localhorst/smart-oil-heating-control-system
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refactoring

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Hendrik Schutter 2025-03-01 15:36:05 +01:00
parent c9b7313608
commit 8ca3d97165
1 changed files with 60 additions and 100 deletions
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182
main/control.c
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@ -8,28 +8,31 @@
#include "safety.h" #include "safety.h"
#include "sntp.h" #include "sntp.h"
#define PERIODIC_INTERVAL 1U // run control loop every 1sec #define PERIODIC_INTERVAL 1U // Run control loop every 1 second
// Temperature thresholds
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f
#define CHAMPER_TEMPERATURE_TARGET 80.0f // Max cut off temperature, burner will stop if chamber is even or higher #define CHAMBER_TEMPERATURE_TARGET 80.0f // Max cutoff temperature
#define CHAMPER_TEMPERATURE_THRESHOLD 45.0f // Min threshold temperature for enabling burner, burner will only start if chamber is even or lower #define CHAMBER_TEMPERATURE_THRESHOLD 45.0f // Min threshold for burner enable
#define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f // Min threshold temperature for enabling burner, burner will only start if outdoor is even or lower #define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f // Min threshold for burner enable
#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 3U) // Detect burner fault if after 3 minutes no burner start detected #define BURNER_FAULT_DETECTION_THRESHOLD (60U * 3U) // Burner fault detection after 3 minutes
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;
// Control table for daily schedules
static sControlDay aControlTable[] = { static sControlDay aControlTable[] = {
{MONDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {MONDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
{TUESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {TUESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
{WEDNESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {WEDNESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
{THURSDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {THURSDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
{FRIDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{23, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {FRIDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{23, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
{SATURDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{23, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {SATURDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{23, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
{SUNDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_TEMPERATURE_TARGET}}}, {SUNDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}},
}; };
// Function prototypes
void taskControl(void *pvParameters); void taskControl(void *pvParameters);
eControlWeekday getCurrentWeekday(void); eControlWeekday getCurrentWeekday(void);
sControlTemperatureEntry getCurrentTemperatureEntry(void); sControlTemperatureEntry getCurrentTemperatureEntry(void);
@ -65,88 +68,81 @@ void taskControl(void *pvParameters)
{ {
vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS); vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
// Handle safety faults
if (getSafetyState() != SAFETY_NO_ERROR) if (getSafetyState() != SAFETY_NO_ERROR)
{ {
ESP_LOGW(TAG, "Control not possible due to safety fault!"); ESP_LOGW(TAG, "Control not possible due to safety fault!");
sControlState = CONTROL_FAULT_SAFETY; sControlState = CONTROL_FAULT_SAFETY;
if (bHeatingInAction == true)
{
ESP_LOGW(TAG, "Control not possible due to safety fault: Disable burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
if (getSntpState() != SYNC_SUCCESSFUL)
{
ESP_LOGW(TAG, "Control not possible due to sntp fault!");
sControlState = CONTROL_FAULT_SNTP;
if (bHeatingInAction == true)
{
ESP_LOGW(TAG, "Control not possible due to sntp fault: Disable burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
sControlTemperatureEntry currentControlEntry = getCurrentTemperatureEntry();
// ESP_LOGI(TAG, "Control Entry Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", currentControlEntry.timestamp.hour, currentControlEntry.timestamp.minute, currentControlEntry.fChamberTemperature, currentControlEntry.fReturnFlowTemperature);
if (bHeatingInAction == true)
{
if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) || (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
{
ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
else
{
if (bHeatingInAction) if (bHeatingInAction)
{ {
int64_t i64Delta = esp_timer_get_time() - i64BurnerEnableTimestamp; ESP_LOGW(TAG, "Disabling burner due to safety fault");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
if ((i64Delta / 1000000U) >= BURNER_FAULT_DETECTION_THRESHOLD) // Handle SNTP faults
if (getSntpState() != SYNC_SUCCESSFUL)
{
ESP_LOGW(TAG, "Control not possible due to SNTP fault!");
sControlState = CONTROL_FAULT_SNTP;
if (bHeatingInAction)
{
ESP_LOGW(TAG, "Disabling burner due to SNTP fault");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
// Get current temperature entry
sControlTemperatureEntry currentControlEntry = getCurrentTemperatureEntry();
if (bHeatingInAction)
{
if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) ||
(getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
{
ESP_LOGI(TAG, "Chamber target temperature reached: Disabling burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
