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cable-length-cutter/main/control.cpp
jonny_l480 84c88e8f02 Fix deadlock in windingWidth, Handle 0 width, optimize UI 
guide-stepper:
- fix deadlock when editing winding width
- fix behaivor when windingWidth is set to 0 (disable guide)

control:
- add dead time to prevent setTarget when exiting setWindingWidth with buttons
- fix typo and conditons
- increase max winding width
- optimize display text
2024-03-16 11:47:20 +01:00

583 lines
24 KiB
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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 ---------------
//-----------------------------------------
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_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
static int potiRead = 0; //voltage read from adc
static uint32_t timestamp_motorStarted = 0; //timestamp winding started
//automatic cut
static int cut_msRemaining = 0;
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
if (controlState == stateNew) {
return; //already at target state -> nothing to do
}
//log change
ESP_LOGW(TAG, "changed state from %s to %s", systemStateStr[(int)controlState], systemStateStr[(int)stateNew]);
//change state
controlState = stateNew;
//update timestamp
timestamp_lastStateChange = esp_log_timestamp();
}
//=================================
//===== handle Stop Condition =====
//=================================
//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 -> reached state, stop motor, display message
if (lengthRemaining <= 0 ) {
changeState(systemState_t::TARGET_REACHED);
vfd_setState(false);
displayTop->blink(1, 0, 1000, " S0LL ");
displayBot->blink(1, 0, 1000, "ERREICHT");
buzzer.beep(2, 100, 100);
return true;
}
//start button released -> idle state, stop motor, display message
else if (SW_START.state == false) {
changeState(systemState_t::COUNTING);
vfd_setState(false);
displayTop->blink(2, 900, 1000, "- STOP -");
displayBot->blink(2, 900, 1000, " TASTER ");
buzzer.beep(3, 200, 100);
return true;
} else {
return false;
}
}
//===================================
//===== set dynamic speed level =====
//===================================
//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;
//define speed level according to difference
if (lengthRemaining < 40) {
lvl = 0;
} else if (lengthRemaining < 300) {
lvl = 1;
} else if (lengthRemaining < 700) {
lvl = 2;
} else { //more than last step remaining
lvl = 3;
}
//limit to max lvl
if (lvl > lvlMax) {
lvl = lvlMax;
}
//update vfd speed level
vfd_setSpeedLevel(lvl);
}
//========================
//===== control task =====
//========================
//task that controls the entire machine
void task_control(void *pvParameter)
{
//-- initialize display --
max7219_t two7SegDisplays = display_init();
//create two separate custom handled display instances
handledDisplay displayTop(two7SegDisplays, 0);
handledDisplay displayBot(two7SegDisplays, 8);
//-- display welcome msg --
//display welcome message on two 7 segment displays
//currently show name and date and scrolling 'hello'
display_ShowWelcomeMsg(two7SegDisplays);
// ##############################
// ######## control loop ########
// ##############################
// repeatedly handle the machine
while(1){
vTaskDelay(10 / portTICK_PERIOD_MS);
//------ handle switches ------
//run handle functions for all switches used here
SW_START.handle();
SW_RESET.handle();
SW_SET.handle();
SW_PRESET1.handle();
SW_PRESET2.handle();
SW_PRESET3.handle();
SW_CUT.handle();
SW_AUTO_CUT.handle();
//------ handle cutter ------
//TODO: separate task for cutter?
cutter_handle();
//------ rotary encoder ------
//get current length since last reset
lengthNow = encoder_getLenMm();
//--------- buttons ---------
//#### RESET switch ####
if (SW_RESET.risingEdge) {
//dont reset when press used for stopping pending auto-cut
if (controlState != systemState_t::AUTO_CUT_WAITING) {
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 ");
//TODO: stop cutter with reset switch?
//cutter_stop();
}
}
//### CUT switch ####
//start cut cycle immediately
if (SW_CUT.risingEdge) {
//stop cutter if already running
if (cutter_isRunning()) {
cutter_stop();
buzzer.beep(1, 600, 0);
}
else if (controlState == systemState_t::AUTO_CUT_WAITING) {
//do nothing when press used for stopping pending auto-cut
}
//start cutter when motor not active
else if (controlState != systemState_t::WINDING_START //TODO use vfd state here?
