Merge pull request 'Add control loop state' (#7) from feature/control-status into main

Reviewed-on: #7
2024-12-21 22:12:44 +01:00 · 2024-12-21 22:12:44 +01:00 · 859611f991
commit 859611f991
parent 9abf64f9dd 23e8f05df9
6 changed files with 130 additions and 25 deletions
--- a/README.md
+++ b/README.md
@ -40,6 +40,7 @@ Sntp <|-- Metrics
    class Control{
        +taskControl()
        -timetable
+        +getControlState()
    }

    class Safety{
@ -71,12 +72,91 @@ Sntp <|-- Metrics
    }
 ```

-### Hardware
+### Prometheus Metrics
+`curl http://X.X.X.X:9100/metrics`
+#### Example
+```
+burner_fault_pending 1
+circulation_pump_enabled 0
+burner_enabled 1
+safety_contact_enabled 1
+chamber_temperature 21.812500
+chamber_temperature_avg10 21.837500
+chamber_temperature_avg60 21.825521
+inlet_flow_temperature 22.437500
+inlet_flow_temperature_avg10 22.437500
+inlet_flow_temperature_avg60 22.434896
+outdoor_temperature 21.937500
+outdoor_temperature_avg10 21.937500
+outdoor_temperature_avg60 21.933594
+return_flow_temperature 22.375000
+return_flow_temperature_avg10 22.375000
+return_flow_temperature_avg60 22.375000
+chamber_temperature_state 0
+outdoor_temperature_state 0
+inlet_flow_temperature_state 0
+return_flow_temperature_state 0
+safety_state 0
+control_state 5
+sntp_state 0
+system_unixtime 1734814285
+uptime_seconds 90
+wifi_rssi -63
+```
+
+#### Status Encoding
+##### Digital Themperatur Sensor DS10B20
+ - chamber_temperature_state
+ - outdoor_temperature_state
+ - inlet_flow_temperature_state
+ - return_flow_temperature_state
+
+| Enum eSensorErrorState in [safety.h](main/safety.h) | Value | Description         |
+|-----------------------------------------------------|-------|---------------------|
+| SENSOR_NO_ERROR                                     | 0     |                     |
+| SENSOR_TOO_HIGH                                     | 1     | Sanity check failed |
+| SENSOR_TOO_LOW                                      | 2     | Sanity check failed |
+| SENSOR_UNCHANGED                                    | 3     | Sanity check failed |
+| SENSOR_NOT_FOUND                                    | 4     | No Communication    |
+
+##### Safety Loop
+ - safety_state
+
+| Enum eSafetyState in [safety.h](main/safety.h) | Value | Description                |
+|------------------------------------------------|-------|----------------------------|
+| SAFETY_NO_ERROR                                | 0     |                            |
+| SAFETY_SENSOR_ERROR                            | 1     | At least one sensor failed |
+| SAFETY_INTERNAL_ERROR                          | 2     | Internal error             |
+
+##### Control Loop
+ - control_state
+
+| Enum eControlState in [control.h](main/control.h) | Value | Description           |
+|---------------------------------------------------|-------|-----------------------|
+| CONTROL_STARTING                                  | 0     |                       |
+| CONTROL_HEATING                                   | 1     | Burner running        |
+| CONTROL_OUTDOOR_TOO_WARM                          | 2     | Heating not needed    |
+| CONTROL_RETURN_FLOW_TOO_WARM                      | 3     | Heating not needed    |
+| CONTROL_BURNER_FAULT                              | 4     | Burner reported fault |
+| CONTROL_FAULT                                     | 5     | Unable to control     |
+
+##### SNTP Client
+ - sntp_state
+
+| Enum eSntpState in [sntp.h](main/sntp.h) | Value | Description |
+|------------------------------------------|-------|-------------|
+| SYNC_SUCCESSFUL                          | 0     |             |
+| SYNC_NOT_STARTED                         | 1     |             |
+| SYNC_FAILED                              | 2     |             |
+
+## Hardware
+
+| Function                              | ESP32 | PLC ES32C14       |
