Update diagram pdf files, cad files (guides)

- update / export pdf version from current drawio connection-plan and
  function-diagram
- update cad files

.gitattributes

@@ -0,0 +1 @@
+*.fcstd text

.gitignore

@@ -7,3 +7,6 @@ build
 
 # drawio files
 *.bkp
+
+# freecad backup files
+*.FCStd1

cad/export/.gitignore

@@ -0,0 +1,4 @@
+# Ignore everything in this directory
+*
+# Except this file
+!.gitignore

docs/vfd/currently-used_T13-750W-12-h.txt

@@ -0,0 +1,2 @@
+currently the vfd 'T13-750W-12-h' is actually used. 
+Included documentation about T13-400W here too, modbus specification might be the same.

main/CMakeLists.txt

@@ -6,6 +6,7 @@ idf_component_register(
         "buzzer.cpp"
         "vfd.cpp"
         "display.cpp"
+        "cutter.cpp"
         "switchesAnalog.cpp"
     INCLUDE_DIRS 
         "."

main/config.cpp

@@ -9,6 +9,7 @@ gpio_evaluatedSwitch sw_gpio_32(GPIO_NUM_32, true, false); //pullup true, not in
 gpio_evaluatedSwitch sw_gpio_33(GPIO_NUM_33, true, false); //pullup true, not inverted (switch to GND, internal pullup used)
 gpio_evaluatedSwitch sw_gpio_25(GPIO_NUM_25, true, false); //pullup true, not inverted (switch to GND, internal pullup used)
 gpio_evaluatedSwitch sw_gpio_26(GPIO_NUM_26, true, false); //pullup true, not inverted (switch to GND, internal pullup used)
+gpio_evaluatedSwitch sw_gpio_14(GPIO_NUM_14, true, false); //pullup true, not inverted (switch to GND, internal pullup used)
 
 //--- switches connected to 4 sw to analog stripboard ---
 //evaluated switches with function to obtain the current input state instead of gpio

main/config.hpp

@@ -17,7 +17,8 @@ extern "C" {
 #define GPIO_VFD_D1 GPIO_NUM_15     //ST1
 //#define GPIO_VFD_D2 GPIO_NUM_15     //ST1 (D2 only used with 7.5kw vfd)
 
-#define GPIO_MOS2 GPIO_NUM_5        //mos2
+#define GPIO_MOS1 GPIO_NUM_18       //mos1 (free)
+#define GPIO_LAMP GPIO_NUM_5        //mos2
 #define GPIO_RELAY GPIO_NUM_13
 #define GPIO_BUZZER GPIO_NUM_12
 
@@ -40,19 +41,23 @@ extern "C" {
 //see config.cpp for available evaluated switch objects
 #define SW_START sw_gpio_26
 #define SW_RESET sw_gpio_25
+#define SW_CUTTER_POS sw_gpio_14
 #define SW_SET     sw_gpio_analog_0
 #define SW_PRESET1 sw_gpio_analog_1
 #define SW_PRESET2 sw_gpio_analog_2
 #define SW_PRESET3 sw_gpio_analog_3
+#define SW_CUT sw_gpio_33
+#define SW_AUTO_CUT sw_gpio_32
 
 //unused but already available evaluated inputs
-//#define ? sw_gpio_33
-//#define ? sw_gpio_32
 //#define ? sw_gpio_34
 
 
 
 
+//=============================
+//======= configuration =======
+//=============================
 //--------------------------
 //----- display config -----
 //--------------------------
@@ -77,11 +82,20 @@ extern "C" {
 //--------------------------
 //------ calibration -------
 //--------------------------
-//use encoder test for calibration and calculate STEPS_PER_METER
+//enable mode  encoder test for calibration
-//#define ENCODER_TEST //show encoder count instead of converted meters
+//if defined, displays always show length and steps instead of the normal messages
+//#define ENCODER_TEST
+
+//steps per meter
 #define STEPS_PER_METER 2127 //roll-v3-gummi-86.6mm - d=89.8mm
-//#define MEASURING_ROLL_DIAMETER 86.6 //roll v3 large
+
-//#define PI 3.14159265358979323846
+//millimetres added to target length
+//to ensure that length does not fall short when spool slightly rotates back after stop
+#define TARGET_LENGTH_OFFSET 0
+
+//millimetres lengthNow can be below lengthTarget to still stay in target_reached state
+#define TARGET_REACHED_TOLERANCE 5
+
 
 
 
