#include "freertos/FreeRTOS.h" #include "freertos/task.h" #include "esp_timer.h" #include "esp_log.h" #include "control.h" #include "outputs.h" #include "inputs.h" #include "safety.h" #include "sntp.h" #define PERIODIC_INTERVAL 1U // run control loop every 1sec #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_DAY 30.0f #define RETURN_FLOW_TEMPERATURE_LOWER_LIMIT_NIGHT 25.0f #define CHAMPER_TEMPERATURE_TARGET 80.0f // Max cut off temperature, burner will stop if chamber is even or higher #define CHAMPER_TEMPERATURE_THRESHOLD 45.0f // Min threshold temperature for enabling burner, burner will only start if chamber is even or lower #define OUTDOOR_TEMPERATURE_THRESHOLD 15.0f // Min threshold temperature for enabling burner, burner will only start if outdoor is even or lower #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; 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}}}, }; void taskControl(void *pvParameters); eControlWeekday getCurrentWeekday(void); sControlTemperatureEntry getCurrentTemperatureEntry(void); void initControl(void) { BaseType_t taskCreated = xTaskCreate( taskControl, // Function to implement the task "taskControl", // Task name 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) ); if (taskCreated == pdPASS) { ESP_LOGI(TAG, "Task created successfully!"); } else { ESP_LOGE(TAG, "Failed to create task"); } } 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); if (getSafetyState() != SAFETY_NO_ERROR) { ESP_LOGW(TAG, "Control not possible due to safety fault!"); sControlState = CONTROL_FAULT_SAFETY; if (bHeatingInAction == true) { ESP_LOGW(TAG, "Control not possible due to safety fault: Disable burner"); bHeatingInAction = false; setCirculationPumpState(ENABLED); setBurnerState(DISABLED); setSafetyControlState(ENABLED); } continue; } if (getSntpState() != SYNC_SUCCESSFUL) { ESP_LOGW(TAG, "Control not possible due to sntp fault!"); sControlState = CONTROL_FAULT_SNTP; if (bHeatingInAction == true) { ESP_LOGW(TAG, "Control not possible due to sntp fault: Disable burner"); bHeatingInAction = false; setCirculationPumpState(ENABLED); setBurnerState(DISABLED); setSafetyControlState(ENABLED); } continue; } 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 ((getChamberTemperature().fCurrentValue >= currentControlEntry.fChamberTemperature) || (getChamberTemperature().predict60s.fValue >= currentControlEntry.fChamberTemperature)) { ESP_LOGI(TAG, "Chamber Target Temperature reached: Disable burner"); bHeatingInAction = false; setCirculationPumpState(ENABLED); setBurnerState(DISABLED); setSafetyControlState(ENABLED); } else { 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 (getOutdoorTemperature().average60s.fValue >= OUTDOOR_TEMPERATURE_THRESHOLD) { ESP_LOGI(TAG, "Outdoor temperature too warm: Waiting for winter."); setCirculationPumpState(DISABLED); setBurnerState(DISABLED); setSafetyControlState(DISABLED); sControlState = CONTROL_OUTDOOR_TOO_WARM; } else { if ((getReturnFlowTemperature().average60s.fValue <= currentControlEntry.fReturnFlowTemperature) && (getChamberTemperature().fCurrentValue <= CHAMPER_TEMPERATURE_THRESHOLD)) { ESP_LOGI(TAG, "Return Flow Target Temperature reached: Enable Burner"); bHeatingInAction = true; setCirculationPumpState(ENABLED); setBurnerState(ENABLED); setSafetyControlState(ENABLED); i64BurnerEnableTimestamp = esp_timer_get_time(); sControlState = CONTROL_HEATING; } else { sControlState = CONTROL_RETURN_FLOW_TOO_WARM; } } } } } eControlState getControlState(void) { return sControlState; } eControlWeekday getCurrentWeekday(void) { time_t now; struct tm *timeinfo; // Get the current time time(&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; // 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); 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) { // 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; }