Merge branch 'dev' - dynamic winding width

main/config.h

@@ -101,6 +101,30 @@
 //options affecting movement are currently defined in guide-stepper.cpp
 
 
+//---------------------------
+//------- cable guide -------
+//---------------------------
+// default axis coordinates the guide changes direction (winding width)
+#define GUIDE_MIN_MM 0  // TODO add feature so guide stays at zero for some steps (negative MIN_MM?), currently seems appropriate for even winding
+#define GUIDE_MAX_MM 90 // 95 still to long at max pos - actual reel is 110, but currently guide turned out to stay at max position for too long, due to cable running diagonal from guide to reel
+
+// tolerance added to last stored position at previous shutdown.
+// When calibrating at startup the stepper moves for that sum to get track of zero position (ensure crashes into hardware limit for at least some time)
+#define AUTO_HOME_TRAVEL_ADD_TO_LAST_POS_MM 20
+#define MAX_TOTAL_AXIS_TRAVEL_MM 103 // max possible travel distance, needed as fallback for auto-home
+#define LAYER_THICKNESS_MM 5         // height of one cable layer on reel -> increase in radius every layer
+#define D_CABLE 6                    // determines winds per layer / guide speed
+#define D_REEL 160                   // start diameter of empty reel
+
+// max winding width that can be set using potentiometer (SET+PRESET1 buttons)
+#define MAX_SELECTABLE_WINDING_WIDTH_MM 100;
+// max target length that can be selected using potentiometer (SET button)
+#define MAX_SELECTABLE_LENGTH_POTI_MM 100000
+
+// calculate new winding width each time target length changes, according to custom thresholds defined in guide-stepper.cpp
+// if not defined, winding width is always GUIDE_MAX_MM even for short lengths
+#define DYNAMIC_WINDING_WIDTH_ENABLED
+
 
 //--------------------------
 //------ calibration -------

main/control.cpp

@@ -54,6 +54,10 @@ static uint32_t timestamp_cut_lastBeep = 0;
 static uint32_t autoCut_delayMs = 2500; //TODO add this to config
 static bool autoCutEnabled = false; //store state of toggle switch (no hotswitch)
 
+//user interface
+static uint32_t timestamp_lastWidthSelect = 0;
+//ignore new set events for that time after last value set using poti
+#define DEAD_TIME_POTI_SET_VALUE 1000
 
 
 //-----------------------------------------
@@ -157,6 +161,9 @@ void task_control(void *pvParameter)
     //currently show name and date and scrolling 'hello'
     display_ShowWelcomeMsg(two7SegDisplays);
 
+    //-- set initial winding width for default length --
+    guide_setWindingWidth(guide_targetLength2WindingWidth(lengthTarget));
+
     // ##############################
     // ######## control loop ########
     // ##############################
@@ -252,13 +259,44 @@ void task_control(void *pvParameter)
             buzzer.beep(3, 100, 60);
         }
 
-        //##### SET switch #####
-        //set target length to poti position when SET switch is pressed
-        if (SW_SET.state == true) {
+        //##### SET switch + Potentiometer #####
+        //## set winding-width (SET+PRESET1+POTI) ##
+        // set winding width (axis travel) with poti position
+        // when SET and PRESET1 button are pressed
+        if (SW_SET.state == true && SW_PRESET1.state == true) {
+            timestamp_lastWidthSelect = esp_log_timestamp();
             //read adc
             potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
             //scale to target length range
-            int lengthTargetNew = (float)potiRead / 4095 * 50000;
+            uint8_t windingWidthNew = (float)potiRead / 4095 * MAX_SELECTABLE_WINDING_WIDTH_MM;
+            //apply hysteresis and round to whole meters //TODO optimize this
+            if (windingWidthNew % 5 < 2) { //round down if remainder less than 2mm
+                ESP_LOGD(TAG, "Poti input = %d -> rounding down", windingWidthNew);
+                windingWidthNew = (windingWidthNew/5 ) * 5; //round down
+            } else if (windingWidthNew % 5 > 4 ) { //round up if remainder more than 4mm
+                ESP_LOGD(TAG, "Poti input = %d -> rounding up", windingWidthNew);
+                windingWidthNew = (windingWidthNew/5 + 1) * 5; //round up
+            } else {
+                ESP_LOGD(TAG, "Poti input = %d -> hysteresis", windingWidthNew);
+                windingWidthNew = guide_getWindingWidth();
+            }
+            //update target width and beep when effectively changed
+            if (windingWidthNew != guide_getWindingWidth()) {
+                //TODO update at button release only?
+                guide_setWindingWidth(windingWidthNew);
+                ESP_LOGW(TAG, "Changed winding width to %d mm", windingWidthNew);
+                buzzer.beep(1, 30, 10);
+            }
+        }
+
+        //## set target length (SET+POTI) ##
+        //set target length to poti position when only SET button is pressed and certain dead time passed after last setWindingWidth (SET and PRESET1 button) to prevent set target at release
+        // FIXME: when going to edit the winding width (SET+PRESET1) sometimes the target-length also updates when initially pressing SET -> update only at actual poti change (works sometimes)
+        else if (SW_SET.state == true && (esp_log_timestamp() - timestamp_lastWidthSelect > DEAD_TIME_POTI_SET_VALUE)) {
+            //read adc
+            potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
+            //scale to target length range
+            int lengthTargetNew = (float)potiRead / 4095 * MAX_SELECTABLE_LENGTH_POTI_MM;
             //apply hysteresis and round to whole meters //TODO optimize this
             if (lengthTargetNew % 1000 < 200) { //round down if less than .2 meter
                 ESP_LOGD(TAG, "Poti input = %d -> rounding down", lengthTargetNew);
@@ -274,6 +312,7 @@ void task_control(void *pvParameter)
             if (lengthTargetNew != lengthTarget) {
                 //TODO update lengthTarget only at button release?
                 lengthTarget = lengthTargetNew;
+                guide_setWindingWidth(guide_targetLength2WindingWidth(lengthTarget));
                 ESP_LOGI(TAG, "Changed target length to %d mm", lengthTarget);
                 buzzer.beep(1, 25, 10);
             }
@@ -289,19 +328,22 @@ void task_control(void *pvParameter)
 
