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Rework fan control: single pin, more delay, config

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- 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
This commit is contained in:
jonny_l480 2023-08-15 17:10:59 +02:00
parent 3f73344b93
commit be40a8c2d3
5 changed files with 76 additions and 47 deletions
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13
main/config.cpp
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@ -97,15 +97,12 @@ joystick_config_t configJoystick = {
//---------------------------- //----------------------------
//--- configure fan contol --- //--- configure fan contol ---
//---------------------------- //----------------------------
fan_config_t configFanLeft = { fan_config_t configCooling = {
.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 = {
.gpio_fan = GPIO_NUM_13, .gpio_fan = GPIO_NUM_13,
.msRun = 5000, .dutyThreshold = 40,
.dutyThreshold = 35 .minOnMs = 1500,
.minOffMs = 3000,
.turnOffDelayMs = 5000,
}; };

7
main/config.hpp
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@ -14,7 +14,7 @@
//in IDLE mode: set loglevel for evaluatedJoystick to DEBUG //in IDLE mode: set loglevel for evaluatedJoystick to DEBUG
//and repeatedly read joystick e.g. for manually calibrating / testing joystick //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 //create global controlledMotor instances for both motors
@ -39,7 +39,6 @@ extern automatedArmchair armchair;
//create global httpJoystick object //create global httpJoystick object
extern httpJoystick httpJoystickMain; extern httpJoystick httpJoystickMain;
//configuration for fans //configuration for fans / cooling
extern fan_config_t configFanLeft; extern fan_config_t configCooling;
extern fan_config_t configFanRight;

76
main/fan.cpp
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@ -15,15 +15,16 @@ static const char * TAG = "fan-control";
//----------------------------- //-----------------------------
//-------- constructor -------- //-------- constructor --------
//----------------------------- //-----------------------------
controlledFan::controlledFan(fan_config_t config_f, controlledMotor* motor_f ){ controlledFan::controlledFan (fan_config_t config_f, controlledMotor* motor1_f, controlledMotor* motor2_f ){
//copy config //copy config
config = config_f; config = config_f;
//copy pointer to motor object //copy pointer to motor objects
motor = motor_f; motor1 = motor1_f;
motor2 = motor2_f;
//initialize gpio pin //initialize gpio pin
gpio_pad_select_gpio(config.gpio_fan); gpio_pad_select_gpio(config.gpio_fan);
gpio_set_direction(config.gpio_fan, GPIO_MODE_OUTPUT); gpio_set_direction(config.gpio_fan, GPIO_MODE_OUTPUT);
} }
@ -32,25 +33,50 @@ controlledFan::controlledFan(fan_config_t config_f, controlledMotor* motor_f ){
//--------- handle --------- //--------- handle ---------
//-------------------------- //--------------------------
void controlledFan::handle(){ void controlledFan::handle(){
//get current state of the motor //get current state of the motor
motorStatus = motor->getStatus(); motor1Status = motor1->getStatus();
motor2Status = motor2->getStatus();
//TODO Add statemachine for more specific control? Exponential average? //update timestamp if any threshold exceeded
//update timestamp if threshold exceeded if (motor1Status.duty > config.dutyThreshold
if (motorStatus.duty > config.dutyThreshold){ || motor2Status.duty > config.dutyThreshold){ //TODO add temperature threshold
timestamp_lastThreshold = esp_log_timestamp(); 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) { //turn off condition
gpio_set_level(config.gpio_fan, 1); if (fanRunning
ESP_LOGD(TAG, "fan is on (gpio: %d)", (int)config.gpio_fan); && !needsCooling //no more cooling required
} && (motor1Status.duty == 0) && (motor2Status.duty == 0) //both motors are off
//otherwise turn fan off //-> keeps fans running even when lower than threshold already, however turnOffDelay already started TODO: start turn off delay after motor stop only?
else { && (esp_log_timestamp() - timestamp_lastThreshold) > config.turnOffDelayMs){ //turn off delay passed
gpio_set_level(config.gpio_fan, 0); fanRunning = false;
ESP_LOGD(TAG, "fan is off (gpio: %d)", (int)config.gpio_fan); 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);
} }

19
main/fan.hpp
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@ -12,8 +12,10 @@ extern "C"
//struct with all config parameters for a fan //struct with all config parameters for a fan
typedef struct fan_config_t { typedef struct fan_config_t {
gpio_num_t gpio_fan; gpio_num_t gpio_fan;
uint32_t msRun;
float dutyThreshold; float dutyThreshold;
uint32_t minOnMs;
uint32_t minOffMs;
uint32_t turnOffDelayMs;
} fan_config; } fan_config;
@ -24,7 +26,7 @@ typedef struct fan_config_t {
class controlledFan { class controlledFan {
public: public:
//--- constructor --- //--- constructor ---
controlledFan (fan_config_t config_f, controlledMotor* motor_f ); controlledFan (fan_config_t config_f, controlledMotor* motor1_f, controlledMotor* motor2_f );
//--- functions --- //--- functions ---
void handle(); void handle();
@ -32,9 +34,16 @@ class controlledFan {
private: private:
//--- variables --- //--- 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; fan_config_t config;
controlledMotor * motor; controlledMotor * motor1;
controlledMotor * motor2;
motorCommand_t motorStatus; motorCommand_t motor1Status;
motorCommand_t motor2Status;
}; };

8
main/main.cpp
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@ -88,12 +88,10 @@ void task_button( void * pvParameters ){
void task_fans( void * pvParameters ){ void task_fans( void * pvParameters ){
ESP_LOGI(TAG, "Initializing fans and starting fan handle loop"); ESP_LOGI(TAG, "Initializing fans and starting fan handle loop");
//create fan instances with config defined in config.cpp //create fan instances with config defined in config.cpp
controlledFan fanLeft(configFanLeft, &motorLeft); controlledFan fan(configCooling, &motorLeft, &motorRight);
controlledFan fanRight(configFanRight, &motorRight); //repeatedly run fan handle function in a slow loop
//repeatedly run fan handle functions in a slow loop
while(1){ while(1){
fanLeft.handle(); fan.handle();
fanRight.handle();
vTaskDelay(1000 / portTICK_PERIOD_MS); vTaskDelay(1000 / portTICK_PERIOD_MS);
} }
} }