Wi-Fi over USB tab for firmware with the USB console (v13)

Writes / reads / removes the box's Wi-Fi over the serial port with the
usb_console commands (kota ping, wifi set|get|clear, health) and follows
the box through the restart until it joins the network. The password is
sent hex-encoded and never logged.

firmware/ now holds merged-binary-v13.bin (build 3ae273ec) instead of the
previous 1.0.16 build; error_ids.csv synced with the firmware.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

tests/test_commands.py

@@ -0,0 +1,162 @@
+"""Wi-Fi over USB (firmware usb_console api=1): encoding, replies and the whole
+write/clear/read job, driven with reply lines in the firmware's exact format."""
+
+import pytest
+
+from kota_tech.core.logline import parse_line
+from kota_tech.diag.engine import DiagnosticsEngine
+from kota_tech.serialio.commands import (
+    CONNECT_TIMEOUT_S, PING_TIMEOUT_S, Step, WifiFlow, loggable, parse_reply, validate_wifi, wifi_set_command)
+
+PING = "I (5000) KOTA: cmd ping ok=1 fw=1.0.16 api=1"
+BOOT = ("I (2843) KOTA: boot fw=1.0.16 build=3ae273ec hw=2 mac=A4CB8FC946F8 reset=RTC_SW_SYS_RST "
+        "mode={mode} commissioned=- last_restart={last}")
+HEALTH = ("I (9000) KOTA: cmd health ok=1 up=9s status=OK wifi={wifi} rssi={rssi} time_valid=1 sd=ok buffer=0 "
+          "heap=90000 psram=7.6M last_upload=never ota=registered")
+
+
+class Clock:
+    def __init__(self):
+        self.t = 0.0
+
+    def __call__(self):
+        return self.t
+
+
+def make(action, **kw):
+    sent, events, clock = [], [], Clock()
+    flow = WifiFlow(action, lambda c: sent.append(c) or True, events.append, now=clock, **kw)
+    return flow, sent, events, clock
+
+
+def feed(flow, text):
+    flow.feed(parse_line(text))
+
+
+# ------------------------------------------------------------- encoding
+
+def test_wifi_set_command_is_hex_utf8():
+    assert wifi_set_command("Biuro 2.4", "tajne=haslo1") == \
+        "kota wifi set 426975726f20322e34 74616a6e653d6861736c6f31"
+    assert wifi_set_command("Łąka", "zażółć1234").split()[3] == "c581c4856b61"
+
+
+@pytest.mark.parametrize("ssid,password,problem", [
+    ("", "12345678", "network name"),
+    ("x" * 33, "12345678", "32 bytes"),
+    ("net", "1234567", "8-63"),
+    ("net", "x" * 64, "8-63"),
+    ("net\n", "12345678", "line break"),
+])
+def test_validation_matches_firmware_limits(ssid, password, problem):
+    assert any(problem in p for p in validate_wifi(ssid, password))
+    with pytest.raises(ValueError):
+        wifi_set_command(ssid, password)
+
+
+def test_password_never_logged():
+    cmd = wifi_set_command("Biuro", "sekretne-haslo")
+    assert "sekretne" not in loggable(cmd) and "7365" not in loggable(cmd)
+    assert "Biuro" in loggable(cmd)
+
+
+def test_reply_parsing():
+    r = parse_reply(parse_line("I (1) KOTA: cmd wifi_set ok=0 err=password_length"))
+    assert r.name == "wifi_set" and not r.ok and "8-63" in r.error
+    assert parse_reply(parse_line("I (1) KOTA: health up=1s")) is None
+
+
+# ----------------------------------------------------------------- flows
+
+def test_write_wifi_happy_path():
+    flow, sent, events, clock = make("set", ssid="Biuro", password="haslo1234")
+    flow.start()
+    assert sent == ["kota ping"]
+    feed(flow, PING)
+    assert sent[-1] == wifi_set_command("Biuro", "haslo1234") and flow.step == Step.SEND
+    feed(flow, "I (5100) KOTA: cmd wifi_set ok=1 restart=1")
+    assert flow.step == Step.RESTART
+    feed(flow, "W (5101) KOTA: restart reason=usb_wifi_set")
+    feed(flow, BOOT.format(mode="wifi", last="usb_wifi_set"))
+    assert flow.step == Step.CONNECT
+    clock.t += 6
+    flow.tick()
+    assert sent[-1] == "kota health"
+    feed(flow, HEALTH.format(wifi="disconnected", rssi=0))
+    assert flow.step == Step.CONNECT
+    feed(flow, HEALTH.format(wifi="connected", rssi=-58))