+|---------------------------------------|-------|-------------------|
+| Output CirculationPump                | IO27  | Relay 1 NC1       |
+| Output Burner Fire Signal             | IO14  | Relay 2 NC2       |
+| Output Safety Contact (powers Burner) | IO12  | Relay 3 NC2       |
+| Input Burner Fault                    | IO19  | Digital Input IN1 |
+| Input Temperature DS10B20             | IO04  | 1-Wire            |
+

-| Function                              | ESP32 | PLC ES32C14               |
-|---------------------------------------|-------|---------------------------|
-| Output CirculationPump                | IO27  | Relay 1 NC1               |
-| Output Burner Fire Signal             | IO14  | Relay 2 NC2               |
-| Output Safety Contact (powers Burner) | IO12  | Relay 3 NC2               |
-| Input Burner Fault                    | IO19  | Digital Input IN1         |
-| Input Temperature DS10B20             | IO04  | 1-Wire                    |
--- a/main/control.c
+++ b/main/control.c
@ -10,7 +10,7 @@
 #define PERIODIC_INTERVAL 1U // run safety checks every 1sec

 static const char *TAG = "smart-oil-heater-control-system-control";
-
+static eControlState sControlState = CONTROL_STARTING;
 void taskControl(void *pvParameters);

 void initControl(void)
@ -44,12 +44,14 @@ void taskControl(void *pvParameters)
        if (getSafetyState() != SAFETY_NO_ERROR)
        {
            ESP_LOGW(TAG, "Control not possible due to safety fault!");
+            sControlState = CONTROL_FAULT;
            continue;
        }

        if (getSntpState() != SYNC_SUCCESSFUL)
        {
            ESP_LOGW(TAG, "Control not possible due to sntp fault!");
+            sControlState = CONTROL_FAULT;
            continue;
        }

@ -58,4 +60,9 @@ void taskControl(void *pvParameters)
        setBurnerState(ENABLED);
        setSafetyControlState(ENABLED);
    }
-}
+}
+
+eControlState getControlState(void)
+{
+    return sControlState;
+}
--- a/main/control.h
+++ b/main/control.h
@ -1,3 +1,14 @@
 #pragma once

-void initControl(void);
+typedef enum _ControlState
+{
+    CONTROL_STARTING,
+    CONTROL_HEATING,
+    CONTROL_OUTDOOR_TOO_WARM,
+    CONTROL_RETURN_FLOW_TOO_WARM,
+    CONTROL_BURNER_FAULT,
+    CONTROL_FAULT,
+} eControlState;
+
+void initControl(void);
+eControlState getControlState(void);
--- a/main/metrics.c
+++ b/main/metrics.c
@ -12,6 +12,7 @@
 #include "inputs.h"
 #include "safety.h"
 #include "sntp.h"
+#include "control.h"

 static const char *TAG = "smart-oil-heater-control-system-metrics";

@ -181,15 +182,15 @@ void taskMetrics(void *pvParameters)
        aMetrics[u16MetricCounter].fMetricValue = getReturnFlowTemperature().average60s.fValue;
        u16MetricCounter++;

-        /*Sensor status*/
+        /*Sensor State*/
        sSensorSanityCheck aChecks[NUMBER_OF_SENSOR_SANITY_CHECKS];
        getSensorSanityStates(aChecks);
        for (size_t i = 0; i < NUMBER_OF_SENSOR_SANITY_CHECKS; i++)
        {
            strcpy(aMetrics[u16MetricCounter].caMetricName, aChecks[i].name);
-            strcat(aMetrics[u16MetricCounter].caMetricName, "_status");
+            strcat(aMetrics[u16MetricCounter].caMetricName, "_state");
            aMetrics[u16MetricCounter].type = INTEGER_U8;
-            aMetrics[u16MetricCounter].u8MetricValue = aChecks[i].status;
+            aMetrics[u16MetricCounter].u8MetricValue = aChecks[i].state;
            u16MetricCounter++;
        }

@ -199,8 +200,14 @@ void taskMetrics(void *pvParameters)
        aMetrics[u16MetricCounter].u8MetricValue = getSafetyState();
        u16MetricCounter++;

-        /*SNTP Status*/
-        strcpy(aMetrics[u16MetricCounter].caMetricName, "sntp_status");
+        /*Control State*/
+        strcpy(aMetrics[u16MetricCounter].caMetricName, "control_state");
+        aMetrics[u16MetricCounter].type = INTEGER_U8;
+        aMetrics[u16MetricCounter].u8MetricValue = getControlState();
