overheat monitor with auto poweroff

- needs passwordless sudo on target machine or deploy to run as root

pi/ui/config.json

@@ -0,0 +1,7 @@
+{
+  "overheat": {
+    "threshold_celsius": 75.0,
+    "trigger_duration_sec": 10,
+    "shutdown_delay_sec": 10
+  }
+}

pi/ui/lib/app_root.dart

@@ -2,6 +2,9 @@ import 'package:flutter/material.dart';
 
 import 'screens/splash_screen.dart';
 import 'screens/dashboard_screen.dart';
+import 'screens/overheat_screen.dart';
+import 'services/config_service.dart';
+import 'services/overheat_monitor.dart';
 
 /// Root widget that manages app state transitions
 class AppRoot extends StatefulWidget {
@@ -13,6 +16,7 @@ class AppRoot extends StatefulWidget {
 
 class _AppRootState extends State<AppRoot> {
   bool _initialized = false;
+  bool _overheatTriggered = false;
   String _initStatus = 'Starting...';
 
   @override
@@ -21,7 +25,17 @@ class _AppRootState extends State<AppRoot> {
     _runInitSequence();
   }
 
+  @override
+  void dispose() {
+    OverheatMonitor.instance.stop();
+    super.dispose();
+  }
+
   Future<void> _runInitSequence() async {
+    // Load config first
+    setState(() => _initStatus = 'Loading config...');
+    await ConfigService.instance.load();
+
     // Simulate init checks - replace with real checks later
     // (UART, GPS, sensors, etc.)
 
@@ -37,16 +51,31 @@ class _AppRootState extends State<AppRoot> {
     setState(() => _initStatus = 'Ready');
     await Future.delayed(const Duration(milliseconds: 300));
 
+    // Start overheat monitoring
+    OverheatMonitor.instance.start(
+      onOverheat: () {
+        setState(() => _overheatTriggered = true);
+      },
+    );
+
     setState(() => _initialized = true);
   }
 
   @override
   Widget build(BuildContext context) {
+    // Determine which screen to show (priority: overheat > splash > dashboard)
+    Widget child;
+    if (_overheatTriggered) {
+      child = const OverheatScreen(key: ValueKey('overheat'));
+    } else if (!_initialized) {
+      child = SplashScreen(key: const ValueKey('splash'), status: _initStatus);
+    } else {
+      child = const DashboardScreen(key: ValueKey('dashboard'));
+    }
+
     return AnimatedSwitcher(
       duration: const Duration(milliseconds: 500),
-      child: _initialized
-          ? const DashboardScreen(key: ValueKey('dashboard'))
-          : SplashScreen(key: const ValueKey('splash'), status: _initStatus),
+      child: child,
     );
   }
 }