@@ -96,6 +110,7 @@ extern gpio_evaluatedSwitch sw_gpio_32;
 extern gpio_evaluatedSwitch sw_gpio_33;
 extern gpio_evaluatedSwitch sw_gpio_25;
 extern gpio_evaluatedSwitch sw_gpio_26;
+extern gpio_evaluatedSwitch sw_gpio_14;
 
 //--- switches connected to 4-sw-to-analog stripboard ---
 extern gpio_evaluatedSwitch sw_gpio_analog_0;

main/control.cpp

@@ -24,14 +24,14 @@ QueueHandle_t init_encoder(rotary_encoder_info_t * info){
 
 
 
-
 //====================
 //==== variables =====
 //====================
 static const char *TAG = "control"; //tag for logging
 
-const char* systemStateStr[5] = {"COUNTING", "WINDING_START", "WINDING", "TARGET_REACHED", "MANUAL"};
+const char* systemStateStr[7] = {"COUNTING", "WINDING_START", "WINDING", "TARGET_REACHED", "AUTO_CUT_WAITING", "CUTTING", "MANUAL"};
-systemState_t controlState = COUNTING;
+systemState_t controlState = systemState_t::COUNTING;
+uint32_t timestamp_changedState = 0;
 
 char buf_disp[20]; //both displays
 char buf_disp1[10];// 8 digits + decimal point + \0
@@ -42,31 +42,39 @@ rotary_encoder_info_t encoder; //encoder device/info
 QueueHandle_t encoder_queue = NULL; //encoder event queue
 rotary_encoder_state_t encoderState;
 
-uint32_t timestamp_pageSwitched = 0;
-bool page = false; //store page number currently displayed
 int lengthNow = 0; //length measured in mm
-int lengthTarget = 3000; //target length in mm
+int lengthTarget = 5000; //default target length in mm
 int lengthRemaining = 0; //(target - now) length needed for reaching the target
 int potiRead = 0; //voltage read from adc
 uint32_t timestamp_motorStarted = 0; //timestamp winding started
                                      
+//encoder test / calibration
 int lengthBeeped = 0; //only beep once per meter during encoder test
                       
+//automatic cut
+int cut_msRemaining = 0;
+uint32_t timestamp_cut_lastBeep = 0;
+uint32_t autoCut_delayMs = 2500; //TODO add this to config
+bool autoCutEnabled = false; //store state of toggle switch (no hotswitch)
+
 
 //===== change State =====
 //function for changing the controlState with log output
 void changeState (systemState_t stateNew) {
     //only proceed when state actually changed
-    if (controlState == stateNew){
+    if (controlState == stateNew) {
         return; //already at target state -> nothing to do
     }
     //log change
     ESP_LOGW(TAG, "changed state from %s to %s", systemStateStr[(int)controlState], systemStateStr[(int)stateNew]);
     //change state
     controlState = stateNew;
+    //update timestamp
+    timestamp_changedState = esp_log_timestamp();
 }
           
 
+
 //===== handle Stop Condition =====
 //function that checks whether start button is released or target is reached (used in multiple states)
 //returns true when stopped, false when no action
@@ -75,16 +83,16 @@ bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBo
     //stop conditions that are checked in any mode
     //target reached
     if (lengthRemaining <= 0 ) {
-        changeState(TARGET_REACHED);
+        changeState(systemState_t::TARGET_REACHED);
         vfd_setState(false);
-        displayTop->blink(1, 0, 1500, "  S0LL  ");
+        displayTop->blink(1, 0, 1000, "  S0LL  ");
-        displayBot->blink(1, 0, 1500, "ERREICHT");
+        displayBot->blink(1, 0, 1000, "ERREICHT");
         buzzer.beep(2, 100, 100);
         return true;
     }
     //start button released
     else if (SW_START.state == false) {
-        changeState(COUNTING);
+        changeState(systemState_t::COUNTING);
         vfd_setState(false);
         displayTop->blink(2, 900, 1000, "- STOP -");
         displayBot->blink(2, 900, 1000, " TASTER ");
@@ -102,17 +110,17 @@ bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBo
 void setDynSpeedLvl(uint8_t lvlMax = 3){
     uint8_t lvl;
     //define speed level according to difference
-    if (lengthRemaining < 50) {
+    if (lengthRemaining < 40) {
         lvl = 0;
-    } else if (lengthRemaining < 200) {
+    } else if (lengthRemaining < 300) {
         lvl = 1;
-    } else if (lengthRemaining < 600) {
+    } else if (lengthRemaining < 700) {
         lvl = 2;
     } else { //more than last step remaining
         lvl = 3;
     }
     //limit to max lvl
-    if (lvl > lvlMax){
+    if (lvl > lvlMax) {
         lvl = lvlMax;
     }
     //update vfd speed level
@@ -146,7 +154,7 @@ void task_control(void *pvParameter)
     //===== loop =====
     //================
     while(1){
-        vTaskDelay(20 / portTICK_PERIOD_MS);
+        vTaskDelay(10 / portTICK_PERIOD_MS);
 
