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

Reviewed-on: #7

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                    |

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;
+}

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);

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*/
+        /*Control State*/
-        strcpy(aMetrics[u16MetricCounter].caMetricName, "sntp_status");
+        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++;

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);

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;