Merge pull request 'fix/burner-fault-detection' (#23) from fix/burner-fault-detection into feature/summer-mode

Reviewed-on: #23

README.md

@@ -77,31 +77,35 @@ Sntp <|-- Metrics
 #### Example
 ```
 burner_fault_pending 1
-circulation_pump_enabled 0
+circulation_pump_enabled 1
-burner_enabled 1
+burner_enabled 0
-safety_contact_enabled 1
+safety_contact_enabled 0
-chamber_temperature 21.812500
+chamber_temperature 58.750000
-chamber_temperature_avg10 21.837500
+chamber_temperature_avg10 58.931252
-chamber_temperature_avg60 21.825521
+chamber_temperature_avg60 59.190475
-inlet_flow_temperature 22.437500
+chamber_temperature_pred60 55.870998
-inlet_flow_temperature_avg10 22.437500
+inlet_flow_temperature 53.875000
-inlet_flow_temperature_avg60 22.434896
+inlet_flow_temperature_avg10 53.900002
-outdoor_temperature 21.937500
+inlet_flow_temperature_avg60 53.994320
-outdoor_temperature_avg10 21.937500
+inlet_flow_temperature_pred60 52.848743
-outdoor_temperature_avg60 21.933594
+outdoor_temperature 18.000000
-return_flow_temperature 22.375000
+outdoor_temperature_avg10 18.006250
-return_flow_temperature_avg10 22.375000
+outdoor_temperature_avg60 18.002840
-return_flow_temperature_avg60 22.375000
+outdoor_temperature_pred60 18.050785
+return_flow_temperature 48.625000
+return_flow_temperature_avg10 48.718750
+return_flow_temperature_avg60 48.846592
+return_flow_temperature_pred60 47.383083
 chamber_temperature_state 0
 outdoor_temperature_state 0
 inlet_flow_temperature_state 0
 return_flow_temperature_state 0
 safety_state 0
-control_state 5
+control_state 3
 sntp_state 0
-system_unixtime 1734814285
+system_unixtime 1735242392
-uptime_seconds 90
+uptime_seconds 40
-wifi_rssi -63
+wifi_rssi -74
 ```
 
 #### Status Encoding
@@ -132,12 +136,12 @@ wifi_rssi -63
  - 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_BURNER                              | 4     | Burner reported fault after threshold is reached |
 | CONTROL_FAULT_SAFETY                              | 5     | Unable to control due safety fault               |
 | CONTROL_FAULT_SNTP                                | 6     | Unable to control due SNTP fault                 |
 

main/control.c

@@ -1,5 +1,6 @@
 #include "freertos/FreeRTOS.h"
 #include "freertos/task.h"
+#include "esp_timer.h"
 #include "esp_log.h"
 #include "control.h"
 #include "outputs.h"
@@ -7,25 +8,31 @@
 #include "safety.h"
 #include "sntp.h"
 
-#define PERIODIC_INTERVAL 1U // run control loop every 1sec
+#define PERIODIC_INTERVAL 1U // Run control loop every 1 second
 
-#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0
+// Temperature thresholds
-#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0
+#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f
-#define CHAMPER_TEMPERATURE_TARGET 70.0
+#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f
+#define CHAMBER_TEMPERATURE_TARGET 80.0f            // Max cutoff temperature
+#define CHAMBER_TEMPERATURE_THRESHOLD 45.0f         // Min threshold for burner enable
+#define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f         // Min threshold for burner 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 eControlState sControlState = CONTROL_STARTING;
 
+// Control table for daily schedules
 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);
 eControlWeekday getCurrentWeekday(void);
 sControlTemperatureEntry getCurrentTemperatureEntry(void);
@@ -35,7 +42,7 @@ void initControl(void)
     BaseType_t taskCreated = xTaskCreate(
         taskControl,   // Function to implement the task
         "taskControl", // Task name
-        4096,          // Stack size (in words, not bytes)
+        8192,          // Stack size (in words, not bytes)
         NULL,          // Parameters to the task function (none in this case)
         5,             // Task priority (higher number = higher priority)
         NULL           // Task handle (optional)
@@ -51,20 +58,31 @@ void initControl(void)
     }
 }
 
+typedef enum _BurnerState
+{
+    BURNER_UNKNOWN,
+    BURNER_FIRED,
+    BURNER_FAULT
+} eBurnerState;
+
 void taskControl(void *pvParameters)
 {
     bool bHeatingInAction = false;
+    eBurnerState eBurnerState = BURNER_UNKNOWN;
+    int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
+
     while (1)
     {
         vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
 
