Harden OpenPocket Rev-A preproduction design and release gates

.gitattributes

@@ -0,0 +1,2 @@
+*.step binary
+*.wrl binary

.gitignore

@@ -8,6 +8,11 @@
 
 # Local build and editor files
 build/
+__pycache__/
+*.pyc
 .DS_Store
+.easyeda_cache/
+/manufacturing/
+hardware/rev-a/easyeda/**/CONN-SMD_DF40C-100DS-0.4V-51.*
 *.swp
 *~

README.md

@@ -12,9 +12,16 @@
 </p>
 
 <p align="center">
-  <strong>An open ESP32-S3 handheld that combines RivetTX, ExpressLRS, an RX5808 receiver, an AT7456E OSD, and an AMT630A snow-screen display.</strong>
+  <strong>A compact all-in-one ESP32-S3 handheld PCB combining RivetTX, ExpressLRS, RX5808 video, AT7456E OSD, and an AMT630A-driven 5-inch TFT.</strong>
 </p>
 
+<p align="center">
+  <img src="docs/assets/openpocket-pcb-placement-top.png" alt="OpenPocket Revision-A top-side component placement without board text or signal traces" width="90%">
+  <img src="docs/assets/openpocket-pcb-placement-bottom.png" alt="OpenPocket Revision-A bottom-side component placement without board text or signal traces" width="90%">
+</p>
+
+<p align="center"><em>Revision-A top and bottom placement previews — production-board text and signal routing intentionally omitted.</em></p>
+
 <p align="center">
   <a href="#why-openpocket">Why OpenPocket</a> ·
   <a href="#architecture">Architecture</a> ·
@@ -42,7 +49,7 @@ backend. The ESP32 never has to capture or process video pixels.
 | **One handheld** | Gimbals, switches, ExpressLRS control, telemetry, video, and menus in a single enclosure. |
 | **Purpose-built MCU** | ESP32-S3 provides the GPIO, native USB, and task separation needed by the complete controller. |
 | **Low-latency video** | RX5808 composite video passes through the AT7456E into an AMT630A TFT controller without digital capture. |
-| **Snow-screen display** | The selected AMT630A board keeps weak or lost analog video visible as noise instead of hiding it behind a blue screen. |
+| **Integrated snow-screen display** | The PCB-installed AMT630A keeps weak or lost analog video visible as noise instead of hiding it behind a blue screen. |
 | **Native analog OSD** | PAL/NTSC autodetection, a 30×16 character grid, custom glyphs, delta updates, and video-loss recovery. |
 | **Bounded background work** | OSD and receiver services cannot delay control, CRSF, or telemetry processing. |
 | **Open development path** | Wiring, BOM decisions, bring-up evidence, and future KiCad sources live in this repository. |
@@ -60,8 +67,8 @@ flowchart LR
 
     E[5.8 GHz antenna] --> F[RX5808]
     F -->|composite video| G[AT7456E]
-    G -->|video + overlay| H[AMT630A<br/>snow-screen board]
-    H --> I[Matched TFT panel]
+    G -->|internal PCB trace| H[AMT630A<br/>on the same PCB]
+    H -->|24-bit RGB + sync| I[AT050TN33 V.1<br/>40-pin TFT]
 
     B -->|tune + RSSI| F
     B -->|bounded SPI| G
@@ -82,12 +89,12 @@ path.
 
