Harden OBD connection and telemetry

Co-authored-by: Copilot <[email protected]>

PLAN.md

@@ -676,23 +676,10 @@ returns HTTP 200 with no "relay" text over the real network) and the remote serv
 CORS-hook removal is baked into the image at build time - confirmed `/health` still returns
 `{"status":"ok"}` and the response no longer carries any `Access-Control-*` header).
 
-**Handoff note for next session (2026-08-09, end of session)**: Phase 12 is fully done/deployed/
+**Update 2026-08-09**: Phase 17 (OBD hardening) was completed next; see its section below.
-verified as described above - nothing left to do there. Work had just started on **Phase 17 (OBD
+Phase 14 is the recommended next software phase because Phases 15/16 and the later list-based
-hardening)** next - picked because it's pure Python with zero risk to the Pi's live filesystem,
+features depend on its shared UI foundation. Phase 13 remains independent but requires a careful
-in contrast to Phase 13's overlay-FS work which is riskier and deserves its own careful pass.
+hardware/filesystem deployment pass rather than ordinary application deployment.
-**No code was written for Phase 17 yet** - only read `modules/app_events.py` (confirms
-`app_obd.obd_connection()` is only called from the Socket.IO `connect` handler, exactly as
-previously noted) and `modules/app_gps.py` (to use its `_poll_loop()`/`start_gps()` background-
-thread pattern as the template for OBD's new reconnect loop - lock+while-True+`time.sleep`,
-daemon thread, idempotent `start_*()` guard against double-starting). A `pip install obd` on the
-dev machine to inspect `python-obd`'s actual API (for DTC codes, ELM327 version/protocol
-attributes, exception types) was attempted but interrupted by a tool permission prompt before
-producing any output - **this still needs to be done** (or just read the `python-obd` source
-directly, e.g. via `pip download`/GitHub) before writing the DTC/diagnostics/protocol-override
-parts of Phase 17, to get exact attribute/method names right (e.g. `connection.protocol_name()`,
-`obd.commands.GET_DTC`, whatever `python-obd`'s actual exception class is called) rather than
-guessing. Phases 13 and 14 (UI foundation) are also fully ready to start (no blocking deps) if
-picking a different phase first makes more sense than continuing Phase 17.
 
 ### Phase 13: Power-loss resilience & watchdog — 🚧 PLANNED
 **New phase, not code-dependent on anything else — OS/hardware-level, can be done anytime,
@@ -772,7 +759,7 @@ Same file-browser treatment for videos already imported to the Pi's own disk
   Settings page - e.g. "delete local copies older than N days once uploaded", off by default)
   so the Pi's limited storage doesn't need to be babysat manually as the dashcam backlog grows.
 
-### Phase 17: OBD real-hardware readiness (code hardening) — 🚧 PLANNED
+### Phase 17: OBD real-hardware readiness (code hardening) — ✅ DONE
 **Independent of everything else in this plan — only touches `app_obd.py`/`app_events.py`, no UI
 dependency for the backend part, so this can be done anytime/in parallel with the phases above.**
 Nothing has been installed or tested in the actual 2013 Yaris yet - `modules/app_obd.py` has
@@ -814,6 +801,25 @@ all in `modules/app_obd.py` / `modules/app_events.py`:
   confirmed once tested against the real car (falls under "code hardening only" for now - add
   the query with graceful "unsupported" handling rather than assuming it will work).
 
+**Implemented 2026-08-09**:
+- Added an idempotent, browser-independent reconnect daemon started from `app.py`; it retries
+  every 10 seconds and restarts any dead polling workers after reconnect.
+- Serialized all python-obd queries so speed, RPM, and the expanded sensor worker cannot issue
+  overlapping serial exchanges. Query exceptions and silent connection-state changes now close
+  and discard the stale handle, emit disconnected state, and hand recovery back to the reconnect
+  loop instead of permanently killing a worker.
+- Added `OBD_PROTOCOL` support and distinct logs for no serial adapter, failed ELM327 handshake,
+  and ELM327 connected but no ECU response. Successful connections log port, ELM327 firmware,
+  negotiated protocol ID, and protocol name once.
+- Added backend polling/emits for coolant temperature, fuel level, throttle position, MIL/DTC
+  status, stored DTCs, and SAE PID `0xA6` odometer. Odometer uses a custom python-obd command with
+  a null/unsupported result left as `None`; support is not assumed for the 2013 Yaris.
+- Verified against the Pi's installed python-obd 0.7.3 API, plus focused mocked checks covering
+  successful connection, forced protocol, ECU-off status, silent disconnect cleanup, query
+  exceptions, and odometer decoding. The Pi currently has `/dev/ttyUSB0` present but is not
+  connected to the car, so actual PID availability and negotiated Toyota protocol still require
+  the user-planned first in-car test.
+
 ### Phase 18: Trip history & replay — 🚧 PLANNED
 **New phase.** Right now the `tracking` table (Phase 7) is just a raw stream of GPS/speed points
 with no concept of a discrete "trip" - there's no way to look back and see "trip #47, left home

