DFPlayer module.
------------------------------------------------------------------------------
*/

Expand Down Expand Up @@ -106,10 +110,8 @@ static const uint32_t TIMEOUT_MS = 600;
// DFPlayer bookkeeping + SD cache
HardwareSerial dfSerial(2);
DFRobotDFPlayerMini dfPlayer;
enum dfState { DF_UNKNOWN,
DF_OK,
DF_FAIL };
static bool dfState = DF_UNKNOWN;
enum dfState_t { DF_UNKNOWN, DF_OK, DF_FAIL };
static dfState_t dfState = DF_UNKNOWN;
// SD cache: read file count ONCE during test [5], reuse during test [6]
static bool g_sdChecked = false;
static int g_sdFileCount = -999;
Expand Down Expand Up @@ -602,54 +604,37 @@ static bool initDFPlayer() {

if (dfState == DF_OK) {
if (dfPlayerResponding()) return true;

Serial.println(F(" DFPlayer was OK but no reply now -> clearing cache & re-init..."));
Serial.println(F("DFPlayer lost response, clearing cache."));
clearDFPlayerCache();
}

if (dfState == DF_FAIL) return false;

Serial.println(F("Initializing DFPlayer (UART2)..."));

pinMode(DF_BUSY_IN, INPUT_PULLUP);

dfSerial.begin(9600, SERIAL_8N1, DF_RXD2, DF_TXD2);
delay(300);
dfPlayer.begin(dfSerial, true, true);
delay(300);
dfPlayer.setTimeOut(1000); // give replies more time (some modules are slow)
delay(300);
dfPlayer.outputDevice(DFPLAYER_DEVICE_SD);

int version = dfPlayer.available(); //
Serial.print("InitDFPlayer, dfPlayer.available(): ");
Serial.println(version);

// doReset=true helps a LOT with SD indexing reliability
if (!dfPlayer.begin(dfSerial, true, true)) {
Serial.println(F(" DFPlayer not detected. Check wiring & power."));
Serial.println(F("DFPlayer not detected (begin failed)."));
dfState = DF_FAIL;
return false;
}

dfPlayer.setTimeOut(1000); // give replies more time (some modules are slow)

// Force device selection (important on some clones)
dfPlayer.setTimeOut(1000);
dfPlayer.outputDevice(DFPLAYER_DEVICE_SD);
delay(1200); // let TF card mount + index after reset/device select
version = dfPlayer.available(); //
Serial.print("Afer OutputDevice InitDFPOlayer, dfPlayer.available(): ");
Serial.println(version);

delay(1200);

// Optional: verify it actually replies after init
if (!dfPlayerResponding()) {
Serial.println(F(" DFPlayer init done, but still no reply -> FAIL"));
Serial.println(F("DFPlayer init completed but no response."));
dfState = DF_FAIL;
return false;
}

dfState = DF_OK;
Serial.println(F(" DFPlayer detected and initialized (SD selected)."));
Serial.println(F("DFPlayer detected and responding."));
return true;
}

Expand Down Expand Up @@ -745,82 +730,34 @@ void printDetail(uint8_t type, int value) {


static bool runTest_DFPlayer(bool forceReinit = false) {
// If you want live DFPlayer diagnostics, call this elsewhere during waits:
// if (dfPlayer.available()) printDetail(dfPlayer.readType(), dfPlayer.read());
Serial.println(F("\n[4] DF Player"));

if (forceReinit) {
clearDFPlayerCache();
}

// initDFPlayer();
// //Check Mini MP3 Player availability. Works on TD5580A too.
// int version = dfPlayer.available(); //
// Serial.print("dfPlayer.available(): ");
// Serial.println(version);

if (!initDFPlayer()) {
Serial.println(F(" DFPlayer initializing Failed (DFPlayer not detected)."));
dfState = DF_FAIL;
// //Check Mini MP3 Player availability. Works on TD5580A too.
delay(1000);
int version = dfPlayer.available(); //
Serial.print("dfPlayer.available(): ");
Serial.println(version);
Serial.println(F("DFPlayer test FAIL: module not detected or not responding."));
return false;
} else {
// Serial.println(F("\n[6] DFPlayer + Speaker"));
Serial.println(F("DFPlayer Mini online."));
dfState = DF_OK;
int version = dfPlayer.available(); //
Serial.print("dfPlayer.available(): ");
Serial.println(version);
if (dfPlayer.available()) printDetail(dfPlayer.readType(), dfPlayer.read());
}


Serial.println(F("DFPlayer test PASS: module detected and responding."));
return true;
// Force device selection (important on some clones)
dfPlayer.outputDevice(DFPLAYER_DEVICE_SD);
delay(1200); // let TF card mount + index after reset/device select

bool ok = (dfState);
Serial.printf("DFPLAYER Initialized: %s\n", ok ? "PASS" : "FAIL (wiring/MAX3232/pins)");
return ok;
}

static bool runTest_SD() {
Serial.println(F("\n[5] SD (DFPlayer card)"));

