feat: Add /join route and WiFi setup screen improvements

embedded/libs/esp-web-server/src/esp_web_server.cpp

@@ -228,6 +228,9 @@ void ESPWebServer::handleRoot() {
                 if (status.connected) {
                     el.className = 'status connected';
                     el.innerHTML = 'Connected to <strong>' + status.ssid + '</strong><br>IP: ' + status.ip + ' | Signal: ' + status.rssi + ' dBm';
+                } else if (status.ap_mode) {
+                    el.className = 'status disconnected';
+                    el.innerHTML = 'Access Point Mode<br>IP: ' + status.ip + '<br><small>Connect to a WiFi network below</small>';
                 } else {
                     el.className = 'status disconnected';
                     el.textContent = 'Not connected';
@@ -453,6 +456,11 @@ void ESPWebServer::handleWiFiConnect() {
     const char* ssid = doc["ssid"];
     const char* password = doc["password"] | "";
 
+    // Stop AP mode if running before connecting to a new network
+    if (WiFiMgr.isAPMode()) {
+        WiFiMgr.stopAP();
+    }
+
     WiFiMgr.connect(ssid, password);
 
     sendJson(200, "{\"success\":true,\"message\":\"Connecting...\"}");
@@ -463,9 +471,10 @@ void ESPWebServer::handleWiFiStatus() {
     JsonDocument doc;
 
     doc["connected"] = WiFiMgr.isConnected();
-    doc["ssid"] = WiFiMgr.getSSID();
-    doc["ip"] = WiFiMgr.getIP();
-    doc["rssi"] = WiFiMgr.getRSSI();
+    doc["ap_mode"] = WiFiMgr.isAPMode();
+    doc["ssid"] = WiFiMgr.isAPMode() ? "" : WiFiMgr.getSSID();
+    doc["ip"] = WiFiMgr.isAPMode() ? WiFiMgr.getAPIP() : WiFiMgr.getIP();
+    doc["rssi"] = WiFiMgr.isAPMode() ? 0 : WiFiMgr.getRSSI();
 
     sendJson(200, doc);
 }

embedded/libs/lilygo-display/src/lilygo_display.cpp

@@ -198,6 +198,69 @@ void LilyGoDisplay::showConfigPortal(const char* apName, const char* ip) {
     _display.setTextDatum(lgfx::top_left);
 }
 
+void LilyGoDisplay::showSetupScreen(const char* apName) {
+    _display.fillScreen(COLOR_BACKGROUND);
+
+    // Header
+    _display.setFont(&fonts::FreeSansBold9pt7b);
+    _display.setTextColor(COLOR_ACCENT);
+    _display.setTextDatum(lgfx::top_center);
+    _display.drawString("WiFi Setup", SCREEN_WIDTH / 2, 8);
+
+    // Step 1: Connect to WiFi AP
+    _display.setFont(&fonts::Font2);
+    _display.setTextColor(COLOR_TEXT);
+    _display.drawString("1. Connect to WiFi:", SCREEN_WIDTH / 2, 38);
+
+    _display.setFont(&fonts::FreeSansBold9pt7b);
+    _display.setTextColor(COLOR_STATUS_OK);
+    _display.drawString(apName, SCREEN_WIDTH / 2, 58);
+
+    // QR Code section - generate QR for http://192.168.4.1
+    const char* configUrl = "http://192.168.4.1";
+    QRCode qrCode;
+    qrcode_initText(&qrCode, _qrCodeData, QR_VERSION, ECC_LOW, configUrl);
+
+    // Calculate QR code size and position
+    int qrSize = qrCode.size;
+    int pixelSize = 100 / qrSize;  // Target ~100px QR code
+    if (pixelSize < 1) pixelSize = 1;
+
+    int actualQrSize = pixelSize * qrSize;
+    int qrX = (SCREEN_WIDTH - actualQrSize) / 2;
+    int qrY = 90;
+
+    // Draw white background for QR code
+    _display.fillRect(qrX - 4, qrY - 4, actualQrSize + 8, actualQrSize + 8, COLOR_QR_BG);
+
+    // Draw QR code modules
+    for (uint8_t y = 0; y < qrSize; y++) {
+        for (uint8_t x = 0; x < qrSize; x++) {
+            if (qrcode_getModule(&qrCode, x, y)) {
+                _display.fillRect(qrX + x * pixelSize, qrY + y * pixelSize, pixelSize, pixelSize, COLOR_QR_FG);
+            }
+        }
+    }
+
+    // Step 2: Instructions below QR code
+    int instructionY = qrY + actualQrSize + 16;
+
+    _display.setFont(&fonts::Font2);
+    _display.setTextColor(COLOR_TEXT);
+    _display.drawString("2. Scan QR code or", SCREEN_WIDTH / 2, instructionY);
+    _display.drawString("open in browser:", SCREEN_WIDTH / 2, instructionY + 18);
+
+    _display.setFont(&fonts::FreeSansBold9pt7b);
+    _display.setTextColor(COLOR_ACCENT);
+    _display.drawString("192.168.4.1", SCREEN_WIDTH / 2, instructionY + 40);
+
+    _display.setFont(&fonts::Font0);
+    _display.setTextColor(COLOR_TEXT_DIM);
+    _display.drawString("to configure settings", SCREEN_WIDTH / 2, instructionY + 65);
+
+    _display.setTextDatum(lgfx::top_left);
+}
+
 void LilyGoDisplay::setSessionId(const char* sessionId) {
     _sessionId = sessionId ? sessionId : "";
 }