else if (esp_timer_get_time() - i64BurnerEnableTimestamp >= BURNER_FAULT_DETECTION_THRESHOLD * 1000000U)
{ {
if (getBurnerError() == FAULT) if (getBurnerError() == FAULT)
{ {
ESP_LOGW(TAG, "Detected burner fault after %lli seconds!", (i64Delta / 1000000U)); ESP_LOGW(TAG, "Burner fault detected after timeout!");
ESP_LOGW(TAG, "Control not possible due to burner fault: Disable burner");
sControlState = CONTROL_FAULT_BURNER;
bHeatingInAction = false; bHeatingInAction = false;
bBurnerFaultDetected = true; bBurnerFaultDetected = true;
sControlState = CONTROL_FAULT_BURNER;
setCirculationPumpState(ENABLED); setCirculationPumpState(ENABLED);
setBurnerState(DISABLED); setBurnerState(DISABLED);
setSafetyControlState(ENABLED); setSafetyControlState(ENABLED);
} }
} }
} }
}
}
if ((bHeatingInAction == false) && (bBurnerFaultDetected == false)) if (!bHeatingInAction && !bBurnerFaultDetected)
{ {
if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD) if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD)
{ {
ESP_LOGI(TAG, "Outdoor temperature too warm: Waiting for winter."); ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
setCirculationPumpState(DISABLED); setCirculationPumpState(DISABLED);
setBurnerState(DISABLED); setBurnerState(DISABLED);
setSafetyControlState(DISABLED); setSafetyControlState(DISABLED);
sControlState = CONTROL_OUTDOOR_TOO_WARM; sControlState = CONTROL_OUTDOOR_TOO_WARM;
} }
else else if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) &&
(getChamberTemperature().fCurrentValue <= CHAMBER_TEMPERATURE_THRESHOLD))
{ {
if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= CHAMPER_TEMPERATURE_THRESHOLD)) ESP_LOGI(TAG, "Enabling burner: Return flow temperature target reached");
{
ESP_LOGI(TAG, "Return Flow Target Temperature reached: Enable Burner");
bHeatingInAction = true; bHeatingInAction = true;
setCirculationPumpState(ENABLED); setCirculationPumpState(ENABLED);
setBurnerState(ENABLED); setBurnerState(ENABLED);
@ -160,7 +156,6 @@ void taskControl(void *pvParameters)
} }
} }
} }
}
} }
eControlState getControlState(void) eControlState getControlState(void)
@ -173,71 +168,36 @@ eControlWeekday getCurrentWeekday(void)
time_t now; time_t now;
struct tm *timeinfo; struct tm *timeinfo;
// Get the current time
time(&now); time(&now);
timeinfo = localtime(&now); // Convert to local time timeinfo = localtime(&now);
// Get the day of the week (0 = Sunday, 1 = Monday, ..., 6 = Saturday)
int day = timeinfo->tm_wday; int day = timeinfo->tm_wday;
return (eControlWeekday)((day == 0) ? 6 : day - 1);
// Adjust so that Monday = 0, Sunday = 6
if (day == 0)
{
day = 6; // Sunday becomes 6
}
else
{
day -= 1; // Shift other days to make Monday = 0
}
return (eControlWeekday)day;
} }
sControlTemperatureEntry getCurrentTemperatureEntry(void) sControlTemperatureEntry getCurrentTemperatureEntry(void)
{ {
sControlTemperatureEntry result = aControlTable[0].aTemperatureEntries[0]; sControlTemperatureEntry result = aControlTable[0].aTemperatureEntries[0];
eControlWeekday currentDay = getCurrentWeekday(); eControlWeekday currentDay = getCurrentWeekday();
time_t now; time_t now;
struct tm timeinfo; struct tm timeinfo;
// Get the current time
time(&now); time(&now);
// Convert to local time structure
localtime_r(&now, &timeinfo); localtime_r(&now, &timeinfo);
// Extract hour and minute
int hour = timeinfo.tm_hour; // Hour (0-23)
int minute = timeinfo.tm_min; // Minute (0-59)u
// ESP_LOGI(TAG, "Current Day: %i Hour: %i Minute: %i", currentDay, hour, minute); int hour = timeinfo.tm_hour;
int minute = timeinfo.tm_min;
for (int i = 0; i < sizeof(aControlTable) / sizeof(aControlTable[0]); i++) for (int i = 0; i < sizeof(aControlTable) / sizeof(aControlTable[0]); i++)
{ {
/// loops through days
// ESP_LOGI(TAG, "Day %d: %d", i + 1, aControlTable[i].day);
// int numberOfEntries = aControlTable[i].entryCount;
// ESP_LOGI(TAG, "Number of entries: %i", numberOfEntries);
for (int j = 0; j < aControlTable[i].entryCount; j++) for (int j = 0; j < aControlTable[i].entryCount; j++)
{ {
if ((aControlTable[i].day) > currentDay) if ((aControlTable[i].day > currentDay) ||
(aControlTable[i].day == currentDay && aControlTable[i].aTemperatureEntries[j].timestamp.hour > hour) ||
(aControlTable[i].day == currentDay && aControlTable[i].aTemperatureEntries[j].timestamp.hour == hour && aControlTable[i].aTemperatureEntries[j].timestamp.minute >= minute))
{ {
// ESP_LOGI(TAG, "DAY Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature); return aControlTable[i].aTemperatureEntries[j];
return result;
} }
if ((aControlTable[i].day == currentDay) && (aControlTable[i].aTemperatureEntries[j].timestamp.hour > hour))
{
// ESP_LOGI(TAG, "HOUR Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
return result;
}
if ((aControlTable[i].day == currentDay) && (aControlTable[i].aTemperatureEntries[j].timestamp.hour == hour) && (aControlTable[i].aTemperatureEntries[j].timestamp.minute == minute))
{
// ESP_LOGI(TAG, "MINUTE Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
return result;
}
// ESP_LOGI(TAG, "SET Return Control Entry Day: %i Hour: %i Minute: %i ChamberTemp: %lf ReturnFlowTemp: %lf", aControlTable[i].day, aControlTable[i].aTemperatureEntries[j].timestamp.hour, aControlTable[i].aTemperatureEntries[j].timestamp.minute, aControlTable[i].aTemperatureEntries[j].fChamberTemperature, aControlTable[i].aTemperatureEntries[j].fReturnFlowTemperature);
result = aControlTable[i].aTemperatureEntries[j]; result = aControlTable[i].aTemperatureEntries[j];
} }
} }