 
         //##### target length preset buttons #####
-        if (controlState != systemState_t::MANUAL) { //dont apply preset length while controlling motor with preset buttons
+        if (controlState != systemState_t::MANUAL && SW_SET.state == false) { //dont apply preset length while controlling motor with preset buttons
             if (SW_PRESET1.risingEdge) {
                 lengthTarget = 5000;
+                guide_setWindingWidth(guide_targetLength2WindingWidth(lengthTarget));
                 buzzer.beep(lengthTarget/1000, 25, 30);
                 displayBot.blink(2, 100, 100, "S0LL    ");
             }
             else if (SW_PRESET2.risingEdge) {
                 lengthTarget = 10000;
+                guide_setWindingWidth(guide_targetLength2WindingWidth(lengthTarget));
                 buzzer.beep(lengthTarget/1000, 25, 30);
                 displayBot.blink(2, 100, 100, "S0LL    ");
             }
             else if (SW_PRESET3.risingEdge) {
                 lengthTarget = 15000;
+                guide_setWindingWidth(guide_targetLength2WindingWidth(lengthTarget));
                 buzzer.beep(lengthTarget/1000, 25, 30);
                 displayBot.blink(2, 100, 100, "S0LL    ");
             }
@@ -475,6 +517,10 @@ void task_control(void *pvParameter)
         if (controlState == systemState_t::AUTO_CUT_WAITING) {
             displayTop.blinkStrings(" CUT 1N ", "        ", 70, 30);
         }
+        //setting winding width: blink info message
+        else if (SW_SET.state && SW_PRESET1.state){
+            displayTop.blinkStrings("SET WIND", " WIDTH  ", 900, 900);
+        }
         //otherwise show current position
         else {
             sprintf(buf_tmp, "1ST %5.4f", (float)lengthNow/1000);
@@ -489,17 +535,8 @@ void task_control(void *pvParameter)
         //--------------------------
         //run handle function
         displayBot.handle();
-        //setting target length: blink target length
-        if (SW_SET.state == true) {
-            sprintf(buf_tmp, "S0LL%5.3f", (float)lengthTarget/1000);
-            displayBot.blinkStrings(buf_tmp, "S0LL    ", 300, 100);
-        }
-        //manual state: blink "manual"
-        else if (controlState == systemState_t::MANUAL) {
-            displayBot.blinkStrings(" MANUAL ", buf_disp2, 400, 800);
-        }
         //notify that cutter is active
-        else if (cutter_isRunning()) {
+        if (cutter_isRunning()) {
             displayBot.blinkStrings("CUTTING]", "CUTTING[", 100, 100);
         }
         //show ms countdown to cut when pending
@@ -508,6 +545,20 @@ void task_control(void *pvParameter)
             //displayBot.showString(buf_disp2); //TODO:blink "erreicht" overrides this. for now using blink as workaround
             displayBot.blinkStrings(buf_disp2, buf_disp2, 100, 100);
         }
+        //manual state: blink "manual"
+        else if (controlState == systemState_t::MANUAL) {
+            displayBot.blinkStrings(" MANUAL ", buf_disp2, 400, 800);
+        }
+        //setting winding width: blink currently set windingWidth
+        else if (SW_SET.state && SW_PRESET1.state){
+            sprintf(buf_tmp, "  %03d mm", guide_getWindingWidth());
+            displayBot.blinkStrings(buf_tmp, "        ", 300, 100);
+        }
+        //setting target length: blink target length
+        else if (SW_SET.state == true) {
+            sprintf(buf_tmp, "S0LL%5.3f", (float)lengthTarget/1000);
+            displayBot.blinkStrings(buf_tmp, "S0LL    ", 300, 100);
+        }
         //otherwise show target length
         else {
             //sprintf(buf_disp2, "%06.1f cm", (float)lengthTarget/10); //cm