+        u16MetricCounter++;
+
+        /*SNTP State*/
+        strcpy(aMetrics[u16MetricCounter].caMetricName, "sntp_state");
        aMetrics[u16MetricCounter].type = INTEGER_U8;
        aMetrics[u16MetricCounter].u8MetricValue = getSntpState();
        u16MetricCounter++;
--- a/main/safety.c
+++ b/main/safety.c
@ -77,7 +77,7 @@ void checkSensorSanity(void)
    for (int i = 0; i < NUMBER_OF_SENSOR_SANITY_CHECKS; i++)
    {
        // printf("Check sanity of sensor %s:\n", sanityChecks[i].name);
-        // printf("  Status: %u\n", sanityChecks[i].status);
+        // printf("  state: %u\n", sanityChecks[i].state);
        // 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);

@ -86,7 +86,7 @@ void checkSensorSanity(void)
        if (sCurrentMeasurement.state == MEASUREMENT_FAULT)
        {
            ESP_LOGE(TAG, "%s Sensor not found!", sanityChecks[i].name);
-            sanityChecks[i].status = SENSOR_NOT_FOUND;
+            sanityChecks[i].state = SENSOR_NOT_FOUND;
            sSafetyState = SAFETY_SENSOR_ERROR;
        }
        else
@ -97,7 +97,7 @@ void checkSensorSanity(void)
                if (sanityChecks[i].uUnchangedCounter >= (SENSOR_GRACE_PERIOD / PERIODIC_INTERVAL))
                {
                    ESP_LOGE(TAG, "%s Sensor reported unchanged value! %lf == %lf", sanityChecks[i].name, sCurrentMeasurement.fCurrentValue, sanityChecks[i].fSensorTemperatureLast);
-                    sanityChecks[i].status = SENSOR_UNCHANGED;
+                    sanityChecks[i].state = SENSOR_UNCHANGED;
                    sSafetyState = SAFETY_SENSOR_ERROR;
                }
            }
@ -108,23 +108,23 @@ void checkSensorSanity(void)
                if (sCurrentMeasurement.fCurrentValue > sanityChecks[i].sSensorLimit.max)
                {
                    ESP_LOGE(TAG, "%s Sensor reported too high value! %lf > %lf", sanityChecks[i].name, sCurrentMeasurement.fCurrentValue, sanityChecks[i].sSensorLimit.max);
-                    sanityChecks[i].status = SENSOR_TOO_HIGH;
+                    sanityChecks[i].state = SENSOR_TOO_HIGH;
                    sSafetyState = SAFETY_SENSOR_ERROR;
                }
                else if (sCurrentMeasurement.fCurrentValue < sanityChecks[i].sSensorLimit.min)
                {
                    ESP_LOGE(TAG, "%s Sensor reported too low value! %lf < %lf", sanityChecks[i].name, sCurrentMeasurement.fCurrentValue, sanityChecks[i].sSensorLimit.min);
-                    sanityChecks[i].status = SENSOR_TOO_LOW;
+                    sanityChecks[i].state = SENSOR_TOO_LOW;
                    sSafetyState = SAFETY_SENSOR_ERROR;
                }
                else
                {
                    sanityChecks[i].uUnchangedCounter = 0U;
-                    sanityChecks[i].status = SENSOR_NO_ERROR;
+                    sanityChecks[i].state = SENSOR_NO_ERROR;
                }
            }
        }
-        // printf("  Status: %u\n", sanityChecks[i].status);
+        // printf("  state: %u\n", sanityChecks[i].state);
    }
 }

@ -142,7 +142,7 @@ void getSensorSanityStates(sSensorSanityCheck *pSensorSanityChecks)
        for (size_t i = 0; i < NUMBER_OF_SENSOR_SANITY_CHECKS; i++)
        {
            // Copy only the needed attributes
-            pSensorSanityChecks[i].status = sanityChecks[i].status;
+            pSensorSanityChecks[i].state = sanityChecks[i].state;
            strcpy(pSensorSanityChecks[i].name, sanityChecks[i].name);
        }
        xSemaphoreGiveRecursive(xMutexAccessSafety);
--- a/main/safety.h
+++ b/main/safety.h
@ -30,7 +30,7 @@ typedef struct _TemperatureSensorLimit
 } sTemperatureSensorLimit;
 typedef struct _SensorSanityCheck
 {
-    eSensorErrorState status;
+    eSensorErrorState state;
    char name[MAX_ERROR_STRING_SIZE];
    sTemperatureSensorLimit sSensorLimit;
    float fSensorTemperatureLast;