Merge branch 'dev' - dynamic winding width

Due to color changes of linked parts all files got changed
(meaning no actual modifications to parts was made)

.gitignore

@@ -1,15 +1,29 @@
 # ESP-IDF default build directory
 build
+sdkconfig.old
+dependencies.lock
 
 # VIM files
 *.swp
 *.swo
+**/.cache
+
+# VS-code
+settings.json
 
 # drawio files
 *.bkp
 
 # freecad backup files
 *.FCStd1
+*.FCBak
+# stl files are usually temporary
+*.stl
 
 # kicad backup files
 pcb/*/*backups/
+
+# other
+octave-workspace
+del
+screenshots

CMakeLists.txt

@@ -6,4 +6,4 @@ cmake_minimum_required(VERSION 3.5)
 
 #set(EXTRA_COMPONENT_DIRS ../esp-idf-lib/components)
 include($ENV{IDF_PATH}/tools/cmake/project.cmake)
-project(cable-length-cutting)
+project(cable-length-cutter)

README.md

@@ -1,18 +1,94 @@
-# Hardware
+# Overview
-## connection plan
+Firmware and documentation of a custom built machine that winds and cuts cable to certain lengths.  
-See [connection-plan.pdf](connection-plan.pdf)  
+Extensive details about this project can be found on the website: [pfusch.zone/cable-length-cutter](https://pfusch.zone/cable-length-cutter)
+
+<img src="img/cable-length-cutter.jpg" alt="Photo machine" style="width:60%;">
+
+Photo of the built machine
+
+## Current Features
+- Measure length using rotary encoder
+- Wind to set length while start-button is pressed
+- Automatic wire cutter
+- Control interface:
+  - 2x 7-Segment display showing lengths and notifications
+  - Buzzer for acoustic notifications
+  - 4 Buttons and Potentiometer for setting the target length
+  - Reset and Cut Button
+- Stepper motor controlling a linear axis guiding the cable while winding
+- Store last axis position at shutdown
+
+
+# Usage
+![Panel Layout](img/panel-layout.svg)
+
+
+# Electrical Details
+For detailed documentation of all electrical aspects, see [connection-plan.pdf](connection-plan.pdf).
+
+
+# Printed Parts
+All designed and 3D-printed parts can be found in the [cad/](cad/) folder. These parts were designed using FreeCAD.
 
 
 # Components
-## rotary encoder LPD3806-600BM-G5-24C
+### Custom pcb with ESP-32 microcontroller
-    - Pulses: 600 p/r (Single-phase 600 pulses /R,Two phase 4 frequency doubling to 2400 pulses)
+See [connection-plan.pdf](connection-plan.pdf)  
-    - Power source: DC5-24V
-    - Shaft: 6*13mm/0.23*0.51"
-    - Size: 38*35.5mm/1.49*1.39"
-    - Output :AB 2phase output rectangular orthogonal pulse circuit, the output for the NPN open collector output type
-    - Maximum mechanical speed: 5000 R / min
-    - Response frequency: 0-20KHz
-    - Cable length: 1.5 meter
-    - size: http://domoticx.com/wp-content/uploads/2020/05/LPD3806-afmetingen.jpg
-    - Wires: Green = A phase, white = B phase, red = Vcc power +, black = V0
 
+### Rotary encoder LPD3806-600BM-G5-24C
+```
+- Pulses: 600 p/r (Single-phase 600 pulses /R,Two phase 4 frequency doubling to 2400 pulses)
+- Power source: DC5-24V
+- Shaft: 6*13mm/0.23*0.51"
+- Size: 38*35.5mm/1.49*1.39"
+- Output :AB 2phase output rectangular orthogonal pulse circuit, the output for the NPN open collector output type
+- Maximum mechanical speed: 5000 R / min
+- Response frequency: 0-20KHz
+- Cable length: 1.5 meter
+- size: http://domoticx.com/wp-content/uploads/2020/05/LPD3806-afmetingen.jpg
+- Wires: Green = A phase, white = B phase, red = Vcc power +, black = V0
+```
+### Variable Frequency Drive T13-400W-12-H
+See [docs/vfd/](docs/vfd/)
+
+### Stepper-driver TB6600
+See [docs/stepper-driver_TB6600-Manual.pdf](docs/stepper-driver_TB6600-Manual.pdf)
+
+### Linear Axis with Nema-12 28HB40 Stepper
+See [connection-plan.pdf](connection-plan.pdf)  
+
+
+
+
+# Installation
+For this project **ESP-IDF v4.4.4** is required (with other versions it might not compile)
+```bash
+#download esp-idf
+yay -S esp-idf 
+#alternatively clone the esp-idf repository from github and do `git checkout release/4.4`
+
+#run installation script in installed folder
+/opt/esp-idf/install.sh
+```
+
+# Build
+### Set up environment
+```bash
+source /opt/esp-idf/export.sh
+```
+(run once per terminal)
+
+### Compile
+```bash
+cd board_single
+idf.py build
+```
+
+# Flash
+- connect FTDI programmer to board (VCC to VCC; TX to RX; RX to TX)
+- press REST and BOOT button
+- release RESET button (keep pressing boot)
+- run flash command:
+```bash
+idf.py flash
+```

components/DendoStepper/DendoStepper.cpp

@@ -116,21 +116,35 @@ timer_avail:
 
 esp_err_t DendoStepper::runPos(int32_t relative)
 {
-    if (!relative) // why would u call it with 0 wtf
+    //TODO only enable when actually moving
-        return ESP_ERR_NOT_SUPPORTED;
-    if (ctrl.status > IDLE)
-    { // we are running, we need to adjust steps accordingly, for now just stop the movement
-        STEP_LOGW("DendoStepper", "Finising previous move, this command will be ignored");
-        return ESP_ERR_NOT_SUPPORTED;
-    }
-
     if (ctrl.status == DISABLED) // if motor is disabled, enable it
         enableMotor();
+
+    if (!relative) // why would u call it with 0 wtf
+        return ESP_ERR_NOT_SUPPORTED;
+
+    if (ctrl.status > IDLE) { //currently moving
+        bool newDir = (relative < 0); // CCW if <0, else set CW
+        if (ctrl.dir == newDir){ //current direction is the same
+            ctrl.statusPrev = ctrl.status; //update previous status
+            ctrl.status = ctrl.status==COAST ? COAST : ACC; //stay at coast otherwise switch to ACC
+            calc(abs(relative + ctrl.stepsRemaining)); //calculate new velolcity profile for new+remaining steps
+        } else { //direction has changed
+                 //direction change not supported TODO wait for decel finish / queue?
+            STEP_LOGW("DendoStepper", "DIRECTION HOT-CHANGE NOT SUPPORTED - Finising previous move, this command will be ignored");
+            return ESP_ERR_NOT_SUPPORTED;
+        }
+    }
+    else { //current state is IDLE
+        ctrl.statusPrev = ctrl.status; //update previous status
         ctrl.status = ACC;
         setDir(relative < 0); // set CCW if <0, else set CW
-    currentPos += relative;
         calc(abs(relative));                                                                         // calculate velocity profile
+    }
+
+    currentPos += relative; //(target position / not actual)
     ESP_ERROR_CHECK(timer_set_alarm_value(conf.timer_group, conf.timer_idx, ctrl.stepInterval)); // set HW timer alarm to stepinterval
+                                                                                                 //TODO timer has to be stopped before update if already running?
     ESP_ERROR_CHECK(timer_start(conf.timer_group, conf.timer_idx));                              // start the timer
 
     return ESP_OK;
@@ -195,6 +209,37 @@ void DendoStepper::setSpeedMm(uint32_t speed, uint16_t accT, uint16_t decT)
     STEP_LOGI("DendoStepper", "Speed set: v=%d mm/s t+=%d s t-=%d s", speed, accT, decT);
 }
 
+//CUSTOM - change speed while running 
+//FIXME: this approach does not work, since calc function would have to be run after change, this will mess up target steps...
+//void DendoStepper::changeSpeed(uint32_t speed)
+//{
+//    //TODO reduce duplicate code (e.g. call setSpeed function)
+//    //change speed
+//    ctrl.speed = speed;
+//    //change status to ACC/DEC
+//    STEP_LOGI("DendoStepper", "Speed changed: from v=%.2f rad/s to v=%.2f rad/s", ctrl.speed, speed);
+//    if (speed > ctrl.speed) ctrl.status = ACC;
+//    if (speed < ctrl.speed) ctrl.status = DEC;
+//}
+//
+//void DendoStepper::changeSpeedMm(uint32_t speed)
+//{
+//    //TODO reduce duplicate code (e.g. call setSpeedMm function)
+//    if (ctrl.stepsPerMm == 0)
+//    {
+//        STEP_LOGE("DendoStepper", "Steps per millimeter not set, cannot set the speed!");
+//    }
+//    //calc new speed
+//    float speedNew = speed * ctrl.stepsPerMm;
+//    //change status to ACC/DEC
+//    if (speedNew > ctl.speed) ctrl.status = ACC;
+//    if (speedNew < ctl.speed) ctrl.status = DEC;
+//    //update speed, log output
+//    ctrl.speed = speedNew;
+//    STEP_LOGI("DendoStepper", "Speed changed: from v=%.2f rad/s to v=%.2f rad/s", ctrl.speed, speedNew);
+//}
+
+
 void DendoStepper::setStepsPerMm(uint16_t steps)
 {
     ctrl.stepsPerMm = steps;
@@ -261,6 +306,7 @@ void DendoStepper::stop()
     }
     ctrl.runInfinite = false;
     timer_pause(conf.timer_group, conf.timer_idx); // stop the timer
+    ctrl.statusPrev = ctrl.status; //update previous status
     ctrl.status = IDLE;
     ctrl.stepCnt = 0;
     gpio_set_level((gpio_num_t)conf.stepPin, 0);
@@ -287,10 +333,20 @@ bool DendoStepper::xISR()
 
     ctrl.stepCnt++;
 
+    //CUSTOM: track actual precice current position
+    if (ctrl.dir) {
+        ctrl.posActual ++;
+    } else {
+        ctrl.posActual --;
+    }
+    //CUSTOM: track remaining steps for eventually resuming
+    ctrl.stepsRemaining = ctrl.stepCnt - ctrl.stepCnt; 
+
     // we are done
     if (ctrl.stepsToGo == ctrl.stepCnt && !ctrl.runInfinite)
     {
         timer_pause(conf.timer_group, conf.timer_idx); // stop the timer
+        ctrl.statusPrev = ctrl.status; //update previous status
         ctrl.status = IDLE;
         ctrl.stepCnt = 0;
         return 0;
@@ -299,16 +355,19 @@ bool DendoStepper::xISR()
     if (ctrl.stepCnt > 0 && ctrl.stepCnt < ctrl.accEnd)
     { // we are accelerating
         ctrl.currentSpeed += ctrl.accInc;
+        ctrl.statusPrev = ctrl.status; //update previous status
         ctrl.status = ACC; // we are accelerating, note that*/
     }
     else if (ctrl.stepCnt > ctrl.coastEnd && !ctrl.runInfinite)
     { // we must be deccelerating then
         ctrl.currentSpeed -= ctrl.decInc;
+        ctrl.statusPrev = ctrl.status; //update previous status
         ctrl.status = DEC; // we are deccelerating
     }
     else
     {
         ctrl.currentSpeed = ctrl.targetSpeed;
+        ctrl.statusPrev = ctrl.status; //update previous status
         ctrl.status = COAST; // we are coasting
     }
 