+        // Handle safety faults
         if (getSafetyState() != SAFETY_NO_ERROR)
         {
             ESP_LOGW(TAG, "Control not possible due to safety fault!");
             sControlState = CONTROL_FAULT_SAFETY;
-            if (bHeatingInAction == true)
+            if (bHeatingInAction)
             {
-                ESP_LOGI(TAG, "Control not possible due to safety fault: Disable burner");
+                ESP_LOGW(TAG, "Disabling burner due to safety fault");
                 bHeatingInAction = false;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
@@ -73,13 +91,14 @@ void taskControl(void *pvParameters)
             continue;
         }
 
+        // Handle SNTP faults
         if (getSntpState() != SYNC_SUCCESSFUL)
         {
-            ESP_LOGW(TAG, "Control not possible due to sntp fault!");
+            ESP_LOGW(TAG, "Control not possible due to SNTP fault!");
             sControlState = CONTROL_FAULT_SNTP;
-            if (bHeatingInAction == true)
+            if (bHeatingInAction)
             {
-                ESP_LOGI(TAG, "Control not possible due to sntp fault: Disable burner");
+                ESP_LOGW(TAG, "Disabling burner due to SNTP fault");
                 bHeatingInAction = false;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
@@ -88,37 +107,63 @@ void taskControl(void *pvParameters)
             continue;
         }
 
+        // Get current temperature entry
         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 (bHeatingInAction)
         {
-            if (getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature)
+            if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) ||
+                (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
             {
-                ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner");
+                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 (eBurnerState == BURNER_UNKNOWN)
+                {
+                    if (getBurnerError() == FAULT)
+                    {
+                        ESP_LOGW(TAG, "Burner fault detected after threshold!");
+                        bHeatingInAction = false;
+                        eBurnerState = BURNER_FAULT;
+                        sControlState = CONTROL_FAULT_BURNER;
+                        setCirculationPumpState(ENABLED);
+                        setBurnerState(DISABLED);
+                        setSafetyControlState(ENABLED);
+                    }
                     else
                     {
-                if (bHeatingInAction)
+                        ESP_LOGW(TAG, "No Burner fault detected after threshold!");
-                {
+                        eBurnerState = BURNER_FIRED;
-                    // TODO: Check burner fault signal here
+                    }
                 }
             }
         }
 
-        if (bHeatingInAction == false)
+        if (!bHeatingInAction && (eBurnerState != BURNER_FAULT))
         {
-            if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0))
+            if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD)
             {
-                ESP_LOGI(TAG, "Return Flow Target Temperature reached: Enable Burner");
+                // ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
+                setCirculationPumpState(DISABLED);
+                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;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(ENABLED);
                 setSafetyControlState(ENABLED);
+                i64BurnerEnableTimestamp = esp_timer_get_time();
                 sControlState = CONTROL_HEATING;
             }
             else
@@ -139,71 +184,36 @@ eControlWeekday getCurrentWeekday(void)
     time_t now;
     struct tm *timeinfo;
 
-    // Get the current time
     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;
-
+    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 result = aControlTable[0].aTemperatureEntries[0];
     eControlWeekday currentDay = getCurrentWeekday();
+
     time_t now;
     struct tm timeinfo;
-
-    // Get the current time
     time(&now);
-    // Convert to local time structure
     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++)
     {
-        /// 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++)
         {
-            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];
         }
     }

main/control.h

@@ -9,7 +9,7 @@ typedef enum _ControlState
     CONTROL_HEATING,
     CONTROL_OUTDOOR_TOO_WARM,
     CONTROL_RETURN_FLOW_TOO_WARM,
-    CONTROL_BURNER_FAULT,
+    CONTROL_FAULT_BURNER,
     CONTROL_FAULT_SAFETY,
     CONTROL_FAULT_SNTP,
 } eControlState;

main/inputs.c

@@ -1,6 +1,8 @@
 #include "freertos/FreeRTOS.h"
 #include "freertos/task.h"
 #include "driver/gpio.h"
+#include <string.h>
+#include <math.h>
 #include "esp_log.h"
 #include <ds18x20.h>
 
