monitors industrial signals on ESP32, detects anomalies on-device, and publishes resilient MQTT telemetry.

What It Does

• Samples DHT22, gas analog input, and MPU6050 vibration.
• Runs FreeRTOS task pipeline with queue-based handoff.
• Applies threshold-based alarm logic with latched safety behavior.
• Computes lightweight anomaly score (0.0-1.0) and anomaly source.
• Publishes JSON telemetry over MQTT with offline queue + retry.
• Persists runtime thresholds to ESP32 NVS.
• Exposes operator controls via UART console.

Architecture

sensor_task -> processing_task -> control_task -> shared runtime
                     |                              |
                     |                              +-> telemetry_task (MQTT)
                     +-> anomaly detector           +-> console_task (UART)

supervisor_task monitors heartbeats of all tasks and forces FAULT on stalls.

Prototype

Key Modules

• src/main.cpp: task wiring, runtime orchestration, supervisor.
• src/alarm_logic.cpp: threshold and latched alarm state machine.
• src/anomaly_detector.cpp: adaptive baseline + variance anomaly scoring.
• src/mqtt_telemetry.cpp: WiFi/MQTT client with retry and offline buffering.
• src/config_persistence_esp32.cpp: threshold save/load with NVS.
• test/test_core.cpp: host-runnable tests for core logic.

Quick Start

1. Install PlatformIO:

brew install platformio

2. Build firmware:

pio run -e esp32dev

3. Run Wokwi simulation (uses diagram.json and wokwi.toml), then open serial monitor at 115200.

UART Commands

help
status
thresholds
reset_alarm
set temp_warn 36
set temp_alarm 44
set hum_warn 72
set hum_alarm 85
set vib_warn 0.18
set vib_alarm 0.35
set gas_warn 1900
set gas_alarm 2900
set safe_ms 10000

MQTT Telemetry

• Broker: broker.hivemq.com:1883
• Topic: karimFin/esp32-edge-monitor-firmware/telemetry
• Includes: sensor averages, state, fault info, anomaly_score, anomaly_src
• Reliability: bounded offline queue + reconnect flush
• Optional security flags in platformio.ini: MQTT_USE_TLS, MQTT_USERNAME, MQTT_PASSWORD

Demo Narrative

1. Start in NORMAL with stable sensor values.
2. Increase gas/vibration to trigger WARNING and ALARM.
3. Observe anomaly score rising before or during threshold transitions.
4. Use UART set commands to tune thresholds live.
5. Disconnect/reconnect network and confirm queued telemetry flushes.
6. Reboot and verify threshold settings reload from NVS.

Host Tests

mkdir -p build
clang++ -std=c++17 -Iinclude test/test_core.cpp src/alarm_logic.cpp src/anomaly_detector.cpp src/console_parser.cpp src/mpu6050_driver.cpp src/telemetry_utils.cpp -o build/test_core
./build/test_core

CI

• GitHub Actions runs on push/PR:
• host unit tests
• pio run -e esp32dev