@@ -316,15 +375,18 @@ bool DendoStepper::xISR()
     // set alarm to calculated interval and disable pin
     GPIO.out_w1tc = (1ULL << conf.stepPin);
     timer_set_alarm_value(conf.timer_group, conf.timer_idx, ctrl.stepInterval);
+    ctrl.stepCnt++;
     return 1;
 }
 
 void DendoStepper::calc(uint32_t targetSteps)
 {
-
+    //steps from ctrl.speed -> 0:
-    ctrl.accSteps = 0.5 * ctrl.acc * (ctrl.speed / ctrl.acc) * (ctrl.speed / ctrl.acc);
-
     ctrl.decSteps = 0.5 * ctrl.dec * (ctrl.speed / ctrl.dec) * (ctrl.speed / ctrl.dec);
+    //steps from 0 -> ctrl.speed:
+    //ctrl.accSteps = 0.5 * ctrl.acc * (ctrl.speed / ctrl.acc) * (ctrl.speed / ctrl.acc);
+    //steps from ctrl.currentSpeed -> ctrl.speed:
+    ctrl.accSteps = 0.5 * ctrl.acc * (ctrl.speed / ctrl.acc) * (ctrl.speed / ctrl.acc)  * (ctrl.speed - ctrl.currentSpeed) / ctrl.speed;
 
     if (targetSteps < (ctrl.decSteps + ctrl.accSteps))
     {

components/DendoStepper/include/DendoStepper.h

@@ -94,6 +94,9 @@ typedef struct
     float dec = 100;        // decceleration in rad*second^-2
     uint32_t accSteps = 0;
     uint32_t decSteps = 0;
+    int32_t stepsRemaining = 0;
+    uint64_t posActual = 0; //actual current pos incremented at every step
+    uint8_t statusPrev = DISABLED; //FIXME currently unused
     uint8_t status = DISABLED;
     bool dir = CW;
     bool runInfinite = false;
@@ -208,6 +211,9 @@ public:
      */
     void setSpeedMm(uint32_t speed, uint16_t accT, uint16_t decT);
 
+    //CUSTOM: change speed while running
+    void changeSpeedMm(uint32_t speed);
+
     /**
      * @brief Set steps per 1 mm of linear movement
      *

function-diagram.drawio

@@ -1,6 +1,6 @@
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   <diagram id="pYACIs8yIpksGCPkkI0E" name="control, cutter, buttons, encoder">
-    <mxGraphModel dx="1240" dy="730" grid="1" gridSize="5" guides="1" tooltips="1" connect="1" arrows="1" fold="1" page="1" pageScale="1" pageWidth="1169" pageHeight="1654" math="0" shadow="0">
+    <mxGraphModel dx="1194" dy="741" grid="1" gridSize="5" guides="1" tooltips="1" connect="1" arrows="1" fold="1" page="1" pageScale="1" pageWidth="1169" pageHeight="1654" math="0" shadow="0">
       <root>
         <mxCell id="0" />
         <mxCell id="1" parent="0" />
@@ -25,7 +25,7 @@
         <mxCell id="Jo9Ue6hLqtK935TEgpBK-28" value="SW_RESET.state" style="rhombus;whiteSpace=wrap;html=1;" parent="E9gbP4vXqY4O4zoDVCtS-22" vertex="1">
           <mxGeometry x="120" y="110" width="120" height="70" as="geometry" />
         </mxCell>
-        <mxCell id="Jo9Ue6hLqtK935TEgpBK-29" value="// lengthNow = 0&lt;br&gt;encoder_reset()" style="rounded=1;whiteSpace=wrap;html=1;" parent="E9gbP4vXqY4O4zoDVCtS-22" vertex="1">
+        <mxCell id="Jo9Ue6hLqtK935TEgpBK-29" value="// lengthNow = 0&lt;br&gt;encoder_reset()&lt;br&gt;guide_moveToZero()" style="rounded=1;whiteSpace=wrap;html=1;" parent="E9gbP4vXqY4O4zoDVCtS-22" vertex="1">
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@@ -205,7 +205,7 @@
           </mxGeometry>
         </mxCell>
         <mxCell id="1-PaxUM0a53oYDua-TxR-2" value="autoCutEnabled == true" style="edgeStyle=orthogonalEdgeStyle;rounded=0;orthogonalLoop=1;jettySize=auto;html=1;exitX=0.75;exitY=1;exitDx=0;exitDy=0;entryX=0.5;entryY=0;entryDx=0;entryDy=0;" parent="E9gbP4vXqY4O4zoDVCtS-33" source="Jo9Ue6hLqtK935TEgpBK-20" target="1-PaxUM0a53oYDua-TxR-1" edge="1">
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+          <mxGeometry x="-0.6954" y="6" relative="1" as="geometry">
             <Array as="points">
               <mxPoint x="299" y="1100" />
               <mxPoint x="267" y="1100" />
@@ -230,11 +230,11 @@
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           <mxGeometry relative="1" as="geometry" />
         </mxCell>
-        <mxCell id="8zFeNdrfwlNlW0LlzPxK-14" value="wind at dynamic speed&lt;br&gt;(slower speed when closer to target)" style="text;html=1;strokeColor=none;fillColor=none;align=center;verticalAlign=middle;whiteSpace=wrap;rounded=0;fontColor=#0000FF;labelBackgroundColor=#FFFFFF;" parent="E9gbP4vXqY4O4zoDVCtS-33" vertex="1">
+        <mxCell id="8zFeNdrfwlNlW0LlzPxK-14" value="wind at dynamic speed&lt;br&gt;(slower speed when closer to target)" style="text;html=1;strokeColor=none;fillColor=none;align=center;verticalAlign=middle;whiteSpace=wrap;rounded=0;fontColor=#0000FF;labelBackgroundColor=none;" parent="E9gbP4vXqY4O4zoDVCtS-33" vertex="1">
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@@ -348,13 +348,13 @@
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+          <mxGeometry x="401.25" y="836.5" width="130" height="25" as="geometry" />
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-        <mxCell id="Jo9Ue6hLqtK935TEgpBK-25" value="&lt;font color=&quot;#0000ff&quot;&gt;start counting (no motor)&lt;br&gt;(pull and attach wire manually to spool)&lt;/font&gt;" style="text;html=1;strokeColor=none;fillColor=none;align=center;verticalAlign=middle;whiteSpace=wrap;rounded=0;labelBackgroundColor=#FFFFFF;" parent="E9gbP4vXqY4O4zoDVCtS-33" vertex="1">
+        <mxCell id="Jo9Ue6hLqtK935TEgpBK-25" value="&lt;font color=&quot;#0000ff&quot;&gt;start counting (no motor)&lt;br&gt;(pull and attach wire manually to spool)&lt;/font&gt;" style="text;html=1;strokeColor=none;fillColor=none;align=center;verticalAlign=middle;whiteSpace=wrap;rounded=0;labelBackgroundColor=none;" parent="E9gbP4vXqY4O4zoDVCtS-33" vertex="1">
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+        <mxCell id="8zFeNdrfwlNlW0LlzPxK-15" value="start or resume slow for some time&lt;br&gt;(time for verifying it winds correctly)" style="text;html=1;strokeColor=none;fillColor=none;align=center;verticalAlign=middle;whiteSpace=wrap;rounded=0;fontColor=#0000FF;labelBackgroundColor=none;" parent="E9gbP4vXqY4O4zoDVCtS-33" vertex="1">
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main/CMakeLists.txt

@@ -1,7 +1,7 @@
 idf_component_register(
     SRCS 
         "main.cpp"
-        "config.cpp"
+        "global.cpp"
         "control.cpp"
         "buzzer.cpp"
         "vfd.cpp"
@@ -11,6 +11,10 @@ idf_component_register(
 		"stepper.cpp"
         "guide-stepper.cpp"
         "encoder.cpp"
+        "shutdown.cpp"
     INCLUDE_DIRS 
         "."
     )
+
+# colored build output (errors, warnings...)
+idf_build_set_property(COMPILE_OPTIONS "-fdiagnostics-color=always" APPEND)

main/buzzer.cpp

@@ -1,5 +1,5 @@
 #include "buzzer.hpp"
-#include "config.hpp"
+#include "config.h"
 
 static const char *TAG_BUZZER = "buzzer";
 

main/config.h

@@ -0,0 +1,151 @@
+#pragma once
+
+#include "esp_idf_version.h"
+
+//note: global variables and objects were moved to global.hpp
+
+//===================================
+//===== define output gpio pins =====
+//===================================
+//4x stepper mosfet outputs for VFD
+#define GPIO_VFD_FWD GPIO_NUM_4     //ST4
+#define GPIO_VFD_REV GPIO_NUM_5     //mos2
+#define GPIO_VFD_D0 GPIO_NUM_2      //ST2
+#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_MOS1 GPIO_NUM_18       //mos1 (free) 2022.02.28: pin used for stepper
+#define GPIO_LAMP GPIO_NUM_0        //mos2 (5) 2022.02.28: lamp disabled, pin used for stepper
+#define GPIO_RELAY GPIO_NUM_13
+#define GPIO_BUZZER GPIO_NUM_12
+
+
+//==================================
+//==== define analog input pins ====
+//==================================
+#define GPIO_POTI GPIO_NUM_36
+#define ADC_CHANNEL_POTI ADC1_CHANNEL_0
+#define GPIO_4SW_TO_ANALOG GPIO_NUM_39
+#define ADC_CHANNEL_4SW_TO_ANALOG ADC1_CHANNEL_3 //gpio 39
+
+#define ADC_CHANNEL ADC_CHANNEL_0
+//#define ADC_LOW_VOLTAGE_THRESHOLD 1000 //adc value where shut down is detected (store certain values before power loss)
+#define GPIO_PIN GPIO_NUM_2
+
+#define ADC_CHANNEL_SUPPLY_VOLTAGE ADC1_CHANNEL_7//gpio35 onboard supply voltage
+//ADC1_CHANNEL_0 gpio36
+//ADC1_CHANNEL_6 gpio_34
+//ADC1_CHANNEL_3 gpio_39
+
+
+//=====================================
+//==== assign switches to objects =====
+//=====================================
+//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
+//#define ? sw_gpio_34
+//note: actual objects are created in global.cpp
+
+
+
+
+//=============================
+//======= configuration =======
+//=============================
+//--------------------------
+//----- display config -----
+//--------------------------
+#if ESP_IDF_VERSION < ESP_IDF_VERSION_VAL(4, 0, 0)
+#define HOST    HSPI_HOST
+#else
+#define HOST    SPI2_HOST
+#endif
+#define DISPLAY_PIN_NUM_MOSI GPIO_NUM_23
+#define DISPLAY_PIN_NUM_CLK GPIO_NUM_22
+#define DISPLAY_PIN_NUM_CS GPIO_NUM_27
+#define DISPLAY_DELAY 2000
+#define DISPLAY_BRIGHTNESS 8
+
+//--------------------------
+//----- encoder config -----
+//--------------------------
+#define ROT_ENC_A_GPIO GPIO_NUM_19
+#define ROT_ENC_B_GPIO GPIO_NUM_21
+#define ENABLE_HALF_STEPS false  // Set to true to enable tracking of rotary encoder at half step resolution
+#define FLIP_DIRECTION    false  // Set to true to reverse the clockwise/counterclockwise sense
+
+
+
+//--------------------------
+//----- stepper config -----
+//--------------------------
+//enable stepper test mode (dont start control and encoder task)
+//#define STEPPER_TEST
+//pins
+#define STEPPER_STEP_PIN		GPIO_NUM_18    //mos1
+#define STEPPER_DIR_PIN			GPIO_NUM_16     //ST3
+//driver settings
+#define STEPPER_STEPS_PER_MM	(200/2)	//steps/mm (steps-per-rot / spindle-slope)
+#define STEPPER_SPEED_DEFAULT	25		//mm/s
+#define STEPPER_SPEED_MIN		4		//mm/s  - speed threshold at which stepper immediately starts/stops
+#define STEPPER_ACCEL_INC		3		//steps/s increment per cycle 
+#define STEPPER_DECEL_INC		7		//steps/s decrement per cycle
+//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 -------
+//--------------------------
+//enable mode  encoder test for calibration (determine ENCODER_STEPS_PER_METER)
+//if defined, displays always show length and steps instead of the normal messages
+//#define ENCODER_TEST
+//TODO: add way to calibrate without flashing -> enter calibration mode with certain button sequence, enter steps-per-meter with poti, store in nvs
+
+//steps per meter
+//this value is determined experimentally while ENCODER_TEST is enabled
+//#define ENCODER_STEPS_PER_METER 2127 //until 2024.03.13 roll-v3-gummi-86.6mm - d=89.8mm
+#define ENCODER_STEPS_PER_METER 2118 //2024.03.13 roll-v3-gummi measured 86.5mm
+
+//millimeters added to target length
+//to ensure that length does not fall short when spool slightly rotates back after stop
+#define TARGET_LENGTH_OFFSET 0
+
+//millimeters lengthNow can be below lengthTarget to still stay in target_reached state
+#define TARGET_REACHED_TOLERANCE 5
+
+
+
+