@@ -14,10 +16,10 @@ static const char *TAG = "smart-oil-heater-control-system-inputs";
 const uint8_t uBurnerFaultPin = 19U;
 const uint8_t uDS18B20Pin = 4U;
 
-const onewire_addr_t uChamperTempSensorAddr = 0x3e0000001754be28;
+const onewire_addr_t uChamperTempSensorAddr = 0xd00000108cd01d28;
-const onewire_addr_t uOutdoorTempSensorAddr = 0x880000001648e328;
+const onewire_addr_t uOutdoorTempSensorAddr = 0xd70000108a9b9128;
-const onewire_addr_t uInletFlowTempSensorAddr = 0xe59cdef51e64ff28;
+const onewire_addr_t uInletFlowTempSensorAddr = 0x410000108b8c0628;
-const onewire_addr_t uReturnFlowTempSensorAddr = 0xa7a8e1531f64ff28;
+const onewire_addr_t uReturnFlowTempSensorAddr = 0x90000108cc77c28;
 
 onewire_addr_t uOneWireAddresses[MAX_DN18B20_SENSORS];
 float fDS18B20Temps[MAX_DN18B20_SENSORS];
@@ -31,7 +33,10 @@ static sMeasurement sInletFlowTemperature;
 static sMeasurement sReturnFlowTemperature;
 
 void taskInput(void *pvParameters);
+void initMeasurement(sMeasurement *pMeasurement);
 void updateAverage(sMeasurement *pMeasurement);
+void updatePrediction(sMeasurement *pMeasurement);
+float linearRegressionPredict(const float *samples, size_t count, size_t bufferIndex, float futureIndex);
 
 void initInputs(void)
 {
@@ -53,6 +58,11 @@ void initInputs(void)
     }
     xSemaphoreGiveRecursive(xMutexAccessInputs);
 
+    initMeasurement(&sChamperTemperature);
+    initMeasurement(&sOutdoorTemperature);
+    initMeasurement(&sInletFlowTemperature);
+    initMeasurement(&sReturnFlowTemperature);
+
     BaseType_t taskCreated = xTaskCreate(
         taskInput,   // Function to implement the task
         "taskInput", // Task name
@@ -72,8 +82,36 @@ void initInputs(void)
     }
 }
 
+void initMeasurement(sMeasurement *pMeasurement)
+{
+    if (!pMeasurement)
+        return;
+
+    pMeasurement->state = MEASUREMENT_FAULT;
+    pMeasurement->fCurrentValue = 0.0f;
+
+    pMeasurement->average10s.fValue = 0.0f;
+    pMeasurement->average10s.bufferCount = 0U;
+    pMeasurement->average10s.bufferIndex = 0U;
+    memset(pMeasurement->average10s.samples, 0U, AVG10_SAMPLE_SIZE);
+
+    pMeasurement->average60s.fValue = 0.0f;
+    pMeasurement->average60s.bufferCount = 0U;
+    pMeasurement->average60s.bufferIndex = 0U;
+    memset(pMeasurement->average60s.samples, 0U, AVG60_SAMPLE_SIZE);
+
+    pMeasurement->predict60s.fValue = 0.0f;
+    pMeasurement->predict60s.bufferCount = 0U;
+    pMeasurement->predict60s.bufferIndex = 0U;
+    memset(pMeasurement->predict60s.samples, 0U, PRED60_SAMPLE_SIZE);
+}
+
 void updateAverage(sMeasurement *pMeasurement)
-{ /* Average form the last 10sec */
+{
+    if (!pMeasurement)
+        return;
+
+    // Average form the last 10sec
     pMeasurement->average10s.samples[pMeasurement->average10s.bufferIndex] = pMeasurement->fCurrentValue;
     pMeasurement->average10s.bufferIndex = (pMeasurement->average10s.bufferIndex + 1) % AVG10_SAMPLE_SIZE;
 
@@ -82,20 +120,15 @@ void updateAverage(sMeasurement *pMeasurement)
         pMeasurement->average10s.bufferCount++;
     }
 
-    if (pMeasurement->average10s.bufferCount == 0U)
-    {
-        pMeasurement->average10s.fValue = pMeasurement->fCurrentValue;
-    }
-
     float sum = 0.0;
-    for (int i = 0; i < pMeasurement->average10s.bufferCount; i++)
+    for (int i = 0; i <= pMeasurement->average10s.bufferCount; i++)
     {
         sum += pMeasurement->average10s.samples[i];
     }
 
     pMeasurement->average10s.fValue = sum / pMeasurement->average10s.bufferCount;
 