 | Component | Role |
 |---|---|
-| ESP32-S3 development board or module | RivetTX, inputs, UI, storage, USB, and hardware services |
-| ExpressLRS TX hardware | full-duplex 3.3 V CRSF control and telemetry link |
-| RX5808 module | tunable 5.8 GHz analog receiver, composite video, and RSSI |
-| AT7456E OSD module | PAL/NTSC character overlay between the receiver and display |
-| AMT630A snow-screen controller board | PAL/NTSC composite decoding without blue-screen signal masking |
-| matched parallel-RGB TFT panel | live FPV image and the complete OpenPocket interface |
+| ESP32-S3-MINI-1U-N8 | PCB-installed RivetTX MCU, native USB, 8 MiB flash, no PSRAM |
+| user-installed ExpressLRS nano receiver | four-wire full-duplex CRSF control and telemetry link |
+| PCBWay-installed RX5808 module | tunable 5.8 GHz analog receiver, internal composite video, and RSSI |
+| PCB-installed AT7456E | PAL/NTSC character overlay in the internal video path |
+| PCB-installed AMT630A and flash | PAL/NTSC composite decoding and direct 24-bit RGB panel drive |
+| AT050TN33 V.1-compatible TFT | user-plugged 40-pin panel; arbitrary 40-pin TFTs are unsupported |
 | two dual-axis gimbals | four primary analog control axes |
 | switches, menu buttons, and optional encoder | arming, AUX controls, navigation, and editing |
 | validated regulators and protection | clean supplies sized for RF, display, video, and logic peaks |
@@ -108,29 +115,28 @@ The existing RivetTX compositor produces a hardware-independent 30-column by
 - bounded asynchronous transfers instead of full-screen blocking redraws
 - communication retry/backoff and redraw after video loss or recovery
 
-The RX5808 feeds baseband video to the AT7456E; the AT7456E overlays text and
-passes the result to the AMT630A board, which drives its matched TFT panel. The
+The RX5808 feeds baseband video to the AT7456E over an internal PCB trace; the
+AT7456E overlays text and passes it internally to the AMT630A, which drives the
+edge-connected TFT directly. The user never wires composite video. The
 AMT630A's internal OSD is not used for OpenPocket menus. See the
 [complete wiring guide](docs/wiring.md).
 
 ## Build path
 
 Bring up one subsystem at a time:
 
-1. Read the [bill of materials](docs/bom.md) and record the exact revisions of
-   every module.
-2. Build and measure the protected 5 V and 3.3 V rails on a current-limited
-   supply.
-3. Add the ESP32-S3, controls, and ExpressLRS link with RF output constrained.
-4. Prove the direct RX5808-to-AMT630A composite path in PAL and NTSC, including
-   snow-screen behavior with no received signal.
-5. Insert the AT7456E, level shifting, and SPI control lines.
-6. Configure RivetTX, then complete every item in the
-   [bring-up checklist](docs/bring-up.md).
+1. Review the [Revision-A engineering package](hardware/rev-a/README.md) and
+   resolve every machine-readable release blocker.
+2. Complete independent schematic, layout, sourcing, and Gerber reviews.
+3. Assemble first articles through PCBWay with the RX5808 consigned/manual
+   operation and no unapproved substitutions.
+4. Power the board from a current-limited source and validate rails before
+   inserting the TFT, battery, or ExpressLRS receiver.
+5. Complete the factory and HIL gates before any propeller-on use.
 
 The [bench build guide](docs/build-guide.md) contains the full sequence and
-stop conditions. Do not design a battery pack or order a PCB production run
-from the provisional module-level BOM.
+stop conditions. Do not order from provisional files or bypass the release
+gate in `hardware/rev-a`.
 
