localhorst/smart-oil-heating-control-system
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fix search algo

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Hendrik Schutter
2025-11-01 17:43:25 +01:00
parent 55b62d7438
commit d992218a7d
1 changed files with 274 additions and 191 deletions
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main/control.c
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@ -1,10 +1,10 @@
#include "control.h"
#include "esp_log.h"
#include "esp_timer.h"
#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 "control.h"
#include "outputs.h"
#include "inputs.h" #include "inputs.h"
#include "outputs.h"
#include "safety.h" #include "safety.h"
#include "sntp.h" #include "sntp.h"
@ -13,225 +13,308 @@
// Temperature thresholds // 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 CHAMBER_TEMPERATURE_TARGET 80.0f // Max cutoff temperature #define CHAMBER_TEMPERATURE_TARGET 80.0f // Max cutoff temperature
#define CHAMBER_TEMPERATURE_THRESHOLD 45.0f // Min threshold for burner enable #define CHAMBER_TEMPERATURE_THRESHOLD 45.0f // Min threshold for burner enable
#define SUMMER_MODE_TEMPERATURE_THRESHOLD_HIGH 20.0f // Summer mode will be activated #define SUMMER_MODE_TEMPERATURE_THRESHOLD_HIGH \
#define SUMMER_MODE_TEMPERATURE_THRESHOLD_LOW 15.0f // Summer mode will be deactivated --> Heating starts 20.0f // Summer mode will be activated
#define CIRCULATION_PUMP_TEMPERATURE_THRESHOLD 30.0f // Min threshold of chamber for circulation pump enable #define SUMMER_MODE_TEMPERATURE_THRESHOLD_LOW \
#define BURNER_FAULT_DETECTION_THRESHOLD (60U * 4U) // Burner fault detection after 4 minutes 15.0f // Summer mode will be deactivated --> Heating starts
#define CIRCULATION_PUMP_TEMPERATURE_THRESHOLD \
30.0f // Min threshold of chamber for circulation pump enable
#define BURNER_FAULT_DETECTION_THRESHOLD \
(60U * 4U) // Burner fault detection after 4 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 // Control table for daily schedules
static const sControlDay aControlTable[] = { static const sControlDay aControlTable[] = {
{MONDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}}, {MONDAY,
{TUESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}}, 2U,
{WEDNESDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}}, {{{4, 45},
{THURSDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY,
{FRIDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{23, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}}, CHAMBER_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}}}, {{22, 0},
{SUNDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMBER_TEMPERATURE_TARGET}, {{22, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMBER_TEMPERATURE_TARGET}}}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT,
CHAMBER_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,
CHAMBER_TEMPERATURE_TARGET},
{{22, 0},
RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT,
CHAMBER_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,
CHAMBER_TEMPERATURE_TARGET},
{{23, 0},
RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT,
CHAMBER_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,
CHAMBER_TEMPERATURE_TARGET},
{{22, 30},
RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT,
CHAMBER_TEMPERATURE_TARGET}}},
}; };
static sControlTemperatureEntry currentControlEntry = aControlTable[0].aTemperatureEntries[0]; static sControlTemperatureEntry currentControlEntry =
aControlTable[0].aTemperatureEntries[0];
// Function prototypes // Function prototypes
void taskControl(void *pvParameters); void taskControl(void *pvParameters);
void findControlCurrentTemperatureEntry(void); void findControlCurrentTemperatureEntry(void);
void initControl(void) void initControl(void) {
{ BaseType_t taskCreated =
BaseType_t taskCreated = xTaskCreate( xTaskCreate(taskControl, // Function to implement the task