-    /* Average form the last 60sec */
+    // Average form the last 60sec
     pMeasurement->average60s.samples[pMeasurement->average60s.bufferIndex] = pMeasurement->fCurrentValue;
     pMeasurement->average60s.bufferIndex = (pMeasurement->average60s.bufferIndex + 1) % AVG60_SAMPLE_SIZE;
 
@@ -104,13 +137,8 @@ void updateAverage(sMeasurement *pMeasurement)
         pMeasurement->average60s.bufferCount++;
     }
 
-    if (pMeasurement->average60s.bufferCount == 0U)
-    {
-        pMeasurement->average60s.fValue = pMeasurement->fCurrentValue;
-    }
-
     sum = 0.0;
-    for (int i = 0; i < pMeasurement->average60s.bufferCount; i++)
+    for (int i = 0; i <= pMeasurement->average60s.bufferCount; i++)
     {
         sum += pMeasurement->average60s.samples[i];
     }
@@ -118,6 +146,26 @@ void updateAverage(sMeasurement *pMeasurement)
     pMeasurement->average60s.fValue = sum / pMeasurement->average60s.bufferCount;
 }
 
+void updatePrediction(sMeasurement *pMeasurement)
+{
+    if (!pMeasurement)
+        return;
+
+    // Update predict60s buffer
+    sPredict *predict60s = &pMeasurement->predict60s;
+    predict60s->samples[predict60s->bufferIndex] = pMeasurement->fCurrentValue;
+    predict60s->bufferIndex = (predict60s->bufferIndex + 1) % PRED60_SAMPLE_SIZE;
+    if (predict60s->bufferCount < PRED60_SAMPLE_SIZE)
+        predict60s->bufferCount++;
+
+    // Predict 60s future value using linear regression
+    predict60s->fValue = linearRegressionPredict(
+        predict60s->samples,
+        predict60s->bufferCount,
+        predict60s->bufferIndex,
+        predict60s->bufferCount + 60.0f);
+}
+
 void taskInput(void *pvParameters)
 {
     while (1)
@@ -163,7 +211,7 @@ void taskInput(void *pvParameters)
                     if (ds18x20_measure_and_read_multi(uDS18B20Pin, uOneWireAddresses, sSensorCount, fDS18B20Temps) != ESP_OK)
                     {
                         ESP_LOGE(TAG, "1-Wire devices read error");
-                        vTaskDelay(PERIODIC_INTERVAL * 100U / portTICK_PERIOD_MS); //Wait 100ms if bus error occurred
+                        vTaskDelay(PERIODIC_INTERVAL * 100U / portTICK_PERIOD_MS); // Wait 100ms if bus error occurred
                     }
                     else
                     {
@@ -178,21 +226,25 @@ void taskInput(void *pvParameters)
                                 sChamperTemperature.fCurrentValue = temp_c;
                                 sChamperTemperature.state = MEASUREMENT_NO_ERROR;
                                 updateAverage(&sChamperTemperature);
+                                updatePrediction(&sChamperTemperature);
                                 break;
                             case ((uint64_t)uOutdoorTempSensorAddr):
                                 sOutdoorTemperature.fCurrentValue = temp_c;
                                 sOutdoorTemperature.state = MEASUREMENT_NO_ERROR;
                                 updateAverage(&sOutdoorTemperature);
+                                updatePrediction(&sOutdoorTemperature);
                                 break;
                             case ((uint64_t)uInletFlowTempSensorAddr):
                                 sInletFlowTemperature.fCurrentValue = temp_c;
                                 sInletFlowTemperature.state = MEASUREMENT_NO_ERROR;
                                 updateAverage(&sInletFlowTemperature);
+                                updatePrediction(&sInletFlowTemperature);
                                 break;
                             case ((uint64_t)uReturnFlowTempSensorAddr):
                                 sReturnFlowTemperature.fCurrentValue = temp_c;
                                 sReturnFlowTemperature.state = MEASUREMENT_NO_ERROR;
                                 updateAverage(&sReturnFlowTemperature);
+                                updatePrediction(&sReturnFlowTemperature);
                                 break;
                             default:
                                 break;
@@ -216,6 +268,39 @@ void taskInput(void *pvParameters)
     }
 }
 