app.py

@@ -8,7 +8,7 @@ app = Flask(__name__)
 app_events.socketio.init_app(app)
 
 account = app_account.Account()
-obd = app_obd.OBD()
+obd = app_obd.start_obd()
 car = app_car.Car()
 gps = app_gps.start_gps()
 app_sql.start_logging()

modules/app_events.py

@@ -10,7 +10,7 @@ thread_uptime = None
 @socketio.on('connect')
 def connect_event():
     print('Client connected')
-    print('Getting OBD status...')
+    print('Getting current OBD status...')
     app_obd.obd_connection()
     uptime()
 
@@ -42,4 +42,3 @@ def loop_uptime():
         uptime_lock.release()
 
     
-

modules/app_obd.py

@@ -1,141 +1,394 @@
-from modules import app_gps, app_sql, app_events
+from datetime import datetime
-import glob, obd, os, time, threading
+from threading import Event, Lock, Thread
-from datetime import datetime
+import glob
-from threading import Event, Thread
+import os
-
+import time
-status = None
+
-speed = 0
+import obd
-rpm = None
+
-
+from modules import app_events, app_gps
-class OBD:
+
-    def __init__(self):
+
-        self.status = status
+RECONNECT_INTERVAL = 10
-        self.rpm = rpm
+SENSOR_POLL_INTERVAL = 5
-        self.speed = speed
+
-
+status = None
-obd_status = ["Disconnected", "Connected", "Connection...", "wtf"]
+speed = 0
-obd_speed_lock = threading.Lock()
+rpm = None
-obd_rpm_lock = threading.Lock()
+coolant_temp = None
-thread_speed = None
+fuel_level = None
-thread_rpm = None
+throttle_position = None
-stop_speed = Event()
+mil_on = None
-stop_rpm = Event()
+dtc_codes = []
-
+odometer = None
-connection = None
+
-
+
-
+class OBD:
-def _find_obd_port():
+    def __init__(self):
-    """Locate the USB-serial OBD-II adapter.
+        self.status = status
-
+        self.rpm = rpm
-    Honors an OBD_PORT env var override; otherwise picks the first
+        self.speed = speed
-    /dev/ttyUSB* device found (the PL2303 USB adapter shows up here).
+
-    Returns None if nothing is found, letting python-obd fall back to its
+
-    own auto-scan (which also covers /dev/rfcomm* for the old Bluetooth setup).
+obd_status = ["Disconnected", "Connected", "Connecting"]
-    """
+obd_speed_lock = Lock()
-    env_port = os.environ.get("OBD_PORT")
+obd_rpm_lock = Lock()
-    if env_port:
+obd_sensor_lock = Lock()
-        return env_port
+_connection_lock = Lock()
-    ports = sorted(glob.glob("/dev/ttyUSB*"))
+_connect_lock = Lock()
-    return ports[0] if ports else None
+_query_lock = Lock()
-
+thread_speed = None
-
+thread_rpm = None
-def connect_obd():
+thread_sensors = None
-    """(Re)connect to the OBD-II adapter. Safe to call repeatedly."""
+_reconnect_thread = None
-    global connection
+stop_speed = Event()
-    port = _find_obd_port()
+stop_rpm = Event()
-    try:
+stop_sensors = Event()
-        print(obd_status[2])
+
-        connection = obd.OBD(portstr=port) if port else obd.OBD()
+connection = None
-    except Exception as e:
+
-        print("An error occurred:", str(e))
+
-        connection = None
+def _decode_odometer(messages):
-    return connection
+    data = messages[0].data[2:]
-
+    if len(data) != 4:
-
+        raise ValueError(f"expected 4 odometer bytes, received {len(data)}")
-connect_obd()
+    return int.from_bytes(bytes(data), byteorder="big") / 10
-
+
-
+
-def get_speedtime():
+ODOMETER_COMMAND = obd.OBDCommand(
-    global speed
+    "ODOMETER",
-    time_now = str(datetime.now().strftime("%H:%M:%S"))
+    "Vehicle odometer",
-    return [time_now, speed]
+    b"01A6",
-
+    6,
-
+    _decode_odometer,
-def obd_connection():
+)
-    global thread_speed, thread_rpm
+
-
+
-    if connection is None or not connection.is_connected():
+def _find_obd_port():
-        connect_obd()
+    """Locate the USB-serial OBD-II adapter."""
-
+    env_port = os.environ.get("OBD_PORT")
-    if connection is not None and connection.is_connected():
+    if env_port:
-        print(obd_status[1])
+        return env_port
-        app_events.socketio.emit('obd_status', obd_status[1])
+    ports = sorted(glob.glob("/dev/ttyUSB*"))
-        print("OBD connection established.")
+    return ports[0] if ports else None
-
+
-        if thread_speed is None or not thread_speed.is_alive():
+
-            stop_speed.clear()
+def _connection_status(candidate):
