Swap AIO for HA Autodiscovery - #2
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July 26, 2026 09:06
- Replace Adafruit IO with direct Home Assistant MQTT connection - Implement MQTT auto-discovery for 3 main sensors + 3 diagnostic sensors - Add graceful offline publish queue (50-entry circular buffer) - Add exponential backoff reconnection with jitter (30s -> 10min) - Add WiFi recovery monitoring and continuous reconnection - Add diagnostic sensor publishing (WiFi RSSI, MQTT status, uptime) - Create MqttHandler class encapsulating all resilience logic - Add config.h template with device identity and connection settings - Update .gitignore to exclude config.h credentials from version control Device info: - Name: Smart Litter Tray - Version: 2025.07.26 - Manufacturer: andycb Resilience improvements: - Survives prolonged WiFi/MQTT outages without hard reset - Queues sensor data during disconnection - Implements exponential backoff to prevent network flooding - Designed for multi-month uptime without intervention
- Update software version to 2026.07.26 - Add hardware version field 1.0 to device identification - Add 'Data Age' sensor that tracks queue delay for each reading - For immediate publishes: age = 0 seconds - For queued publishes: age = time_in_queue_seconds - Automatically recalculate age when draining offline queue - Include hardware version in Home Assistant device discovery payload - New Home Assistant sensor: sensor.smart_litter_tray_data_age This allows monitoring data freshness and queue performance.
Changed from additive percentage model to multiplicative multiplier: - Old: delay + (delay * jitterPercent / 100) where jitterPercent=-10 to 10 - New: (delay * jitterMultiplier) / 100 where jitterMultiplier=90 to 110 This produces proper ±10% jitter (0.9x to 1.1x) instead of additive offset.
Diagnostics (WiFi RSSI, MQTT status, uptime) are now ephemeral: - Only published when MQTT is actively connected - Not queued to offline buffer - Changed publishDiagnostics() to use direct mqttClient.publish() instead of publishTopic() - Added early return if MQTT disconnected This preserves queue space for actual sensor data (cat weight, poop weight, duration, age).
- Renamed enum values to avoid PubSubClient library macro conflicts: - MQTT_DISCONNECTED → MQTT_STATE_DISCONNECTED - MQTT_CONNECTING → MQTT_STATE_CONNECTING - MQTT_CONNECTED → MQTT_STATE_CONNECTED - MQTT_FAILED → MQTT_STATE_FAILED - WIFI_DISCONNECTED → WIFI_STATE_DISCONNECTED - WIFI_CONNECTING → WIFI_STATE_CONNECTING - WIFI_CONNECTED → WIFI_STATE_CONNECTED - Added forward declaration of OnNewReading() in SmartLitterBoxSketch.ino to resolve undefined reference error This fixes all PubSubClient macro name collision issues.
LitterScale has const member variables, which makes the default move assignment operator implicitly deleted. Removed the explicit assignment 'this->m_litterScale = LitterScale()' and rely on default initialization of the member variable instead. This resolves the compilation error about deleted move assignment operator.
Added extensive debug output to help diagnose connection issues: MQTT connection debug: - Print server IP, port, client ID, username, password when attempting - Add human-readable error messages for all MQTT state codes - Specifically identify MQTT_CONNECT_FAILED (-2) as bad credentials/rejected WiFi connection debug: - Print current WiFi status code when attempting reconnection - Help identify WiFi status issues This helps identify whether the issue is: 1. Wrong MQTT credentials 2. MQTT broker not accessible on that port 3. WiFi connection issues 4. Client ID being rejected by broker
The issue was using WiFiClientSecure with setInsecure() for plain MQTT (port 1883). WiFiClientSecure can interfere with plain MQTT connections. Now automatically selects the correct client type based on port: - Port 1883 (plain MQTT): Uses WiFiClient (no TLS overhead) - Port 8883+ (MQTT with TLS): Uses WiFiClientSecure with setInsecure() This resolves MQTT_CONNECT_FAILED (-2) errors on plain MQTT brokers.
Print the exact discovery topic and JSON payload being sent to Home Assistant. This helps verify: 1. Topic structure is correct for MQTT discovery 2. JSON payload is properly formatted 3. Publish operation succeeds with retain flag This will help diagnose why entities don't appear in Home Assistant.
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