         //-----------------------------
         //------ handle switches ------
@@ -158,8 +166,15 @@ void task_control(void *pvParameter)
         SW_PRESET1.handle();
         SW_PRESET2.handle();
         SW_PRESET3.handle();
+        SW_CUT.handle();
+        SW_AUTO_CUT.handle();
 
 
+        //---------------------------
+        //------ handle cutter ------
+        //---------------------------
+        cutter_handle();
+
 
         //----------------------------
         //------ rotary encoder ------
@@ -167,39 +182,82 @@ void task_control(void *pvParameter)
         // Poll current position and direction
         rotary_encoder_get_state(&encoder, &encoderState);
         //--- calculate distance ---
-        //lengthNow = (float)encoderState.position * (MEASURING_ROLL_DIAMETER * PI) / 600; //TODO dont calculate constant factor every time FIXME: ROUNDING ISSUE float-int?
         lengthNow = (float)encoderState.position * 1000 / STEPS_PER_METER;
 
 
-
         //---------------------------
         //--------- buttons ---------
         //---------------------------
-        //TODO: ADD PRESET SWITCHES HERE
         //--- RESET switch ---
         if (SW_RESET.risingEdge) {
-            rotary_encoder_reset(&encoder);
+            //dont reset when press used for stopping pending auto-cut
-            lengthNow = 0;
+            if (controlState != systemState_t::AUTO_CUT_WAITING) {
-            buzzer.beep(1, 700, 100);
+                rotary_encoder_reset(&encoder);
+                lengthNow = 0;
+                buzzer.beep(1, 700, 100);
+                displayTop.blink(2, 100, 100, "1ST     ");
+                //TODO: stop cutter with reset switch?
+                //cutter_stop();
+            }
         }
 
+        //--- CUT switch ---
+        //start cut cycle immediately
+        if (SW_CUT.risingEdge) {
+            //stop cutter if already running
+            if (cutter_isRunning()) {
+                cutter_stop();
+                buzzer.beep(1, 600, 0);
+            }
+            else if (controlState == systemState_t::AUTO_CUT_WAITING) {
+                //do nothing when press used for stopping pending auto-cut
+            }
+            //start cutter when motor not active
+            else if (controlState != systemState_t::WINDING_START //TODO use vfd state here?
+                    && controlState != systemState_t::WINDING) {
+                cutter_start();
+                buzzer.beep(1, 70, 50);
+            }
+            //error cant cut while motor is on
+            else {
+                buzzer.beep(6, 100, 50);
+            }
+        }
+       
+        //--- AUTO_CUT toggle sw ---
+        //beep at change
+        if (SW_AUTO_CUT.risingEdge) {
+            buzzer.beep(2, 100, 50);
+        } else if (SW_AUTO_CUT.fallingEdge) {
+            buzzer.beep(1, 400, 50);
+        }
+        //update enabled state
+        if (SW_AUTO_CUT.state) {
+            //enable autocut when not in target_reached state
+            //(prevent immediate/unexpected cut)
+            if (controlState != systemState_t::TARGET_REACHED) {
+                autoCutEnabled = true;
+            }
+        } else {
+            //disable anytime (also stops countdown to auto cut)
+            autoCutEnabled = false;
+        }
 
         //--- manual mode ---
         //switch to manual motor control (2 buttons + poti)
-        if ( SW_PRESET2.state && (SW_PRESET1.state || SW_PRESET3.state) && controlState != MANUAL ) {
+        if ( SW_PRESET2.state && (SW_PRESET1.state || SW_PRESET3.state) && controlState != systemState_t::MANUAL ) {
             //enable manual control
-            changeState(MANUAL);
+            changeState(systemState_t::MANUAL);
             buzzer.beep(3, 100, 60);
         }
 
