Error handling on system boot (#30)

Implements #3 Reviewed-on: #30 Co-authored-by: localhorst <localhorst@mosad.xyz> Co-committed-by: localhorst <localhorst@mosad.xyz>
2026-05-10 12:39:47 +02:00
parent 085f5b4acb
commit a7d577a948
16 changed files with 930 additions and 399 deletions
@@ -1,83 +1,41 @@
-# smart-oil-heating-control-system
+# Smart Oil Heating Control System

-## Software
-### Design
+ESP32-based control system for oil-fired central heating with schedule-based temperature management, safety monitoring, and Prometheus metrics export.

+## Features
+
+- **Schedule Control**: Day/night temperature targets per weekday
+- **Summer Mode**: Automatic heating disable based on outdoor temperature
+- **Safety Monitoring**: Sensor sanity checks with automatic safe-state fallback
+- **Prometheus Metrics**: HTTP endpoint at port 9100
+
+## System Overview
 ```mermaid
-classDiagram
-Inputs <|-- Control
-Outputs <|-- Control
-Sntp <|-- Control
-Inputs <|-- Safety
-Outputs <|--|> Safety
+flowchart TB
+    subgraph OUTSIDE[" "]
+        OT[/"🌡️ Outdoor Temp<br/>DS18B20"/]
+    end

-Inputs <|-- Metrics
-Outputs <|-- Metrics
-Control <|-- Metrics
-Safety <|-- Metrics
-Sntp <|-- Metrics
+    subgraph BURNER["OIL BURNER"]
+        CT[/"🌡️ Chamber Temp<br/>DS18B20"/]
+        BF[["⚠️ Burner Fault<br/>GPIO19 INPUT"]]
+        BR(["🔥 Burner Relay<br/>GPIO14"])
+        SC(["🔌 Safety Contact<br/>GPIO12"])
+    end

-    class Inputs{
-        +initInputs()
-        -initMeasurement()
-        -updateAverage()
-        -updatePrediction()
-        -taskInput()
-        -linearRegressionPredict()
-        +getChamberTemperature()
-        +getOutdoorTemperature()
-        +getInletFlowTemperature()
-        +getReturnFlowTemperature()
-        +getBurnerError()
-    }
+    subgraph CIRCUIT["HEATING CIRCUIT"]
+        IT[/"🌡️ Inlet Temp<br/>DS18B20"/]
+        CP(["💧 Circulation Pump<br/>GPIO27"])
+        RT[/"🌡️ Return Temp<br/>DS18B20"/]
+    end

-    class Outputs{
-        +initOutputs()
-        +getCirculationPumpState()
-        +setCirculationPumpState()
-        +getBurnerState()
-        +setBurnerState()
-        +getSafetyControlState()
-        +setSafetyControlState()
-    }
+    RAD["🏠 Radiators"]

-    class Control{
-        initControl()
-        +taskControl()
-        +getControlCurrentWeekday()
-        -findControlCurrentTemperatureEntry()
-        +getControlCurrentTemperatureEntry()
-        -controlTable
-        +getControlState()
-    }
-
-    class Safety{
-        +initSafety()
-        -taskSafety()
-        -setSafeState()
-        -checkSensorSanity()
-        +getSensorSanityStates()
-        +getSafetyState()
-    }
-
-
-    class Wifi{
-        +initWifi()
-    }
-
-    class Sntp{
-        +initSntp()
-        +getSntpState()
-    }
-
-    class Metrics{
-        +initMetrics()
-        -taskMetrics()
-        -metrics
-        +event_handler()
-        +connect_wifi()
-        +setMetrics()
-    }
+    BURNER -->|"hot water"| IT
+    IT --> CP
+    CP --> RAD
+    RAD --> RT
+    RT -->|"cold water"| BURNER
 ```

 ### Prometheus Metrics
@@ -88,26 +46,26 @@ burner_fault_pending 1
 circulation_pump_enabled 1
 burner_enabled 0
 safety_contact_enabled 1
-chamber_temperature 37.250000
-chamber_temperature_avg10 37.237499
-chamber_temperature_avg60 37.438541
-chamber_temperature_damped 42.185040
-chamber_temperature_pred60 36.638443
-inlet_flow_temperature 35.625000
-inlet_flow_temperature_avg10 35.618752
-inlet_flow_temperature_avg60 35.415627
-inlet_flow_temperature_damped 39.431259
-inlet_flow_temperature_pred60 36.078678
-outdoor_temperature 14.687500
-outdoor_temperature_avg10 14.662500
-outdoor_temperature_avg60 14.646875
-outdoor_temperature_damped 9.169084
-outdoor_temperature_pred60 14.660233
-return_flow_temperature 39.937500
-return_flow_temperature_avg10 40.087502
-return_flow_temperature_avg60 41.146873
-return_flow_temperature_damped 32.385151
-return_flow_temperature_pred60 37.311958
+chamber_temperature 37.312500
+chamber_temperature_avg10 37.393749
+chamber_temperature_avg60 37.689583
+chamber_temperature_damped 38.058098
+chamber_temperature_pred60 36.697266
+inlet_flow_temperature 34.562500
+inlet_flow_temperature_avg10 34.587502
+inlet_flow_temperature_avg60 34.880207
+inlet_flow_temperature_damped 35.255993
+inlet_flow_temperature_pred60 33.910374
+outdoor_temperature 1.812500
+outdoor_temperature_avg10 1.825000
+outdoor_temperature_avg60 1.821875
+outdoor_temperature_damped 2.390663
+outdoor_temperature_pred60 1.840263
+return_flow_temperature 34.125000
+return_flow_temperature_avg10 34.162498
+return_flow_temperature_avg60 34.304165
+return_flow_temperature_damped 31.430506
+return_flow_temperature_pred60 33.858772
 chamber_temperature_state 0
 outdoor_temperature_state 0
 inlet_flow_temperature_state 0
@@ -115,13 +73,13 @@ return_flow_temperature_state 0
 safety_state 0
 control_state 3
 control_current_weekday 5
-control_current_entry_time 17100
+control_current_entry_time 24300
 control_current_entry_chamber_temperature 80.000000
 control_current_entry_return_flow_temperature 30.000000
 sntp_state 0
-system_unixtime 1762012743
-uptime_seconds 465229
-wifi_rssi -72
+system_unixtime 1768067412
+uptime_seconds 344878
+wifi_rssi -59
 ```

 #### Status Encoding
@@ -180,4 +138,20 @@ wifi_rssi -72
 | Input Burner Fault                    | IO19  | Digital Input IN1 |
 | Input Temperature DS10B20             | IO04  | 1-Wire            |

+## Configuration

+All parameters configurable via `idf.py menuconfig`:
+- WiFi credentials and static IP
+- GPIO pin assignments
+- 1-Wire sensor addresses
+- Temperature thresholds and limits
+- Heating schedule (day/night per weekday)
+- Damping factors
+
+## Building
+
+```bash
+idf.py set-target esp32
+idf.py menuconfig  # Configure settings
+idf.py build flash monitor
+```