&& controlState != systemState_t::WINDING) {
cutter_start();
buzzer.beep(1, 70, 50);
}
//error cant cut while motor is on
else {
buzzer.beep(6, 100, 50);
}
}
//#### AUTO_CUT toggle sw ####
//beep at change
if (SW_AUTO_CUT.risingEdge) {
buzzer.beep(2, 100, 50);
} else if (SW_AUTO_CUT.fallingEdge) {
buzzer.beep(1, 400, 50);
}
//update enabled state
if (SW_AUTO_CUT.state) {
//enable autocut when not in target_reached state
//(prevent immediate/unexpected cut)
if (controlState != systemState_t::TARGET_REACHED) {
autoCutEnabled = true;
}
} else {
//disable anytime (also stops countdown to auto cut)
autoCutEnabled = false;
}
//#### manual mode ####
//switch to manual motor control (2 buttons + poti)
if ( SW_PRESET2.state && (SW_PRESET1.state || SW_PRESET3.state) && controlState != systemState_t::MANUAL ) {
//enable manual control
changeState(systemState_t::MANUAL);
buzzer.beep(3, 100, 60);
}
//##### SET switch + Potentiometer #####
//## set winding-width (SET+PRESET1+POTI) ##
// set winding width (axis travel) with poti position
// when SET and PRESET1 button are pressed
if (SW_SET.state == true && SW_PRESET1.state == true) {
timestamp_lastWidthSelect = esp_log_timestamp();
//read adc
potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
//scale to target length range
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);
lengthTargetNew = (lengthTargetNew/1000 ) * 1000; //round down
} else if (lengthTargetNew % 1000 > 800 ) { //round up if more than .8 meter
ESP_LOGD(TAG, "Poti input = %d -> rounding up", lengthTargetNew);
lengthTargetNew = (lengthTargetNew/1000 + 1) * 1000; //round up
} else {
ESP_LOGD(TAG, "Poti input = %d -> hysteresis", lengthTargetNew);
lengthTargetNew = lengthTarget;
}
//update target length and beep when effectively changed
if (lengthTargetNew != lengthTarget) {
//TODO update lengthTarget only at button release?
lengthTarget = lengthTargetNew;
ESP_LOGI(TAG, "Changed target length to %d mm", lengthTarget);
buzzer.beep(1, 25, 10);
}
}
//beep start and end of editing
if (SW_SET.risingEdge) {
buzzer.beep(1, 70, 50);
}
if (SW_SET.fallingEdge) {
buzzer.beep(2, 70, 50);
displayBot.blink(2, 100, 100, "S0LL ");
}
//##### target length 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;
buzzer.beep(lengthTarget/1000, 25, 30);
displayBot.blink(2, 100, 100, "S0LL ");
}
else if (SW_PRESET2.risingEdge) {
lengthTarget = 10000;
buzzer.beep(lengthTarget/1000, 25, 30);
displayBot.blink(2, 100, 100, "S0LL ");
}
else if (SW_PRESET3.risingEdge) {
lengthTarget = 15000;
buzzer.beep(lengthTarget/1000, 25, 30);
displayBot.blink(2, 100, 100, "S0LL ");
}
}
//---------------------------
//--------- control ---------
//---------------------------
//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, 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 ---
if (SW_START.risingEdge) {
changeState(systemState_t::WINDING_START);
vfd_setSpeedLevel(1); //start at low speed
vfd_setState(true); //start motor
timestamp_motorStarted = esp_log_timestamp(); //save time started
buzzer.beep(1, 100, 0);
}
break;
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);
}
handleStopCondition(&displayTop, &displayBot); //stops if button released or target reached
//TODO: cancel when there was no cable movement during start time?
break;
case systemState_t::WINDING: //wind fast, slow down when close
//set vfd speed depending on remaining distance
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: //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);
}
//initiate countdown to auto-cut if enabled
else if ( (autoCutEnabled)
&& (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 already reached (-> reset button has to be pressed)
if (SW_START.risingEdge) {
buzzer.beep(2, 50, 30);
displayTop.blink(2, 600, 500, " S0LL ");
displayBot.blink(2, 600, 500, "ERREICHT");
}
break;
case systemState_t::AUTO_CUT_WAITING: //handle delayed start of cut
cut_msRemaining = autoCut_delayMs - (esp_log_timestamp() - timestamp_lastStateChange);
//- countdown stop conditions -
//stop with any button
if (!autoCutEnabled
|| SW_RESET.state || SW_CUT.state
|| SW_SET.state || SW_PRESET1.state
|| SW_PRESET2.state || SW_PRESET3.state) {//TODO: also stop when target not reached anymore?