taskControl, // Function to implement the task "taskControl", // Task name
"taskControl", // Task name 8192, // Stack size (in words, not bytes)
8192, // Stack size (in words, not bytes) NULL, // Parameters to the task function (none in this case)
NULL, // Parameters to the task function (none in this case) 5, // Task priority (higher number = higher priority)
5, // Task priority (higher number = higher priority) NULL // Task handle (optional)
NULL // Task handle (optional) );
);
if (taskCreated == pdPASS) if (taskCreated == pdPASS) {
{ ESP_LOGI(TAG, "Task created successfully!");
ESP_LOGI(TAG, "Task created successfully!"); } else {
ESP_LOGE(TAG, "Failed to create task");
}
}
void taskControl(void *pvParameters) {
bool bHeatingInAction = false;
bool bSummerMode = false;
eBurnerState eBurnerState = BURNER_UNKNOWN;
int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
while (1) {
vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
// Check for safety faults
if (getSafetyState() != SAFETY_NO_ERROR) {
ESP_LOGW(TAG, "Control not possible due to safety fault!");
sControlState = CONTROL_FAULT_SAFETY;
if (bHeatingInAction) {
ESP_LOGW(TAG, "Disabling burner due to safety fault");
bHeatingInAction = false;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
} }
else
{ // Check for SNTP faults
ESP_LOGE(TAG, "Failed to create task"); 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;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
} }
findControlCurrentTemperatureEntry();
sControlTemperatureEntry currentControlEntry =
getControlCurrentTemperatureEntry();
if (getOutdoorTemperature().fDampedValue >=
SUMMER_MODE_TEMPERATURE_THRESHOLD_HIGH) {
bSummerMode = true;
} else if (getOutdoorTemperature().fDampedValue <=
SUMMER_MODE_TEMPERATURE_THRESHOLD_LOW) {
bSummerMode = false;
}
// Enable burner if outdoor temperature is low and return flow temperature
// is cooled down
if (!bHeatingInAction && (eBurnerState != BURNER_FAULT)) {
if (bSummerMode) {
// ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
setBurnerState(DISABLED);
setSafetyControlState(DISABLED);
sControlState = CONTROL_OUTDOOR_TOO_WARM;
} else if ((getReturnFlowTemperature().average60s.fValue <=
currentControlEntry.fReturnFlowTemperature) &&
(getChamberTemperature().fCurrentValue <=
CHAMBER_TEMPERATURE_THRESHOLD)) {
ESP_LOGI(TAG,
"Enabling burner: Return flow temperature target reached");
eBurnerState = BURNER_UNKNOWN;
bHeatingInAction = true;
setBurnerState(ENABLED);
setSafetyControlState(ENABLED);
i64BurnerEnableTimestamp = esp_timer_get_time();
sControlState = CONTROL_HEATING;
} else {
// ESP_LOGI(TAG, "Return flow temperature too warm: Disabling heating");
sControlState = CONTROL_RETURN_FLOW_TOO_WARM;
}
}
// Disable burner if target temperature is reached or a fault occurred
if (bHeatingInAction) {
if ((getChamberTemperature().fCurrentValue >=
currentControlEntry.fChamberTemperature) ||
(getChamberTemperature().predict60s.fValue >=
currentControlEntry.fChamberTemperature)) {
ESP_LOGI(TAG, "Chamber target temperature reached: Disabling burner");
bHeatingInAction = false;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
} else if (esp_timer_get_time() - i64BurnerEnableTimestamp >=
BURNER_FAULT_DETECTION_THRESHOLD * 1000000U) {
if (eBurnerState == BURNER_UNKNOWN) {
if (getBurnerError() == FAULT) {
// ESP_LOGW(TAG, "Burner fault detected: Disabling burner");
bHeatingInAction = false;
eBurnerState = BURNER_FAULT;
sControlState = CONTROL_FAULT_BURNER;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
} else {
// ESP_LOGI(TAG, "No burner fault detected: Marking burner as
// fired");
eBurnerState = BURNER_FIRED;
}
}
}
}
// Manage circulation pump
if (getChamberTemperature().fCurrentValue <=
CIRCULATION_PUMP_TEMPERATURE_THRESHOLD) {
// ESP_LOGI(TAG, "Burner cooled down: Disabling circulation pump");
setCirculationPumpState(DISABLED);
} else {
// ESP_LOGI(TAG, "Burner heated: Enabling circulation pump");
