Refactor critical alert border and vibration handling

Moves control of the critical alert border and vibration to the UI task using a new 'criticalAlertsActive' flag in AlertUIUpdate. Adds direct control functions for the border flash, updates alert aggregation and vibration logic, and simplifies border stopping logic. This improves synchronization and ensures UI updates are handled atomically.

Author: zjwhitehead

inc/sp140/alert_display.h

@@ -31,13 +31,16 @@ extern QueueHandle_t alertCarouselQueue;  // depth 1, overwrite
 struct AlertUIUpdate {
   // Counter data
   AlertCounts counts;
-  
+
   // Display message data
   SensorID displayId;       // Valid sensor when showDisplay == true
   AlertLevel displayLevel;  // Alert level for dynamic abbreviations
   bool displayCritical;     // true = critical colouring
   bool showDisplay;         // false = hide label
-  
+
+  // Critical alert state (for border/vibration control)
+  bool criticalAlertsActive;  // true = show red border + vibration
+
   // Synchronization
   uint32_t updateEpoch;     // Ensures atomicity
 };

inc/sp140/lvgl/lvgl_updates.h

@@ -66,4 +66,11 @@ void stopCriticalBorderFlash();
  */
 bool isCriticalBorderFlashing();
 
+/**
+ * @brief Direct control functions for use within UI task (no mutex).
+ * These should only be called when the LVGL mutex is already held.
+ */
+void startCriticalBorderFlashDirect();
+void stopCriticalBorderFlashDirect();
+
 #endif // LVGL_UPDATES_H

src/sp140/alert_display.cpp

@@ -86,6 +86,7 @@ static void alertAggregationTask(void* parameter) {
         update.displayId = g_activeList[g_rotateIdx];
         update.displayLevel = g_currentLevels[g_activeList[g_rotateIdx]];
         update.displayCritical = g_showingCrit;
+        update.criticalAlertsActive = (g_currentCounts.criticalCount > 0);
         update.updateEpoch = g_epoch;
         if (alertUIQueue) {
           xQueueOverwrite(alertUIQueue, &update);
@@ -99,6 +100,7 @@ static void alertAggregationTask(void* parameter) {
         AlertUIUpdate update;
         update.counts = g_currentCounts;
         update.showDisplay = false;
+        update.criticalAlertsActive = (g_currentCounts.criticalCount > 0);
         update.updateEpoch = g_epoch;
         if (alertUIQueue) xQueueOverwrite(alertUIQueue, &update);
         hideSent = true;
@@ -154,6 +156,7 @@ static void recalcCountsAndPublish() {
 
     AlertUIUpdate update;
     update.counts = g_currentCounts;
+    update.criticalAlertsActive = (g_currentCounts.criticalCount > 0);
     update.updateEpoch = g_epoch;
 
     if (g_activeList.empty()) {
@@ -165,6 +168,9 @@ static void recalcCountsAndPublish() {
       update.displayCritical = g_showingCrit;
     }
 
+    USBSerial.printf("[Alert] Sending UI update: crit=%d warn=%d critActive=%d\n",
+                     update.counts.criticalCount, update.counts.warningCount, update.criticalAlertsActive);
+
     if (alertUIQueue) {
       xQueueOverwrite(alertUIQueue, &update);
     }
@@ -187,25 +193,16 @@ static void recalcCountsAndPublish() {
 
