Improve efficiency (#21)

- Change to new One Wire Sensors that are no fakes
- Increase chamber temperature

Reviewed-on: #21
Co-authored-by: localhorst <localhorst@mosad.xyz>
Co-committed-by: localhorst <localhorst@mosad.xyz>

README.md

@@ -77,31 +77,35 @@ Sntp <|-- Metrics
 #### Example
 ```
 burner_fault_pending 1
-circulation_pump_enabled 0
-burner_enabled 1
-safety_contact_enabled 1
-chamber_temperature 21.812500
-chamber_temperature_avg10 21.837500
-chamber_temperature_avg60 21.825521
-inlet_flow_temperature 22.437500
-inlet_flow_temperature_avg10 22.437500
-inlet_flow_temperature_avg60 22.434896
-outdoor_temperature 21.937500
-outdoor_temperature_avg10 21.937500
-outdoor_temperature_avg60 21.933594
-return_flow_temperature 22.375000
-return_flow_temperature_avg10 22.375000
-return_flow_temperature_avg60 22.375000
+circulation_pump_enabled 1
+burner_enabled 0
+safety_contact_enabled 0
+chamber_temperature 58.750000
+chamber_temperature_avg10 58.931252
+chamber_temperature_avg60 59.190475
+chamber_temperature_pred60 55.870998
+inlet_flow_temperature 53.875000
+inlet_flow_temperature_avg10 53.900002
+inlet_flow_temperature_avg60 53.994320
+inlet_flow_temperature_pred60 52.848743
+outdoor_temperature 18.000000
+outdoor_temperature_avg10 18.006250
+outdoor_temperature_avg60 18.002840
+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
-uptime_seconds 90
-wifi_rssi -63
+system_unixtime 1735242392
+uptime_seconds 40
+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"
@@ -11,7 +12,8 @@
 
 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0
 #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0
-#define CHAMPER_TEMPERATURE_TARGET 70.0
+#define CHAMPER_TEMPERATURE_TARGET 80.0
+#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 eControlState sControlState = CONTROL_STARTING;
@@ -54,6 +56,9 @@ void initControl(void)
 void taskControl(void *pvParameters)
 {
     bool bHeatingInAction = false;
+    bool bBurnerFaultDetected = false;
+    int64_t i64BurnerEnableTimestamp = esp_timer_get_time();
+
     while (1)
     {
         vTaskDelay(PERIODIC_INTERVAL * 1000U / portTICK_PERIOD_MS);
@@ -64,7 +69,7 @@ void taskControl(void *pvParameters)
             sControlState = CONTROL_FAULT_SAFETY;
             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;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
@@ -79,7 +84,7 @@ void taskControl(void *pvParameters)
             sControlState = CONTROL_FAULT_SNTP;
             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;
                 setCirculationPumpState(ENABLED);
                 setBurnerState(DISABLED);
@@ -93,7 +98,7 @@ void taskControl(void *pvParameters)
 
         if (bHeatingInAction == true)
         {
-            if (getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature)
+            if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) || (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
             {
                 ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner");
                 bHeatingInAction = false;
@@ -105,12 +110,27 @@ void taskControl(void *pvParameters)
             {
                 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))
             {
@@ -119,6 +139,7 @@ void taskControl(void *pvParameters)
                 setCirculationPumpState(ENABLED);
                 setBurnerState(ENABLED);
                 setSafetyControlState(ENABLED);
+                i64BurnerEnableTimestamp = esp_timer_get_time();
                 sControlState = CONTROL_HEATING;
             }
             else

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

@@ -16,10 +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 = 0x78000000c6c2f728;
+const onewire_addr_t uChamperTempSensorAddr = 0xd00000108cd01d28;
 const onewire_addr_t uOutdoorTempSensorAddr = 0x78000000c6c2f728;
-const onewire_addr_t uInletFlowTempSensorAddr = 0x78000000c6c2f728;
-const onewire_addr_t uReturnFlowTempSensorAddr = 0x78000000c6c2f728;
+const onewire_addr_t uInletFlowTempSensorAddr = 0x410000108b8c0628;
+const onewire_addr_t uReturnFlowTempSensorAddr = 0x90000108cc77c28;
 
 onewire_addr_t uOneWireAddresses[MAX_DN18B20_SENSORS];
 float fDS18B20Temps[MAX_DN18B20_SENSORS];
@@ -36,7 +36,7 @@ void taskInput(void *pvParameters);
 void initMeasurement(sMeasurement *pMeasurement);
 void updateAverage(sMeasurement *pMeasurement);
 void updatePrediction(sMeasurement *pMeasurement);
-float linearRegressionPredict(const float *samples, size_t count, float futureIndex);
+float linearRegressionPredict(const float *samples, size_t count, size_t bufferIndex, float futureIndex);
 
 void initInputs(void)
 {
@@ -162,6 +162,7 @@ void updatePrediction(sMeasurement *pMeasurement)
     predict60s->fValue = linearRegressionPredict(
         predict60s->samples,
         predict60s->bufferCount,
+        predict60s->bufferIndex,
         predict60s->bufferCount + 60.0f);
 }
 
@@ -217,7 +218,7 @@ void taskInput(void *pvParameters)
                         for (int j = 0; j < sSensorCount; j++)
                         {
                             float temp_c = fDS18B20Temps[j];
-                            ESP_LOGI(TAG, "Sensor: %08" PRIx64 " reports %lf°C", (uint64_t)uOneWireAddresses[j], temp_c);
+                            // ESP_LOGI(TAG, "Sensor: %08" PRIx64 " reports %lf°C", (uint64_t)uOneWireAddresses[j], temp_c);
 
                             switch ((uint64_t)uOneWireAddresses[j])
                             {
@@ -226,17 +227,20 @@ void taskInput(void *pvParameters)
                                 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);
@@ -264,7 +268,7 @@ void taskInput(void *pvParameters)
     }
 }
 
-float linearRegressionPredict(const float *samples, size_t count, float futureIndex)
+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
@@ -273,8 +277,11 @@ float linearRegressionPredict(const float *samples, size_t count, float futureIn
 
     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[i]; // Sample value
+        float y = samples[circularIndex]; // Sample value
 
         sumX += x;
         sumY += y;
@@ -285,7 +292,7 @@ float linearRegressionPredict(const float *samples, size_t count, float futureIn
     // 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[count - 1]; // Return last value as prediction
+        return samples[bufferIndex]; // Return the latest value as prediction
 
     float m = (count * sumXY - sumX * sumY) / denominator;
     float b = (sumY - m * sumX) / count;