From be40a8c2d340e5d5492076bb9e7a17f4ec68c55c Mon Sep 17 00:00:00 2001
From: jonny_l480 <jonny@wwad.de>
Date: Tue, 15 Aug 2023 17:10:59 +0200
Subject: [PATCH] Rework fan control: single pin, more delay, config
- remove second fan instance since both fans are controlled via one pin
now
- more config options so fans turn on less at short movements
=> less noise and less relay cycles
---
main/config.cpp | 13 ++++-----
main/config.hpp | 7 ++---
main/fan.cpp | 76 +++++++++++++++++++++++++++++++++----------------
main/fan.hpp | 19 +++++++++----
main/main.cpp | 8 ++----
5 files changed, 76 insertions(+), 47 deletions(-)
diff --git a/main/config.cpp b/main/config.cpp
index f1003f3..f26d5cd 100644
--- a/main/config.cpp
+++ b/main/config.cpp
@@ -97,15 +97,12 @@ joystick_config_t configJoystick = {
//----------------------------
//--- configure fan contol ---
//----------------------------
-fan_config_t configFanLeft = {
- .gpio_fan = GPIO_NUM_13, //FIXME simplify fan control! now only one pin used - might cause issues
- .msRun = 5000,
- .dutyThreshold = 35
-};
-fan_config_t configFanRight = {
+fan_config_t configCooling = {
.gpio_fan = GPIO_NUM_13,
- .msRun = 5000,
- .dutyThreshold = 35
+ .dutyThreshold = 40,
+ .minOnMs = 1500,
+ .minOffMs = 3000,
+ .turnOffDelayMs = 5000,
};
diff --git a/main/config.hpp b/main/config.hpp
index 1857310..e81734e 100644
--- a/main/config.hpp
+++ b/main/config.hpp
@@ -14,7 +14,7 @@
//in IDLE mode: set loglevel for evaluatedJoystick to DEBUG
//and repeatedly read joystick e.g. for manually calibrating / testing joystick
-#define JOYSTICK_LOG_IN_IDLE
+//#define JOYSTICK_LOG_IN_IDLE
//create global controlledMotor instances for both motors
@@ -39,7 +39,6 @@ extern automatedArmchair armchair;
//create global httpJoystick object
extern httpJoystick httpJoystickMain;
-//configuration for fans
-extern fan_config_t configFanLeft;
-extern fan_config_t configFanRight;
+//configuration for fans / cooling
+extern fan_config_t configCooling;
diff --git a/main/fan.cpp b/main/fan.cpp
index d6be041..eeafb99 100644
--- a/main/fan.cpp
+++ b/main/fan.cpp
@@ -15,15 +15,16 @@ static const char * TAG = "fan-control";
//-----------------------------
//-------- constructor --------
//-----------------------------
-controlledFan::controlledFan(fan_config_t config_f, controlledMotor* motor_f ){
- //copy config
- config = config_f;
- //copy pointer to motor object
- motor = motor_f;
+controlledFan::controlledFan (fan_config_t config_f, controlledMotor* motor1_f, controlledMotor* motor2_f ){
+ //copy config
+ config = config_f;
+ //copy pointer to motor objects
+ motor1 = motor1_f;
+ motor2 = motor2_f;
- //initialize gpio pin
- gpio_pad_select_gpio(config.gpio_fan);
- gpio_set_direction(config.gpio_fan, GPIO_MODE_OUTPUT);
+ //initialize gpio pin
+ gpio_pad_select_gpio(config.gpio_fan);
+ gpio_set_direction(config.gpio_fan, GPIO_MODE_OUTPUT);
}
@@ -32,25 +33,50 @@ controlledFan::controlledFan(fan_config_t config_f, controlledMotor* motor_f ){
//--------- handle ---------
//--------------------------
void controlledFan::handle(){
- //get current state of the motor
- motorStatus = motor->getStatus();
+ //get current state of the motor
+ motor1Status = motor1->getStatus();
+ motor2Status = motor2->getStatus();
- //TODO Add statemachine for more specific control? Exponential average?