main/config.hpp

@@ -1,138 +0,0 @@
-#pragma once
-extern "C" {
-#include "driver/adc.h"
-}
-#include "gpio_evaluateSwitch.hpp"
-#include "buzzer.hpp"
-#include "switchesAnalog.hpp"
-
-
-//===================================
-//===== define output gpio pins =====
-//===================================
-//4x stepper mosfet outputs for VFD
-#define GPIO_VFD_FWD GPIO_NUM_4     //ST4
-#define GPIO_VFD_REV GPIO_NUM_5     //mos2
-#define GPIO_VFD_D0 GPIO_NUM_2      //ST2
-#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_MOS1 GPIO_NUM_18       //mos1 (free) 2022.02.28: pin used for stepper
-#define GPIO_LAMP GPIO_NUM_0        //mos2 (5) 2022.02.28: lamp disabled, pin used for stepper
-#define GPIO_RELAY GPIO_NUM_13
-#define GPIO_BUZZER GPIO_NUM_12
-
-
-//==================================
-//==== define analog input pins ====
-//==================================
-#define GPIO_POTI GPIO_NUM_36
-#define ADC_CHANNEL_POTI ADC1_CHANNEL_0
-#define GPIO_4SW_TO_ANALOG GPIO_NUM_39
-#define ADC_CHANNEL_4SW_TO_ANALOG ADC1_CHANNEL_3 //gpio 39
-//ADC1_CHANNEL_0 gpio36
-//ADC1_CHANNEL_6 gpio_34
-//ADC1_CHANNEL_3 gpio_39
-
-
-//=====================================
-//==== assign switches to objects =====
-//=====================================
-//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_34
-
-
-
-
-//=============================
-//======= configuration =======
-//=============================
-//--------------------------
-//----- display config -----
-//--------------------------
-#if ESP_IDF_VERSION < ESP_IDF_VERSION_VAL(4, 0, 0)
-#define HOST    HSPI_HOST
-#else
-#define HOST    SPI2_HOST
-#endif
-#define DISPLAY_PIN_NUM_MOSI GPIO_NUM_23
-#define DISPLAY_PIN_NUM_CLK GPIO_NUM_22
-#define DISPLAY_PIN_NUM_CS GPIO_NUM_27
-#define DISPLAY_DELAY 2000
-
-//--------------------------
-//----- encoder config -----
-//--------------------------
-#define ROT_ENC_A_GPIO GPIO_NUM_19
-#define ROT_ENC_B_GPIO GPIO_NUM_21
-#define ENABLE_HALF_STEPS false  // Set to true to enable tracking of rotary encoder at half step resolution
-#define FLIP_DIRECTION    false  // Set to true to reverse the clockwise/counterclockwise sense
-
-
-
-//--------------------------
-//----- stepper config -----
-//--------------------------
-//enable stepper test mode (dont start control and encoder task)
-#define STEPPER_TEST
-#define STEPPER_STEP_PIN GPIO_NUM_18    //mos1
-#define STEPPER_DIR_PIN GPIO_NUM_16     //ST3
-#define STEPPER_EN_PIN GPIO_NUM_0       //not connected (-> stepper always on)
-//more detailed options for testing are currently defined in guide-stepper.cpp
-
-
-
-//--------------------------
-//------ calibration -------
-//--------------------------
-//enable mode  encoder test for calibration
-//if defined, displays always show length and steps instead of the normal messages
-//#define ENCODER_TEST
-
-//steps per meter
-#define ENCODER_STEPS_PER_METER 2127 //roll-v3-gummi-86.6mm - d=89.8mm
-
-//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
-
-
-
-
-//============================
-//===== global variables =====
-//============================
-//create global evaluated switch objects
-//--- switches on digital gpio pins ---
-//extern gpio_evaluatedSwitch sw_gpio_39;
-extern gpio_evaluatedSwitch sw_gpio_34;
-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;
-extern gpio_evaluatedSwitch sw_gpio_analog_1;
-extern gpio_evaluatedSwitch sw_gpio_analog_2;
-extern gpio_evaluatedSwitch sw_gpio_analog_3;
-
-
-
-//create global buzzer object
-extern buzzer_t buzzer;

main/control.cpp

@@ -1,20 +1,47 @@
-#include "control.hpp"
+extern "C"
+{
+#include <stdio.h>
+#include <freertos/FreeRTOS.h>
+#include <freertos/task.h>
+#include <esp_idf_version.h>
+#include "freertos/queue.h"
+#include "esp_system.h"
+#include "esp_log.h"
+#include "driver/adc.h"
+
+#include "max7219.h"
+
+}
+#include <cmath>
+#include "config.h"
+#include "gpio_evaluateSwitch.hpp"
+#include "gpio_adc.hpp"
+#include "buzzer.hpp"
+#include "vfd.hpp"
+#include "display.hpp"
+#include "cutter.hpp"
 #include "encoder.hpp"
+#include "guide-stepper.hpp"
+#include "global.hpp"
+#include "control.hpp"
 
 
-//====================
+//-----------------------------------------
-//==== variables =====
+//--------------- variables ---------------
-//====================
+//-----------------------------------------
 static const char *TAG = "control"; //tag for logging
 
+//control
 const char* systemStateStr[7] = {"COUNTING", "WINDING_START", "WINDING", "TARGET_REACHED", "AUTO_CUT_WAITING", "CUTTING", "MANUAL"};
 systemState_t controlState = systemState_t::COUNTING;
-static uint32_t timestamp_changedState = 0;
+static uint32_t timestamp_lastStateChange = 0;
 
+//display
 static char buf_disp1[10];// 8 digits + decimal point + \0
 static char buf_disp2[10];// 8 digits + decimal point + \0
 static char buf_tmp[15];
 
+//track length
 static int lengthNow = 0; //length measured in mm
 static int lengthTarget = 5000; //default target length in mm
 static int lengthRemaining = 0; //(target - now) length needed for reaching the target
@@ -27,8 +54,19 @@ 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
 
+
+//-----------------------------------------
+//--------------- functions ---------------
+//-----------------------------------------
+
+//========================
 //===== change State =====
+//========================
 //function for changing the controlState with log output
 void changeState (systemState_t stateNew) {
     //only proceed when state actually changed
@@ -40,18 +78,21 @@ void changeState (systemState_t stateNew) {
     //change state
     controlState = stateNew;
     //update timestamp
-    timestamp_changedState = esp_log_timestamp();
+    timestamp_lastStateChange = 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
+//function that checks whether start button is released or target is reached 
+//and takes according action if so (used in multiple states)
+//returns true when stop condition was met, false when no action required
 bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBot){
     //--- stop conditions ---
     //stop conditions that are checked in any mode
-    //target reached
+    //target reached -> reached state, stop motor, display message
     if (lengthRemaining <= 0 ) {
         changeState(systemState_t::TARGET_REACHED);
         vfd_setState(false);
@@ -60,7 +101,7 @@ bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBo
         buzzer.beep(2, 100, 100);
         return true;
     }
-    //start button released
+    //start button released -> idle state, stop motor, display message
     else if (SW_START.state == false) {
         changeState(systemState_t::COUNTING);
         vfd_setState(false);
@@ -74,8 +115,11 @@ bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBo
 }
 
 
+
+//===================================
 //===== set dynamic speed level =====
-//function that sets the vfd speed level dynamicly depending on the remaining distance
+//===================================
+//function that sets the vfd speed level dynamically depending on the remaining distance
 //closer to target -> slower
 void setDynSpeedLvl(uint8_t lvlMax = 3){
     uint8_t lvl;
@@ -103,31 +147,33 @@ void setDynSpeedLvl(uint8_t lvlMax = 3){
 //========================
 //===== control task =====
 //========================
+//task that controls the entire machine
 void task_control(void *pvParameter)
 {
-
+    //-- initialize display --
-    //initialize display
     max7219_t two7SegDisplays = display_init();
-    //create two separate handled display instances
+    //create two separate custom handled display instances
     handledDisplay displayTop(two7SegDisplays, 0);
     handledDisplay displayBot(two7SegDisplays, 8);
 
-    //--- display welcome msg ---
+    //-- display welcome msg --
     //display welcome message on two 7 segment displays
     //currently show name and date and scrolling 'hello'
     display_ShowWelcomeMsg(two7SegDisplays);
 
+    //-- set initial winding width for default length --
+    guide_setWindingWidth(guide_targetLength2WindingWidth(lengthTarget));
 
-    //================
+    // ##############################
-    //===== loop =====
+    // ######## control loop ########
-    //================
+    // ##############################
+    // repeatedly handle the machine
     while(1){
         vTaskDelay(10 / portTICK_PERIOD_MS);
 
-        //-----------------------------
+
         //------ handle switches ------
-        //-----------------------------
+        //run handle functions for all switches used here
-        //run handle functions for all switches
         SW_START.handle();
         SW_RESET.handle();
         SW_SET.handle();
@@ -138,27 +184,23 @@ void task_control(void *pvParameter)
         SW_AUTO_CUT.handle();
 
 
-        //---------------------------
         //------ handle cutter ------
-        //---------------------------
+        //TODO: separate task for cutter?
         cutter_handle();
 
 
-        //----------------------------
         //------ rotary encoder ------
-        //----------------------------
+        //get current length since last reset
-        //--- get current length since last reset ---
         lengthNow = encoder_getLenMm();
 
         
-        //---------------------------
         //--------- buttons ---------
-        //---------------------------
+        //#### RESET switch ####
-        //--- RESET switch ---
         if (SW_RESET.risingEdge) {
             //dont reset when press used for stopping pending auto-cut
             if (controlState != systemState_t::AUTO_CUT_WAITING) {
-                encoder_reset();
+                guide_moveToZero(); //move axis guiding the cable to start position
+                encoder_reset(); //reset length measurement
                 lengthNow = 0;
                 buzzer.beep(1, 700, 100);
                 displayTop.blink(2, 100, 100, "1ST     ");
@@ -167,7 +209,7 @@ void task_control(void *pvParameter)
             }
         }
 