pi/ui/lib/screens/overheat_screen.dart

@@ -0,0 +1,152 @@
+import 'dart:async';
+import 'dart:io';
+
+import 'package:flutter/material.dart';
+
+import '../services/config_service.dart';
+import '../services/pi_io.dart';
+
+/// Overheat warning screen with shutdown countdown
+///
+/// Shows current temp, threshold, and countdown to poweroff.
+/// When countdown hits zero, executes system shutdown.
+class OverheatScreen extends StatefulWidget {
+  const OverheatScreen({super.key});
+
+  @override
+  State<OverheatScreen> createState() => _OverheatScreenState();
+}
+
+class _OverheatScreenState extends State<OverheatScreen> {
+  Timer? _countdownTimer;
+  Timer? _tempRefreshTimer;
+  late int _secondsRemaining;
+  double? _currentTemp;
+
+  @override
+  void initState() {
+    super.initState();
+
+    _secondsRemaining = ConfigService.instance.shutdownDelay.inSeconds;
+    _currentTemp = PiIO.instance.getTemperature();
+
+    // Countdown timer - ticks every second
+    _countdownTimer = Timer.periodic(const Duration(seconds: 1), (_) {
+      setState(() {
+        _secondsRemaining--;
+      });
+
+      if (_secondsRemaining <= 0) {
+        _countdownTimer?.cancel();
+        _executeShutdown();
+      }
+    });
+
+    // Keep temp display updated
+    _tempRefreshTimer = Timer.periodic(const Duration(milliseconds: 500), (_) {
+      setState(() {
+        _currentTemp = PiIO.instance.getTemperature();
+      });
+    });
+  }
+
+  @override
+  void dispose() {
+    _countdownTimer?.cancel();
+    _tempRefreshTimer?.cancel();
+    super.dispose();
+  }
+
+  Future<void> _executeShutdown() async {
+    // Try shutdown commands in order of preference
+    // Requires passwordless sudo for 'shutdown' command (see sudoers note below)
+    final commands = [
+      ['sudo', 'shutdown', '-h', 'now'],
+      ['sudo', 'poweroff'],
+      ['systemctl', 'poweroff'],  // Might work with polkit
+    ];
+
+    for (final cmd in commands) {
+      try {
+        final result = await Process.run(cmd.first, cmd.skip(1).toList());
+        if (result.exitCode == 0) return;  // Success
+      } catch (e) {
+        // Command not found or other error, try next
+      }
+    }
+    // All failed - we're probably not on Linux or no permissions
+    // Pi should have passwordless sudo configured:
+    //   echo "pi ALL=(ALL) NOPASSWD: /sbin/shutdown" | sudo tee /etc/sudoers.d/shutdown
+  }
+
+  @override
+  Widget build(BuildContext context) {
+    final threshold = ConfigService.instance.overheatThreshold;
+
+    return Scaffold(
+      backgroundColor: Colors.black,
+      body: Center(
+        child: Column(
+          mainAxisAlignment: MainAxisAlignment.center,
+          children: [
+            // Warning icon
+            const Icon(
+              Icons.warning_amber_rounded,
+              size: 100,
+              color: Colors.red,
+            ),
+
+            const SizedBox(height: 16),
+
+            // OVERHEATING text
+            const Text(
+              'OVERHEATING',
+              style: TextStyle(
+                fontSize: 48,
+                fontWeight: FontWeight.bold,
+                color: Colors.red,
+                letterSpacing: 4,
+              ),
+            ),
+
+            const SizedBox(height: 48),
+
+            // Current temperature
+            Text(
+              _currentTemp != null ? '${_currentTemp!.toStringAsFixed(1)}°C' : '—',
+              style: const TextStyle(
+                fontSize: 120,
+                fontWeight: FontWeight.w200,
+                color: Colors.white,
+                height: 1,
+              ),
+            ),
+
+            const SizedBox(height: 8),
+
+            // Threshold info
+            Text(
+              'Threshold: ${threshold.toStringAsFixed(0)}°C',
+              style: const TextStyle(
+                fontSize: 24,
+                color: Colors.grey,
+              ),
+            ),
+
+            const SizedBox(height: 48),
+
+            // Countdown
+            Text(
+              'Shutdown in $_secondsRemaining s',
+              style: const TextStyle(
+                fontSize: 32,
+                color: Colors.orange,
+                fontWeight: FontWeight.w500,
+              ),
+            ),
+          ],
+        ),
+      ),
+    );
+  }
+}

pi/ui/lib/services/config_service.dart

@@ -0,0 +1,69 @@
+import 'dart:convert';
+import 'dart:io';
+
+/// Configuration service - loads and caches values from config.json
+///
+/// Uses singleton pattern. Falls back to defaults if config file missing.
+class ConfigService {
+  ConfigService._();
+  static final instance = ConfigService._();
+
+  // Loaded config cache
+  Map<String, dynamic>? _config;
+  bool _loaded = false;
+
+  // Defaults
+  static const double _defaultThreshold = 80.0;
+  static const int _defaultTriggerDuration = 10;
+  static const int _defaultShutdownDelay = 10;
+
+  /// Load config from JSON file
+  ///
+  /// Looks for config.json in same directory as executable.
+  /// Safe to call multiple times - only loads once.
+  Future<void> load() async {
+    if (_loaded) return;
+
+    try {
+      // Config file sits next to the executable
+      final exePath = Platform.resolvedExecutable;
+      final exeDir = File(exePath).parent.path;
+      final configPath = '$exeDir${Platform.pathSeparator}config.json';
+
+      final file = File(configPath);
+      if (await file.exists()) {
+        final content = await file.readAsString();
+        _config = jsonDecode(content) as Map<String, dynamic>;
+      }
+    } catch (e) {
+      // Config parse error - fall back to defaults
+      _config = null;
+    }
+
+    _loaded = true;
+  }
+
+  /// CPU temperature threshold in Celsius
+  double get overheatThreshold {
+    final overheat = _config?['overheat'] as Map<String, dynamic>?;
+    final value = overheat?['threshold_celsius'];
+    if (value is num) return value.toDouble();
+    return _defaultThreshold;
+  }
+
+  /// How long temp must exceed threshold before triggering
+  Duration get overheatTriggerDuration {
+    final overheat = _config?['overheat'] as Map<String, dynamic>?;
+    final value = overheat?['trigger_duration_sec'];
+    if (value is int) return Duration(seconds: value);
+    return Duration(seconds: _defaultTriggerDuration);
+  }
+
+  /// Countdown before shutdown after overheat triggers
+  Duration get shutdownDelay {
+    final overheat = _config?['overheat'] as Map<String, dynamic>?;
+    final value = overheat?['shutdown_delay_sec'];
+    if (value is int) return Duration(seconds: value);
+    return Duration(seconds: _defaultShutdownDelay);
+  }
+}

