From 0dcbae7ec620b6eb7cd9b712aa19e0136ba55a66 Mon Sep 17 00:00:00 2001
From: Joe Kearney <joe@clubk.club>
Date: Sat, 22 Nov 2025 16:51:33 -0600
Subject: [PATCH] Better USB plug/unplug handling.

---
 components/NVM/USB.c | 35 ++++++++++++++++++++++-------------
 components/NVM/USB.h |  2 +-
 main/main.c          | 11 +++++++++--
 3 files changed, 32 insertions(+), 16 deletions(-)

diff --git a/components/NVM/USB.c b/components/NVM/USB.c
index c5ab98b..85f4d1f 100644
--- a/components/NVM/USB.c
+++ b/components/NVM/USB.c
@@ -57,6 +57,7 @@ static const char *OTA_FILE = "/usb/esp/OTA_URL.txt";
 const char *CONFIG_FILE = "/usb/esp/config.txt";
 
 __NOINIT_ATTR uint_fast8_t Restarts;
+static bool Device_Connected_This_Power_Cycle = false;
 
 typedef enum
 {
@@ -274,8 +275,6 @@ static void usb_host_task(void *args)
 
 static void app_usb_task(void *args)
 {
-    SemaphoreHandle_t init_complete = args;
-
     static USB_State_T Current_State = USB_STATE_UNINITIALIZED;
     static msc_host_device_handle_t msc_device = NULL;
     static msc_host_vfs_handle_t vfs_handle = NULL;
@@ -311,20 +310,31 @@ static void app_usb_task(void *args)
                 {
                     device_address = msg.data.new_dev_address;
                     Current_State = USB_STATE_DEVICE_CONNECTED;
+                    Device_Connected_This_Power_Cycle = true;
+                    Restarts = 0;
                     KLOG_INFO(TAG, "Device connected.");
                 }
             }
             else
             {
-                if (Restarts <= 3)
+                if (Device_Connected_This_Power_Cycle == false)
                 {
-                    KLOG_ERROR(TAG, "No flash drive detected--rebooting.");
-                    vTaskDelay(pdMS_TO_TICKS(100));
-                    esp_restart();
-                }
-                else
-                {
-                    KLOG_WARN(TAG, "No flash drive detected after multiple attempts.");
+                    if (Restarts <= 3)
+                    {
+                        KLOG_ERROR(TAG, "No flash drive detected--rebooting.");
+                        vTaskDelay(pdMS_TO_TICKS(100));
+                        esp_restart();
+                    }
+                    else
+                    {
+                        static bool warning_sent = false;
+
+                        if (warning_sent == false)
+                        {
+                            KLOG_WARN(TAG, "No flash drive detected after multiple attempts.");
+                            warning_sent = true;
+                        }
+                    }
                 }
             }
         }
@@ -356,7 +366,6 @@ static void app_usb_task(void *args)
                 {
                     Current_State = USB_STATE_VFS_REGISTERED;
                     xEventGroupSetBits(Get_System_Events(), SYS_USB_FS_PRESENT);
-                    xSemaphoreGive(init_complete);
                 }
             }
         }
@@ -401,7 +410,7 @@ static void app_usb_task(void *args)
     }
 }
 
-void Initialize_USB(SemaphoreHandle_t init_complete)
+void Initialize_USB(void)
 {
     KLOG_INFO(TAG, "Initializing USB file system...");
 
@@ -416,7 +425,7 @@ void Initialize_USB(SemaphoreHandle_t init_complete)
         app_usb_task,          // Function that implements the task.
         "USB NVM",             // Text name for the task.
         STACK_SIZE,            // Stack size in bytes, not words.
-        (void *)init_complete, // Parameter passed into the task.
+        NULL,                  // Parameter passed into the task.
         tskIDLE_PRIORITY + 2,  // Priority at which the task is created.
         xStack,                // Array to use as the task's stack.
         &xTaskBuffer,          // Variable to hold the task's data structure.
diff --git a/components/NVM/USB.h b/components/NVM/USB.h
index f56e9fa..d64a531 100644
--- a/components/NVM/USB.h
+++ b/components/NVM/USB.h
@@ -21,7 +21,7 @@
 
 #pragma once
 
-void Initialize_USB(SemaphoreHandle_t init_complete);
+void Initialize_USB(void);
 
 extern const char *CONFIG_FILE;
 
diff --git a/main/main.c b/main/main.c
index f6a7b41..a1741cd 100644
--- a/main/main.c
+++ b/main/main.c
@@ -93,8 +93,15 @@ void app_main(void)
         KLOG_ERROR(TAG, "Timeout initializing SPIFFS!");
     }
 
-    Initialize_USB(init_complete_semaphore);
-    if (xSemaphoreTake(init_complete_semaphore, pdMS_TO_TICKS(INITIALIZATION_TIMEOUT_IN_ms)) != pdTRUE)
+    Initialize_USB();
+    EventBits_t bits = xEventGroupWaitBits(
+        Get_System_Events(),
+        SYS_USB_FS_PRESENT,
+        pdFALSE,
+        pdTRUE,
+        pdMS_TO_TICKS(INITIALIZATION_TIMEOUT_IN_ms));
+
+    if ((bits & SYS_USB_FS_PRESENT) == 0)
     {
         KLOG_ERROR(TAG, "Timeout initializing USB!");
     }