localhorst/smart-oil-heating-control-system
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rework sanity checks for temperature sensors

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Hendrik Schutter 2024-12-11 22:37:43 +01:00
parent 97956882dd
commit 6e6d2965f7
3 changed files with 54 additions and 41 deletions
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3
.vscode/settings.json vendored
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@ -11,7 +11,8 @@
"compare": "c", "compare": "c",
"inputs.h": "c", "inputs.h": "c",
"cstdlib": "c", "cstdlib": "c",
"typeinfo": "c" "typeinfo": "c",
"limits": "c"
}, },
"idf.openOcdConfigs": [ "idf.openOcdConfigs": [
"board/esp32-wrover-kit-3.3v.cfg" "board/esp32-wrover-kit-3.3v.cfg"

56
main/safety.c
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@ -2,26 +2,16 @@
#include "freertos/task.h" #include "freertos/task.h"
#include "esp_log.h" #include "esp_log.h"
#include "safety.h" #include "safety.h"
#include "outputs.h"
#include "inputs.h"
#define PERIODIC_INTERVAL 1U // run safety checks every 1sec #define PERIODIC_INTERVAL 1U // run safety checks every 1sec
typedef struct _TemperatureSensorLimit
{
float max; // Maximum temperature limit
float min; // Minimum temperature limit
} sTemperatureSensorLimit;
static const char *TAG = "smart-oil-heater-control-system-safety"; static const char *TAG = "smart-oil-heater-control-system-safety";
static SemaphoreHandle_t xMutexAccessSafety = NULL; static SemaphoreHandle_t xMutexAccessSafety = NULL;
sSafetyStateElement safetyStates[NUMBER_OF_ERROR_STATES] = { sSensorSanityCheck sanityChecks[NUMBER_OF_SENSOR_SANITY_CHECKS] = {
{0, "Emergency Stop"}, {0, "chamber_temperature", {95.0f, -10.0f}, 0.0f, getChamberTemperature},
{0, "Safety Door Open"}, {0, "outdoor_temperature", {45.0f, -20.0f}, 0.0f, getOutdoorTemperature},
{0, "Overheating"}, {0, "inlet_flow_temperature", {95.0f, -10.0f}, 0.0f, getInletFlowTemperature},
{0, "Low Battery"}}; {0, "return_flow_temperature", {95.0f, -10.0f}, 0.0f, getReturnFlowTemperature}};
static const sTemperatureSensorLimit sChamperTemperatureLimit = {75.0f, 15.0f};
void taskSafety(void *pvParameters); void taskSafety(void *pvParameters);
void checkSensorSanity(void); void checkSensorSanity(void);
@ -67,33 +57,41 @@ void taskSafety(void *pvParameters)
void checkSensorSanity(void) void checkSensorSanity(void)
{ {
static float fChamperTemperatureLast;
static float fOutdoorTemperatureLast;
static float fInletFlowTemperatureLast;
static float fReturnFlowTemperatureLast;
const float fChamperTemperatureCurrent = getChamberTemperature(CURRENT); for (int i = 0; i < NUMBER_OF_SENSOR_SANITY_CHECKS; i++)
if (fChamperTemperatureCurrent == fChamperTemperatureLast)
{ {
ESP_LOGE(TAG, "Champer Temperature Sensor reported unchanged value!"); //printf("Check sanity of sensor %s:\n", sanityChecks[i].name);
//printf(" Status: %u\n", sanityChecks[i].status);
//printf(" Sensor Limits: Max = %.2f, Min = %.2f\n", sanityChecks[i].sSensorLimit.max, sanityChecks[i].sSensorLimit.min);
//printf(" Last Sensor Temperature: %.2f\n", sanityChecks[i].fSensorTemperatureLast);
const float fSensorTemperatureCurrent = sanityChecks[i].getSensor(CURRENT);
if (fSensorTemperatureCurrent == sanityChecks[i].fSensorTemperatureLast)
{
ESP_LOGE(TAG, "%s Sensor reported unchanged value! %lf == %lf",sanityChecks[i].name, fSensorTemperatureCurrent, sanityChecks[i].fSensorTemperatureLast);
sanityChecks[i].status = 1;
} }
else else
{ {
fChamperTemperatureLast = fChamperTemperatureCurrent; sanityChecks[i].fSensorTemperatureLast = fSensorTemperatureCurrent;
if (fChamperTemperatureCurrent > sChamperTemperatureLimit.max) if (fSensorTemperatureCurrent > sanityChecks[i].sSensorLimit.max)
{ {
ESP_LOGE(TAG, "Champer Temperature Sensor reported too high value!"); ESP_LOGE(TAG, "%s Sensor reported too high value! %lf > %lf", sanityChecks[i].name, fSensorTemperatureCurrent, sanityChecks[i].sSensorLimit.max);
sanityChecks[i].status = 1;
} }
else if (fChamperTemperatureCurrent < sChamperTemperatureLimit.min) else if (fSensorTemperatureCurrent < sanityChecks[i].sSensorLimit.min)
{ {
ESP_LOGE(TAG, "Champer Temperature Sensor reported too low value!"); ESP_LOGE(TAG, "%s Sensor reported too low value! %lf < %lf", sanityChecks[i].name, fSensorTemperatureCurrent, sanityChecks[i].sSensorLimit.min);
sanityChecks[i].status = 1;
} }
else else
{ {
// everything ok sanityChecks[i].status = 0;
} }
} }
//printf(" Status: %u\n", sanityChecks[i].status);
}
} }
void setSafeState(void) void setSafeState(void)
@ -102,7 +100,9 @@ void setSafeState(void)
setBurnerState(DISABLED); setBurnerState(DISABLED);
} }
/*
sSafetyStateElement *getSafetyStates(void) sSafetyStateElement *getSafetyStates(void)
{ {
return safetyStates; return safetyStates;
} }
*/

20
main/safety.h
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@ -1,14 +1,26 @@
#pragma once #pragma once
#include "outputs.h"
#include "inputs.h"
#define MAX_ERROR_STRING_SIZE 64U #define MAX_ERROR_STRING_SIZE 64U
#define NUMBER_OF_ERROR_STATES 4U #define NUMBER_OF_SENSOR_SANITY_CHECKS 4U
typedef struct _SafetyStateElement{ typedef float (*GetSensorValue)(eMeasurementMode);
typedef struct _TemperatureSensorLimit
{
float max; // Maximum temperature limit
float min; // Minimum temperature limit
} sTemperatureSensorLimit;
typedef struct _SensorSanityCheck
{
unsigned int status; unsigned int status;
char name[MAX_ERROR_STRING_SIZE]; char name[MAX_ERROR_STRING_SIZE];
} sSafetyStateElement; sTemperatureSensorLimit sSensorLimit;
float fSensorTemperatureLast;
GetSensorValue getSensor;
} sSensorSanityCheck;
void initSafety(void); void initSafety(void);
sSafetyStateElement* getSafetyStates(void); //sSensorSanityCheck *getSafetyStates(void);