tdpro & t5s3 pro - lock screen power saving improvements; fix stupid stupid merged firmware - bug

examples/companion_radio/main.cpp

@@ -1662,6 +1662,27 @@ void loop() {
   // CPU frequency auto-timeout back to idle
   cpuPower.loop();
 
+  // Low-power mode — drop CPU to 40 MHz and throttle loop when lock screen
+  // is active.  The mesh radio has its own FIFO so packets are buffered;
+  // 50 ms yield means the loop still runs 20×/sec which is more than enough
+  // to drain the radio FIFO before overflow.
+#if defined(LilyGo_T5S3_EPaper_Pro) || defined(LilyGo_TDeck_Pro)
+  {
+    static bool wasLocked = false;
+    bool nowLocked = ui_task.isLocked();
+    if (nowLocked && !wasLocked) {
+      cpuPower.setLowPower();
+      Serial.printf("[Power] Low-power mode: CPU %d MHz, loop throttled\n",
+                    cpuPower.getFrequencyMHz());
+    } else if (!nowLocked && wasLocked) {
+      cpuPower.clearLowPower();
+      Serial.printf("[Power] Normal mode: CPU %d MHz\n",
+                    cpuPower.getFrequencyMHz());
+    }
+    wasLocked = nowLocked;
+  }
+#endif
+
   // Audiobook: service audio decode regardless of which screen is active
   #if defined(LilyGo_TDeck_Pro) && !defined(HAS_4G_MODEM)
   {
@@ -2182,6 +2203,16 @@ void loop() {
     }
   }
   #endif
+
+  // Low-power loop throttle — yield CPU when lock screen is active.
+  // The RTOS idle task executes WFI (wait-for-interrupt) during delay(),
+  // dramatically reducing CPU power draw.  50 ms gives 20 loop cycles/sec
+  // which is ample for LoRa packet reception (radio has hardware FIFO).
+#if defined(LilyGo_T5S3_EPaper_Pro) || defined(LilyGo_TDeck_Pro)
+  if (ui_task.isLocked()) {
+    delay(50);
+  }
+#endif
 }
 
 // ============================================================================

examples/companion_radio/ui-new/UITask.cpp

@@ -1844,7 +1844,7 @@ void UITask::lockScreen() {
   _next_refresh = 0;  // Draw lock screen immediately
   _auto_off = millis() + 60000;  // 60s before display off while locked
   _lastLockRefresh = millis();   // Start 15-min clock refresh cycle
-  Serial.println("[UI] Screen locked");
+  Serial.println("[UI] Screen locked — entering low-power mode");
 }
 
 void UITask::unlockScreen() {
@@ -1863,7 +1863,7 @@ void UITask::unlockScreen() {
   _auto_off = millis() + AUTO_OFF_MILLIS;
   _lastInputMillis = millis();  // Reset auto-lock idle timer
   _next_refresh = 0;
-  Serial.println("[UI] Screen unlocked");
+  Serial.println("[UI] Screen unlocked — exiting low-power mode");
 }
 #endif // LilyGo_T5S3_EPaper_Pro || LilyGo_TDeck_Pro
 

merge_firmware.py

@@ -21,7 +21,7 @@ def merge_bin(source, target, env):
     bootloader = os.path.join(build_dir, "bootloader.bin")
     partitions = os.path.join(build_dir, "partitions.bin")
     firmware   = os.path.join(build_dir, "firmware.bin")
-    output     = os.path.join(build_dir, "firmware_merged.bin")
+    output     = os.path.join(build_dir, "firmware-merged.bin")
 
     # Verify all inputs exist
     for f in [bootloader, partitions, firmware]:

variants/lilygo_t5s3_epaper_pro/CPUPowerManager.h

@@ -8,9 +8,10 @@
 //   240 MHz  ~70-80 mA
 //   160 MHz  ~50-60 mA
 //    80 MHz  ~30-40 mA
+//    40 MHz  ~15-20 mA  (low-power / lock screen mode)
 //
 // SPI peripherals and UART use their own clock dividers from the APB clock,
-// so LoRa, e-ink, and GPS serial all work fine at 80MHz.
+// so LoRa, e-ink, and GPS serial all work fine at 80MHz and 40MHz.
 
 #ifdef ESP32
 
@@ -22,23 +23,36 @@
 #define CPU_FREQ_BOOST  240    // MHz — heavy processing
 #endif
 
+#ifndef CPU_FREQ_LOW_POWER
+#define CPU_FREQ_LOW_POWER  40 // MHz — lock screen / idle standby
+#endif
+
 #ifndef CPU_BOOST_TIMEOUT_MS
 #define CPU_BOOST_TIMEOUT_MS  10000  // 10 seconds
 #endif
 
 class CPUPowerManager {
 public:
-  CPUPowerManager() : _boosted(false), _boost_started(0) {}
+  CPUPowerManager() : _boosted(false), _lowPower(false), _boost_started(0) {}
 
   void begin() {
     setCpuFrequencyMhz(CPU_FREQ_IDLE);
     _boosted = false;
+    _lowPower = false;
     MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz", CPU_FREQ_IDLE);
   }
 
   void loop() {
     if (_boosted && (millis() - _boost_started >= CPU_BOOST_TIMEOUT_MS)) {
-      setIdle();
+      // Return to low-power if locked, otherwise normal idle
+      if (_lowPower) {
+        setCpuFrequencyMhz(CPU_FREQ_LOW_POWER);
+        MESH_DEBUG_PRINTLN("CPU power: boost expired, returning to low-power %d MHz", CPU_FREQ_LOW_POWER);
+      } else {
+        setCpuFrequencyMhz(CPU_FREQ_IDLE);
+        MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz", CPU_FREQ_IDLE);
+      }
+      _boosted = false;
     }
   }
 