+float linearRegressionPredict(const float *samples, size_t count, size_t bufferIndex, float futureIndex)
+{
+    if (count == 0)
+        return 0.0f; // No prediction possible with no data
+
+    float sumX = 0.0f, sumY = 0.0f, sumXY = 0.0f, sumX2 = 0.0f;
+
+    for (size_t i = 0; i < count; i++)
+    {
+        // Calculate the circular buffer index for the current sample
+        size_t circularIndex = (bufferIndex + i + 1) % count;
+
+        float x = (float)i;               // Time index
+        float y = samples[circularIndex]; // Sample value
+
+        sumX += x;
+        sumY += y;
+        sumXY += x * y;
+        sumX2 += x * x;
+    }
+
+    // Calculate slope (m) and intercept (b) of the line: y = mx + b
+    float denominator = (count * sumX2 - sumX * sumX);
+    if (fabs(denominator) < 1e-6)    // Avoid division by zero
+        return samples[bufferIndex]; // Return the latest value as prediction
+
+    float m = (count * sumXY - sumX * sumY) / denominator;
+    float b = (sumY - m * sumX) / count;
+
+    // Predict value at futureIndex
+    return m * futureIndex + b;
+}
+
 sMeasurement getChamberTemperature(void)
 {
     sMeasurement ret;

main/inputs.h

@@ -3,6 +3,7 @@
 #define MAX(a, b) ((a) > (b) ? (a) : (b))
 #define AVG10_SAMPLE_SIZE 10U
 #define AVG60_SAMPLE_SIZE 60U
+#define PRED60_SAMPLE_SIZE 60U
 
 typedef enum _BurnerErrorState
 {
@@ -24,11 +25,20 @@ typedef struct _Average
     size_t bufferCount;
 } sAverage;
 
+typedef struct _Predict
+{
+    float fValue;
+    float samples[PRED60_SAMPLE_SIZE];
+    size_t bufferIndex;
+    size_t bufferCount;
+} sPredict;
+
 typedef struct _Measurement
 {
     float fCurrentValue;
     sAverage average10s;
     sAverage average60s;
+    sPredict predict60s;
     eMeasurementErrorState state;
 } sMeasurement;
 

main/metrics.c

@@ -32,7 +32,7 @@ void initMetrics(void)
     BaseType_t taskCreated = xTaskCreate(
         taskMetrics,   // Function to implement the task
         "taskMetrics", // Task name
-        16384,         // Stack size (in words, not bytes)
+        32768,         // Stack size (in words, not bytes)
         NULL,          // Parameters to the task function (none in this case)
         5,             // Task priority (higher number = higher priority)
         NULL           // Task handle (optional)
@@ -56,13 +56,13 @@ void taskMetrics(void *pvParameters)
 
         u16MetricCounter = 0U;
 
-        /*Burner Error State*/
+        // Burner Error State
         strcpy(aMetrics[u16MetricCounter].caMetricName, "burner_fault_pending");
         aMetrics[u16MetricCounter].type = INTEGER_U8;
         aMetrics[u16MetricCounter].u8MetricValue = getBurnerError();
         u16MetricCounter++;
 
-        /*Circulation Pump State*/
+        // Circulation Pump State
         if (getCirculationPumpState() == ENABLED)
         {
             strcpy(aMetrics[u16MetricCounter].caMetricName, "circulation_pump_enabled");
@@ -78,7 +78,7 @@ void taskMetrics(void *pvParameters)
             u16MetricCounter++;
         }
 
-        /*Burner State*/
+        // Burner State
         if (getBurnerState() == ENABLED)
         {
             strcpy(aMetrics[u16MetricCounter].caMetricName, "burner_enabled");
@@ -94,7 +94,7 @@ void taskMetrics(void *pvParameters)
             u16MetricCounter++;
         }
 
-        /*Safety Contact State*/
+        // Safety Contact State
         if (getSafetyControlState() == ENABLED)
         {
             strcpy(aMetrics[u16MetricCounter].caMetricName, "safety_contact_enabled");
@@ -110,79 +110,103 @@ void taskMetrics(void *pvParameters)
             u16MetricCounter++;
         }
 
-        /*Chamber Temperature*/
+        // Chamber Temperature
         strcpy(aMetrics[u16MetricCounter].caMetricName, "chamber_temperature");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getChamberTemperature().fCurrentValue;
         u16MetricCounter++;
 