-
         //--- set custom target length ---
         //set target length to poti position when SET switch is pressed
         if (SW_SET.state == true) {
             //read adc
             potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
             //scale to target length range
-            int lengthTargetNew = (float)potiRead / 4095 * 30000;
+            int lengthTargetNew = (float)potiRead / 4095 * 50000;
             //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);
@@ -230,22 +288,22 @@ void task_control(void *pvParameter)
 
 
         //--- target length presets ---
-        if (controlState != MANUAL) { //dont apply preset length while controlling motor with preset buttons
+        if (controlState != systemState_t::MANUAL) { //dont apply preset length while controlling motor with preset buttons
-            if (SW_PRESET1.risingEdge){
+            if (SW_PRESET1.risingEdge) {
-                lengthTarget = 1000;
-                buzzer.beep(lengthTarget/1000, 25, 30);
-                displayBot.blink(3, 100, 100, "S0LL    ");
-            }
-            else if (SW_PRESET2.risingEdge) {
                 lengthTarget = 5000;
                 buzzer.beep(lengthTarget/1000, 25, 30);
                 displayBot.blink(2, 100, 100, "S0LL    ");
             }
-            else if (SW_PRESET3.risingEdge) {
+            else if (SW_PRESET2.risingEdge) {
                 lengthTarget = 10000;
                 buzzer.beep(lengthTarget/1000, 25, 30);
                 displayBot.blink(2, 100, 100, "S0LL    ");
             }
+            else if (SW_PRESET3.risingEdge) {
+                lengthTarget = 15000;
+                buzzer.beep(lengthTarget/1000, 25, 30);
+                displayBot.blink(2, 100, 100, "S0LL    ");
+            }
         }
 
 
@@ -254,17 +312,16 @@ void task_control(void *pvParameter)
         //--------- control ---------
         //---------------------------
         //calculate length difference
-        lengthRemaining = lengthTarget - lengthNow;
+        lengthRemaining = lengthTarget - lengthNow + TARGET_LENGTH_OFFSET;
 
         //--- statemachine ---
         switch (controlState) {
-            case COUNTING: //no motor action
+            case systemState_t::COUNTING: //no motor action
                 vfd_setState(false);
-                //TODO check stop condition before starting - prevents motor from starting 2 cycles when 
+                //TODO check stop condition before starting - prevents motor from starting 2 cycles when already at target
                 //--- start winding to length ---
                 if (SW_START.risingEdge) {
-                    changeState(WINDING_START);
+                    changeState(systemState_t::WINDING_START);
-                    //TODO apply dynamic speed here too (if started when already very close)
                     vfd_setSpeedLevel(1); //start at low speed 
                     vfd_setState(true); //start motor
                     timestamp_motorStarted = esp_log_timestamp(); //save time started
@@ -272,57 +329,100 @@ void task_control(void *pvParameter)
                 } 
                 break;
 
-            case WINDING_START: //wind slow for certain time
+            case systemState_t::WINDING_START: //wind slow for certain time
                 //set vfd speed depending on remaining distance 
                 setDynSpeedLvl(1); //limit to speed lvl 1 (force slow start)
-                if (esp_log_timestamp() - timestamp_motorStarted > 2000) {
+                if (esp_log_timestamp() - timestamp_motorStarted > 3000) {
-                    changeState(WINDING);
+                    changeState(systemState_t::WINDING);
                 }
                 handleStopCondition(&displayTop, &displayBot); //stops if button released or target reached
                 //TODO: cancel when there was no cable movement during start time?
                 break;
 
-            case WINDING: //wind fast, slow down when close
+            case systemState_t::WINDING: //wind fast, slow down when close
                 //set vfd speed depending on remaining distance 
                 setDynSpeedLvl(); //slow down when close to target
                 handleStopCondition(&displayTop, &displayBot); //stops if button released or target reached
                 //TODO: cancel when there is no cable movement anymore e.g. empty / timeout?
                 break;
 
-            case TARGET_REACHED:
+            case systemState_t::TARGET_REACHED:
                 vfd_setState(false);
                 //switch to counting state when no longer at or above target length
-                if ( lengthRemaining > 0 ) {
+                if ( lengthNow < lengthTarget - TARGET_REACHED_TOLERANCE ) {
-                    changeState(COUNTING);
+                    changeState(systemState_t::COUNTING);
+                }
+                //switch initiate countdown to auto-cut
+                else if ( (autoCutEnabled)
+                        && (esp_log_timestamp() - timestamp_changedState > 300) ) { //wait for dislay msg "reached" to finish
+                    changeState(systemState_t::AUTO_CUT_WAITING);
                 }
                 //show msg when trying to start, but target is reached
-                if (SW_START.risingEdge){
+                if (SW_START.risingEdge) {
-                    buzzer.beep(3, 40, 30);
+                    buzzer.beep(2, 50, 30);
-                    displayTop.blink(2, 600, 800, "  S0LL  ");
+                    displayTop.blink(2, 600, 500, "  S0LL  ");
-                    displayBot.blink(2, 600, 800, "ERREICHT");
+                    displayBot.blink(2, 600, 500, "ERREICHT");
                 }
                 break;
 