main/guide-stepper.cpp

@@ -6,6 +6,7 @@ extern "C"
 #include "esp_log.h"
 #include "driver/adc.h"
 #include "freertos/queue.h"
+#include "freertos/semphr.h"
 }
 
 #include "stepper.hpp"
@@ -22,36 +23,24 @@ extern "C"
 //---------------------
 //--- configuration ---
 //---------------------
-//also see config.h
-//for pin definition
+//also see config.h 
+//for pin definitions and guide parameters
 
+// configure testing modes
 #define STEPPER_TEST_TRAVEL 65     // mm
-
-#define MIN_MM 0 //TODO add feature so guide stays at zero for some steps (negative MIN_MM?), currently seems appropriate for even winding
-#define MAX_MM 95 //actual reel is 110, but currently guide turned out to stay at max position for too long
-#define POS_MAX_STEPS MAX_MM * STEPPER_STEPS_PER_MM
-#define POS_MIN_STEPS MIN_MM * STEPPER_STEPS_PER_MM
-
-//tolerance added to last stored position at previous shutdown.
-//When calibrating at startup the stepper moves for that sum to get track of zero position (ensure crashes into hardware limit for at least some time)
-#define AUTO_HOME_TRAVEL_ADD_TO_LAST_POS_MM 20
-#define MAX_TOTAL_AXIS_TRAVEL_MM 103 //max possible travel distance, needed for auto-home
-
 // speeds for testing with potentiometer (test task only)
 #define SPEED_MIN 2.0   // mm/s
 #define SPEED_MAX 70.0  // mm/s
 //note: actual speed is currently defined in config.h with STEPPER_SPEED_DEFAULT
-
-#define LAYER_THICKNESS_MM 5 //height of one cable layer on reel -> increase in radius
-#define D_CABLE 6
-#define D_REEL 160
-#define PI 3.14159
-
-
 //simulate encoder with reset button to test stepper ctl task
 //note STEPPER_TEST has to be defined as well
 //#define STEPPER_SIMULATE_ENCODER
 
+#define PI 3.14159
+//#define POS_MAX_STEPS GUIDE_MAX_MM * STEPPER_STEPS_PER_MM  //note replaced with posMaxSteps
+#define POS_MIN_STEPS GUIDE_MIN_MM * STEPPER_STEPS_PER_MM
+
+
 //----------------------
 //----- variables ------
 //----------------------
@@ -67,6 +56,12 @@ static int layerCount = 0;
 // queue for sending commands to task handling guide movement
 static QueueHandle_t queue_commandsGuideTask;
 
+// mutex to prevent multiple axis to config variables also accessed/modified by control task
+SemaphoreHandle_t configVariables_mutex = xSemaphoreCreateMutex();
+
+// configured winding width: position the axis returns again in steps
+static uint32_t posMaxSteps = GUIDE_MAX_MM * STEPPER_STEPS_PER_MM; //assign default width
+
 
 //----------------------
 //----- functions ------
@@ -82,6 +77,67 @@ int guide_getAxisPosSteps(){
 }
 
