localhorst/smart-oil-heating-control-system
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Merge pull request 'detect burner fault' (#17) from feature/burner-fault-detection into main

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Reviewed-on: #17
This commit is contained in:
Hendrik Schutter
2024-12-26 20:37:50 +01:00
parent 4ffa416f6f 25b0a11694
commit 8672241151
3 changed files with 35 additions and 14 deletions
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18
README.md
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@ -131,15 +131,15 @@ wifi_rssi -63
##### Control Loop ##### Control Loop
- control_state - control_state
| Enum eControlState in [control.h](main/control.h) | Value | Description | | Enum eControlState in [control.h](main/control.h) | Value | Description |
|---------------------------------------------------|-------|------------------------------------| |---------------------------------------------------|-------|--------------------------------------------------|
| CONTROL_STARTING | 0 | | | CONTROL_STARTING | 0 | |
| CONTROL_HEATING | 1 | Burner running | | CONTROL_HEATING | 1 | Burner running |
| CONTROL_OUTDOOR_TOO_WARM | 2 | Heating not needed | | CONTROL_OUTDOOR_TOO_WARM | 2 | Heating not needed |
| CONTROL_RETURN_FLOW_TOO_WARM | 3 | Heating not needed | | CONTROL_RETURN_FLOW_TOO_WARM | 3 | Heating not needed |
| CONTROL_BURNER_FAULT | 4 | Burner reported fault | | CONTROL_FAULT_BURNER | 4 | Burner reported fault after threshold is reached |
| CONTROL_FAULT_SAFETY | 5 | Unable to control due safety fault | | CONTROL_FAULT_SAFETY | 5 | Unable to control due safety fault |
| CONTROL_FAULT_SNTP | 6 | Unable to control due SNTP fault | | CONTROL_FAULT_SNTP | 6 | Unable to control due SNTP fault |
##### SNTP Client ##### SNTP Client
- sntp_state - sntp_state

29
main/control.c
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@ -1,5 +1,6 @@
#include "freertos/FreeRTOS.h" #include "freertos/FreeRTOS.h"
#include "freertos/task.h" #include "freertos/task.h"
#include "esp_timer.h"
#include "esp_log.h" #include "esp_log.h"
#include "control.h" #include "control.h"
#include "outputs.h" #include "outputs.h"
@ -12,6 +13,7 @@
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0
#define CHAMPER_TEMPERATURE_TARGET 70.0 #define CHAMPER_TEMPERATURE_TARGET 70.0
#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 3U) // Detect burner fault if after 3 minutes no burner start detected
static const char *TAG = "smart-oil-heater-control-system-control"; static const char *TAG = "smart-oil-heater-control-system-control";
static eControlState sControlState = CONTROL_STARTING; static eControlState sControlState = CONTROL_STARTING;
@ -54,6 +56,9 @@ void initControl(void)
void taskControl(void *pvParameters) void taskControl(void *pvParameters)
{ {
bool bHeatingInAction = false; bool bHeatingInAction = false;
bool bBurnerFaultDetected = false;
int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
while (1) while (1)
{ {
vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS); vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
@ -64,7 +69,7 @@ void taskControl(void *pvParameters)
sControlState = CONTROL_FAULT_SAFETY; sControlState = CONTROL_FAULT_SAFETY;
if (bHeatingInAction == true) if (bHeatingInAction == true)
{ {
ESP_LOGI(TAG, "Control not possible due to safety fault: Disable burner"); ESP_LOGW(TAG, "Control not possible due to safety fault: Disable burner");
bHeatingInAction = false; bHeatingInAction = false;
setCirculationPumpState(ENABLED); setCirculationPumpState(ENABLED);
setBurnerState(DISABLED); setBurnerState(DISABLED);
@ -79,7 +84,7 @@ void taskControl(void *pvParameters)
sControlState = CONTROL_FAULT_SNTP; sControlState = CONTROL_FAULT_SNTP;
if (bHeatingInAction == true) if (bHeatingInAction == true)
{ {
ESP_LOGI(TAG, "Control not possible due to sntp fault: Disable burner"); ESP_LOGW(TAG, "Control not possible due to sntp fault: Disable burner");
bHeatingInAction = false; bHeatingInAction = false;
setCirculationPumpState(ENABLED); setCirculationPumpState(ENABLED);
setBurnerState(DISABLED); setBurnerState(DISABLED);
@ -105,12 +110,27 @@ void taskControl(void *pvParameters)
{ {
if (bHeatingInAction) if (bHeatingInAction)
{ {
// TODO: Check burner fault signal here int64_t i64Delta = esp_timer_get_time() - i64BurnerEnableTimestamp;
if ((i64Delta / 1000000U) >= BURNER_FAULT_DETECTION_THRESHOLD)
{
if (getBurnerError() == FAULT)
{
ESP_LOGW(TAG, "Detected burner fault after %lli seconds!", (i64Delta / 1000000U));
ESP_LOGW(TAG, "Control not possible due to burner fault: Disable burner");
sControlState = CONTROL_FAULT_BURNER;
bHeatingInAction = false;
bBurnerFaultDetected = true;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
}
} }
} }
} }
if (bHeatingInAction == false) if ((bHeatingInAction == false) && (bBurnerFaultDetected == false))
{ {
if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0)) if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0))
{ {
@ -119,6 +139,7 @@ void taskControl(void *pvParameters)
setCirculationPumpState(ENABLED); setCirculationPumpState(ENABLED);
setBurnerState(ENABLED); setBurnerState(ENABLED);
setSafetyControlState(ENABLED); setSafetyControlState(ENABLED);
i64BurnerEnableTimestamp = esp_timer_get_time();
sControlState = CONTROL_HEATING; sControlState = CONTROL_HEATING;
} }
else else

2
main/control.h
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@ -9,7 +9,7 @@ typedef enum _ControlState
CONTROL_HEATING, CONTROL_HEATING,
CONTROL_OUTDOOR_TOO_WARM, CONTROL_OUTDOOR_TOO_WARM,
CONTROL_RETURN_FLOW_TOO_WARM, CONTROL_RETURN_FLOW_TOO_WARM,
CONTROL_BURNER_FAULT, CONTROL_FAULT_BURNER,
CONTROL_FAULT_SAFETY, CONTROL_FAULT_SAFETY,
CONTROL_FAULT_SNTP, CONTROL_FAULT_SNTP,
} eControlState; } eControlState;