// reset SD cache each time test [5] runs (so it stays consistent per run)
// g_sdChecked = false;
// g_sdFileCount = -999;

g_sdChecked = true;
g_sdFileCount = -1;

// if (!promptYesNo(F("Is the SD card inserted with audio files?"), PROMPT_TIMEOUT_MS, true)) {
// Serial.println(F("SD test: FAIL (operator says SD not inserted)."));
// g_sdChecked = true;
// g_sdFileCount = -1;
// return false;
// }

initDFPlayer();

//Check Mini MP3 Player availability. Works on TD5580A too.
int version = dfPlayer.available(); //
Serial.print("dfPlayer.available(): ");
Serial.println(version);



if (!initDFPlayer()) {
Serial.println(F("SD test: FAIL (DFPlayer not detected)."));
Serial.println(F("SD test skipped: DFPlayer not present."));
g_sdChecked = true;
g_sdFileCount = -1;
return false;
}

g_sdChecked = true;
g_sdFileCount = -1;

Serial.println(F("Reading SD file count (once)..."));
g_sdFileCount = dfPlayer.readFileCounts();

Expand All @@ -837,34 +774,24 @@ static bool runTest_SD() {
Serial.println(F("SD test: FAIL (no readable files)."));
return false;
}
return true;

bool ok = runTest_SD();
Serial.printf("SD test: %s\n", ok ? "PASS" : "FAIL");

void printDetail(uint8_t type, int value);
return true;
}

static bool runTest_Speaker() {
Serial.println(F("\n[6] Speaker"));
Serial.println(F("Playing track #1 for ~3 seconds..."));

// if (!initDFPlayer()) {
// Serial.println(F("Speaker test: FAIL (DFPlayer not detected)."));
// return false;
// }

// if (!g_sdChecked) {
// Serial.println(F("DFPlayer test requires SD test first."));
// Serial.println(F("Run [5] SD test, then run speaker test."));
// return false;
// }

// Serial.printf(" Using cached SD file count = %d\n", g_sdFileCount);
// if (g_sdFileCount <= 0) {
// Serial.println(F("No readable SD/files -> NOT playing audio. Speaker test FAIL."));
// return false;
// }
if (dfState != DF_OK) {
Serial.println(F("Speaker test FAIL: DFPlayer not present."));
return false;
}

if (!g_sdChecked || g_sdFileCount <= 0) {
Serial.println(F("Speaker test FAIL: SD not ready or no readable files."));
return false;
}

const int VOL = 30;
dfPlayer.volume(VOL);
Serial.printf("DFPlayer volume set to: %d\n", VOL);
Expand All @@ -873,17 +800,15 @@ static bool runTest_Speaker() {

uint32_t start = millis();
while (millis() - start < 3000) {
// Optional: report DFPlayer events while playing
if (dfPlayer.available()) {
printDetail(dfPlayer.readType(), dfPlayer.read());
}
delay(10);
}

dfPlayer.stop();
delay(200);

bool ok = promptYesNo(F("Did you hear audio from the speaker?"), PROMPT_TIMEOUT_MS, true);
bool ok = promptYesNo(F("Did you hear audio from the speaker?"),
PROMPT_TIMEOUT_MS,
true);
Serial.printf("Speaker test: %s\n", ok ? "PASS" : "FAIL");
return ok;
}
Expand Down Expand Up @@ -1046,11 +971,6 @@ static bool runTest_SPI() {
Serial.println("[SPI] PASS: RJ12 loopback OK");
}
return pass;

Serial.printf("SPI sent 0x%02X, received 0x%02X\n", RX, TX);
bool ok = runTest_UART0();
Serial.printf("SPI loopback test: %s\n", ok ? "PASS" : "FAIL (check jumper)");
return ok;
}

static bool runTest_RS232() {
Expand Down Expand Up @@ -1117,10 +1037,6 @@ static bool runTest_RS232() {
Serial.print(rx);
Serial.println("[rs232] PASS: UART1 loopback OK");
return true;

bool ok = (rx == payload);
Serial.printf("RS-232 loopback test: %s\n", ok ? "PASS" : "FAIL (wiring/MAX3232/pins)");
return ok;
}

// ============================================================================
Expand Down Expand Up @@ -1152,14 +1068,6 @@ static void runAllTests() {
for (int i = 0; i < T_COUNT; ++i) {
if (g_pendingCmd) break;

// skip audio play if SD failed
if (i == T_DFPLAYER && testResults[T_SD] == false) {
Serial.println(F("\n[6] DFPlayer + Speaker"));
Serial.println(F("Skipping audio play because SD test FAILED."));
testResults[T_DFPLAYER] = false;
continue;
}

testResults[i] = runSingleTestFromIndex(static_cast<TestIndex>(i));
}

Expand Down Expand Up @@ -1242,4 +1150,4 @@ void loop() {
Serial.println(up(c)); // echo
handleCommand(c);
}
}
}