-        //--- CUT switch ---
+        //### CUT switch ####
         //start cut cycle immediately
         if (SW_CUT.risingEdge) {
             //stop cutter if already running
@@ -190,7 +232,7 @@ void task_control(void *pvParameter)
             }
         }
        
-        //--- AUTO_CUT toggle sw ---
+        //#### AUTO_CUT toggle sw ####
         //beep at change
         if (SW_AUTO_CUT.risingEdge) {
             buzzer.beep(2, 100, 50);
@@ -209,7 +251,7 @@ void task_control(void *pvParameter)
             autoCutEnabled = false;
         }
 
-        //--- manual mode ---
+        //#### manual mode ####
         //switch to manual motor control (2 buttons + poti)
         if ( SW_PRESET2.state && (SW_PRESET1.state || SW_PRESET3.state) && controlState != systemState_t::MANUAL ) {
             //enable manual control
@@ -217,13 +259,44 @@ void task_control(void *pvParameter)
             buzzer.beep(3, 100, 60);
         }
 
-        //--- set custom target length ---
+        //##### SET switch + Potentiometer #####
-        //set target length to poti position when SET switch is pressed
+        //## set winding-width (SET+PRESET1+POTI) ##
-        if (SW_SET.state == true) {
+        // 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);
@@ -239,6 +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);
             }
@@ -253,36 +327,40 @@ void task_control(void *pvParameter)
         }
 
 
-        //--- target length presets ---
+        //##### 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    ");
             }
         }
 
 
-
         //---------------------------
         //--------- control ---------
         //---------------------------
-        //calculate length difference
+        //statemachine handling the sequential winding process
+
+        //calculate current length difference
         lengthRemaining = lengthTarget - lengthNow + TARGET_LENGTH_OFFSET;
 
         //--- statemachine ---
         switch (controlState) {
-            case systemState_t::COUNTING: //no motor action
+            case systemState_t::COUNTING: //no motor action, just show current length on display
                 vfd_setState(false);
                 //TODO check stop condition before starting - prevents motor from starting 2 cycles when already at target
                 //--- start winding to length ---
@@ -298,6 +376,7 @@ void task_control(void *pvParameter)
             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)
+                //switch to WINDING state (full speed) when 3s have passed
                 if (esp_log_timestamp() - timestamp_motorStarted > 3000) {
                     changeState(systemState_t::WINDING);
                 }
@@ -307,23 +386,23 @@ void task_control(void *pvParameter)
 
             case systemState_t::WINDING: //wind fast, slow down when close
                 //set vfd speed depending on remaining distance 
-                setDynSpeedLvl(); //slow down when close to target
+                setDynSpeedLvl(); //set motor speed, 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 systemState_t::TARGET_REACHED:
+            case systemState_t::TARGET_REACHED: //prevent further motor rotation and start auto-cut
                 vfd_setState(false);
                 //switch to counting state when no longer at or above target length
                 if ( lengthNow < lengthTarget - TARGET_REACHED_TOLERANCE ) {
                     changeState(systemState_t::COUNTING);
                 }
-                //switch initiate countdown to auto-cut
+                //initiate countdown to auto-cut if enabled
                 else if ( (autoCutEnabled)
-                        && (esp_log_timestamp() - timestamp_changedState > 300) ) { //wait for dislay msg "reached" to finish
+                        && (esp_log_timestamp() - timestamp_lastStateChange > 300) ) { //wait for dislay msg "reached" to finish
                     changeState(systemState_t::AUTO_CUT_WAITING);
                 }
-                //show msg when trying to start, but target is reached
+                //show msg when trying to start, but target is already reached (-> reset button has to be pressed)
                 if (SW_START.risingEdge) {
                     buzzer.beep(2, 50, 30);
                     displayTop.blink(2, 600, 500, "  S0LL  ");
@@ -331,9 +410,8 @@ void task_control(void *pvParameter)
                 }
                 break;
 
-            case systemState_t::AUTO_CUT_WAITING:
+            case systemState_t::AUTO_CUT_WAITING: //handle delayed start of cut
-                //handle delayed start of cut
+                cut_msRemaining = autoCut_delayMs - (esp_log_timestamp() - timestamp_lastStateChange);
-                cut_msRemaining = autoCut_delayMs - (esp_log_timestamp() - timestamp_changedState);
                 //- countdown stop conditions -
                 //stop with any button
                 if (!autoCutEnabled
@@ -357,13 +435,14 @@ void task_control(void *pvParameter)
                 }
                 break;
 
-            case systemState_t::CUTTING:
+            case systemState_t::CUTTING: //prevent any action while cutter is active
                 //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?
-                    encoder_reset();
+                    guide_moveToZero(); //move axis guiding the cable to start position
+                    encoder_reset(); //reset length measurement
                     lengthNow = 0;
                     buzzer.beep(1, 700, 100);
                 }
@@ -400,30 +479,34 @@ void task_control(void *pvParameter)
         }
 
 
-
+#ifdef ENCODER_TEST
         //--------------------------
         //------ encoder test ------
         //--------------------------
-#ifdef ENCODER_TEST
+        //mode for calibrating the cable length measurement (determine ENCODER_STEPS_PER_METER in config.h)
         //run display handle functions
         displayTop.handle();
         displayBot.handle();
         //-- show encoder steps on display1 ---
-        sprintf(buf_disp1, "EN %05d", encoder_getSteps); //count
+        sprintf(buf_disp1, "EN %05d", encoder_getSteps()); //count
         displayTop.showString(buf_disp1);
         //--- show converted distance on display2 ---
         sprintf(buf_disp2, "Met %5.3f", (float)lengthNow/1000); //m
         displayBot.showString(buf_disp2);
-        //--- beep every 1m ---
+        //--- beep every 0.5m ---
-        //note: only works precicely in forward/positive direction
+        //note: only works precisely in forward/positive direction, in reverse it it beeps by tolerance too early
-        if (lengthNow % 1000 < 50) { //with tolerance in case of missed exact value
+        static int lengthBeeped = 0;
-            if (fabs(lengthNow - lengthBeeped) >= 900) { //dont beep multiple times at same meter
+        if (lengthNow % 500 < 50) { //with tolerance in case of missed exact value
-                //TODO: add case for reverse direction. currently beeps 0.1 too early
+            if (fabs(lengthNow - lengthBeeped) >= 400) { //dont beep multiple times at same distance
-                buzzer.beep(1, 400, 100 );
+                //TODO: add case for reverse direction. currently beeps 50mm too early
+                if (lengthNow % 1000 < 50) // 1m beep
+                    buzzer.beep(1, 400, 100);
+                else // 0.5m beep
+                    buzzer.beep(1, 200, 100);
                 lengthBeeped = lengthNow;
             }
         }
-#else
+#else //not in encoder calibration mode
 
         //--------------------------
         //-------- display1 --------
@@ -434,6 +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);
@@ -443,23 +530,13 @@ void task_control(void *pvParameter)
             displayTop.showString(buf_disp1);
         }
 
-
         //--------------------------
         //-------- display2 --------
         //--------------------------
         //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
@@ -468,6 +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
@@ -476,6 +567,7 @@ void task_control(void *pvParameter)
             displayBot.showString(buf_tmp);
         }
 
+#endif // end else ifdef ENCODER_TEST
 
         //----------------------------
         //------- control lamp -------
@@ -492,10 +584,6 @@ void task_control(void *pvParameter)
             gpio_set_level(GPIO_LAMP, 0);
         }
 
+    } //end while(1)
 
-
+} //end task_control
-#endif
-        
-    }
-
-}

main/control.hpp

@@ -1,34 +1,12 @@
 #pragma once
-extern "C"
-{
-#include <stdio.h>
-#include <freertos/FreeRTOS.h>
-#include <freertos/task.h>
-#include <esp_idf_version.h>
-#include "freertos/queue.h"
-#include "esp_system.h"
-#include "esp_log.h"
-#include "driver/adc.h"
-
-#include "max7219.h"
-
-}
-#include <cmath>
-
-#include "config.hpp"
-#include "gpio_evaluateSwitch.hpp"
-#include "gpio_adc.hpp"
-#include "buzzer.hpp"
-#include "vfd.hpp"
-#include "display.hpp"
-#include "cutter.hpp"
-
 
 
 //enum describing the state of the system
 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

@@ -1,4 +1,6 @@
 #include "cutter.hpp"
+#include "config.h"
+#include "global.hpp"
 
 const char* cutter_stateStr[5] = {"IDLE", "START", "CUTTING", "CANCELED", "TIMEOUT"}; //define strings for logging the state
                                                                           
@@ -39,7 +41,6 @@ void cutter_stop(){
     if(cutter_state != cutter_state_t::IDLE){
         setState(cutter_state_t::CANCELED);
     }
-    //starts motor on state change
 }
 
 
@@ -131,7 +132,6 @@ void cutter_handle(){
     //SW_CUTTER_POS.minOnMs = 10;
     //SW_CUTTER_POS.minOffMs = 10;
 
-
     switch(cutter_state){
         case cutter_state_t::IDLE:
         case cutter_state_t::TIMEOUT:
@@ -142,14 +142,13 @@ void cutter_handle(){
         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
+            if (SW_CUTTER_POS.state == true) { //contact closed -> not at idle pos anymore
                 setState(cutter_state_t::CUTTING);
             }
             //--- timeout ---
             else {
                 checkTimeout();
             }
-
             break;
 
         case cutter_state_t::CUTTING:

main/display.cpp

@@ -1,5 +1,6 @@
 #include "display.hpp"
 
+#include "config.h"
 
 //=== variables ===
 static const char *TAG = "display"; //tag for logging
@@ -34,7 +35,7 @@ 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)); //TODO add this to config
+    ESP_ERROR_CHECK(max7219_set_brightness(&dev, DISPLAY_BRIGHTNESS));
     return dev;
     //display = dev;
     ESP_LOGI(TAG, "initializing display - done");
@@ -50,7 +51,7 @@ 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  29.09.2022");
+    max7219_draw_text_7seg(&dev, 0, "CUTTER  15.03.2024");
     //                                   1234567812 34 5678
     vTaskDelay(pdMS_TO_TICKS(700));
     //scroll "hello" over 2 displays
@@ -64,7 +65,7 @@ void display_ShowWelcomeMsg(max7219_t dev){
     //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
+    ESP_ERROR_CHECK(max7219_set_brightness(&dev, DISPLAY_BRIGHTNESS));
 }
 
 
@@ -83,9 +84,9 @@ handledDisplay::handledDisplay(max7219_t displayDevice, uint8_t posStart_f) {
 
 
 
-//--------------------------------
+//================================
-//---------- showString ----------
+//========== showString ==========
-//--------------------------------
+//================================
 //function that displays a given string on the display
 void handledDisplay::showString(const char * buf, uint8_t pos_f){
     //calculate actual absolute position
@@ -103,11 +104,11 @@ void handledDisplay::showString(const char * buf, uint8_t pos_f){
 
 
 //TODO: blinkStrings() and blink() are very similar - can be optimized?
-//only difficulty currently is the reset behaivor of blinkStrings through showString (blink does not reset)
+//only difficulty is the reset behaivor of blinkStrings through showString (blink does not reset)
 
-//----------------------------------
+//==================================
-//---------- blinkStrings ----------
+//========== blinkStrings ==========
-//----------------------------------
+//==================================
 //function switches between two strings in a given interval
 void handledDisplay::blinkStrings(const char * strOn_f, const char * strOff_f, uint32_t msOn_f, uint32_t msOff_f){
     //copy/update variables
@@ -130,9 +131,9 @@ void handledDisplay::blinkStrings(const char * strOn_f, const char * strOff_f, u
 
 
 