 /**
  * Handle vibration alerts based on state transitions
+ * Note: This now only handles one-shot vibration patterns.
+ * Critical alert border/vibration is handled by UI task based on criticalAlertsActive flag.
  */
 static void handleAlertVibration(const AlertCounts& newCounts, const AlertCounts& previousCounts) {
-  if (newCounts.criticalCount > 0) {
-    // Use the new synchronized alert service
-    if (!isCriticalAlertActive()) {
-      startCriticalAlerts();
-    }
-  } else {
-    // Stop synchronized alerts if no critical alerts remain
-    if (isCriticalAlertActive()) {
-      stopCriticalAlerts();
-    }
-
-    // Handle warning transitions (only when no critical alerts)
-    if (previousCounts.warningCount == 0 && newCounts.warningCount > 0) {
-      // Short delay to sync with UI
-      vTaskDelay(pdMS_TO_TICKS(250));
-      // Transition from 0 warnings to >0 warnings - trigger double pulse
-      executeVibePattern(VIBE_DOUBLE_PULSE);
-    }
+  // Handle warning transitions (only when no critical alerts)
+  if (newCounts.criticalCount == 0 &&
+      previousCounts.warningCount == 0 && newCounts.warningCount > 0) {
+    // Short delay to sync with UI
+    vTaskDelay(pdMS_TO_TICKS(100));
+    // Transition from 0 warnings to >0 warnings - trigger double pulse
+    executeVibePattern(VIBE_DOUBLE_PULSE);
   }
 }

src/sp140/lvgl/lvgl_updates.cpp

@@ -225,6 +225,26 @@ bool isCriticalBorderFlashing() {
   return isFlashingCriticalBorder;
 }
 
+// Direct control functions for use within UI task (no mutex)
+void startCriticalBorderFlashDirect() {
+  if (critical_border != NULL && !isFlashingCriticalBorder) {
+    isFlashingCriticalBorder = true;
+    lv_obj_clear_flag(critical_border, LV_OBJ_FLAG_HIDDEN); // Start visible
+    critical_border_flash_timer = lv_timer_create(critical_border_flash_timer_cb, 300, NULL);
+  }
+}
+
+void stopCriticalBorderFlashDirect() {
+  if (critical_border_flash_timer != NULL) {
+    lv_timer_del(critical_border_flash_timer);
+    critical_border_flash_timer = NULL;
+  }
+  if (critical_border != NULL) {
+    lv_obj_add_flag(critical_border, LV_OBJ_FLAG_HIDDEN);
+  }
+  isFlashingCriticalBorder = false;
+}
+
 // Update the climb rate indicator
 void updateClimbRateIndicator(float climbRate) {
   // Clamp climb rate to displayable range (-0.6 to +0.6 m/s)

src/sp140/sp140.ino

@@ -452,12 +452,25 @@ void refreshDisplay() {
     if (xQueueReceive(alertUIQueue, &alertUpdate, 0) == pdTRUE) {
       // Update counter and display atomically
       updateAlertCounterDisplay(alertUpdate.counts);
-      
+
       if (alertUpdate.showDisplay) {
         lv_showAlertTextWithLevel(alertUpdate.displayId, alertUpdate.displayLevel, alertUpdate.displayCritical);
       } else {
         lv_hideAlertText();
       }
+
+      // Control critical border and vibration based on state
+      static bool lastCriticalState = false;
+      if (alertUpdate.criticalAlertsActive != lastCriticalState) {
+        if (alertUpdate.criticalAlertsActive) {
+          USBSerial.println("[UI] Starting critical border flash");
+          startCriticalBorderFlashDirect(); // Direct control - we already have the mutex
+        } else {
+          USBSerial.println("[UI] Stopping critical border flash");
+          stopCriticalBorderFlashDirect(); // Direct control - we already have the mutex
+        }
+        lastCriticalState = alertUpdate.criticalAlertsActive;
+      }
     }
 
     // General LVGL update handler

src/sp140/vibration_pwm.cpp

@@ -244,14 +244,8 @@ void stopCriticalAlerts() {
   }
   g_critical_alert_active = false;
 
-  // Stop the master LVGL timer - retry if mutex is busy
+  // Stop the master LVGL timer
   stopCriticalBorderFlash();
-
-  // Verify the border actually stopped - retry up to 3 times if needed
-  for (int retry = 0; retry < 3 && isCriticalBorderFlashing(); retry++) {
-    vTaskDelay(pdMS_TO_TICKS(20)); // Brief delay
-    stopCriticalBorderFlash();
-  }
 }
 
 /**