@@ -57,13 +71,42 @@ public:
       _boosted = false;
       MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz", CPU_FREQ_IDLE);
     }
+    if (_lowPower) {
+      _lowPower = false;
+    }
+  }
+
+  // Low-power mode — drops CPU to 40 MHz for lock screen standby.
+  // If currently boosted, the boost timeout will return to 40 MHz
+  // instead of 80 MHz.
+  void setLowPower() {
+    _lowPower = true;
+    if (!_boosted) {
+      setCpuFrequencyMhz(CPU_FREQ_LOW_POWER);
+      MESH_DEBUG_PRINTLN("CPU power: low-power at %d MHz", CPU_FREQ_LOW_POWER);
+    }
+    // If boosted, the loop() timeout will drop to low-power instead of idle
+  }
+
+  // Exit low-power mode — returns to normal idle (80 MHz).
+  // If currently boosted, the boost timeout will return to idle
+  // instead of low-power.
+  void clearLowPower() {
+    _lowPower = false;
+    if (!_boosted) {
+      setCpuFrequencyMhz(CPU_FREQ_IDLE);
+      MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz (low-power cleared)", CPU_FREQ_IDLE);
+    }
+    // If boosted, the loop() timeout will drop to idle as normal
   }
 
   bool isBoosted() const { return _boosted; }
+  bool isLowPower() const { return _lowPower; }
   uint32_t getFrequencyMHz() const { return getCpuFrequencyMhz(); }
 
 private:
   bool _boosted;
+  bool _lowPower;
   unsigned long _boost_started;
 };
 

variants/lilygo_tdeck_pro/CPUPowerManager.h

@@ -8,9 +8,10 @@
 //   240 MHz  ~70-80 mA
 //   160 MHz  ~50-60 mA
 //    80 MHz  ~30-40 mA
+//    40 MHz  ~15-20 mA  (low-power / lock screen mode)
 //
 // SPI peripherals and UART use their own clock dividers from the APB clock,
-// so LoRa, e-ink, and GPS serial all work fine at 80MHz.
+// so LoRa, e-ink, and GPS serial all work fine at 80MHz and 40MHz.
 
 #ifdef ESP32
 
@@ -22,23 +23,36 @@
 #define CPU_FREQ_BOOST  240    // MHz — heavy processing
 #endif
 
+#ifndef CPU_FREQ_LOW_POWER
+#define CPU_FREQ_LOW_POWER  40 // MHz — lock screen / idle standby
+#endif
+
 #ifndef CPU_BOOST_TIMEOUT_MS
 #define CPU_BOOST_TIMEOUT_MS  10000  // 10 seconds
 #endif
 
 class CPUPowerManager {
 public:
-  CPUPowerManager() : _boosted(false), _boost_started(0) {}
+  CPUPowerManager() : _boosted(false), _lowPower(false), _boost_started(0) {}
 
   void begin() {
     setCpuFrequencyMhz(CPU_FREQ_IDLE);
     _boosted = false;
+    _lowPower = false;
     MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz", CPU_FREQ_IDLE);
   }
 
   void loop() {
     if (_boosted && (millis() - _boost_started >= CPU_BOOST_TIMEOUT_MS)) {
-      setIdle();
+      // Return to low-power if locked, otherwise normal idle
+      if (_lowPower) {
+        setCpuFrequencyMhz(CPU_FREQ_LOW_POWER);
+        MESH_DEBUG_PRINTLN("CPU power: boost expired, returning to low-power %d MHz", CPU_FREQ_LOW_POWER);
+      } else {
+        setCpuFrequencyMhz(CPU_FREQ_IDLE);
+        MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz", CPU_FREQ_IDLE);
+      }
+      _boosted = false;
     }
   }
 
@@ -57,13 +71,42 @@ public:
       _boosted = false;
       MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz", CPU_FREQ_IDLE);
     }
+    if (_lowPower) {
+      _lowPower = false;
+    }
+  }
+
+  // Low-power mode — drops CPU to 40 MHz for lock screen standby.
+  // If currently boosted, the boost timeout will return to 40 MHz
+  // instead of 80 MHz.
+  void setLowPower() {
+    _lowPower = true;
+    if (!_boosted) {
+      setCpuFrequencyMhz(CPU_FREQ_LOW_POWER);
+      MESH_DEBUG_PRINTLN("CPU power: low-power at %d MHz", CPU_FREQ_LOW_POWER);
+    }
+    // If boosted, the loop() timeout will drop to low-power instead of idle
+  }
+
+  // Exit low-power mode — returns to normal idle (80 MHz).
+  // If currently boosted, the boost timeout will return to idle
+  // instead of low-power.
+  void clearLowPower() {
+    _lowPower = false;
+    if (!_boosted) {
+      setCpuFrequencyMhz(CPU_FREQ_IDLE);
+      MESH_DEBUG_PRINTLN("CPU power: idle at %d MHz (low-power cleared)", CPU_FREQ_IDLE);
+    }
+    // If boosted, the loop() timeout will drop to idle as normal
   }
 
   bool isBoosted() const { return _boosted; }
+  bool isLowPower() const { return _lowPower; }
   uint32_t getFrequencyMHz() const { return getCpuFrequencyMhz(); }
 
 private:
   bool _boosted;
+  bool _lowPower;
   unsigned long _boost_started;
 };