 ## Firmware
 
@@ -146,11 +152,9 @@ idf.py build
 idf.py flash monitor
 ```
 
-Enable `Use OpenPocket AT7456E analog OSD instead of SSD1306` under
-`Component config -> RivetTX hardware`, then assign pins for the OSD, CRSF,
-controls, and other peripherals. There is deliberately no universal GPIO map
-until a specific ESP32-S3 module and reviewed schematic are selected. See the
-[firmware guide](docs/firmware.md) for the complete configuration.
+Use RivetTX's checked-in `sdkconfig.openpocket-rev-a.defaults`; it contains the
+authoritative no-PSRAM, 8 MiB flash configuration and GPIO map matching this
+board. See the [firmware guide](docs/firmware.md) for the complete configuration.
 
 ## Documentation
 
@@ -165,19 +169,20 @@ until a specific ESP32-S3 module and reviewed schematic are selected. See the
 | [ESP32-S3 decision](docs/decisions/0001-esp32-s3.md) | why OpenPocket standardizes on the S3 |
 | [AMT630A display decision](docs/decisions/0002-amt630a-snow-screen.md) | why the display stage uses a snow-screen AMT630A board |
 | [Hardware sources](hardware/README.md) | scope and release policy for future KiCad and production files |
+| [Revision-A package](hardware/rev-a/README.md) | integrated board constraints, GPIO, power, BOM, factory test, and release gates |
+| [AMT630A firmware](display/amt630a/README.md) | target behavior, provenance requirements, and deterministic build gate |
 
 ## Project status
 
-RivetTX already contains the 30×16 OpenPocket menus and the physical AT7456E
-backend, including host-side PAL, NTSC, navigation, warning, delta-update,
-glyph-upload, video-loss, standard-change, and SPI-failure tests. RX5808 target
-hardware, the exact AMT630A PCB/panel revision, the final GPIO assignment, the
-reference schematic, PCB, power system, and complete composite-video HIL
-evidence remain open engineering work.
+RivetTX contains the character OSD and physical RX5808/AT7456E services, with
+host coverage for PAL, NTSC, UI, tuning, scanning, RSSI, delta updates, glyphs,
+loss/recovery, and failure isolation. Revision-A startup ordering, board power
+policy, and the no-PSRAM pin/partition profile are under review.
 
-No schematic, PCB, enclosure, or battery design is currently released as
-production-ready. The hardware directory will become the authoritative source
-for those files after design review and measurement.
+No PCB order package is released yet. The exact panel datasheet, AMT630A
+firmware rights/provenance, selected RX5808 consigned module, sourcing review,
+KiCad ERC/DRC, Gerber inspection, and physical HIL evidence remain open. This
+is intentionally an engineering prototype, not a production-ready product.
 
 ## Contributing
 

display/amt630a-openpocket/LICENSE

@@ -0,0 +1,21 @@
+MIT License
+
+Copyright (c) 2026 OpenPocket contributors
+
+Permission is hereby granted, free of charge, to any person obtaining a copy
+of this software and associated documentation files (the "Software"), to deal
+in the Software without restriction, including without limitation the rights
+to use, copy, modify, merge, publish, distribute, sublicense, and/or sell
+copies of the Software, and to permit persons to whom the Software is
+furnished to do so, subject to the following conditions:
+
+The above copyright notice and this permission notice shall be included in all
+copies or substantial portions of the Software.
+
+THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND, EXPRESS OR
+IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY,
+FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT. IN NO EVENT SHALL THE
+AUTHORS OR COPYRIGHT HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES OR OTHER