setCirculationPumpState(ENABLED);
}
} // End of while(1)
} }
void taskControl(void *pvParameters) eControlState getControlState(void) { return sControlState; }
{
bool bHeatingInAction = false;
bool bSummerMode = false;
eBurnerState eBurnerState = BURNER_UNKNOWN;
int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
while (1) eControlWeekday getControlCurrentWeekday(void) {
{ time_t now;
vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS); struct tm *timeinfo;
// Check for safety faults time(&now);
if (getSafetyState() != SAFETY_NO_ERROR) timeinfo = localtime(&now);
{
ESP_LOGW(TAG, "Control not possible due to safety fault!");
sControlState = CONTROL_FAULT_SAFETY;
if (bHeatingInAction)
{
ESP_LOGW(TAG, "Disabling burner due to safety fault");
bHeatingInAction = false;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
// Check for SNTP faults int day = timeinfo->tm_wday;
if (getSntpState() != SYNC_SUCCESSFUL) return (eControlWeekday)((day == 0) ? 6 : day - 1);
{
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;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
findControlCurrentTemperatureEntry();
sControlTemperatureEntry currentControlEntry = getControlCurrentTemperatureEntry();
if (getOutdoorTemperature().fDampedValue >= SUMMER_MODE_TEMPERATURE_THRESHOLD_HIGH)
{
bSummerMode = true;
}
else if (getOutdoorTemperature().fDampedValue <= SUMMER_MODE_TEMPERATURE_THRESHOLD_LOW)
{
bSummerMode = false;
}
// Enable burner if outdoor temperature is low and return flow temperature is cooled down
if (!bHeatingInAction && (eBurnerState != BURNER_FAULT))
{
if (bSummerMode)
{
// ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
setBurnerState(DISABLED);
setSafetyControlState(DISABLED);
sControlState = CONTROL_OUTDOOR_TOO_WARM;
}
else if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) &&
(getChamberTemperature().fCurrentValue <= CHAMBER_TEMPERATURE_THRESHOLD))
{
ESP_LOGI(TAG, "Enabling burner: Return flow temperature target reached");
eBurnerState = BURNER_UNKNOWN;
bHeatingInAction = true;
setBurnerState(ENABLED);
setSafetyControlState(ENABLED);
i64BurnerEnableTimestamp = esp_timer_get_time();
sControlState = CONTROL_HEATING;
}
else
{
// ESP_LOGI(TAG, "Return flow temperature too warm: Disabling heating");
sControlState = CONTROL_RETURN_FLOW_TOO_WARM;
}
}
// Disable burner if target temperature is reached or a fault occurred
if (bHeatingInAction)
{
if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) ||
(getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
{
ESP_LOGI(TAG, "Chamber target temperature reached: Disabling burner");
bHeatingInAction = false;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
else if (esp_timer_get_time() - i64BurnerEnableTimestamp >= BURNER_FAULT_DETECTION_THRESHOLD * 1000000U)
{
if (eBurnerState == BURNER_UNKNOWN)
{
if (getBurnerError() == FAULT)
{
// ESP_LOGW(TAG, "Burner fault detected: Disabling burner");
bHeatingInAction = false;
eBurnerState = BURNER_FAULT;
sControlState = CONTROL_FAULT_BURNER;
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
else
{
// ESP_LOGI(TAG, "No burner fault detected: Marking burner as fired");
eBurnerState = BURNER_FIRED;
}
}
}
}
// Manage circulation pump
if (getChamberTemperature().fCurrentValue <= CIRCULATION_PUMP_TEMPERATURE_THRESHOLD)
{
// ESP_LOGI(TAG, "Burner cooled down: Disabling circulation pump");
setCirculationPumpState(DISABLED);
}
else
{
// ESP_LOGI(TAG, "Burner heated: Enabling circulation pump");
setCirculationPumpState(ENABLED);
}
} // End of while(1)
} }
eControlState getControlState(void) /**
{ * @brief Finds the active temperature control entry for the current time.
return sControlState; *
} * Searches through the weekly schedule to find the most recent entry
* that should be active at the current date/time. Falls back to the
eControlWeekday getControlCurrentWeekday(void) * last entry in the week if no suitable entry is found.