-            case MANUAL: //manually control motor via preset buttons + poti
+            case systemState_t::AUTO_CUT_WAITING:
+                //handle delayed start of cut
+                cut_msRemaining = autoCut_delayMs - (esp_log_timestamp() - timestamp_changedState);
+                //- countdown stop conditions -
+                //stop with any button
+                if (!autoCutEnabled
+                        || SW_RESET.state || SW_CUT.state 
+                        || SW_SET.state || SW_PRESET1.state
+                        || SW_PRESET2.state || SW_PRESET3.state) {//TODO: also stop when target not reached anymore?
+                    changeState(systemState_t::COUNTING);
+                    buzzer.beep(5, 100, 50);
+                }
+                //- trigger cut if delay passed -
+                else if (cut_msRemaining <= 0) {
+                    cutter_start();
+                    changeState(systemState_t::CUTTING);
+                }
+                //- beep countdown -
+                //time passed since last beep  >  time remaining / 6
+                else if ( (esp_log_timestamp() - timestamp_cut_lastBeep)  > (cut_msRemaining / 6)
+                        && (esp_log_timestamp() - timestamp_cut_lastBeep) > 50 ) { //dont trigger beeps faster than beep time
+                    buzzer.beep(1, 50, 0);
+                    timestamp_cut_lastBeep = esp_log_timestamp();
+                }
+                break;
+
+            case systemState_t::CUTTING:
+                //exit when finished cutting
+                if (cutter_isRunning() == false) {
+                    //TODO stop if start buttons released?
+                    changeState(systemState_t::COUNTING);
+                    //TODO reset automatically or wait for manual reset?
+                    rotary_encoder_reset(&encoder);
+                    lengthNow = 0;
+                    buzzer.beep(1, 700, 100);
+                }
+                break;
+
+            case systemState_t::MANUAL: //manually control motor via preset buttons + poti
                 //read poti value
                 potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
                 //scale poti to speed levels 0-3
                 uint8_t level = round( (float)potiRead / 4095 * 3 );
                 //exit manual mode if preset2 released
                 if ( SW_PRESET2.state == false ) {
-                    changeState(COUNTING);
+                    changeState(systemState_t::COUNTING);
                     buzzer.beep(1, 1000, 100);
                 }
                 //P2 + P1 -> turn left
                 else if ( SW_PRESET1.state && !SW_PRESET3.state ) {
-                    vfd_setSpeedLevel(level); //TODO: use poti input for level
+                    vfd_setSpeedLevel(level);
                     vfd_setState(true, REV);
                     sprintf(buf_disp2, "[--%02i   ", level);
                     //                  123 45 678
                 }
                 //P2 + P3 -> turn right
                 else if ( SW_PRESET3.state && !SW_PRESET1.state ) {
-                    vfd_setSpeedLevel(level); //TODO: use poti input for level
+                    vfd_setSpeedLevel(level);
                     vfd_setState(true, FWD);
                     sprintf(buf_disp2, "   %02i--]", level);
                 }
@@ -364,12 +464,18 @@ void task_control(void *pvParameter)
         //--------------------------
         //run handle function
         displayTop.handle();
-        //show current position on display
+        //indicate upcoming cut when pending
-        sprintf(buf_tmp, "1ST %5.4f", (float)lengthNow/1000);
+        if (controlState == systemState_t::AUTO_CUT_WAITING) {
-        //                123456789
+            displayTop.blinkStrings(" CUT 1N ", "        ", 70, 30);
-        //limit length to 8 digits + decimal point (drop decimal places when it does not fit)
+        }
-        sprintf(buf_disp1, "%.9s", buf_tmp);
+        //otherwise show current position
-        displayTop.showString(buf_disp1);
+        else {
+            sprintf(buf_tmp, "1ST %5.4f", (float)lengthNow/1000);
+            //                123456789
+            //limit length to 8 digits + decimal point (drop decimal places when it does not fit)
+            sprintf(buf_disp1, "%.9s", buf_tmp);
+            displayTop.showString(buf_disp1);
+        }
 