embedded/libs/lilygo-display/src/lilygo_display.h

@@ -200,6 +200,7 @@ class LilyGoDisplay {
     void showConnecting();
     void showError(const char* message, const char* ipAddress = nullptr);
     void showConfigPortal(const char* apName, const char* ip);
+    void showSetupScreen(const char* apName);
 
     // Climb display
     void showClimb(const char* name, const char* grade, const char* gradeColor, int angle, const char* uuid,

embedded/libs/wifi-utils/src/wifi_utils.cpp

@@ -49,6 +49,41 @@ void WiFiUtils::disconnect() {
     setState(WiFiConnectionState::DISCONNECTED);
 }
 
+bool WiFiUtils::startAP(const char* apName) {
+    // Stop any existing connection first
+    WiFi.disconnect();
+
+    // Configure AP mode
+    WiFi.mode(WIFI_AP);
+
+    // Start the access point
+    bool success = WiFi.softAP(apName);
+    if (success) {
+        setState(WiFiConnectionState::AP_MODE);
+    }
+    return success;
+}
+
+void WiFiUtils::stopAP() {
+    WiFi.softAPdisconnect(true);
+    WiFi.mode(WIFI_STA);
+    WiFi.setAutoReconnect(true);
+    setState(WiFiConnectionState::DISCONNECTED);
+}
+
+bool WiFiUtils::isAPMode() {
+    return state == WiFiConnectionState::AP_MODE;
+}
+
+String WiFiUtils::getAPIP() {
+    return WiFi.softAPIP().toString();
+}
+
+bool WiFiUtils::hasSavedCredentials() {
+    String ssid = Config.getString(KEY_SSID);
+    return ssid.length() > 0;
+}
+
 bool WiFiUtils::isConnected() {
     return WiFi.status() == WL_CONNECTED;
 }
@@ -83,6 +118,11 @@ void WiFiUtils::setState(WiFiConnectionState newState) {
 }
 
 void WiFiUtils::checkConnection() {
+    // Don't check STA connection in AP mode
+    if (state == WiFiConnectionState::AP_MODE) {
+        return;
+    }
+
     bool connected = WiFi.status() == WL_CONNECTED;
 
     switch (state) {
@@ -109,5 +149,9 @@ void WiFiUtils::checkConnection() {
                 connect(currentSSID.c_str(), currentPassword.c_str(), false);
             }
             break;
+
+        case WiFiConnectionState::AP_MODE:
+            // Handled at the top of the function
+            break;
     }
 }

embedded/libs/wifi-utils/src/wifi_utils.h

@@ -8,8 +8,10 @@
 
 #define WIFI_CONNECT_TIMEOUT_MS 30000
 #define WIFI_RECONNECT_INTERVAL_MS 5000
+#define DEFAULT_AP_NAME "Boardsesh-Setup"
+#define DEFAULT_AP_IP "192.168.4.1"
 
