diff --git a/main/control.c b/main/control.c index 29a6295..02d0ebc 100644 --- a/main/control.c +++ b/main/control.c @@ -8,26 +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 -#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 +// 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 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}}}, - {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}}}, + {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}}}, }; +// Function prototypes void taskControl(void *pvParameters); eControlWeekday getCurrentWeekday(void); sControlTemperatureEntry getCurrentTemperatureEntry(void); @@ -56,37 +61,37 @@ void initControl(void) void taskControl(void *pvParameters) { bool bHeatingInAction = false; - bool bBurnerFaultDetected = 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 == true) + if (bHeatingInAction) { - ESP_LOGW(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); 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 == true) + if (bHeatingInAction) { - ESP_LOGW(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); setSafetyControlState(ENABLED); } @@ -94,49 +99,23 @@ 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); - if (bHeatingInAction == true) + // Enable burner if outdoor temperature is low and return flow temperature is cooled down + if (!bHeatingInAction && (eBurnerState != BURNER_FAULT)) { - if ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) || (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature)) + if (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD) { - ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner"); - bHeatingInAction = false; - setCirculationPumpState(ENABLED); + // ESP_LOGI(TAG, "Outdoor temperature too warm: Disabling heating"); setBurnerState(DISABLED); - setSafetyControlState(ENABLED); + setSafetyControlState(DISABLED); + sControlState = CONTROL_OUTDOOR_TOO_WARM; } - else + else if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && + (getChamberTemperature().fCurrentValue <= CHAMBER_TEMPERATURE_THRESHOLD)) { - 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"); + 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(); @@ -144,10 +123,57 @@ 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) @@ -160,73 +186,38 @@ 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; - - // 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; + return (eControlWeekday)((day == 0) ? 6 : day - 1); } 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 result; + return aControlTable[i].aTemperatureEntries[j]; } - - 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; -} \ No newline at end of file +} diff --git a/main/control.h b/main/control.h index ba60d4c..fe7f3ad 100644 --- a/main/control.h +++ b/main/control.h @@ -14,6 +14,13 @@ 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, diff --git a/main/inputs.c b/main/inputs.c index 62e7086..0c118e7 100644 --- a/main/inputs.c +++ b/main/inputs.c @@ -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 = 0x78000000c6c2f728; +const onewire_addr_t uOutdoorTempSensorAddr = 0xd70000108a9b9128; const onewire_addr_t uInletFlowTempSensorAddr = 0x410000108b8c0628; const onewire_addr_t uReturnFlowTempSensorAddr = 0x90000108cc77c28;