firmware/build.py

from pathlib import Path
import csv
from SCons.Script import Import

# Import PlatformIO's SCons environment
Import("env")
senv = env  # avoid shadowing with the action's 'env' parameter

# Optional: keep your extra flag
senv.Append(CXXFLAGS=["-Wno-conversion-null"])

# ---- Detect MCU and map bootloader offsets ----
board_config = senv.BoardConfig()
mcu = (board_config.get("build.mcu") or senv.get("BOARD_MCU") or "").lower()

BOOT_OFFSETS = {
    "esp32":   0x1000,  # ESP32
    "esp32s3": 0x0000,  # ESP32-S3
    "esp32c5": 0x2000,  # ESP32-C5
}
boot_offset = BOOT_OFFSETS.get(mcu, 0x0000)  # safe fallback

# Default offsets (adjust if your partitions.csv uses custom addresses)
PART_TABLE_OFFSET = 0x8000
APP_OFFSET        = 0x10000

# Paths
build_dir = Path(senv.subst("$BUILD_DIR"))
proj_dir  = Path(senv.subst("$PROJECT_DIR"))
pioenv    = senv.subst("${PIOENV}")

boot_bin = build_dir / "bootloader.bin"
part_bin = build_dir / "partitions.bin"
app_bin  = build_dir / "firmware.bin"

out_bin  = proj_dir / f"Bruce-{pioenv}.bin"

# Esptool from PlatformIO + Python executable
esptool_pkg = senv.PioPlatform().get_package_dir("tool-esptoolpy")
esptool_py  = str(Path(esptool_pkg) / "esptool")
python_exe  = senv.get("PYTHONEXE", "python")

chip_arg = mcu if mcu else "esp32"

def _merge_bins_callback(target, source, env):
    """
    Post-action callback executed after firmware.bin is built.
    Merges bootloader, partitions, and app into a single binary.
    NOTE: This function signature must be (target, source, env) so SCons can call it.
    """
    # Check files
    missing = [p for p in [boot_bin, part_bin, app_bin] if not p.exists()]
    if missing:
        print("[merge_bin] Missing files, merge aborted:")
        for p in missing:
            print(f" - {p}")
        return

    # Quote paths for Windows safety
    def q(p): return f"\"{p}\""

    # ---- Read partition CSV to get test partition size and ota_0 offset ----
    part_csv_name = board_config.get("build.partitions") or env.GetProjectOption(
        "board_build.partitions", default=""
    )
    part_csv = proj_dir / part_csv_name if part_csv_name else proj_dir / "partitions.csv"
    ota_size = None
    ota0_offset = None
    if part_csv.exists():
        with open(part_csv, newline="") as f:
            reader = csv.reader(f)
            for row in reader:
                if not row or row[0].startswith("#"):
                    continue
                cols = [c.strip() for c in row]
                if len(cols) < 5:
                    continue
                name, ptype, subtype, offset, size = cols[:5]
                subtype = subtype.lower()
                if subtype == "ota_0" and ota_size is None:
                    try:
                        ota_size = int(size, 0)
                        ota0_offset = int(offset, 0)
                    except ValueError:
                        pass

    # ---- Firmware size check against test partition ----
    if ota_size:
        fw_size = app_bin.stat().st_size
        percent = (fw_size / ota_size) * 100 if ota_size else 0
        bar_len = 20
        filled = int(bar_len * fw_size / ota_size)
        bar = "=" * filled + " " * (bar_len - filled)
        print(
            f"BRUCE: [{bar}] {percent:.1f}% (used 0x{fw_size:X} bytes of 0x{ota_size:X} of OTA partition)"
        )
        if fw_size > ota_size:
            print("[merge_bin] Error: firmware.bin exceeds OTA partition size")
            env.Exit(1)

    cmd = " ".join([
        q(python_exe), "-m", "platformio", "pkg", "exec", "-p", q("tool-esptoolpy"), "--", "esptool.py",
        "--chip", chip_arg,
        "merge-bin",
        "--output", q(out_bin),
        hex(boot_offset), q(boot_bin),
        hex(PART_TABLE_OFFSET), q(part_bin),
        hex(APP_OFFSET), q(app_bin),
    ])

    print("[merge_bin] Merging binaries:")
    print(" ", cmd)
    rc = env.Execute(cmd)
    if rc != 0:
        print(f"[merge_bin] Failed with exit code {rc}")
        env.Exit(rc)
    else:
        try:
            size = out_bin.stat().st_size
        except FileNotFoundError:
            size = 0
        print(f"[merge_bin] Success -> {out_bin} ({size} bytes)")
        if ota0_offset:
            if size < (ota0_offset + ota_size):
                print("[Final bin] Valid bin to upload")
            else:
                print(
                    f"[Final bin] Error: bin size 0x{size:X} exceeds ota_0 offset 0x{(ota0_offset+ota_size):X}"
                )
                env.Exit(1)

# Automatically run after firmware.bin is generated
senv.AddPostAction(str(app_bin), _merge_bins_callback)

# Optional manual target: depend on the three binaries and run the same callback
# Wrap it in a lambda so SCons can call it without (target, source, env) if needed.
senv.AddCustomTarget(
    name="build-firmware",
    dependencies=[str(boot_bin), str(part_bin), str(app_bin)],
    actions=[_merge_bins_callback],
    title="Build Firmware (merge)",
    description="Merge bootloader + partitions + app into a single .bin file"
)

# Keep your upload-nobuild helper
senv.AddCustomTarget(
    name="upload-nobuild",
    dependencies=None,
    actions=[f"platformio run -t upload -t nobuild -e {pioenv}"],
    title="Upload Nobuild",
    description="Run upload without rebuilding"
)