-        /*Chamber Temperature Average 10s*/
+        // Chamber Temperature Average 10s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "chamber_temperature_avg10");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getChamberTemperature().average10s.fValue;
         u16MetricCounter++;
 
-        /*Chamber Temperature Average 60s*/
+        // Chamber Temperature Average 60s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "chamber_temperature_avg60");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getChamberTemperature().average60s.fValue;
         u16MetricCounter++;
 
-        /*Inlet Flow Temperature*/
+        // Chamber Temperature Predict 60s
+        strcpy(aMetrics[u16MetricCounter].caMetricName, "chamber_temperature_pred60");
+        aMetrics[u16MetricCounter].type = FLOAT;
+        aMetrics[u16MetricCounter].fMetricValue = getChamberTemperature().predict60s.fValue;
+        u16MetricCounter++;
+
+        // Inlet Flow Temperature
         strcpy(aMetrics[u16MetricCounter].caMetricName, "inlet_flow_temperature");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getInletFlowTemperature().fCurrentValue;
         u16MetricCounter++;
 
-        /*Inlet Flow Temperature Average 10s*/
+        // Inlet Flow Temperature Average 10s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "inlet_flow_temperature_avg10");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getInletFlowTemperature().average10s.fValue;
         u16MetricCounter++;
 
-        /*Inlet Flow Temperature Average 60s*/
+        // Inlet Flow Temperature Average 60s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "inlet_flow_temperature_avg60");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getInletFlowTemperature().average60s.fValue;
         u16MetricCounter++;
 
-        /*Outdoor Temperature*/
+        // Inlet Flow Temperature Predict 60s
+        strcpy(aMetrics[u16MetricCounter].caMetricName, "inlet_flow_temperature_pred60");
+        aMetrics[u16MetricCounter].type = FLOAT;
+        aMetrics[u16MetricCounter].fMetricValue = getInletFlowTemperature().predict60s.fValue;
+        u16MetricCounter++;
+
+        // Outdoor Temperature
         strcpy(aMetrics[u16MetricCounter].caMetricName, "outdoor_temperature");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getOutdoorTemperature().fCurrentValue;
         u16MetricCounter++;
 
-        /*Outdoor Temperature Average 10s*/
+        // Outdoor Temperature Average 10s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "outdoor_temperature_avg10");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getOutdoorTemperature().average10s.fValue;
         u16MetricCounter++;
 
-        /*Outdoor Temperature Average 60s*/
+        // Outdoor Temperature Average 60s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "outdoor_temperature_avg60");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getOutdoorTemperature().average60s.fValue;
         u16MetricCounter++;
 
-        /*Return Flow Temperature*/
+        // Outdoor Temperature Predict 60s
+        strcpy(aMetrics[u16MetricCounter].caMetricName, "outdoor_temperature_pred60");
+        aMetrics[u16MetricCounter].type = FLOAT;
+        aMetrics[u16MetricCounter].fMetricValue = getOutdoorTemperature().predict60s.fValue;
+        u16MetricCounter++;
+
+        // Return Flow Temperature
         strcpy(aMetrics[u16MetricCounter].caMetricName, "return_flow_temperature");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getReturnFlowTemperature().fCurrentValue;
         u16MetricCounter++;
 
-        /*Return Flow Temperature Average 10s*/
+        // Return Flow Temperature Average 10s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "return_flow_temperature_avg10");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getReturnFlowTemperature().average10s.fValue;
         u16MetricCounter++;
 
-        /*Return Flow Temperature Average 60s*/
+        // Return Flow Temperature Average 60s
         strcpy(aMetrics[u16MetricCounter].caMetricName, "return_flow_temperature_avg60");
         aMetrics[u16MetricCounter].type = FLOAT;
         aMetrics[u16MetricCounter].fMetricValue = getReturnFlowTemperature().average60s.fValue;
         u16MetricCounter++;
 
-        /*Sensor State*/
+        // Return Flow Temperature Predict 60s
+        strcpy(aMetrics[u16MetricCounter].caMetricName, "return_flow_temperature_pred60");
+        aMetrics[u16MetricCounter].type = FLOAT;
+        aMetrics[u16MetricCounter].fMetricValue = getReturnFlowTemperature().predict60s.fValue;
+        u16MetricCounter++;
+
+        // Sensor State
         sSensorSanityCheck aChecks[NUMBER_OF_SENSOR_SANITY_CHECKS];
         getSensorSanityStates(aChecks);
         for (size_t i = 0; i < NUMBER_OF_SENSOR_SANITY_CHECKS; i++)
@@ -194,25 +218,25 @@ void taskMetrics(void *pvParameters)
             u16MetricCounter++;
         }
 