 
+//=============================
+//=== guide_setWindingWidth ===
+//=============================
+// set custom winding width (axis position the guide returns in mm)
+void guide_setWindingWidth(uint8_t maxPosMm)
+{
+    if (xSemaphoreTake(configVariables_mutex, portMAX_DELAY) == pdTRUE) // mutex to prevent multiple access by control and stepper-ctl task
+    {
+        posMaxSteps = maxPosMm * STEPPER_STEPS_PER_MM;
+        ESP_LOGI(TAG, "set winding width / max pos to %dmm", maxPosMm);
+        xSemaphoreGive(configVariables_mutex);
+    }
+}
+
+
+//=======================================
+//=== guide_targetLength2WindingWidth ===
+//=======================================
+// calculate dynamic winding width in mm from cable length in mm
+uint8_t guide_targetLength2WindingWidth(int lenMm)
+{
+#ifdef DYNAMIC_WINDING_WIDTH_ENABLED
+    uint8_t width;
+    //--- config ---
+    // define thresholds for winding widths according to target length:
+    if (lenMm <= 5000) // 0-5m
+        width = 15;
+    else if (lenMm <= 10000) // 6-10m
+        width = 25;
+    else if (lenMm <= 15000) // 11-15m
+        width = 30;
+    else if (lenMm <= 25000) // 16-25m
+        width = 65;
+    else // >25m
+        width = GUIDE_MAX_MM;
+    ESP_LOGW(TAG, "length2width: calculated windingWidth=%dmm from targetLength=%dm", width, lenMm);
+    return width;
+#else
+    ESP_LOGD(TAG, "length2width: dynamic windingWidh not enabled, stay at GUIDE_MAX=%d", GUIDE_MAX_MM);
+    return GUIDE_MAX_MM;
+#endif
+//TODO update winding width here as well already?
+}
+
+
+//=============================
+//=== guide_getWindingWidth ===
+//=============================
+// get currently configured winding width (axis position at which the guide returns in mm)
+uint8_t guide_getWindingWidth()
+{
+    if (xSemaphoreTake(configVariables_mutex, portMAX_DELAY) == pdTRUE) // mutex to prevent multiple access by control and stepper-ctl task
+    {
+        uint8_t returnValue = posMaxSteps / STEPPER_STEPS_PER_MM;
+        xSemaphoreGive(configVariables_mutex);
+        return returnValue;
+    }
+    return 0;
+}
+
+
 //==========================
 //==== guide_moveToZero ====
 //==========================
@@ -100,6 +156,12 @@ void guide_moveToZero(){
 void travelSteps(int stepsTarget){
 	//TODO simplify this function, one simple calculation of new position?
 	//with new custom driver no need to detect direction change
+
+    // cancel when width is zero or no steps received
+    if (posMaxSteps == 0 || stepsTarget == 0){
+        ESP_LOGD(TAG, "travelSteps: MaxSteps or stepsTarget = 0 -> nothing to do");
+        return;
+    }
 	
     int stepsToGo, remaining;
 
@@ -113,11 +175,12 @@ void travelSteps(int stepsTarget){
     while (stepsToGo != 0){
         //--- currently moving right ---
         if (currentAxisDirection == AXIS_MOVING_RIGHT){               //currently moving right
-            remaining = POS_MAX_STEPS - posNow;     //calc remaining distance fom current position to limit
+        if (xSemaphoreTake(configVariables_mutex, portMAX_DELAY) == pdTRUE) { //prevent multiple acces on posMaxSteps by control-task
+            remaining = posMaxSteps - posNow;     //calc remaining distance fom current position to limit
             if (stepsToGo > remaining){             //new distance will exceed limit
-                stepper_setTargetPosSteps(POS_MAX_STEPS);        //move to limit
+                stepper_setTargetPosSteps(posMaxSteps);        //move to limit
 				stepper_waitForStop(1000);
-                posNow = POS_MAX_STEPS;
+                posNow = posMaxSteps;
                 currentAxisDirection = AXIS_MOVING_LEFT;            //change current direction for next iteration
                 //increment/decrement layer count depending on current cable direction
                 layerCount += (stepsTarget > 0) - (stepsTarget < 0);
@@ -131,6 +194,8 @@ void travelSteps(int stepsTarget){
                 posNow += stepsToGo;
                 stepsToGo = 0;                      //finished, reset target length (could as well exit loop/break)
             }
+            xSemaphoreGive(configVariables_mutex);
+        }
         }
 
         //--- currently moving left ---
@@ -321,6 +386,18 @@ void task_stepper_ctl(void *pvParameter)
 
     //repeatedly read changes in measured cable length and move axis accordingly
     while(1){
+
+        // guide is disabled when posMaxSteps is zero:
+        if (posMaxSteps == 0)
+        {
+            // move to starting position
+            stepper_setTargetPosSteps(0);
+            vTaskDelay(1000 / portTICK_PERIOD_MS);
+            ESP_LOGD(TAG, "posMaxSteps is zero -> guide disabled, doing nothing");
+            // stop loop iteration
+            continue;
+        }
+
 #ifdef STEPPER_SIMULATE_ENCODER
 		//TESTING - simulate encoder using switch
 		SW_RESET.handle();

main/guide-stepper.hpp

@@ -15,6 +15,16 @@ void task_stepper_ctl(void *pvParameter);
 //tell stepper-control task to move cable guide to zero position
 void guide_moveToZero();
 
+
 // return local variable posNow that stores the current position of cable guide axis in steps
 // needed by shutdown to store last axis position in nvs
-int guide_getAxisPosSteps();
+int guide_getAxisPosSteps();
+
+// set custom winding width (axis position the guide returns in mm)
+void guide_setWindingWidth(uint8_t maxPosMm);
+
+// get currently configured winding width (axis position the guide returns in mm)
+uint8_t guide_getWindingWidth();
+
+// calculate dynamic winding width in mm from cable length in mm according to fixed thresholds
+uint8_t guide_targetLength2WindingWidth(int lenMm);