-//-------------------------------
+//===============================
-//------------ blink ------------
+//============ blink ============
-//-------------------------------
+//===============================
 //function triggers certain count and interval of off durations
 void handledDisplay::blink(uint8_t count_f, uint32_t msOn_f, uint32_t msOff_f, const char * strOff_f) {
     //copy/update parameters
@@ -156,9 +157,9 @@ void handledDisplay::blink(uint8_t count_f, uint32_t msOn_f, uint32_t msOff_f, c
 
 
 
-//--------------------------------
+//================================
-//------------ handle ------------
+//============ handle ============
-//--------------------------------
+//================================
 //function that handles time based modes
 //writes text to the 7 segment display depending on the current mode
 void handledDisplay::handle() {

main/display.hpp

@@ -16,9 +16,8 @@ extern "C"
 #include <cstring>
 
 
-#include "config.hpp"
 
-//function for initializing the display using configuration from macros in config.hpp
+//function for initializing the display using configuration from macros in config.h
 max7219_t display_init();
 
 //show welcome message on the entire display
@@ -44,8 +43,8 @@ class handledDisplay {
         //TODO: blinkStrings and blink are very similar - optimize?
         //TODO: add 'scroll string' method
 
-    private:
 
+    private:
         //--- variables ---
         //config
         max7219_t dev;

main/encoder.cpp

@@ -8,6 +8,8 @@ extern "C" {
 }
 
 #include "encoder.hpp"
+#include "config.h"
+#include "global.hpp"
 
 
 //----------------------------
@@ -17,10 +19,14 @@ static rotary_encoder_info_t encoder; //encoder device/info
 QueueHandle_t encoder_queue = NULL; //encoder event queue
 
 
+
 //-------------------------
 //------- functions -------
 //-------------------------
-//--- encoder_init ---
+
+//======================
+//==== encoder_init ====
+//======================
 //initialize encoder and return event queue
 QueueHandle_t encoder_init(){
     // esp32-rotary-encoder requires that the GPIO ISR service is installed before calling rotary_encoder_register()
@@ -41,7 +47,9 @@ QueueHandle_t encoder_init(){
 }
 
 
-//--- encoder_getSteps ---
+//========================
+//=== encoder_getSteps ===
+//========================
 //get steps counted since last reset
 int encoder_getSteps(){
     // Poll current position and direction
@@ -52,14 +60,18 @@ int encoder_getSteps(){
 }
 
 
-//--- encoder_getLenMm ---
+//========================
+//=== encoder_getLenMm ===
+//========================
 //get current length in Mm since last reset
 int encoder_getLenMm(){
     return (float)encoder_getSteps() * 1000 / ENCODER_STEPS_PER_METER; 
 }
 
 
-//--- encoder_reset ---
+//=======================
+//==== encoder_reset ====
+//=======================
 //reset counted steps / length to 0
 void encoder_reset(){
     rotary_encoder_reset(&encoder);

main/encoder.hpp

@@ -6,7 +6,6 @@ extern "C" {
 #include <freertos/task.h>
 }
 
-#include "config.hpp"
 
 
 //----------------------------
@@ -34,7 +33,6 @@ int encoder_getSteps();
 int encoder_getLenMm();
 
     
-    
 //--- encoder_reset ---
 //reset counted steps / length to 0
 void encoder_reset();

main/global.cpp

@@ -1,4 +1,5 @@
-#include "config.hpp"
+#include "global.hpp"
+#include "config.h"
 
 
 //--- inputs ---

main/global.hpp

@@ -0,0 +1,33 @@
+#pragma once
+
+extern "C" {
+#include "driver/adc.h"
+}
+#include "gpio_evaluateSwitch.hpp"
+#include "buzzer.hpp"
+#include "switchesAnalog.hpp"
+
+//note: in the actual code macro variables to these objects from config.h are used as the objects names
+
+//============================
+//===== global variables =====
+//============================
+//create global evaluated switch objects for all available pins
+//--- switches on digital gpio pins ---
+//extern gpio_evaluatedSwitch sw_gpio_39;
+extern gpio_evaluatedSwitch sw_gpio_34;
+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;
+extern gpio_evaluatedSwitch sw_gpio_analog_1;
+extern gpio_evaluatedSwitch sw_gpio_analog_2;
+extern gpio_evaluatedSwitch sw_gpio_analog_3;
+
+
+//create global buzzer object
+extern buzzer_t buzzer;

main/guide-stepper.cpp

@@ -5,170 +5,276 @@ extern "C"
 #include "freertos/task.h"
 #include "esp_log.h"
 #include "driver/adc.h"
+#include "freertos/queue.h"
+#include "freertos/semphr.h"
 }
 
 #include "stepper.hpp"
-#include "config.hpp"
+#include "config.h"
+#include "global.hpp"
 #include "guide-stepper.hpp"
 #include "encoder.hpp"
+#include "shutdown.hpp"
 
 
+//macro to get smaller value out of two
+#define MIN(a, b) (((a) < (b)) ? (a) : (b))
 
 //---------------------
 //--- configuration ---
 //---------------------
-//also see config.hpp
+//also see config.h 
-//for pin definition
+//for pin definitions and guide parameters
 
-#define STEPPER_TEST_TRAVEL 65     //mm
+// configure testing modes
-                                   //
+#define STEPPER_TEST_TRAVEL 65     // mm
-#define MIN_MM 0
+// speeds for testing with potentiometer (test task only)
-#define MAX_MM 60 
+#define SPEED_MIN 2.0   // mm/s
-#define POS_MAX_STEPS MAX_MM * STEPPER_STEPS_PER_MM
+#define SPEED_MAX 70.0  // mm/s
-#define POS_MIN_STEPS MIN_MM * STEPPER_STEPS_PER_MM
+//note: actual speed is currently defined in config.h with STEPPER_SPEED_DEFAULT
+//simulate encoder with reset button to test stepper ctl task
+//note STEPPER_TEST has to be defined as well
+//#define STEPPER_SIMULATE_ENCODER
 
-
-#define SPEED_MIN 2.0   //mm/s
-#define SPEED_MAX 60.0 //mm/s
-
-#define ACCEL_MS 100.0  //ms from 0 to max
-#define DECEL_MS 90.0   //ms from max to 0
-
-#define STEPPER_STEPS_PER_ROT 1600
-#define STEPPER_STEPS_PER_MM STEPPER_STEPS_PER_ROT/4
-
-#define D_CABLE 6
-#define D_REEL 160 //actual 170
 #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 ------
 //----------------------
-static const char *TAG = "stepper"; //tag for logging
+typedef enum axisDirection_t {AXIS_MOVING_LEFT = 0, AXIS_MOVING_RIGHT} axisDirection_t;
 
-static bool stepp_direction = true;
+static const char *TAG = "stepper-ctrl"; //tag for logging
+
+static axisDirection_t currentAxisDirection = AXIS_MOVING_RIGHT;
 static uint32_t posNow = 0;
 
+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 ------
 //----------------------
-////move axis certain Steps (relative) between left and right or reverse when negative
-//void travelSteps(int stepsTarget){
-//    //posNow = step.getPositionMm(); //not otherwise controlled, so no update necessary
-//    int stepsToGo, remaining;
-//
-//    stepsToGo = abs(stepsTarget);
-//    if(stepsTarget < 0) stepp_direction = !stepp_direction; //invert direction in reverse mode
-//
-//    while (stepsToGo != 0){
-//        //--- currently moving right ---
-//        if (stepp_direction == true){               //currently moving right
-//            remaining = POS_MAX_STEPS - posNow;     //calc remaining distance fom current position to limit
-//            if (stepsToGo > remaining){             //new distance will exceed limit
-//                //....step.runAbs (POS_MAX_STEPS);        //move to limit
-//                //....while(step.getState() != 1) vTaskDelay(1);  //wait for move to finish
-//                posNow = POS_MAX_STEPS;
-//                stepp_direction = false;            //change current direction for next iteration
-//                stepsToGo = stepsToGo - remaining;  //decrease target length by already traveled distance
-//                ESP_LOGI(TAG, " --- moved to max -> change direction (L) --- \n ");
-//            }
-//            else {                                  //target distance does not reach the limit
-//                //....step.runAbs (posNow + stepsToGo);   //move by (remaining) distance to reach target length
-//                //....while(step.getState() != 1) vTaskDelay(1); //wait for move to finish
-//                ESP_LOGD(TAG, "moving to %d\n", posNow+stepsToGo);
-//                posNow += stepsToGo;
-//                stepsToGo = 0;                      //finished, reset target length (could as well exit loop/break)
-//            }
-//        }
-//
-//        //--- currently moving left ---
-//        else {
-//            remaining = posNow - POS_MIN_STEPS;
-//            if (stepsToGo > remaining){
-//                //....step.runAbs (POS_MIN_STEPS);
-//                //....while(step.getState() != 1) vTaskDelay(2);  //wait for move to finish
-//                posNow = POS_MIN_STEPS;
-//                stepp_direction = true;
-//                stepsToGo = stepsToGo - remaining;
-//                ESP_LOGI(TAG, " --- moved to min -> change direction (R) --- \n ");
-//            }
-//            else {
-//                //....step.runAbs (posNow - stepsToGo);           //when moving left the coordinate has to be decreased
-//                while(step.getState() != 1) vTaskDelay(2);  //wait for move to finish
-//                ESP_LOGD(TAG, "moving to %d\n", posNow - stepsToGo);
-//                posNow -= stepsToGo;
-//                stepsToGo = 0;
-//            }
-//        }
-//    }
-//    if(stepsTarget < 0) stepp_direction = !stepp_direction; //undo inversion of stepp_direction after reverse mode is finished
-//    return;
-//}
-//
-//
-////move axis certain Mm (relative) between left and right or reverse when negative
-//void travelMm(int length){
-//    travelSteps(length * STEPPER_STEPS_PER_MM);
-//}
-//
-//
-////define zero/start position 
-////currently crashes into hardware limitation for certain time 
-////TODO: limit switch
-//void home() {
-//    ESP_LOGW(TAG, "auto-home...");
-//    //....step.setSpeedMm(100, 500, 10);
-//    //....step.runInf(1);
-//    vTaskDelay(1500 / portTICK_PERIOD_MS);
-//    //....step.stop();
-//    //....step.resetAbsolute();
-//    ESP_LOGW(TAG, "auto-home finished");
-//}
 
-
+//=============================
-//initialize/configure stepper instance
+//=== guide_getAxisPosSteps ===
-void init_stepper() {
+//=============================
-//    ESP_LOGW(TAG, "initializing stepper...");
+// return local variable posNow
-//    DendoStepper_config_t step_cfg = {
+// needed at shutdown detection to store last axis position in nvs
-//        .stepPin = STEPPER_STEP_PIN,
+int guide_getAxisPosSteps(){
-//        .dirPin = STEPPER_DIR_PIN,
+    return posNow;
-//        .enPin = STEPPER_EN_PIN,
-//        .timer_group = TIMER_GROUP_0,
-//        .timer_idx = TIMER_0,
-//        .miStep = MICROSTEP_32,
-//        .stepAngle = 1.8};
-//    //....step.config(&step_cfg);
-//    //....step.init();
-//
-//    //....step.setSpeed(1000, 1000, 1000); //random default speed
-//    //....step.setStepsPerMm(STEPPER_STEPS_PER_MM); //guide: 4mm/rot
-
-	stepper_init();
 }
 