+LIABILITY, WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE, ARISING FROM,
+OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR OTHER DEALINGS IN THE
+SOFTWARE.

display/amt630a-openpocket/Makefile

@@ -0,0 +1,38 @@
+SDCC ?= sdcc
+MAKEBIN ?= makebin
+PYTHON ?= python3
+BUILD := build
+TARGET := $(BUILD)/amt630a-openpocket-er-tft050a3-2
+SOURCES := src/main.c src/registers.c src/status_i2c.c
+OBJECTS := $(patsubst src/%.c,$(BUILD)/%.rel,$(SOURCES))
+
+.PHONY: all clean test manifest
+
+all: $(TARGET).bin $(TARGET).bin.sha256 build-manifest.json
+
+$(BUILD):
+	mkdir -p $@
+
+$(BUILD)/%.rel: src/%.c include/amt630a.h | $(BUILD)
+	$(SDCC) -mmcs51 --model-small --iram-size 256 --xram-size 2048 \
+		--code-size 65536 -Iinclude -c $< -o $@
+
+$(TARGET).ihx: $(OBJECTS)
+	$(SDCC) -mmcs51 --model-small --iram-size 256 --xram-size 2048 \
+		--code-size 65536 --out-fmt-ihx $(OBJECTS) -o $@
+
+$(TARGET).bin: $(TARGET).ihx
+	$(MAKEBIN) -s 65536 $< $@
+
+$(TARGET).bin.sha256: $(TARGET).bin
+	sha256sum $< | awk '{print $$1}' > $@
+
+build-manifest.json: $(TARGET).bin $(TARGET).bin.sha256 tools/manifest.py panel-timing.json
+	$(PYTHON) tools/manifest.py
+
+test: all
+	$(PYTHON) -m unittest discover -s tests -v
+
+clean:
+	find $(BUILD) -type f -delete 2>/dev/null || true
+	rmdir $(BUILD) 2>/dev/null || true

display/amt630a-openpocket/README.md

@@ -0,0 +1,18 @@
+# OpenPocket AMT630A firmware
+
+This directory contains an original MIT-licensed SDCC/mcs51 firmware for the
+AMT630A used by OpenPocket Revision A. It is built from register documentation,
+the AMT630A product specification, and public reference-circuit observations;
+it is not a monitor-board dump and contains no vendor firmware.
+
+`make test` builds a deterministic 64 KiB W25X05 image and verifies panel
+timing, PAL/NTSC state handling, sync-loss recovery, CVBS1 selection, RGB pin
+muxing, and that documented snow/blue-substitution controls are disabled. The
+controller keeps TFT timing active during video loss and pulses decoder resync
+until video returns. Whether a particular weak RF signal visibly produces the
+desired snow texture remains a first-article acceptance measurement.
+
+The RivetTX factory service holds AMT RESET low, selects the ESP32 side of U19
+(SN74CB3Q3257PWR), checks JEDEC ID `EF 30 10`, erases/programs/reads every byte,
+compares SHA-256, restores AMT ownership, releases reset, then waits for I2C
+status before enabling the backlight.

display/amt630a-openpocket/build-manifest.json

@@ -0,0 +1,60 @@
+{
+  "compiler": "SDCC : mcs51/z80/z180/r2k/r2ka/r3ka/sm83/tlcs90/ez80_z80/z80n/ds390/TININative/ds400/hc08/s08/stm8/pdk13/pdk14/pdk15/mos6502 4.2.0 #13081 (Linux)",
+  "compiler_sha256": "b34caf6863460b150f2164d4842b2df6a71d27d1a66fe0a3b4a5f84d28315414",
+  "cvbs_input": "CVBS1 after AT7456E",
+  "license": "MIT",
+  "no_signal_policy": "TCON free-runs; blue substitution disabled; decoder resync pulse",
+  "output_binary": "build/amt630a-openpocket-er-tft050a3-2.bin",
+  "output_sha256": "9bd55356861bfe61b36313e531aaae6bde8b2071384f008d3534367b3695aff9",
+  "output_size": 65536,
+  "panel": "EastRising ER-TFT050A3-2 no-touch",
+  "panel_timing": {
+    "active_height": 272,
+    "active_width": 480,
+    "backlight_current_ma": 40,
+    "backlight_max_voltage_v": 19.2,
+    "backlight_topology": "2P6S",
+    "backlight_typical_voltage_v": 18.0,
+    "controller": "ILI6480",
+    "dclk_sample_edge": "rising",
+    "de_polarity": "active-high",
+    "disp_active": "high",
+    "horizontal_back_porch": 39,
+    "horizontal_front_porch": 5,
+    "horizontal_sync_width": 1,
+    "horizontal_total": 525,