+    assert flow.step == Step.DONE and "Connected to 'Biuro'" in events[-1].text and "-58" in events[-1].text
+
+
+def test_old_firmware_without_console_times_out_on_ping():
+    flow, sent, events, clock = make("read")
+    flow.start()
+    clock.t += PING_TIMEOUT_S + 0.1
+    flow.tick()
+    assert flow.step == Step.FAILED and "USB console" in events[-1].text
+
+
+def test_box_rejects_settings():
+    flow, sent, events, _ = make("set", ssid="Biuro", password="haslo1234")
+    flow.start()
+    feed(flow, PING)
+    feed(flow, "I (5100) KOTA: cmd wifi_set ok=0 err=sd_not_mounted")
+    assert flow.step == Step.FAILED and "SD card" in events[-1].text
+
+
+def test_wrong_password_does_not_connect():
+    flow, _, events, clock = make("set", ssid="Biuro", password="zlehaslo1")
+    flow.start()
+    feed(flow, PING)
+    feed(flow, "I (5100) KOTA: cmd wifi_set ok=1 restart=1")
+    feed(flow, BOOT.format(mode="wifi", last="usb_wifi_set"))
+    clock.t += CONNECT_TIMEOUT_S + 1
+    flow.tick()
+    assert flow.step == Step.FAILED and "2.4 GHz" in events[-1].text
+
+
+def test_clear_returns_to_matter():
+    flow, sent, events, _ = make("clear")
+    flow.start()
+    feed(flow, PING)
+    assert sent[-1] == "kota wifi clear"
+    feed(flow, "I (5100) KOTA: cmd wifi_clear ok=1 restart=1")
+    feed(flow, BOOT.format(mode="matter", last="usb_wifi_clear"))
+    assert flow.step == Step.DONE and "Matter" in events[-1].text
+
+
+def test_read_current_settings():
+    flow, sent, events, _ = make("read")
+    flow.start()
+    feed(flow, PING)
+    assert sent[-1] == "kota wifi get"
+    feed(flow, "I (5100) KOTA: cmd wifi_get ok=1 ssid=426975726f password_set=1 mode=wifi")
+    assert flow.step == Step.DONE and flow.info.ssid == "Biuro" and flow.info.password_set
+    assert "local Wi-Fi" in events[-1].text
+
+
+def test_not_connected():
+    events = []
+    flow = WifiFlow("read", lambda c: False, events.append)
+    flow.start()
+    assert flow.step == Step.FAILED and "not connected" in events[-1].text
+
+
+# ---------------------------------------------------------------- engine
+
+def test_engine_treats_usb_wifi_restart_as_intentional_and_reads_replies():
+    e = DiagnosticsEngine()
+    for t in ["ESP-ROM:esp32s3-20210327", "I (1790) KOTA: i2c SDA=1 SCL=1 0x39=AS7341",
+              BOOT.format(mode="matter", last="none"), PING,
+              "I (5100) KOTA: cmd wifi_set ok=1 restart=1", "W (5101) KOTA: restart reason=usb_wifi_set",
+              "ESP-ROM:esp32s3-20210327", "rst:0x3 (RTC_SW_SYS_RST),boot:0xb (SPI_FAST_FLASH_BOOT)",
+              BOOT.format(mode="wifi", last="usb_wifi_set"),
+              "I (6000) KOTA: cmd wifi_get ok=1 ssid=426975726f password_set=1 mode=wifi",
+              HEALTH.format(wifi="connected", rssi=-60)]:
+        e.feed(parse_line(t))
+    r = e.report()
+    assert not any(f.rule_id.startswith("reboot.") for rc in r.roots for f in [rc.finding, *rc.consequences])
+    assert e.console_api == 1
+    box = dict((t, x) for t, x, _ in r.box)
+    assert "network 'Biuro'" in box["Wi-Fi config"] and "Wi-Fi connected (-60 dBm)" in box["Health"]
+    assert any(m == "wifi_connected" and t is not None for m, _, t in r.milestones)

tests/test_ui.py

@@ -0,0 +1,19 @@
+"""The whole window builds (catches errors that only show when the app starts)."""
+
+import os
+
+os.environ.setdefault("QT_QPA_PLATFORM", "offscreen")
+
+
+def test_main_window_builds_with_all_tabs():
+    from PySide6.QtWidgets import QApplication
+
+    from kota_tech.ui.main_window import MainWindow
+    app = QApplication.instance() or QApplication([])
+    w = MainWindow()
+    tabs = w.centralWidget()
+    assert [tabs.tabText(i) for i in range(tabs.count())] == \
+        ["Quick start", "Serial monitor", "Flash firmware", "Wi-Fi (USB)", "SD card"]
+    assert not w.wifi_tab.write_btn.isEnabled()          # nothing connected, nothing typed
+    w.serial_tab.shutdown()
+    app.processEvents()