 
-//function that updates speed value using ADC input and configured MIN/MAX
+//=============================
+//=== 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 ====
+//==========================
+//tell stepper-control task to move cable guide to zero position
+void guide_moveToZero(){
+    bool valueToSend = true; // or false
+    xQueueSend(queue_commandsGuideTask, &valueToSend, portMAX_DELAY);
+    ESP_LOGI(TAG, "sending command to stepper_ctl task via queue");
+}
+
+
+//---------------------
+//---- travelSteps ----
+//---------------------
+//move axis certain Steps (relative) between left and right or reverse when negative
+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;
+
+    stepsToGo = abs(stepsTarget);
+
+    // invert direction in reverse mode (cable gets spooled off reel)
+    if (stepsTarget < 0) {
+    currentAxisDirection = (currentAxisDirection == AXIS_MOVING_LEFT) ? AXIS_MOVING_RIGHT : AXIS_MOVING_LEFT; //toggle between RIGHT<->Left
+    }
+
+    while (stepsToGo != 0){
+        //--- currently moving right ---
+        if (currentAxisDirection == AXIS_MOVING_RIGHT){               //currently moving right
+        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(posMaxSteps);        //move to limit
+				stepper_waitForStop(1000);
+                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);
+                if (layerCount < 0) layerCount = 0; //negative layers are not possible
+                stepsToGo = stepsToGo - remaining;  //decrease target length by already traveled distance
+                ESP_LOGI(TAG, " --- moved to max -> change direction (L) --- \n ");
+            }
+            else {                                  //target distance does not reach the limit
+                stepper_setTargetPosSteps(posNow + stepsToGo);   //move by (remaining) distance to reach target length
+                ESP_LOGD(TAG, "moving to %d\n", posNow+stepsToGo);
+                posNow += stepsToGo;
+                stepsToGo = 0;                      //finished, reset target length (could as well exit loop/break)
+            }
+            xSemaphoreGive(configVariables_mutex);
+        }
+        }
+
+        //--- currently moving left ---
+        else if (currentAxisDirection == AXIS_MOVING_LEFT){
+            remaining = posNow - POS_MIN_STEPS;
+            if (stepsToGo > remaining){
+                stepper_setTargetPosSteps(POS_MIN_STEPS);
+				stepper_waitForStop(1000);
+                posNow = POS_MIN_STEPS;
+                currentAxisDirection = AXIS_MOVING_RIGHT; //switch direction
+                //increment/decrement layer count depending on current cable direction
+                layerCount += (stepsTarget > 0) - (stepsTarget < 0);
+                if (layerCount < 0) layerCount = 0; //negative layers are not possible
+                stepsToGo = stepsToGo - remaining;
+                ESP_LOGI(TAG, " --- moved to min -> change direction (R) --- \n ");
+            }
+            else {
+                stepper_setTargetPosSteps(posNow - stepsToGo);           //when moving left the coordinate has to be decreased
+                ESP_LOGD(TAG, "moving to %d\n", posNow - stepsToGo);
+                posNow -= stepsToGo;
+                stepsToGo = 0;
+            }
+        }
+    }
+
+    // undo inversion of currentAxisDirection after reverse mode is finished
+    if (stepsTarget < 0) {
+    currentAxisDirection = (currentAxisDirection == AXIS_MOVING_LEFT) ? AXIS_MOVING_RIGHT : AXIS_MOVING_LEFT; //toggle between RIGHT<->Left
+    }
+
+    return;
+}
+
+
+//------------------
+//---- travelMm ----
+//------------------
+//move axis certain Mm (relative) between left and right or reverse when negative
+void travelMm(int length){
+    travelSteps(length * STEPPER_STEPS_PER_MM);
+}
+
+
+//----------------------
+//---- init_stepper ----
+//----------------------
+//initialize/configure stepper instance
+void init_stepper() {
+	//TODO unnecessary wrapper?
+    ESP_LOGW(TAG, "initializing stepper...");
+	stepper_init();
+    // create queue for sending commands to task handling guide movement
+    // currently length 1 and only one command possible, thus bool
+    queue_commandsGuideTask = xQueueCreate(1, sizeof(bool));
+}
+
+
+//--------------------------
+//--- updateSpeedFromAdc ---
+//--------------------------
+//function that updates speed value using ADC input and configured MIN/MAX - used for testing only
 void updateSpeedFromAdc() {
     int potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095 GPIO34
     double poti = potiRead/4095.0;
     int speed = poti*(SPEED_MAX-SPEED_MIN) + SPEED_MIN;
-    //....step.setSpeedMm(speed, ACCEL_MS, DECEL_MS);
+	stepper_setSpeed(speed);
     ESP_LOGW(TAG, "poti: %d (%.2lf%%), set speed to: %d", potiRead, poti*100, speed);
 }
 
 
 
-//----------------------------
+//============================
-//---- TASK stepper-test -----
+//==== TASK stepper_test =====
-//----------------------------
+//============================
+//test axis without using encoder input
+#ifndef STEPPER_SIMULATE_ENCODER
 void task_stepper_test(void *pvParameter)
 {
 	stepper_init();
-	int state = 0;
 	while(1){
 		vTaskDelay(20 / portTICK_PERIOD_MS);
 
@@ -183,6 +289,8 @@ void task_stepper_test(void *pvParameter)
 		SW_CUT.handle();
 		SW_AUTO_CUT.handle();
 
+#ifdef ONE_BUTTON_TEST //test with "reset-button" only
+        static int state = 0;
         //cycle through test commands with one button
 		if (SW_RESET.risingEdge) {
 			switch (state){
@@ -208,80 +316,152 @@ void task_stepper_test(void *pvParameter)
 					break;
 			}
 		}
+#else //test with all buttons
+		if (SW_RESET.risingEdge) {
+			buzzer.beep(1, 500, 100);
+			stepper_setTargetPosMm(0);
+		}
+		if (SW_PRESET1.risingEdge) {
+			buzzer.beep(1, 200, 100);
+			stepper_setTargetPosMm(50);
+		}
+		if (SW_PRESET2.risingEdge) {
+			buzzer.beep(2, 200, 100);
+			stepper_setTargetPosMm(75);
+		}
+		if (SW_PRESET3.risingEdge) {
+			buzzer.beep(3, 200, 100);
+			stepper_setTargetPosMm(100);
+		}
+#endif
 	}
-	//	if (SW_PRESET1.risingEdge) {
-	//		buzzer.beep(2, 300, 100);
-	//		stepperSw_setTargetSteps(1000);
-	//	}
-	//	if (SW_PRESET2.risingEdge) {
-	//		buzzer.beep(1, 500, 100);
-	//		stepperSw_setTargetSteps(10000);
-	//	}
-	//	if (SW_PRESET3.risingEdge) {
-	//		buzzer.beep(1, 100, 100);
-	//		stepperSw_setTargetSteps(30000);
-	//	}
 }
+#endif //end SIMULATE_ENCODER
 
 
 
-
+//============================
-//----------------------------
+//===== TASK stepper_ctl =====
-//----- TASK stepper-ctl -----
+//============================
-//----------------------------
+//task controlling the linear axis guiding the cable according to wire length spooled
+#ifdef STEPPER_SIMULATE_ENCODER
+void task_stepper_test(void *pvParameter)
+#else
 void task_stepper_ctl(void *pvParameter)
+#endif
 {
-//    //variables
+    //-- variables --
-//    int encStepsNow = 0; //get curret steps of encoder
+    static int encStepsPrev = 0; //measured encoder steps at last run
-//    int encStepsPrev = 0; //steps at last check
+    static double travelStepsPartial = 0; //store resulted remaining partial steps last run
-//    int encStepsDelta = 0; //steps changed since last iteration
+
-//
+    //temporary variables for calculating required steps, or logging
-//    double cableLen = 0;
+    int encStepsNow = 0; //get curretly measured steps of encoder
-//    double travelStepsExact = 0; //steps axis has to travel
+    int encStepsDelta = 0; //encoder steps changed since last iteration
-//    double travelStepsPartial = 0;
+
-//    int travelStepsFull = 0;
+    double cableLen = 0;
-//    double travelMm = 0;
+    double travelStepsExact = 0; //steps axis has to travel
-//    double turns = 0;
+    int travelStepsFull = 0;
-//
+    double travelMm = 0;
-//    float potiModifier;
+    double turns = 0;
-//
+    float currentDiameter;
-//    init_stepper();
+
-//    home();
+
-//
+
-//    while(1){
+    //initialize stepper at task start
-//        //get current length
+    init_stepper();
-//        encStepsNow = encoder_getSteps();
+    //define zero-position
-//
+    // use last known position stored at last shutdown to reduce time crashing into hardware limit
-//        //calculate change
+    int posLastShutdown = nvsReadLastAxisPosSteps();
-//        encStepsDelta = encStepsNow - encStepsPrev; //FIXME MAJOR BUG: when resetting encoder/length in control task, diff will be huge!
+    if (posLastShutdown >= 0)
-//
+    { // would be -1 when failed
-//        //read potentiometer and normalize (0-1) to get a variable for testing
+        ESP_LOGW(TAG, "auto-home: considerting pos last shutdown %dmm + tolerance %dmm",
-//        potiModifier = (float) gpio_readAdc(ADC_CHANNEL_POTI) / 4095; //0-4095 -> 0-1
+        posLastShutdown / STEPPER_STEPS_PER_MM, 
-//        //ESP_LOGI(TAG, "current poti-modifier = %f", potiModifier);
+        AUTO_HOME_TRAVEL_ADD_TO_LAST_POS_MM);
-//
+        // home considering last position and offset, but limit to max distance possible
-//        //calculate steps to move
+        stepper_home(MIN((posLastShutdown/STEPPER_STEPS_PER_MM + AUTO_HOME_TRAVEL_ADD_TO_LAST_POS_MM), MAX_TOTAL_AXIS_TRAVEL_MM));
-//        cableLen = (double)encStepsDelta * 1000 / ENCODER_STEPS_PER_METER;
+    }
-//        turns = cableLen / (PI * D_REEL);
+    else { // default to max travel when read from nvs failed
-//        travelMm = turns * D_CABLE;
+        stepper_home(MAX_TOTAL_AXIS_TRAVEL_MM);
-//        travelStepsExact = travelMm * STEPPER_STEPS_PER_MM  +  travelStepsPartial; //convert mm to steps and add not moved partial steps
+    }
-//        travelStepsPartial = 0;
+
-//        travelStepsFull = (int)travelStepsExact;
+    //repeatedly read changes in measured cable length and move axis accordingly
-//
+    while(1){
-//        //move axis when ready to move at least 1 step
+
-//        if (abs(travelStepsFull) > 1){
+        // guide is disabled when posMaxSteps is zero:
-//            travelStepsPartial = fmod(travelStepsExact, 1); //save remaining partial steps to be added in the next iteration
+        if (posMaxSteps == 0)
-//            ESP_LOGD(TAG, "cablelen=%.2lf, turns=%.2lf, travelMm=%.3lf, travelStepsExact: %.3lf, travelStepsFull=%d, partialStep=%.3lf", cableLen, turns, travelMm, travelStepsExact, travelStepsFull, travelStepsPartial);
+        {
-//            ESP_LOGI(TAG, "MOVING %d steps", travelStepsFull);
+            // move to starting position
-//            //TODO: calculate variable speed for smoother movement? for example intentionally lag behind and calculate speed according to buffered data
+            stepper_setTargetPosSteps(0);
-//            //....step.setSpeedMm(35, 100, 50);
+            vTaskDelay(1000 / portTICK_PERIOD_MS);
-//            //testing: get speed from poti
+            ESP_LOGD(TAG, "posMaxSteps is zero -> guide disabled, doing nothing");
-//            //step.setSpeedMm(35, 1000*potiModifier+1, 1000*potiModifier+1);
+            // stop loop iteration
-//            travelSteps(travelStepsExact);
+            continue;
-//            encStepsPrev = encStepsNow; //update previous length
+        }
-//        }
+
-//        else {
+#ifdef STEPPER_SIMULATE_ENCODER
-//            //TODO use encoder queue to only run this check at encoder event?
+		//TESTING - simulate encoder using switch
-//            vTaskDelay(2);
+		SW_RESET.handle();
-//        }
+		//note 
-//    }
+		if (SW_RESET.risingEdge) encStepsNow += 500;
+#else
+        //get current length
+        encStepsNow = encoder_getSteps();
+#endif
+
+        // move to zero and reset if command received via queue
+        bool receivedValue;
+        if (xQueueReceive(queue_commandsGuideTask, &receivedValue, 0) == pdTRUE)
+        {
+            // Process the received value
+            // TODO support other commands (currently only move to zero possible)
+            ESP_LOGW(TAG, "task: move-to-zero command received via queue, starting move, waiting until position reached");
+            stepper_setTargetPosMm(0);
+            stepper_waitForStop();
+            //reset variables -> start tracking cable movement starting from position zero
+            // ensure stepsDelta is 0
+            encStepsNow = encoder_getSteps();
+            encStepsPrev = encStepsNow;
+            travelStepsPartial = 0;
+            // set locally stored axis position and counted layers to 0 (used for calculating the target axis coordinate and steps)
+            posNow = 0;
+            layerCount = 0;
+            currentAxisDirection = AXIS_MOVING_RIGHT;
+            ESP_LOGW(TAG, "at position 0, reset variables, resuming normal cable guiding operation");
+        }
+
+        //calculate change
+        encStepsDelta = encStepsNow - encStepsPrev;
+        //check if reset happend without moving to zero before - resulting in huge diff
+        if (encStepsDelta != 0 && encStepsNow == 0){  // this should not happen and causes weird movement
+            ESP_LOGE(TAG, "encoder steps changed to 0 (reset) without previous moveToZero() call, resulting in stepsDelta=%d", encStepsDelta);
+        }
+
+        //read potentiometer and normalize (0-1) to get a variable for testing
+        //float potiModifier = (float) gpio_readAdc(ADC_CHANNEL_POTI) / 4095; //0-4095 -> 0-1
+        //ESP_LOGI(TAG, "current poti-modifier = %f", potiModifier);
+
+        //calculate steps to move
+        cableLen = (double)encStepsDelta * 1000 / ENCODER_STEPS_PER_METER;
+        //effective diameter increases each layer
+        currentDiameter = D_REEL + LAYER_THICKNESS_MM * 2 * layerCount;
+        turns = cableLen / (PI * currentDiameter);
+        travelMm = turns * D_CABLE;
+        travelStepsExact = travelMm * STEPPER_STEPS_PER_MM  +  travelStepsPartial; //convert mm to steps and add not moved partial steps
+        travelStepsPartial = 0;
+        travelStepsFull = (int)travelStepsExact;
+
+        //move axis when ready to move at least 1 full step
+        if (abs(travelStepsFull) > 1){
+            travelStepsPartial = fmod(travelStepsExact, 1); //save remaining partial steps to be added in the next iteration
+            ESP_LOGI(TAG, "dCablelen=%.2lf, dTurns=%.2lf, travelMm=%.3lf, StepsExact: %.3lf, StepsFull=%d, StepsPartial=%.3lf, totalLayerCount=%d, diameter=%.1f", cableLen, turns, travelMm, travelStepsExact, travelStepsFull, travelStepsPartial, layerCount, currentDiameter);
+            ESP_LOGD(TAG, "MOVING %d steps", travelStepsFull);
+            travelSteps(travelStepsExact);
+            encStepsPrev = encStepsNow; //update previous length
+        }
+        else {
+            //TODO use encoder queue to only run this check at encoder event?
+            vTaskDelay(5);
+        }
+		vTaskDelay(5 / portTICK_PERIOD_MS);
+    }
 }