-enum class WiFiConnectionState { DISCONNECTED, CONNECTING, CONNECTED, CONNECTION_FAILED };
+enum class WiFiConnectionState { DISCONNECTED, CONNECTING, CONNECTED, CONNECTION_FAILED, AP_MODE };
 
 typedef void (*WiFiStateCallback)(WiFiConnectionState state);
 
@@ -24,6 +26,13 @@ class WiFiUtils {
     bool connectSaved();
     void disconnect();
 
+    // Access Point mode
+    bool startAP(const char* apName = DEFAULT_AP_NAME);
+    void stopAP();
+    bool isAPMode();
+    String getAPIP();
+    bool hasSavedCredentials();
+
     bool isConnected();
     WiFiConnectionState getState();
 

embedded/projects/board-controller/src/main.cpp

@@ -29,6 +29,7 @@
 // State
 bool wifiConnected = false;
 bool backendConnected = false;
+bool bleInitialized = false;
 
 #ifdef ENABLE_DISPLAY
 // Navigation mutation debounce - wait for rapid presses to stop before sending mutation
@@ -86,6 +87,7 @@ void onBLEData(const uint8_t* data, size_t len);
 void onBLELedData(const LedCommand* commands, int count, int angle);
 void onGraphQLStateChange(GraphQLConnectionState state);
 void onGraphQLMessage(JsonDocument& doc);
+void initializeBLE();
 #ifdef ENABLE_DISPLAY
 void handleLedUpdateExtended(JsonObject& data);
 void onQueueSync(const ControllerQueueSyncData& data);
@@ -106,6 +108,47 @@ void sendToAppViaBLE(const uint8_t* data, size_t len) {
 }
 #endif
 
+/**
+ * Initialize BLE - called after WiFi is configured
+ * This is deferred until WiFi is set up so we don't waste resources
+ * scanning for boards when we can't connect to the backend anyway
+ */
+void initializeBLE() {
+    if (bleInitialized) {
+        return;  // Already initialized
+    }
+
+    Logger.logln("Initializing BLE as '%s'...", BLE_DEVICE_NAME);
+#ifdef ENABLE_BLE_PROXY
+    // When proxy is enabled, don't advertise yet - connect to board first
+    // Advertising will start after successful connection to real board
+    BLE.begin(BLE_DEVICE_NAME, false);
+#else
+    BLE.begin(BLE_DEVICE_NAME, true);
+#endif
+    BLE.setConnectCallback(onBLEConnect);
+    BLE.setDataCallback(onBLEData);
+    BLE.setLedDataCallback(onBLELedData);
+
+#ifdef ENABLE_BLE_PROXY
+    // Set up raw data forwarding for proxy mode
+    BLE.setRawForwardCallback(onBLERawForward);
+
+    // Initialize proxy
+    String targetMac = Config.getString("proxy_mac");
+    Proxy.begin(targetMac);
+    Proxy.setStateCallback(onProxyStateChange);
+    Proxy.setSendToAppCallback(sendToAppViaBLE);
+#endif
+
+#ifdef ENABLE_DISPLAY
+    Display.setBleStatus(true, false);  // BLE enabled, not connected
+#endif
+
+    bleInitialized = true;
+    Logger.logln("BLE initialization complete");
+}
+
 void setup() {
     Serial.begin(115200);
     delay(3000);  // Longer delay to ensure serial monitor catches boot messages
@@ -162,36 +205,27 @@ void setup() {
 