-            thread_speed = Thread(target=obd_speed)
+    try:
-            thread_speed.daemon = True
+        return candidate.status()
-            thread_speed.start()
+    except Exception:
-            print(f'thread_speed alive? {thread_speed.is_alive()}')
+        return obd.OBDStatus.NOT_CONNECTED
-
+
-        if thread_rpm is None or not thread_rpm.is_alive():
+
-            stop_rpm.clear()
+def _is_car_connected(candidate=None):
-            thread_rpm = Thread(target=obd_rpm)
+    if candidate is None:
-            thread_rpm.daemon = True
+        with _connection_lock:
-            thread_rpm.start()
+            candidate = connection
-            print(f'thread_rpm alive? {thread_rpm.is_alive()}')
+    return (
-    else:
+        candidate is not None
-        print("OBD connection failed.")
+        and _connection_status(candidate) == obd.OBDStatus.CAR_CONNECTED
-        print(obd_status[0])
+    )
-
+
-        app_events.socketio.emit('obd_status', obd_status[0])
+
-        app_events.socketio.emit('obd_speed', "-")
+def _emit_disconnected():
-        app_events.socketio.emit('obd_error', "-")
+    app_events.socketio.emit("obd_status", obd_status[0])
-        app_events.socketio.emit('obd_rpm', "-")
+    app_events.socketio.emit("obd_speed", "-")
-
+    app_events.socketio.emit("obd_error", "-")
-def obd_speed():
+    app_events.socketio.emit("obd_rpm", "-")
-    global speed
+
-    with obd_speed_lock:
+
-        cmd = obd.commands.SPEED  # select an OBD command (sensor)
+def _close_connection(candidate):
-        while not stop_speed.is_set():
+    try:
-            if connection is None or not connection.is_connected():
+        candidate.close()
-                print("OBD disconnected, stopping speed polling.")
+    except Exception as error:
-                break
+        print("Failed to close OBD connection:", str(error))
-
+
-            response = connection.query(cmd)  # send the command and parse the response
+
-            if response.is_null():
+def _mark_connection_lost(candidate, operation, error):
-                print("No data received. #" + str(get_speedtime()))
+    global connection
-                print(app_gps.get_gps())
+    with _connection_lock:
-            else:
+        if connection is not candidate:
-                speed = round(response.value.to("kph").magnitude, 1)
+            return
-                print("Speed:", speed, "kph")
+        connection = None
-
+    print(f"OBD {operation} failed; reconnecting: {error}")
-            app_events.socketio.emit('obd_speed', get_speedtime())
+    _close_connection(candidate)
-            time.sleep(2)
+    _emit_disconnected()
-
+
-def obd_rpm():
+
-    global rpm
+def _query(command, *, force=False):
-    with obd_rpm_lock:
+    with _connection_lock:
-        cmd = obd.commands.RPM  # select an OBD command (sensor)
+        candidate = connection
-        while not stop_rpm.is_set():
+    if candidate is None:
-            if connection is None or not connection.is_connected():
+        return None
-                print("OBD disconnected, stopping rpm polling.")
+    if not _is_car_connected(candidate):
-                break
+        _mark_connection_lost(
-
+            candidate,
-            response = connection.query(cmd)  # send the command and parse the response
+            "connection check",
-            if response.is_null():
+            f"status changed to {_connection_status(candidate)}",
-                print("No RPM data received. #" + str(get_speedtime()))
+        )
-                app_events.socketio.emit('obd_rpm', "-")
+        return None
-            else:
+
-                rpm = round(response.value.magnitude, 0)
+    try:
-                print("RPM:", rpm)
+        with _query_lock:
-                app_events.socketio.emit('obd_rpm', rpm)
+            return candidate.query(command, force=force)
-
+    except Exception as error:
-            time.sleep(1)
+        _mark_connection_lost(candidate, command.name, error)
-
+        return None
-def kill_obd(obd_type):
+
-    if obd_type == "speed":
+
-        stop_speed.set()
+def _log_connection_diagnostics(candidate):
-    elif obd_type == "rpm":
+    firmware = "unknown"
-        stop_rpm.set()
+    try:
+        with _query_lock:
+            response = candidate.query(obd.commands.ELM_VERSION)
+        if not response.is_null():
+            firmware = str(response.value)
+    except Exception as error:
+        print("Unable to read ELM327 firmware version:", str(error))
+
+    print(
+        "OBD connected:"
+        f" port={candidate.port_name()},"
+        f" ELM327={firmware},"
+        f" protocol={candidate.protocol_id()} ({candidate.protocol_name()})"
+    )
+
+
+def connect_obd():
+    """Connect to the adapter and ECU, with actionable failure diagnostics."""
+    global connection
+    with _connect_lock:
+        if _is_car_connected():
+            return connection
+
+        with _connection_lock:
+            stale_connection = connection
+            connection = None
+        if stale_connection is not None:
+            _close_connection(stale_connection)
+
+        port = _find_obd_port()
+        detected_ports = [port] if port else obd.scan_serial()
+        if not detected_ports:
+            print(
+                "No OBD-II adapter detected. Check USB power/cabling and the "
+                "OBD_PORT setting."
+            )
+            with _connection_lock:
+                connection = None
+            _emit_disconnected()
+            return None
+
+        protocol = os.environ.get("OBD_PROTOCOL") or None
+        selected_port = port or detected_ports[0]
+        print(
+            f"{obd_status[2]} to {selected_port}"
+            + (f" using protocol {protocol}" if protocol else " using auto protocol")
+            + "..."
+        )
+
+        try:
+            candidate = obd.OBD(portstr=selected_port, protocol=protocol)
+        except Exception as error:
+            print(
+                f"OBD adapter detected at {selected_port}, but the ELM327 "
+                f"handshake failed: {error}"
+            )
+            with _connection_lock:
+                connection = None
+            _emit_disconnected()
+            return None
+
+        candidate_status = _connection_status(candidate)
+        if candidate_status == obd.OBDStatus.NOT_CONNECTED:
+            print(
+                f"OBD adapter detected at {selected_port}, but the ELM327 "
+                "handshake failed."
+            )
+            _close_connection(candidate)
+            candidate = None
+        elif candidate_status != obd.OBDStatus.CAR_CONNECTED:
+            print(
+                f"ELM327 handshake succeeded at {selected_port}, but the car ECU "
+                f"did not respond (status: {candidate_status}). Check ignition."
+            )
+            _close_connection(candidate)
+            candidate = None
+
+        with _connection_lock:
+            connection = candidate
+
+        if candidate is None:
+            _emit_disconnected()
+            return None
+
+        _log_connection_diagnostics(candidate)
+        app_events.socketio.emit("obd_status", obd_status[1])
+        _start_polling_threads()
+        return candidate
+
+
+def get_speedtime():
+    time_now = str(datetime.now().strftime("%H:%M:%S"))
+    return [time_now, speed]
+
+
+def obd_connection():
+    """Emit current state for a newly connected browser and ensure OBD is running."""
+    start_obd()
+    if _is_car_connected():
+        app_events.socketio.emit("obd_status", obd_status[1])
+        app_events.socketio.emit("obd_speed", get_speedtime())
+        app_events.socketio.emit("obd_rpm", rpm if rpm is not None else "-")
+    else:
+        _emit_disconnected()
+
+
+def obd_speed():
+    global speed
+    with obd_speed_lock:
+        while not stop_speed.is_set() and _is_car_connected():
+            response = _query(obd.commands.SPEED)
+            if response is None:
+                break
+            if response.is_null():
+                print("No speed data received. #" + str(get_speedtime()))
+                print(app_gps.get_gps())
+            else:
+                speed = round(response.value.to("kph").magnitude, 1)
+                print("Speed:", speed, "kph")
+
+            app_events.socketio.emit("obd_speed", get_speedtime())
+            stop_speed.wait(2)
+
+
+def obd_rpm():
+    global rpm
+    with obd_rpm_lock:
+        while not stop_rpm.is_set() and _is_car_connected():