main/guide-stepper.hpp

@@ -10,3 +10,21 @@ void task_stepper_test(void *pvParameter);
 //task that initializes and controls the stepper motor
 //  - moves stepper according to encoder movement
 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();
+
+// 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);

main/main.cpp

@@ -8,14 +8,17 @@ extern "C"
 #include "esp_system.h"
 #include "esp_log.h"
 #include "driver/adc.h"
+
 }
 
-#include "config.hpp"
+#include "config.h"
+#include "global.hpp"
 #include "control.hpp"
 #include "buzzer.hpp"
 #include "switchesAnalog.hpp"
 #include "guide-stepper.hpp"
 #include "encoder.hpp"
+#include "shutdown.hpp"
 
 #include "stepper.hpp"
 
@@ -23,15 +26,20 @@ extern "C"
 //=================================
 //=========== functions ===========
 //=================================
+
+//------------------------
 //--- configure output ---
-//function to configure gpio pin as output
+//------------------------
+//configure a 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 ---
+//--------------------
+//---- init gpios ----
+//--------------------
 void init_gpios(){
     //--- outputs ---
     //4x stepper mosfets
@@ -53,6 +61,8 @@ void init_gpios(){
     //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
+
+    adc1_config_channel_atten(ADC_CHANNEL_SUPPLY_VOLTAGE, ADC_ATTEN_DB_11); //max voltage
 }
 
 
@@ -74,33 +84,40 @@ void task_buzzer( void * pvParameters ){
 //======================================
 extern "C" void app_main()
 {
-    //init outputs
+    //init outputs and adc
     init_gpios();
 
-    //enable 5V volate regulator
+    //enable 5V volage regulator (needed for display)
     gpio_set_level(GPIO_NUM_17, 1);
 
     //init encoder (global)
     encoder_queue = encoder_init();
     
     //define loglevel
-    esp_log_level_set("*", ESP_LOG_INFO);
+    esp_log_level_set("*", ESP_LOG_INFO); //default loglevel
     esp_log_level_set("buzzer", ESP_LOG_ERROR);
     esp_log_level_set("switches-analog", ESP_LOG_WARN);
     esp_log_level_set("control", ESP_LOG_INFO);
-    esp_log_level_set("stepper", ESP_LOG_DEBUG);
+    esp_log_level_set("stepper-driver", ESP_LOG_WARN);
+    esp_log_level_set("stepper-ctrl", ESP_LOG_WARN);
     esp_log_level_set("Dendostepper", ESP_LOG_WARN); //stepper lib
     esp_log_level_set("calc", ESP_LOG_WARN); //stepper lib
+    esp_log_level_set("lowVoltage", ESP_LOG_INFO);
 
 #ifdef STEPPER_TEST
-    //create task for stepper testing
+    //create task for testing the stepper motor
     xTaskCreate(task_stepper_test, "task_stepper_test", configMINIMAL_STACK_SIZE * 3, NULL, 2, NULL);
     //xTaskCreate(task_stepper_debug, "task_stepper_test", configMINIMAL_STACK_SIZE * 3, NULL, 2, NULL);
 #else
+    //create task for detecting power-off
+    xTaskCreate(&task_shutDownDetection, "task_shutdownDet", 2048, NULL, 2, NULL);
+    // wait for nvs to be initialized in shutDownDetection task
+    vTaskDelay(50 / portTICK_PERIOD_MS);
+
     //create task for controlling the machine
     xTaskCreate(task_control, "task_control", configMINIMAL_STACK_SIZE * 3, NULL, 4, NULL);
 
-    //create task for controlling the stepper
+    //create task for controlling the stepper motor (linear axis that guids the cable)
     xTaskCreate(task_stepper_ctl, "task_stepper_ctl", configMINIMAL_STACK_SIZE * 3, NULL, 2, NULL);
 #endif
 

main/shutdown.cpp

@@ -0,0 +1,120 @@
+extern "C"
+{
+#include <stdio.h>
+#include <freertos/FreeRTOS.h>
+#include <freertos/task.h>
+#include "esp_system.h"
+#include "esp_log.h"
+#include "driver/adc.h"
+#include "nvs_flash.h"
+#include "nvs.h"
+}
+
+#include "config.h"
+#include "shutdown.hpp"
+
+#include "guide-stepper.hpp"
+
+#define ADC_LOW_VOLTAGE_THRESHOLD 3200 // adc value where shut down is detected (store certain values before complete power loss)
+
+static const char *TAG = "lowVoltage"; // tag for logging
+nvs_handle_t nvsHandle; // access nvs that was opened once, in any function
+
+
+
+// store a u32 value in nvs as "lastPosSteps"
+void nvsWriteLastAxisPos(uint32_t value)
+{
+    // update nvs value
+    esp_err_t err = nvs_set_u32(nvsHandle, "lastPosSteps", value);
+    if (err != ESP_OK)
+        ESP_LOGE(TAG, "nvs: failed writing");
+    err = nvs_commit(nvsHandle);
+    if (err != ESP_OK)
+        ESP_LOGE(TAG, "nvs: failed committing updates");
+    else
+        ESP_LOGI(TAG, "nvs: successfully committed updates");
+    ESP_LOGW(TAG, "updated value in nvs to %d", value);
+}
+
+
+
+// read "lastPosSteps" from nvs, returns -1 if failed
+int nvsReadLastAxisPosSteps()
+{
+    uint32_t valueRead;
+    esp_err_t err = nvs_get_u32(nvsHandle, "lastPosSteps", &valueRead);
+    switch (err)
+    {
+    case ESP_OK:
+        ESP_LOGW(TAG, "Successfully read value %d from nvs", valueRead);
+        return valueRead;
+        break;
+    case ESP_ERR_NVS_NOT_FOUND:
+        ESP_LOGE(TAG, "nvs: the value '%s' is not initialized yet", "lastPosSteps");
+        return -1;
+        break;
+    default:
+        ESP_LOGE(TAG, "Error (%s) reading nvs!", esp_err_to_name(err));
+        return -1;
+    }
+}
+
+
+
+// task that repeatedly checks supply voltage (12V) and saves certain values to nvs in case of power off detected
+// note: with the 2200uF capacitor in the 12V supply and measuring if 12V start do drop here, there is more than enough time to take action until the 3v3 regulator turns off
+void task_shutDownDetection(void *pvParameter)
+{
+    //--- Initialize NVS ---
+    ESP_LOGW(TAG, "initializing nvs...");
+    esp_err_t err = nvs_flash_init();
+    if (err == ESP_ERR_NVS_NO_FREE_PAGES || err == ESP_ERR_NVS_NEW_VERSION_FOUND)
+    {
+        ESP_LOGE(TAG, "NVS truncated -> deleting flash");
+        // Retry nvs_flash_init
+        ESP_ERROR_CHECK(nvs_flash_erase());
+        err = nvs_flash_init();
+    }
+
+    //--- open nvs-flash ---
+    ESP_LOGW(TAG, "opening NVS-handle...");
+    // create handle available for all functions in this file
+    err = nvs_open("storage", NVS_READWRITE, &nvsHandle);
+    if (err != ESP_OK)
+        ESP_LOGE(TAG, "Error (%s) opening NVS handle!\n", esp_err_to_name(err));
+
+    // read stored value (returns 0 if unitialized/failed)
+    //int lastPosSteps = nvsReadLastAxisPosSteps();
+    //ESP_LOGW(TAG, "=> read value %d from nvs (stored at last shutdown)", lastPosSteps);
+
+    // repeatedly read ADC and check if below low voltage threshold
+    bool voltageBelowThreshold = false;
+    while (1) //TODO limit save frequency in case voltage repeadedly varys between threshold for some reason (e.g. offset drift)
+    {
+        // read adc
+        int adc_reading = adc1_get_raw(ADC_CHANNEL_SUPPLY_VOLTAGE);
+
+        // evaulate threshold
+        if (adc_reading < ADC_LOW_VOLTAGE_THRESHOLD) // below threshold => POWER SHUTDOWN DETECTED
+        {
+            // write to nvs and log once at change to below
+            if (!voltageBelowThreshold){
+                nvsWriteLastAxisPos(guide_getAxisPosSteps());
+                ESP_LOGE(TAG, "voltage now below threshold!  now=%d threshold=%d -> wrote last axis-pos to nvs", adc_reading, ADC_LOW_VOLTAGE_THRESHOLD);
+                voltageBelowThreshold = true;
+            }
+        }
+        else if (voltageBelowThreshold) // above threshold and previously below
+        {
+            // log at change to above
+            ESP_LOGE(TAG, "voltage above threshold again: %d > %d - issue with power supply, or too threshold too high?", adc_reading, ADC_LOW_VOLTAGE_THRESHOLD);
+            voltageBelowThreshold = false;
+        }
+
+        // always log for debugging/calibrating
+        ESP_LOGD(TAG, "read adc battery voltage: %d", adc_reading);
+
+        vTaskDelay(30 / portTICK_PERIOD_MS);
+    }
+}