+    "hsync_polarity": "active-low",
+    "interface": "RGB888",
+    "logic_voltage_v": 3.3,
+    "panel": "EastRising ER-TFT050A3-2 no-touch",
+    "pixel_clock_hz": 9000000,
+    "power_down_sequence": [
+      "disable backlight",
+      "deassert DISP",
+      "wait 2 frames",
+      "stop RGB clocks",
+      "remove PANEL_3V3"
+    ],
+    "power_up_sequence": [
+      "assert DISP low and keep backlight off",
+      "apply PANEL_3V3",
+      "wait 20 ms",
+      "start DCLK/RGB/DE/HSYNC/VSYNC",
+      "wait 10 valid frames",
+      "assert DISP high",
+      "enable backlight after controller-ready"
+    ],
+    "refresh_hz": 59.5238095238,
+    "rgb_order": "RGB",
+    "vertical_back_porch": 7,
+    "vertical_front_porch": 8,
+    "vertical_sync_width": 1,
+    "vertical_total": 288,
+    "vsync_polarity": "active-low"
+  },
+  "source_commit": "49482c2d7e58c815fd9cf4c3b48affb78f0ddbf6",
+  "standards": [
+    "PAL",
+    "NTSC"
+  ]
+}

display/amt630a-openpocket/include/amt630a.h

@@ -0,0 +1,23 @@
+#ifndef OPENPOCKET_AMT630A_H
+#define OPENPOCKET_AMT630A_H
+
+#include <stdint.h>
+
+#define OPENPOCKET_FW_MAJOR 1u
+#define OPENPOCKET_FW_MINOR 0u
+
+typedef struct {
+  uint16_t address;
+  uint8_t value;
+} register_write_t;
+
+extern const __code register_write_t openpocket_registers[];
+extern const __code uint16_t openpocket_register_count;
+
+void register_write(uint16_t address, uint8_t value);
+uint8_t register_read(uint16_t address);
+void delay_cycles(uint16_t cycles);
+void status_i2c_initialize(void);
+void status_update(uint8_t video_flags, uint8_t standard);
+
+#endif

display/amt630a-openpocket/panel-timing.json

@@ -0,0 +1,44 @@
+{
+  "panel": "EastRising ER-TFT050A3-2 no-touch",
+  "controller": "ILI6480",
+  "interface": "RGB888",
+  "pixel_clock_hz": 9000000,
+  "active_width": 480,
+  "horizontal_front_porch": 5,
+  "horizontal_sync_width": 1,
+  "horizontal_back_porch": 39,
+  "horizontal_total": 525,
+  "active_height": 272,
+  "vertical_front_porch": 8,
+  "vertical_sync_width": 1,
+  "vertical_back_porch": 7,
+  "vertical_total": 288,
+  "refresh_hz": 59.5238095238,
+  "de_polarity": "active-high",
+  "hsync_polarity": "active-low",
+  "vsync_polarity": "active-low",
+  "dclk_sample_edge": "rising",
+  "rgb_order": "RGB",
+  "disp_active": "high",
+  "logic_voltage_v": 3.3,
+  "backlight_topology": "2P6S",
+  "backlight_typical_voltage_v": 18.0,
+  "backlight_max_voltage_v": 19.2,
+  "backlight_current_ma": 40,
+  "power_up_sequence": [
+    "assert DISP low and keep backlight off",
+    "apply PANEL_3V3",
+    "wait 20 ms",
+    "start DCLK/RGB/DE/HSYNC/VSYNC",
+    "wait 10 valid frames",
+    "assert DISP high",
+    "enable backlight after controller-ready"
+  ],
+  "power_down_sequence": [
+    "disable backlight",
+    "deassert DISP",
+    "wait 2 frames",
+    "stop RGB clocks",
+    "remove PANEL_3V3"
+  ]
+}

display/amt630a-openpocket/registers.md

@@ -0,0 +1,13 @@
+# Register derivation
+
+The immutable table in `src/registers.c` selects the 480×272 24-bit RGB+DE
+output (`FC00=00`, `FD34..FD43=22`, `FD50=0F`), the documented 480×272 PLL
+tuple (`FD0A=A8`, `FD0F=09`, `FD16=0A`), CVBS1, and separate PAL/NTSC scaler
+timings. `FED7[7,6,1,0]` and `FEDC[7,6,4]` remain clear: those documented bits
+disable snow or request a blue/background substitute.
+
+The selected input sequence is the older-reference CVBS1 mapping:
+`FED7[4:3]=0`, `FED8[7:6]=2`, `FEDC[5:4]=0`, then `FED7[4:3]=3`. A fixture
+test must confirm that CVBS1 corresponds to physical pin 1 on the assembled
+AMT630A; this is an execution check against an already frozen circuit, not an
+unresolved architecture choice.