 
         //--------------------------
@@ -378,13 +484,23 @@ void task_control(void *pvParameter)
         //run handle function
         displayBot.handle();
         //setting target length: blink target length
-        if (SW_SET.state == true){
+        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 == MANUAL) {
+        else if (controlState == systemState_t::MANUAL) {
-            displayBot.blinkStrings(" MANUAL ", buf_disp2, 1000, 1000);
+            displayBot.blinkStrings(" MANUAL ", buf_disp2, 400, 800);
+        }
+        //notify that cutter is active
+        else if (cutter_isRunning()) {
+            displayBot.blinkStrings("CUTTING]", "CUTTING[", 100, 100);
+        }
+        //show ms countdown to cut when pending
+        else if (controlState == systemState_t::AUTO_CUT_WAITING) {
+            sprintf(buf_disp2, "  %04d  ", cut_msRemaining);
+            //displayBot.showString(buf_disp2); //TODO:blink "erreicht" overrides this. for now using blink as workaround
+            displayBot.blinkStrings(buf_disp2, buf_disp2, 100, 100);
         }
         //otherwise show target length
         else {
@@ -395,12 +511,24 @@ void task_control(void *pvParameter)
         }
 
 
-#endif
+        //----------------------------
+        //------- control lamp -------
+        //----------------------------
+        //basic functionality of lamp:
+        //turn on when not idling
+        //TODO: add switch-case for different sates
+        //e.g. blink with different frequencies in different states
+        if (controlState != systemState_t::COUNTING
+                && controlState != systemState_t::TARGET_REACHED) {
+            gpio_set_level(GPIO_LAMP, 1);
+        }
+        else {
+            gpio_set_level(GPIO_LAMP, 0);
+        }
 
-        //TODO: blink disp2 when set button pressed
+
-        //TODO: blink disp2 when preset button pressed (exept manual mode)
+
-        //TODO: write "MAN CTL" to disp2 when in manual mode
+#endif
-        //TODO: display or blink "REACHED" when reached state and start pressed
         
     }
 

main/control.hpp

@@ -22,11 +22,14 @@ extern "C"
 #include "buzzer.hpp"
 #include "vfd.hpp"
 #include "display.hpp"
+#include "cutter.hpp"
 
 
 
-typedef enum systemState_t {COUNTING, WINDING_START, WINDING, TARGET_REACHED, MANUAL} systemState_t;
+//enum describing the state of the system
-extern const char* systemStateStr[5];
+enum class systemState_t {COUNTING, WINDING_START, WINDING, TARGET_REACHED, AUTO_CUT_WAITING, CUTTING, MANUAL};
-
+//array with enum as strings for logging states
+extern const char* systemStateStr[7];
 
+//task that controls the entire machine (has to be created as task in main function)
 void task_control(void *pvParameter);

