localhorst/smart-oil-heating-control-system
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base: localhorst:feature/summer-mode
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localhorst:main
localhorst:feature/summer-mode
localhorst:feature/wifi-stability
localhorst:testing/lab-temperature-sensor
localhorst:a0.0.1
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compare: localhorst:main
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localhorst:feature/summer-mode
localhorst:feature/wifi-stability
localhorst:main
localhorst:testing/lab-temperature-sensor
localhorst:a0.0.1

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feature/su ... main

3 changed files with 105 additions and 103 deletions
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199
main/control.c
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@ -8,31 +8,26 @@
#include "safety.h"
#include "sntp.h"
#define PERIODIC_INTERVAL 1U // Run control loop every 1 second
#define PERIODIC_INTERVAL 1U // run control loop every 1sec
// Temperature thresholds
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f
#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
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0
#define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0
#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;
// Control table for daily schedules
static 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}}},
{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}}},
{MONDAY, 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, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_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}}},
{THURSDAY, 2U, {{{4, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{22, 0}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_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}}},
{SATURDAY, 2U, {{{6, 45}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY, CHAMPER_TEMPERATURE_TARGET}, {{23, 30}, RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT, CHAMPER_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}}},
};
// Function prototypes
void taskControl(void *pvParameters);
eControlWeekday getCurrentWeekday(void);
sControlTemperatureEntry getCurrentTemperatureEntry(void);
@ -61,37 +56,37 @@ void initControl(void)
void taskControl(void *pvParameters)
{
bool bHeatingInAction = false;
eBurnerState eBurnerState = BURNER_UNKNOWN;
bool bBurnerFaultDetected = false;
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)
if (bHeatingInAction == true)
{
ESP_LOGW(TAG, "Disabling burner due to safety fault");
ESP_LOGW(TAG, "Control not possible due to safety fault: Disable burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
continue;
}
// Check for 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)
if (bHeatingInAction == true)
{
ESP_LOGW(TAG, "Disabling burner due to SNTP fault");
ESP_LOGW(TAG, "Control not possible due to sntp fault: Disable burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(ENABLED);
}
@ -99,23 +94,49 @@ void taskControl(void *pvParameters)
}
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);
// Enable burner if outdoor temperature is low and return flow temperature is cooled down
if (!bHeatingInAction && (eBurnerState != BURNER_FAULT))
if (bHeatingInAction == true)
{
if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD)
if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) || (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature))
{
// ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating");
ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner");
bHeatingInAction = false;
setCirculationPumpState(ENABLED);
setBurnerState(DISABLED);
setSafetyControlState(DISABLED);
sControlState = CONTROL_OUTDOOR_TOO_WARM;
setSafetyControlState(ENABLED);
}
else if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) &&
(getChamberTemperature().fCurrentValue <= CHAMBER_TEMPERATURE_THRESHOLD))
else
{
ESP_LOGI(TAG, "Enabling burner: Return flow temperature target reached");
eBurnerState = BURNER_UNKNOWN;
if (bHeatingInAction)
{
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) && (bBurnerFaultDetected == false))
{
if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= 45.0))
{
ESP_LOGI(TAG, "Return Flow Target Temperature reached: Enable Burner");
bHeatingInAction = true;
setCirculationPumpState(ENABLED);
setBurnerState(ENABLED);
setSafetyControlState(ENABLED);
i64BurnerEnableTimestamp = esp_timer_get_time();
@ -123,57 +144,10 @@ void taskControl(void *pvParameters)
}
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 ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) &&
(getChamberTemperature().fCurrentValue <= CHAMBER_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)
@ -186,38 +160,73 @@ eControlWeekday getCurrentWeekday(void)
time_t now;
struct tm *timeinfo;
// Get the current time
time(&now);
timeinfo = localtime(&now);
timeinfo = localtime(&now); // Convert to local time
// 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;
time(&now);
localtime_r(&now, &timeinfo);
int hour = timeinfo.tm_hour;
int minute = timeinfo.tm_min;
// 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);
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) ||
(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))
if ((aControlTable[i].day) > currentDay)
{
return aControlTable[i].aTemperatureEntries[j];
// 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 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];
}
}
return result;
}
}

7
main/control.h
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@ -14,13 +14,6 @@ typedef enum _ControlState
CONTROL_FAULT_SNTP,
} eControlState;
typedef enum _BurnerState
{
BURNER_UNKNOWN, // Burner is disabled or state after enabling is still unkown
BURNER_FIRED, // Burner fired successfully
BURNER_FAULT // Burner was unable to fire successfully
} eBurnerState;
typedef enum _ControlWeekday
{
MONDAY,

2
main/inputs.c
View File

@ -17,7 +17,7 @@ const uint8_t uBurnerFaultPin = 19U;
const uint8_t uDS18B20Pin = 4U;
const onewire_addr_t uChamperTempSensorAddr = 0xd00000108cd01d28;
const onewire_addr_t uOutdoorTempSensorAddr = 0xd70000108a9b9128;
const onewire_addr_t uOutdoorTempSensorAddr = 0x78000000c6c2f728;
const onewire_addr_t uInletFlowTempSensorAddr = 0x410000108b8c0628;
const onewire_addr_t uReturnFlowTempSensorAddr = 0x90000108cc77c28;