- //update timestamp if threshold exceeded
- if (motorStatus.duty > config.dutyThreshold){
- timestamp_lastThreshold = esp_log_timestamp();
- }
+ //update timestamp if any threshold exceeded
+ if (motor1Status.duty > config.dutyThreshold
+ || motor2Status.duty > config.dutyThreshold){ //TODO add temperature threshold
+ if (!needsCooling){
+ timestamp_needsCoolingSet = esp_log_timestamp();
+ needsCooling = true;
+ }
+ timestamp_lastThreshold = esp_log_timestamp();
+ } else {
+ needsCooling = false;
+ }
- //turn fan on if time since last exceeded threshold is less than msRun
- if (esp_log_timestamp() - timestamp_lastThreshold < config.msRun) {
- gpio_set_level(config.gpio_fan, 1);
- ESP_LOGD(TAG, "fan is on (gpio: %d)", (int)config.gpio_fan);
- }
- //otherwise turn fan off
- else {
- gpio_set_level(config.gpio_fan, 0);
- ESP_LOGD(TAG, "fan is off (gpio: %d)", (int)config.gpio_fan);
- }
+
+ //turn off condition
+ if (fanRunning
+ && !needsCooling //no more cooling required
+ && (motor1Status.duty == 0) && (motor2Status.duty == 0) //both motors are off
+ //-> keeps fans running even when lower than threshold already, however turnOffDelay already started TODO: start turn off delay after motor stop only?
+ && (esp_log_timestamp() - timestamp_lastThreshold) > config.turnOffDelayMs){ //turn off delay passed
+ fanRunning = false;
+ gpio_set_level(config.gpio_fan, 0);
+ timestamp_turnedOff = esp_log_timestamp();
+ ESP_LOGI(TAG, "turned fan OFF gpio=%d, minOnMs=%d, WasOnMs=%d", (int)config.gpio_fan, config.minOnMs, esp_log_timestamp()-timestamp_turnedOn);
+ }
+
+ //turn on condition
+ if (!fanRunning
+ && needsCooling
+ && ((esp_log_timestamp() - timestamp_turnedOff) > config.minOffMs) //fans off long enough
+ && ((esp_log_timestamp() - timestamp_needsCoolingSet) > config.minOnMs)){ //motors on long enough
+ fanRunning = true;
+ gpio_set_level(config.gpio_fan, 1);
+ timestamp_turnedOn = esp_log_timestamp();
+ ESP_LOGI(TAG, "turned fan ON gpio=%d, minOffMs=%d, WasOffMs=%d", (int)config.gpio_fan, config.minOffMs, esp_log_timestamp()-timestamp_turnedOff);
+ }
+
+ //TODO Add statemachine for more specific control? Exponential average?
+ //TODO idea: try other aproach? increment a variable with certain weights e.g. integrate over duty, then turn fans on and decrement the variable again
+
+ ESP_LOGD(TAG, "fanState=%d, duty1=%f, duty2=%f, needsCooling=%d", fanRunning, motor1Status.duty, motor2Status.duty, needsCooling);
}
diff --git a/main/fan.hpp b/main/fan.hpp
index 1300fad..a17c9b4 100644
--- a/main/fan.hpp
+++ b/main/fan.hpp
@@ -12,8 +12,10 @@ extern "C"
//struct with all config parameters for a fan
typedef struct fan_config_t {
gpio_num_t gpio_fan;
- uint32_t msRun;
float dutyThreshold;
+ uint32_t minOnMs;
+ uint32_t minOffMs;
+ uint32_t turnOffDelayMs;
} fan_config;
@@ -24,7 +26,7 @@ typedef struct fan_config_t {
class controlledFan {
public:
//--- constructor ---
- controlledFan (fan_config_t config_f, controlledMotor* motor_f );
+ controlledFan (fan_config_t config_f, controlledMotor* motor1_f, controlledMotor* motor2_f );
//--- functions ---
void handle();
@@ -32,9 +34,16 @@ class controlledFan {
private:
//--- variables ---
- uint32_t timestamp_lastThreshold;
+ bool fanRunning = false;
+ bool needsCooling = false;
+ uint32_t timestamp_needsCoolingSet;
+ uint32_t timestamp_lastThreshold = 0;
+ uint32_t timestamp_turnedOn = 0;
+ uint32_t timestamp_turnedOff = 0;
fan_config_t config;
- controlledMotor * motor;
+ controlledMotor * motor1;
+ controlledMotor * motor2;
- motorCommand_t motorStatus;
+ motorCommand_t motor1Status;
+ motorCommand_t motor2Status;
};
diff --git a/main/main.cpp b/main/main.cpp
index a9c8e4d..f37675b 100644
--- a/main/main.cpp
+++ b/main/main.cpp
@@ -88,12 +88,10 @@ void task_button( void * pvParameters ){
void task_fans( void * pvParameters ){
ESP_LOGI(TAG, "Initializing fans and starting fan handle loop");
//create fan instances with config defined in config.cpp
- controlledFan fanLeft(configFanLeft, &motorLeft);
- controlledFan fanRight(configFanRight, &motorRight);
- //repeatedly run fan handle functions in a slow loop
+ controlledFan fan(configCooling, &motorLeft, &motorRight);
+ //repeatedly run fan handle function in a slow loop
while(1){
- fanLeft.handle();
- fanRight.handle();
+ fan.handle();
vTaskDelay(1000 / portTICK_PERIOD_MS);
}
}