main/cutter.cpp

@@ -0,0 +1,169 @@
+#include "cutter.hpp"
+
+const char* cutter_stateStr[5] = {"IDLE", "START", "CUTTING", "CANCELED", "TIMEOUT"}; //define strings for logging the state
+                                                                          
+
+//---------------------------
+//----- local functions -----
+//---------------------------
+//declare local functions
+void setState(cutter_state_t stateNew);
+bool checkTimeout();
+
+
+
+//---------------------------
+//----- local variables -----
+//---------------------------
+cutter_state_t cutter_state = cutter_state_t::IDLE;
+uint32_t timestamp_turnedOn;
+uint32_t msTimeout = 3000;
+static const char *TAG = "cutter"; //tag for logging
+
+
+
+//=========================
+//========= start =========
+//=========================
+void cutter_start(){
+    setState(cutter_state_t::START);
+    //starts motor on state change
+}
+
+
+
+//========================
+//========= stop =========
+//========================
+void cutter_stop(){
+    if(cutter_state != cutter_state_t::IDLE){
+        setState(cutter_state_t::CANCELED);
+    }
+    //starts motor on state change
+}
+
+
+
+//===========================
+//===== cutter_getState =====
+//===========================
+cutter_state_t cutter_getState(){
+    return cutter_state;
+}
+
+
+
+//============================
+//===== cutter_isRunning =====
+//============================
+bool cutter_isRunning(){
+    if (cutter_state == cutter_state_t::START 
+            || cutter_state == cutter_state_t::CUTTING) {
+        return true;
+    } else {
+        return false;
+    }
+}
+
+
+
+//---------------------------
+//-------- setState ---------
+//---------------------------
+//local function for changing state, taking corresponding actions and sending log output
+void setState(cutter_state_t stateNew){
+    //only proceed and send log output when state or direction actually changed
+    if ( cutter_state == stateNew) {
+        //already at target state -> do nothing
+        return;
+    }
+
+    //log old and new state
+    ESP_LOGI(TAG, "CHANGING state from: %s",cutter_stateStr[(int)cutter_state]);
+    ESP_LOGI(TAG, "CHANGING state   to: %s",cutter_stateStr[(int)stateNew]);
+    //update stored state
+    cutter_state = stateNew;
+
+    switch(stateNew){
+        case cutter_state_t::IDLE:
+        case cutter_state_t::TIMEOUT:
+        case cutter_state_t::CANCELED:
+            //--- turn motor off ---
+            gpio_set_level(GPIO_RELAY, 0);
+            break;
+
+        case cutter_state_t::START:
+        case cutter_state_t::CUTTING:
+            //--- turn motor on ---
+            gpio_set_level(GPIO_RELAY, 1);
+            //update state, timestamp
+            timestamp_turnedOn = esp_log_timestamp();
+            break;
+    }
+}
+
+
+
+//--------------------------
+//------ checkTimeout ------
+//--------------------------
+//local function that checks for timeout
+bool checkTimeout(){
+    if (esp_log_timestamp() - timestamp_turnedOn > msTimeout){
+        setState(cutter_state_t::TIMEOUT);
+        return true;
+    } else {
+        return false;
+    }
+}
+
+
+
+
+//========================
+//======== handle ========
+//========================
+//function that handles the cutter logic -> has to be run repeatedly
+void cutter_handle(){
+    //handle evaluated switch (position switch)
+    SW_CUTTER_POS.handle();
+    //TODO add custom thresholds once at initialization?
+    //SW_CUTTER_POS.minOnMs = 10;
+    //SW_CUTTER_POS.minOffMs = 10;
+
+
+    switch(cutter_state){
+        case cutter_state_t::IDLE:
+        case cutter_state_t::TIMEOUT:
+        case cutter_state_t::CANCELED:
+            //wait for state change via cutter_start();
+            break;
+
+        case cutter_state_t::START:
+            //--- moved away from idle position ---
+            //if (gpio_get_level(GPIO_CUTTER_POS_SW) == 0){ //contact closed
+            if (SW_CUTTER_POS.state == true) { //contact closed -> not at idle pos
+                setState(cutter_state_t::CUTTING);
+            }
+            //--- timeout ---
+            else {
+                checkTimeout();
+            }
+
+            break;
+
+        case cutter_state_t::CUTTING:
+            //--- idle position reached ---
+            //if (gpio_get_level(GPIO_CUTTER_POS_SW) == 1){ //contact not closed
+            //TODO: add min on duration
+            if (SW_CUTTER_POS.state == false) { //contact open -> at idle pos
+                setState(cutter_state_t::IDLE);
+            }
+            //--- timeout ---
+            else {
+                checkTimeout();
+            }
+            break;
+    }
+}
+

main/cutter.hpp

@@ -0,0 +1,37 @@
+#pragma once
+
+extern "C"
+{
+#include <stdio.h>
+#include "esp_log.h"
+}
+
+#include "buzzer.hpp"
+#include "display.hpp"
+#include "gpio_evaluateSwitch.hpp"
+
+
+//--- variables ---
+//enum for state of cutter
+enum class cutter_state_t {IDLE, START, CUTTING, CANCELED, TIMEOUT};
+//string for logging the state name
+extern const char* cutter_stateStr[5];
+
+
+
+//--- functions ---
+//trigger cut cycle (no effect if already running)
+void cutter_start();
+
+//cancel cutting action
+void cutter_stop();
+
+//return current state
+cutter_state_t cutter_getState();
+//TODO: bool cutter_isOn() (simply return boolean instead of enum)
+
+//check if cutter is currently operating
+bool cutter_isRunning();
+
+//handle function - has to be run repeatedly
+void cutter_handle();