pi/ui/lib/services/overheat_monitor.dart

@@ -0,0 +1,77 @@
+import 'dart:async';
+
+import 'config_service.dart';
+import 'pi_io.dart';
+
+/// Monitors CPU temperature and triggers overheat condition
+///
+/// Singleton pattern. Polls temp at 500ms intervals to match dashboard.
+/// When temp exceeds threshold for trigger duration, fires callback.
+class OverheatMonitor {
+  OverheatMonitor._();
+  static final instance = OverheatMonitor._();
+
+  Timer? _timer;
+  int _consecutiveOverheatSamples = 0;
+  bool _triggered = false;
+
+  static const Duration _pollInterval = Duration(milliseconds: 500);
+
+  /// Current temperature (from PiIO cache)
+  double? get currentTemp => PiIO.instance.getTemperature();
+
+  /// Whether overheat condition has triggered
+  bool get isTriggered => _triggered;
+
+  /// How long we've been over threshold
+  Duration get timeOverThreshold =>
+      Duration(milliseconds: _consecutiveOverheatSamples * _pollInterval.inMilliseconds);
+
+  /// Start monitoring with callback when overheat triggers
+  ///
+  /// [onOverheat] fires once when temp exceeds threshold for configured duration.
+  /// Safe to call multiple times - restarts monitoring.
+  void start({required VoidCallback onOverheat}) {
+    stop();
+    _triggered = false;
+    _consecutiveOverheatSamples = 0;
+
+    final threshold = ConfigService.instance.overheatThreshold;
+    final triggerDuration = ConfigService.instance.overheatTriggerDuration;
+
+    _timer = Timer.periodic(_pollInterval, (_) {
+      if (_triggered) return; // Already fired
+
+      final temp = PiIO.instance.getTemperature();
+      if (temp == null) return; // No reading yet
+
+      if (temp > threshold) {
+        _consecutiveOverheatSamples++;
+
+        final overThresholdTime = timeOverThreshold;
+        if (overThresholdTime >= triggerDuration) {
+          _triggered = true;
+          onOverheat();
+        }
+      } else {
+        // Temp dropped below threshold - reset counter
+        _consecutiveOverheatSamples = 0;
+      }
+    });
+  }
+
+  /// Stop monitoring
+  void stop() {
+    _timer?.cancel();
+    _timer = null;
+  }
+
+  /// Reset state (for testing/recovery)
+  void reset() {
+    _triggered = false;
+    _consecutiveOverheatSamples = 0;
+  }
+}
+
+/// Callback signature for void functions
+typedef VoidCallback = void Function();

scripts/deploy.py

@@ -16,6 +16,7 @@ SCRIPT_DIR = Path(__file__).parent.resolve()
 PROJECT_ROOT = SCRIPT_DIR.parent
 CONFIG_FILE = SCRIPT_DIR / "deploy_target.json"
 BUILD_DIR = PROJECT_ROOT / "pi" / "ui" / "build" / "elinux" / "arm64" / "release" / "bundle"
+CONFIG_SRC = PROJECT_ROOT / "pi" / "ui" / "config.json"
 
 
 def run(cmd: list[str], check: bool = True, **kwargs) -> subprocess.CompletedProcess:
@@ -63,6 +64,19 @@ def deploy(restart: bool = False) -> bool:
         f"{ssh_target}:{remote_path}/bundle/",
     ])
 
+    # Sync config.json (sits next to executable in bundle)
+    if CONFIG_SRC.exists():
+        print()
+        print("Syncing config.json...")
+        run([
+            "rsync", "-avz",
+            str(CONFIG_SRC),
+            f"{ssh_target}:{remote_path}/bundle/config.json",
+        ])
+    else:
+        print()
+        print("Note: No config.json found, using defaults")
+
     # Restart service if requested
     if restart:
         print()

scripts/deploy.sh

@@ -27,6 +27,7 @@ SERVICE_NAME=$(read_json service_name)
 
 SSH_TARGET="$PI_USER@$PI_HOST"
 BUILD_DIR="$PROJECT_ROOT/pi/ui/build/elinux/arm64/release/bundle"
+CONFIG_SRC="$PROJECT_ROOT/pi/ui/config.json"
 
 echo "=== Smart Serow Deploy ==="
 echo "Target: $SSH_TARGET:$REMOTE_PATH"
@@ -44,6 +45,16 @@ rsync -avz --delete \
     "$BUILD_DIR/" \
     "$SSH_TARGET:$REMOTE_PATH/bundle/"
 
+# Sync config.json (sits next to executable in bundle)
+if [ -f "$CONFIG_SRC" ]; then
+    echo ""
+    echo "Syncing config.json..."
+    rsync -avz "$CONFIG_SRC" "$SSH_TARGET:$REMOTE_PATH/bundle/config.json"
+else
+    echo ""
+    echo "Note: No config.json found, using defaults"
+fi
+
 # Restart service if requested
 RESTART="${1:-}"
 if [ "$RESTART" = "--restart" ] || [ "$RESTART" = "-r" ]; then