{ */
time_t now; /**
struct tm *timeinfo; * @brief Finds the active temperature control entry for the current time.
*
time(&now); * Searches through the weekly schedule to find the most recent entry
timeinfo = localtime(&now); * that should be active at the current date/time. Falls back to the
* last entry in the week if no suitable entry is found.
int day = timeinfo->tm_wday; */
return (eControlWeekday)((day == 0) ? 6 : day - 1); void findControlCurrentTemperatureEntry(void) {
}
void findControlCurrentTemperatureEntry(void)
{
eControlWeekday currentDay = getControlCurrentWeekday(); eControlWeekday currentDay = getControlCurrentWeekday();
// Get current time
time_t now; time_t now;
struct tm timeinfo; struct tm timeinfo;
time(&now); time(&now);
localtime_r(&now, &timeinfo); localtime_r(&now, &timeinfo);
int hour = timeinfo.tm_hour; int currentHour = timeinfo.tm_hour;
int minute = timeinfo.tm_min; int currentMinute = timeinfo.tm_min;
for (int i = 0; i < sizeof(aControlTable) / sizeof(aControlTable[0]); i++) //ESP_LOGI(TAG, "Searching for control entry - Day: %d, Time: %02d:%02d", currentDay, currentHour, currentMinute);
{
for (int j = 0; j < aControlTable[i].entryCount; j++) // Search through all days and entries
{ for (int dayIndex = 0; dayIndex < 7; dayIndex++) {
if ((aControlTable[i].day > currentDay) || const sControlDay* day = &aControlTable[dayIndex];
(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)) for (int entryIndex = 0; entryIndex < day->entryCount; entryIndex++) {
{ const sControlTemperatureEntry* entry = &day->aTemperatureEntries[entryIndex];
currentControlEntry = aControlTable[i].aTemperatureEntries[j];
// Check if this entry is in the future (next active entry)
bool isFutureDay = (day->day > currentDay);
bool isTodayFutureTime = (day->day == currentDay) &&
((entry->timestamp.hour > currentHour) ||
(entry->timestamp.hour == currentHour &&
entry->timestamp.minute > currentMinute));
if (isFutureDay || isTodayFutureTime) {
// Found next scheduled entry, so determine the previous (active) one
if (entryIndex > 0) {
// Use previous entry from same day
currentControlEntry = day->aTemperatureEntries[entryIndex - 1];
} else if (dayIndex > 0) {
// Use last entry from previous day
const sControlDay* previousDay = &aControlTable[dayIndex - 1];
currentControlEntry = previousDay->aTemperatureEntries[previousDay->entryCount - 1];
} else {
// First entry of the week - wrap to last entry of Sunday
const sControlDay* sunday = &aControlTable[6];
currentControlEntry = sunday->aTemperatureEntries[sunday->entryCount - 1];
}
/*
ESP_LOGI(TAG, "Active entry found - Time: %02d:%02d, "
"Return Temp: %lf, Chamber Temp: %lf",
currentControlEntry.timestamp.hour,
currentControlEntry.timestamp.minute,
currentControlEntry.fReturnFlowTemperature,
currentControlEntry.fChamberTemperature);
*/
return;
} }
currentControlEntry = aControlTable[i].aTemperatureEntries[j];
} }
} }
// If we reached here, current time is after all entries this week
// Use the last entry (Sunday evening)
const sControlDay* sunday = &aControlTable[6];
currentControlEntry = sunday->aTemperatureEntries[sunday->entryCount - 1];
ESP_LOGI(TAG, "Using last entry of week - Time: %02d:%02d",
currentControlEntry.timestamp.hour,
currentControlEntry.timestamp.minute);
} }
sControlTemperatureEntry getControlCurrentTemperatureEntry(void) sControlTemperatureEntry getControlCurrentTemperatureEntry(void) {
{ return currentControlEntry;
return currentControlEntry;
} }