changeState(systemState_t::COUNTING);
buzzer.beep(5, 100, 50);
}
//- trigger cut if delay passed -
else if (cut_msRemaining <= 0) {
cutter_start();
changeState(systemState_t::CUTTING);
}
//- beep countdown -
//time passed since last beep > time remaining / 6
else if ( (esp_log_timestamp() - timestamp_cut_lastBeep) > (cut_msRemaining / 6)
&& (esp_log_timestamp() - timestamp_cut_lastBeep) > 50 ) { //dont trigger beeps faster than beep time
buzzer.beep(1, 50, 0);
timestamp_cut_lastBeep = esp_log_timestamp();
}
break;
case systemState_t::CUTTING: //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?
guide_moveToZero(); //move axis guiding the cable to start position
encoder_reset(); //reset length measurement
lengthNow = 0;
buzzer.beep(1, 700, 100);
}
break;
case systemState_t::MANUAL: //manually control motor via preset buttons + poti
//read poti value
potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
//scale poti to speed levels 0-3
uint8_t level = round( (float)potiRead / 4095 * 3 );
//exit manual mode if preset2 released
if ( SW_PRESET2.state == false ) {
changeState(systemState_t::COUNTING);
buzzer.beep(1, 1000, 100);
}
//P2 + P1 -> turn left
else if ( SW_PRESET1.state && !SW_PRESET3.state ) {
vfd_setSpeedLevel(level);
vfd_setState(true, REV);
sprintf(buf_disp2, "[--%02i ", level);
// 123 45 678
}
//P2 + P3 -> turn right
else if ( SW_PRESET3.state && !SW_PRESET1.state ) {
vfd_setSpeedLevel(level);
vfd_setState(true, FWD);
sprintf(buf_disp2, " %02i--]", level);
}
//no valid switch combination -> turn off motor
else {
vfd_setState(false);
sprintf(buf_disp2, " %02i ", level);
}
}
#ifdef ENCODER_TEST
//--------------------------
//------ 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
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 0.5m ---
//note: only works precisely in forward/positive direction, in reverse it it beeps by tolerance too early
static int lengthBeeped = 0;
if (lengthNow % 500 < 50) { //with tolerance in case of missed exact value
if (fabs(lengthNow - lengthBeeped) >= 400) { //dont beep multiple times at same distance
//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 //not in encoder calibration mode
//--------------------------
//-------- display1 --------
//--------------------------
//run handle function
displayTop.handle();
//indicate upcoming cut when pending
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);
// 123456789
//limit length to 8 digits + decimal point (drop decimal places when it does not fit)
sprintf(buf_disp1, "%.9s", buf_tmp);
displayTop.showString(buf_disp1);
}
//--------------------------
//-------- display2 --------
//--------------------------
//run handle function
displayBot.handle();
//notify that cutter is active
if (cutter_isRunning()) {
displayBot.blinkStrings("CUTTING]", "CUTTING[", 100, 100);
}
//show ms countdown to cut when pending
else if (controlState == systemState_t::AUTO_CUT_WAITING) {
sprintf(buf_disp2, " %04d ", cut_msRemaining);
//displayBot.showString(buf_disp2); //TODO:blink "erreicht" overrides this. for now using blink as workaround
displayBot.blinkStrings(buf_disp2, buf_disp2, 100, 100);
}
//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
sprintf(buf_tmp, "S0LL%5.3f", (float)lengthTarget/1000); //m
// 1234 5678
displayBot.showString(buf_tmp);
}
#endif // end else ifdef ENCODER_TEST
//----------------------------
//------- control lamp -------
//----------------------------
//basic functionality of lamp:
//turn on when not idling
//TODO: add switch-case for different sates
//e.g. blink with different frequencies in different states
if (controlState != systemState_t::COUNTING
&& controlState != systemState_t::TARGET_REACHED) {
gpio_set_level(GPIO_LAMP, 1);
}
else {
gpio_set_level(GPIO_LAMP, 0);
}
} //end while(1)
} //end task_control
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