main/shutdown.hpp

@@ -0,0 +1,7 @@
+
+// task that repeatedly checks supply voltage (12V) and saves certain values to nvs in case of it drops below a certain threshold (power off detected)
+void task_shutDownDetection(void *pvParameter);
+
+// read last axis position in steps from nvs
+// returns -1 when reading from nvs failed
+int nvsReadLastAxisPosSteps();

main/stepper.cpp

@@ -1,5 +1,6 @@
 //custom driver for stepper motor
-#include "config.hpp"
+#include "config.h"
+#include "global.hpp"
 #include "hal/timer_types.h"
 #include <cstdint>
 #include <inttypes.h>
@@ -10,16 +11,19 @@ extern "C" {
 #include "esp_log.h"
 }
 
-//config from config.hpp
+
+//=====================
+//=== configuration ===
+//=====================
+//used macros from config.h:
 //#define STEPPER_STEP_PIN GPIO_NUM_18    //mos1
 //#define STEPPER_DIR_PIN GPIO_NUM_16     //ST3
 
-#define STEPPER_STEPS_PER_MM	200/2	//steps/mm
+//#define STEPPER_STEPS_PER_MM	200/2	//steps/mm (steps-per-rot / slope)
-#define STEPPER_SPEED_DEFAULT	20		//mm/s
+//#define STEPPER_SPEED_DEFAULT	20		//mm/s
-#define STEPPER_SPEED_MIN		4		//mm/s  - speed at which stepper immediately starts/stops
+//#define STEPPER_SPEED_MIN		4		//mm/s  - speed threshold at which stepper immediately starts/stops
-#define STEPPER_ACCEL_INC		3		//steps/s per cycle 
+//#define STEPPER_ACCEL_INC		3		//steps/s increment per cycle 
-#define STEPPER_DECEL_INC		8		//steps/s per cycle
+//#define STEPPER_DECEL_INC		8		//steps/s decrement per cycle
-
 
 #define TIMER_F 1000000ULL
 #define TICK_PER_S TIMER_S
@@ -30,7 +34,7 @@ extern "C" {
 //========================
 //=== global variables ===
 //========================
-static const char *TAG = "stepper-ctl"; //tag for logging
+static const char *TAG = "stepper-driver"; //tag for logging
 									
 bool direction = 1;
 bool directionTarget = 1;
@@ -91,7 +95,7 @@ void task_stepper_debug(void *pvParameter){
 //===== set speed =====
 //=====================
 void stepper_setSpeed(uint32_t speedMmPerS) {
-	ESP_LOGW(TAG, "set target speed from %u to %u mm/s  (%u steps/s)",
+	ESP_LOGI(TAG, "set target speed from %u to %u mm/s  (%u steps/s)",
 			speedTarget, speedMmPerS, speedMmPerS * STEPPER_STEPS_PER_MM);
 	speedTarget = speedMmPerS * STEPPER_STEPS_PER_MM;
 }
@@ -102,14 +106,14 @@ void stepper_setSpeed(uint32_t speedMmPerS) {
 //== set target pos STEPS ==
 //==========================
 void stepper_setTargetPosSteps(uint64_t target_steps) {
-	ESP_LOGW(TAG, "update target position from %llu to %llu  steps (stepsNow: %llu", posTarget, target_steps, posNow);
+	ESP_LOGI(TAG, "update target position from %llu to %llu  steps (stepsNow: %llu", posTarget, target_steps, posNow);
 	posTarget = target_steps;
 
   // Check if the timer is currently paused
   if (!timerIsRunning){
     // If the timer is paused, start it again with the updated targetSteps
 	timerIsRunning = true;
-	ESP_LOGW(TAG, "starting timer because did not run before");
+	ESP_LOGI(TAG, "starting timer");
     ESP_ERROR_CHECK(timer_set_alarm_value(timerGroup, timerIdx, 1000));
     //timer_set_counter_value(timerGroup, timerIdx, 1000);
     ESP_ERROR_CHECK(timer_start(timerGroup, timerIdx));
@@ -122,24 +126,67 @@ void stepper_setTargetPosSteps(uint64_t target_steps) {
 //=== set target pos MM ===
 //=========================
 void stepper_setTargetPosMm(uint32_t posMm){
-	ESP_LOGW(TAG, "set target position to %u mm", posMm);
+	ESP_LOGI(TAG, "set target position to %u mm", posMm);
 	stepper_setTargetPosSteps(posMm * STEPPER_STEPS_PER_MM);
 }
 
 
 
+//=======================
+//===== waitForStop =====
+//=======================
+//delay until stepper is stopped, optional timeout in ms, 0 = no limit
+void stepper_waitForStop(uint32_t timeoutMs){
+	ESP_LOGI(TAG, "waiting for stepper to stop...");
+	uint32_t timestampStart = esp_log_timestamp();	
+	while (timerIsRunning) {
+		if ( (esp_log_timestamp() - timestampStart) >= timeoutMs && timeoutMs != 0){
+			ESP_LOGE(TAG, "timeout waiting for stepper to stop");
+			return;
+		}
+		vTaskDelay(100 / portTICK_PERIOD_MS);
+	}
+	ESP_LOGI(TAG, "finished waiting stepper to stop");
+	return;
+}
+
+
+
+//======================
+//======== home ========
+//======================
+//define zero/start position 
+//run to limit and define zero/start position. 
+//Currently simply runs stepper for travelMm and bumps into hardware limit
+void stepper_home(uint32_t travelMm){
+	//TODO add timeout, limitswitch...
+	ESP_LOGW(TAG, "initiate auto-home, moving %d mm...", travelMm);
+	posNow = travelMm * STEPPER_STEPS_PER_MM;
+	while (posNow != 0){
+		//reactivate just in case stopped by other call to prevent deadlock
+		if (!timerIsRunning) {
+			stepper_setTargetPosSteps(0);
+		}
+		vTaskDelay(100 / portTICK_PERIOD_MS);
+	}
+	ESP_LOGW(TAG, "finished auto-home");
+	return;
+}
+
+
+
 //========================
 //===== init stepper =====
 //========================
 void stepper_init(){
-	ESP_LOGW(TAG, "init - configure struct...");
+	ESP_LOGI(TAG, "init - configure struct...");
 
 	// Configure pulse and direction pins as outputs
-	ESP_LOGW(TAG, "init - configure gpio pins...");
+	ESP_LOGI(TAG, "init - configure gpio pins...");
 	gpio_set_direction(STEPPER_DIR_PIN, GPIO_MODE_OUTPUT);
 	gpio_set_direction(STEPPER_STEP_PIN, GPIO_MODE_OUTPUT);
 
-	ESP_LOGW(TAG, "init - initialize/configure timer...");
+	ESP_LOGI(TAG, "init - initialize/configure timer...");
 	timer_config_t timer_conf = {
 		.alarm_en = TIMER_ALARM_EN,         // we need alarm
 		.counter_en = TIMER_PAUSE,          // dont start now lol
@@ -193,8 +240,16 @@ bool timer_isr(void *arg) {
 	//FIXME noticed crash: division by 0 when min speed > target speed
 	uint64_t stepsDecelRemaining = (speedNow - speedMin) / decel_increment;
 	//DECELERATE
+
+	//prevent hard stop (faster stop than decel ramp)
+	//Idea: when target gets lowered while decelerating, 
+	//      move further than target to not exceed decel ramp (overshoot),
+	//      then change dir and move back to actual target pos
+	if (stepsToGo < stepsDecelRemaining/2){ //significantly less steps planned to comply with decel ramp
+		stepsToGo = stepsDecelRemaining; //set to required steps
+	}
+
 	if (stepsToGo <= stepsDecelRemaining) {
-		//FIXME if stepsToGo gets updated (lowered) close to target while close to target, the stepper may stop too fast -> implement possibility to 'overshoot and reverse'?
 		if ((speedNow - speedMin) > decel_increment) {
 			speedNow -= decel_increment;
 		} else {

main/stepper.hpp

@@ -2,12 +2,24 @@
 
 //init stepper pins and timer
 void stepper_init();
+
+//delay until stepper is stopped, optional timeout in ms, 0 = no limit
+void stepper_waitForStop(uint32_t timeoutMs = 0);
+
+//run to limit and define zero/start position. (busy until finished)
+//Currently simply runs stepper for travelMm and bumps into hardware limit
+void stepper_home(uint32_t travelMm = 60);
+
 //set absolute target position in steps
 void stepper_setTargetPosSteps(uint64_t steps);
+
 //set absolute target position in millimeters
 void stepper_setTargetPosMm(uint32_t posMm);
+
 //set target speed in millimeters per second
 void stepper_setSpeed(uint32_t speedMmPerS);
 
+
+
 //task that periodically logs variables for debugging stepper driver
 void task_stepper_debug(void *pvParameter);

main/switchesAnalog.cpp

@@ -1,4 +1,6 @@
 #include "switchesAnalog.hpp"
+#include "config.h"
+#include "global.hpp"
 
 #define CHECK_BIT(var,pos) (((var)>>(pos)) & 1) //TODO duplicate code: same macro already used in vfd.cpp
 

main/switchesAnalog.hpp

@@ -8,7 +8,6 @@ extern "C"
 #include <math.h>
 }
 
-#include "config.hpp"
 #include "gpio_adc.hpp"
 
 

main/vfd.cpp

@@ -1,4 +1,6 @@
 #include "vfd.hpp"
+#include "config.h"
+#include "global.hpp"
 
 #define CHECK_BIT(var,pos) (((var)>>(pos)) & 1)
 

main/vfd.hpp

@@ -9,7 +9,6 @@ extern "C"
 #include "esp_log.h"
 }
 
-#include "config.hpp"
 
 //enum defining motor direction
 typedef enum vfd_direction_t {FWD, REV} vfd_direction_t;

sdkconfig

@@ -415,7 +415,6 @@ CONFIG_ESP_MAC_ADDR_UNIVERSE_ETH=y
 # CONFIG_ESP32_UNIVERSAL_MAC_ADDRESSES_TWO is not set
 CONFIG_ESP32_UNIVERSAL_MAC_ADDRESSES_FOUR=y
 CONFIG_ESP32_UNIVERSAL_MAC_ADDRESSES=4
-# CONFIG_ESP_MAC_IGNORE_MAC_CRC_ERROR is not set
 # end of MAC Config
 
 #