+            response = _query(obd.commands.RPM)
+            if response is None:
+                break
+            if response.is_null():
+                print("No RPM data received. #" + str(get_speedtime()))
+                app_events.socketio.emit("obd_rpm", "-")
+            else:
+                rpm = round(response.value.magnitude)
+                print("RPM:", rpm)
+                app_events.socketio.emit("obd_rpm", rpm)
+
+            stop_rpm.wait(1)
+
+
+def _quantity_value(command, unit=None):
+    response = _query(command)
+    if response is None or response.is_null():
+        return None
+    value = response.value.to(unit) if unit else response.value
+    return round(value.magnitude, 1)
+
+
+def _poll_diagnostics():
+    global coolant_temp, fuel_level, throttle_position
+    global mil_on, dtc_codes, odometer
+
+    coolant_temp = _quantity_value(obd.commands.COOLANT_TEMP, "degC")
+    fuel_level = _quantity_value(obd.commands.FUEL_LEVEL, "percent")
+    throttle_position = _quantity_value(obd.commands.THROTTLE_POS, "percent")
+
+    status_response = _query(obd.commands.STATUS)
+    if status_response is not None and not status_response.is_null():
+        mil_on = bool(status_response.value.MIL)
+        app_events.socketio.emit(
+            "obd_mil",
+            {"on": mil_on, "dtc_count": status_response.value.DTC_count},
+        )
+
+    dtc_response = _query(obd.commands.GET_DTC)
+    if dtc_response is not None and not dtc_response.is_null():
+        dtc_codes = [
+            {"code": code, "description": description}
+            for code, description in dtc_response.value
+        ]
+        app_events.socketio.emit("obd_dtc", dtc_codes)
+
+    odometer_response = _query(ODOMETER_COMMAND, force=True)
+    if odometer_response is not None and not odometer_response.is_null():
+        odometer = round(odometer_response.value, 1)
+
+    app_events.socketio.emit("obd_coolant_temp", coolant_temp)
+    app_events.socketio.emit("obd_fuel_level", fuel_level)
+    app_events.socketio.emit("obd_throttle", throttle_position)
+    app_events.socketio.emit("obd_odometer", odometer)
+
+
+def obd_sensors():
+    with obd_sensor_lock:
+        while not stop_sensors.is_set() and _is_car_connected():
+            _poll_diagnostics()
+            stop_sensors.wait(SENSOR_POLL_INTERVAL)
+
+
+def _start_polling_threads():
+    global thread_speed, thread_rpm, thread_sensors
+
+    thread_specs = (
+        ("speed", obd_speed, stop_speed),
+        ("rpm", obd_rpm, stop_rpm),
+        ("sensors", obd_sensors, stop_sensors),
+    )
+    threads = {
+        "speed": thread_speed,
+        "rpm": thread_rpm,
+        "sensors": thread_sensors,
+    }
+
+    for name, target, stop_event in thread_specs:
+        thread = threads[name]
+        if thread is None or not thread.is_alive():
+            stop_event.clear()
+            thread = Thread(target=target, name=f"obd-{name}", daemon=True)
+            thread.start()
+            if name == "speed":
+                thread_speed = thread
+            elif name == "rpm":
+                thread_rpm = thread
+            else:
+                thread_sensors = thread
+            print(f"OBD {name} thread started, alive: {thread.is_alive()}")
+
+
+def _reconnect_loop():
+    while True:
+        if _is_car_connected():
+            _start_polling_threads()
+        else:
+            connect_obd()
+        time.sleep(RECONNECT_INTERVAL)
+
+
+def start_obd():
+    """Start the browser-independent OBD reconnect loop once."""
+    global _reconnect_thread
+    if _reconnect_thread is None or not _reconnect_thread.is_alive():
+        _reconnect_thread = Thread(
+            target=_reconnect_loop,
+            name="obd-reconnect",
+            daemon=True,
+        )
+        _reconnect_thread.start()
+        print(f"OBD reconnect thread started, alive: {_reconnect_thread.is_alive()}")
+    return OBD()
+
+
+def kill_obd(obd_type):
+    if obd_type == "speed":
+        stop_speed.set()
+    elif obd_type == "rpm":
+        stop_rpm.set()
+    elif obd_type == "sensors":
+        stop_sensors.set()
+    elif obd_type == "all":
+        stop_speed.set()
+        stop_rpm.set()
+        stop_sensors.set()