-        /*Safety State*/
+        // Safety State
         strcpy(aMetrics[u16MetricCounter].caMetricName, "safety_state");
         aMetrics[u16MetricCounter].type = INTEGER_U8;
         aMetrics[u16MetricCounter].u8MetricValue = getSafetyState();
         u16MetricCounter++;
 
-        /*Control State*/
+        // Control State
         strcpy(aMetrics[u16MetricCounter].caMetricName, "control_state");
         aMetrics[u16MetricCounter].type = INTEGER_U8;
         aMetrics[u16MetricCounter].u8MetricValue = getControlState();
         u16MetricCounter++;
 
-        /*SNTP State*/
+        // SNTP State
         strcpy(aMetrics[u16MetricCounter].caMetricName, "sntp_state");
         aMetrics[u16MetricCounter].type = INTEGER_U8;
         aMetrics[u16MetricCounter].u8MetricValue = getSntpState();
         u16MetricCounter++;
 
-        /*System Time*/
+        // System Time
         time_t now;
         time(&now);
         strcpy(aMetrics[u16MetricCounter].caMetricName, "system_unixtime");
@@ -220,13 +244,13 @@ void taskMetrics(void *pvParameters)
         aMetrics[u16MetricCounter].i64MetricValue = now;
         u16MetricCounter++;
 
-        /*Uptime*/
+        // Uptime
         strcpy(aMetrics[u16MetricCounter].caMetricName, "uptime_seconds");
         aMetrics[u16MetricCounter].type = INTEGER_64;
         aMetrics[u16MetricCounter].i64MetricValue = (esp_timer_get_time() / 1000000U);
         u16MetricCounter++;
 
-        /*Wifi RSSI*/
+        // Wifi RSSI
         wifi_ap_record_t ap;
         esp_wifi_sta_get_ap_info(&ap);
         strcpy(aMetrics[u16MetricCounter].caMetricName, "wifi_rssi");
@@ -243,7 +267,7 @@ void vSetMetrics(sMetric *paMetrics, uint16_t u16Size)
 
     if (xSemaphoreTakeRecursive(xMutexAccessMetricResponse, pdMS_TO_TICKS(5000)) == pdTRUE)
     {
-        memset(caHtmlResponse, 0, strlen(caHtmlResponse));
+        memset(caHtmlResponse, 0U, strlen(caHtmlResponse));
         for (uint16_t u16Index = 0U; u16Index < u16Size; u16Index++)
         {
             char caValueBuffer[64];
@@ -263,6 +287,7 @@ void vSetMetrics(sMetric *paMetrics, uint16_t u16Size)
                 break;
             }
 
+            // printf("%s\n", paMetrics[u16Index].caMetricName);
             // printf("%s\n", caValueBuffer);
             strcat(caHtmlResponse, paMetrics[u16Index].caMetricName);
             strcat(caHtmlResponse, caValueBuffer);

main/metrics.h

@@ -2,9 +2,9 @@
 
 #include <esp_http_server.h>
 
-#define HTML_RESPONSE_SIZE 1024U
+#define HTML_RESPONSE_SIZE 4096U
-#define METRIC_NAME_MAX_SIZE 256U
+#define METRIC_NAME_MAX_SIZE 64U
-#define METRIC_MAX_COUNT 64U
+#define METRIC_MAX_COUNT 32U
 
 typedef enum _MetricValueType
 {

main/safety.c

@@ -155,5 +155,16 @@ void getSensorSanityStates(sSensorSanityCheck *pSensorSanityChecks)
 
 eSafetyState getSafetyState(void)
 {
-    return sSafetyState;
+    eSafetyState state = SAFETY_NO_ERROR;
+    if (xSemaphoreTakeRecursive(xMutexAccessSafety, pdMS_TO_TICKS(5000)) == pdTRUE)
+    {
+        state = sSafetyState;
+        xSemaphoreGiveRecursive(xMutexAccessSafety);
+    }
+    else
+    {
+        state = SAFETY_INTERNAL_ERROR;
+        ESP_LOGE(TAG, "Unable to take mutex: getSafetyState()");
+    }
+    return state;
 }