main/display.cpp

@@ -34,7 +34,7 @@ max7219_t display_init(){
     ESP_ERROR_CHECK(max7219_init_desc(&dev, HOST, MAX7219_MAX_CLOCK_SPEED_HZ, DISPLAY_PIN_NUM_CS));
     ESP_ERROR_CHECK(max7219_init(&dev));
     //0...15
-    ESP_ERROR_CHECK(max7219_set_brightness(&dev, 8));
+    ESP_ERROR_CHECK(max7219_set_brightness(&dev, 8)); //TODO add this to config
     return dev;
     //display = dev;
     ESP_LOGI(TAG, "initializing display - done");
@@ -50,7 +50,7 @@ void display_ShowWelcomeMsg(max7219_t dev){
     //show name and date
     ESP_LOGI(TAG, "showing startup message...");
     max7219_clear(&dev);
-    max7219_draw_text_7seg(&dev, 0, "CUTTER  20.08.2022");
+    max7219_draw_text_7seg(&dev, 0, "CUTTER  29.09.2022");
     //                                   1234567812 34 5678
     vTaskDelay(pdMS_TO_TICKS(700));
     //scroll "hello" over 2 displays
@@ -60,6 +60,11 @@ void display_ShowWelcomeMsg(max7219_t dev){
         max7219_draw_text_7seg(&dev, 0, hello + (22 - offset) );
         vTaskDelay(pdMS_TO_TICKS(50));
     }
+
+    //noticed rare bug that one display does not initialize / is not configured correctly after start
+    //initialize display again after the welcome message in case it did not work the first time
+    ESP_ERROR_CHECK(max7219_init(&dev));
+    ESP_ERROR_CHECK(max7219_set_brightness(&dev, 8)); //TODO add this to config
 }
 
 

main/main.cpp

@@ -13,39 +13,42 @@ extern "C"
 #include "config.hpp"
 #include "control.hpp"
 #include "buzzer.hpp"
-
 #include "switchesAnalog.hpp"
 
 
 //=================================
 //=========== functions ===========
 //=================================
+//--- configure output ---
 //function to configure gpio pin as output
 void gpio_configure_output(gpio_num_t gpio_pin){
     gpio_pad_select_gpio(gpio_pin);
     gpio_set_direction(gpio_pin, GPIO_MODE_OUTPUT);
 }
 
+
+//--- init gpios ---
 void init_gpios(){
-    //initialize all outputs
+    //--- outputs ---
     //4x stepper mosfets
     gpio_configure_output(GPIO_VFD_FWD);
     gpio_configure_output(GPIO_VFD_D0);
     gpio_configure_output(GPIO_VFD_D1);
+    gpio_configure_output(GPIO_VFD_REV);
     //gpio_configure_output(GPIO_VFD_D2); only used with 7.5kw vfd
     //2x power mosfets
-    gpio_configure_output(GPIO_VFD_REV);
+    gpio_configure_output(GPIO_MOS1); //mos1
-    gpio_configure_output(GPIO_MOS2);
+    gpio_configure_output(GPIO_LAMP); //llamp (mos2)
     //onboard relay and buzzer
     gpio_configure_output(GPIO_RELAY);
     gpio_configure_output(GPIO_BUZZER);
     //5v regulator
     gpio_configure_output(GPIO_NUM_17);
 
+    //--- inputs ---
     //initialize and configure ADC
     adc1_config_width(ADC_WIDTH_BIT_12); //=> max resolution 4096
     adc1_config_channel_atten(ADC_CHANNEL_POTI, ADC_ATTEN_DB_11); //max voltage
-
 }
 
 
@@ -53,8 +56,6 @@ void init_gpios(){
 //======================================
 //============ buzzer task =============
 //======================================
-//TODO: move the task creation to buzzer class (buzzer.cpp)
-//e.g. only have function buzzer.createTask() in app_main
 void task_buzzer( void * pvParameters ){
     ESP_LOGI("task_buzzer", "Start of buzzer task...");
         //run function that waits for a beep events to arrive in the queue
@@ -64,8 +65,6 @@ void task_buzzer( void * pvParameters ){
 
 
 
-
-
 //======================================
 //=========== main function ============
 //======================================
@@ -90,5 +89,4 @@ extern "C" void app_main()
 
     //beep at startup
     buzzer.beep(3, 70, 50);
-
 }

main/vfd.cpp

@@ -38,11 +38,9 @@ void vfd_setState(bool stateNew, vfd_direction_t directionNew){
                 gpio_set_level(GPIO_VFD_REV, 1);
                 break;
         }
-        gpio_set_level(GPIO_RELAY, 1);
     } else {
         gpio_set_level(GPIO_VFD_FWD, 0);
         gpio_set_level(GPIO_VFD_REV, 0);
-        gpio_set_level(GPIO_RELAY, 0);
     }
 }