     // Try to connect to saved WiFi
     if (!WiFiMgr.connectSaved()) {
-        Logger.logln("No saved WiFi credentials");
-    }
-
-    // Initialize BLE - always use BLE_DEVICE_NAME for Kilter app compatibility
-    Logger.logln("Initializing BLE as '%s'...", BLE_DEVICE_NAME);
-#ifdef ENABLE_BLE_PROXY
-    // When proxy is enabled, don't advertise yet - connect to board first
-    // Advertising will start after successful connection to real board
-    BLE.begin(BLE_DEVICE_NAME, false);
+        Logger.logln("No saved WiFi credentials - starting AP mode");
+#ifdef ENABLE_DISPLAY
+        // Start AP mode for WiFi configuration
+        if (WiFiMgr.startAP()) {
+            Logger.logln("AP mode started: %s", DEFAULT_AP_NAME);
+            Display.showSetupScreen(DEFAULT_AP_NAME);
+        } else {
+            Logger.logln("Failed to start AP mode");
+            Display.showError("AP Failed");
+        }
 #else
-    BLE.begin(BLE_DEVICE_NAME, true);
-#endif
-    BLE.setConnectCallback(onBLEConnect);
-    BLE.setDataCallback(onBLEData);
-    BLE.setLedDataCallback(onBLELedData);
-
-#ifdef ENABLE_BLE_PROXY
-    // Set up raw data forwarding for proxy mode
-    BLE.setRawForwardCallback(onBLERawForward);
-
-    // Initialize proxy
-    String targetMac = Config.getString("proxy_mac");
-    Proxy.begin(targetMac);
-    Proxy.setStateCallback(onProxyStateChange);
-    Proxy.setSendToAppCallback(sendToAppViaBLE);
+        // Without display, just start AP mode silently
+        WiFiMgr.startAP();
 #endif
+        // Don't initialize BLE yet - wait for WiFi to be configured
+    } else {
+        // We have saved WiFi credentials, initialize BLE now
+        initializeBLE();
+    }
 
 #ifdef ENABLE_DISPLAY
-    Display.setBleStatus(true, false);  // BLE enabled, not connected
-
     // Initialize button pins for navigation
     pinMode(BUTTON_1_PIN, INPUT_PULLUP);
     pinMode(BUTTON_2_PIN, INPUT_PULLUP);
@@ -202,27 +236,36 @@ void setup() {
     WebConfig.begin();
 
     Logger.logln("Setup complete!");
-    Logger.logln("IP: %s", WiFiMgr.getIP().c_str());
+    if (WiFiMgr.isAPMode()) {
+        Logger.logln("AP IP: %s", WiFiMgr.getAPIP().c_str());
+    } else {
+        Logger.logln("IP: %s", WiFiMgr.getIP().c_str());
+    }
 
     // Green blink to indicate ready
     LEDs.blink(0, 255, 0, 3, 100);
 
+    // Don't refresh display if in AP mode - keep showing setup screen
 #ifdef ENABLE_DISPLAY
-    Display.refresh();
+    if (!WiFiMgr.isAPMode()) {
+        Display.refresh();
+    }
 #endif
 }
 
 void loop() {
     // Process WiFi
     WiFiMgr.loop();
 
-    // Process BLE
-    BLE.loop();
+    // Process BLE (only if initialized - deferred until WiFi configured)
+    if (bleInitialized) {
+        BLE.loop();
 
 #ifdef ENABLE_BLE_PROXY
-    // Process BLE proxy
-    Proxy.loop();
+        // Process BLE proxy
+        Proxy.loop();
 #endif
+    }
 
     // Process WebSocket if WiFi connected
     if (wifiConnected) {
@@ -323,8 +366,13 @@ void onWiFiStateChange(WiFiConnectionState state) {
 
 #ifdef ENABLE_DISPLAY
             Display.setWiFiStatus(true);
+            // Show normal UI now that we're connected
+            Display.showNoClimb();
 #endif
 
+            // Initialize BLE now that WiFi is connected (if not already done)
+            initializeBLE();
+
             // Get backend config
             String host = Config.getString("backend_host", DEFAULT_BACKEND_HOST);
             int port = Config.getInt("backend_port", DEFAULT_BACKEND_PORT);
@@ -368,6 +416,20 @@ void onWiFiStateChange(WiFiConnectionState state) {
 
         case WiFiConnectionState::CONNECTION_FAILED:
             Logger.logln("WiFi connection failed");
+#ifdef ENABLE_DISPLAY
+            Display.setWiFiStatus(false);
+            // If connection failed and we don't have saved credentials, start AP mode
+            if (!WiFiMgr.hasSavedCredentials()) {
+                Logger.logln("No saved credentials - starting AP mode for configuration");
+                if (WiFiMgr.startAP()) {
+                    Display.showSetupScreen(DEFAULT_AP_NAME);
+                }
+            }
+#endif
+            break;
+
+        case WiFiConnectionState::AP_MODE:
+            Logger.logln("WiFi in AP mode: %s", WiFiMgr.getAPIP().c_str());
 #ifdef ENABLE_DISPLAY
             Display.setWiFiStatus(false);
 #endif