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Chris Rai c48ae896a4 cost service: add platform base + per-VIN resource model with CPU/RAM display

- Updated cost model to show: (Platform Base) + (Per-VIN × VINs)
- Platform base: 176 cores / 896GB RAM (Kafka, ClickHouse, MongoDB, Redis, PostgreSQL, gateway, monitoring)
- Per-VIN marginal: 50mc / 82MB per vehicle
- Added RESOURCE USAGE MODEL and COST FORMULA sections to report
- Added CPU (mc) and RAM (MB) columns to TOP COST VEHICLES table
- Updated README with new report output
- virtual-vehicle: documented Vault cert TTL error troubleshooting

2026-02-04 21:18:24 -05:00

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Virtual Vehicle Simulator

A lightweight vehicle simulator that generates CAN telemetry and sends it to the cloud gateway.

Background

This service replaces the older project-ai/tools/k8s-socket-can tool. We rewrote it because:

Simpler deployment - Pure Go service that runs in K8s without SocketCAN kernel dependencies
No hardware requirements - The original required a CAN interface or vcan setup; this generates synthetic frames
Cloud-native - Designed for K8s from the start, uses the shared cloud-services build/deploy pipeline
Self-registering - Automatically registers with manufacturer API and handles certificate provisioning
Configurable - VIN prefix, send interval, and endpoints all configurable via env vars

The original k8s-socket-can was designed for testing with real CAN hardware or Linux vcan interfaces. For demo/testing purposes where we just need telemetry flowing through the system, this lightweight simulator is more practical.

Overview

This service simulates a connected vehicle (T.Rex) by:

Registering with the manufacturer API to get certificates
Connecting to the gateway via WebSocket with mTLS
Generating and sending CAN frames

Configuration

Env Var	Description	Default
MANUFACTURER_URL	URL for vehicle registration	http://gateway:8077/manufacture/manufacturer
GATEWAY_WS_URL	WebSocket URL for gateway	ws://gateway:8077/session
API_KEY	API key for manufacturer endpoint	-
VIN_PREFIX	Prefix for generated VIN	VIRTUAL
SEND_INTERVAL_MS	Telemetry interval in ms	1000

CAN Frame IDs

CAN ID	Description
0x100	Speed
0x101	RPM
0x102	Battery SOC
0x103	Battery voltage
0x104	Temperature
0x105	GPS latitude
0x106	GPS longitude
0x200	Door status
0x201	Light status
0x300	HVAC

Troubleshooting

503 Error - Vault Certificate TTL Issue

If the service returns a 503 and logs show a Vault error like:

{"level":"error","message":"manufacturer API returned 503: {\"message\":\"Vault unable to create certificate, status code: 400 {\\\"errors\\\":[\\\"cannot satisfy request, as TTL would result in notAfter 2034-02-01T02:34:43.379661987Z that is beyond the expiration of the CA certificate at 2032-04-10T20:21:59Z\\\"]}\\n\",\"error\":\"Service Unavailable\"}"}

This happens when the certificate TTL requested (8 years) would extend beyond the CA certificate's expiration date. The manufacturer service requests a cert that expires in 2034, but the Vault CA expires in 2032.

Fix options:

Reduce the PKI role TTL in Vault (non-disruptive - only affects new certs):

vault write pki/roles/vehicle-cert ttl=17520h max_ttl=17520h  # 2 years

Extend the CA certificate - Regenerate the Vault PKI CA with a longer validity period (disruptive - all existing certs need reissue)
Rotate the CA - Create a new CA with extended validity (disruptive - requires cert reissue)

On dev-cluster, the CA was created with a ~10 year validity but the cert TTL request pushes past that.

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