989f9cce13
- guide-stepper:
- add queue to send commands to stepper-ctl task
- add function that tells stepper task to move to zero
- increase travel length full axis length 110
- control: move guide to zero at reset
- Cmake: enable colored output
505 lines
19 KiB
C++
505 lines
19 KiB
C++
#include "control.hpp"
|
|
#include "encoder.hpp"
|
|
#include "guide-stepper.hpp"
|
|
|
|
|
|
//====================
|
|
//==== variables =====
|
|
//====================
|
|
static const char *TAG = "control"; //tag for logging
|
|
|
|
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 char buf_disp1[10];// 8 digits + decimal point + \0
|
|
static char buf_disp2[10];// 8 digits + decimal point + \0
|
|
static char buf_tmp[15];
|
|
|
|
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)
|
|
|
|
|
|
//===== 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_changedState = esp_log_timestamp();
|
|
}
|
|
|
|
|
|
|
|
//===== handle Stop Condition =====
|
|
//function that checks whether start button is released or target is reached (used in multiple states)
|
|
//returns true when stopped, false when no action
|
|
bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBot){
|
|
//--- stop conditions ---
|
|
//stop conditions that are checked in any mode
|
|
//target reached
|
|
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
|
|
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 dynamicly 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 =====
|
|
//========================
|
|
void task_control(void *pvParameter)
|
|
{
|
|
|
|
//initialize display
|
|
max7219_t two7SegDisplays = display_init();
|
|
//create two separate 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);
|
|
|
|
|
|
//================
|
|
//===== loop =====
|
|
//================
|
|
while(1){
|
|
vTaskDelay(10 / portTICK_PERIOD_MS);
|
|
|
|
//-----------------------------
|
|
//------ handle switches ------
|
|
//-----------------------------
|
|
//run handle functions for all switches
|
|
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 ------
|
|
//---------------------------
|
|
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();
|
|
encoder_reset();
|
|
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 custom target length ---
|
|
//set target length to poti position when SET switch is pressed
|
|
if (SW_SET.state == true) {
|
|
//read adc
|
|
potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
|
|
//scale to target length range
|
|
int lengthTargetNew = (float)potiRead / 4095 * 50000;
|
|
//apply hysteresis and round to whole meters //TODO optimize this
|
|
if (lengthTargetNew % 1000 < 200) { //round down if less than .2 meter
|
|
ESP_LOGD(TAG, "Poti input = %d -> rounding down", lengthTargetNew);
|
|
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 presets ---
|
|
if (controlState != systemState_t::MANUAL) { //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 ---------
|
|
//---------------------------
|
|
//calculate length difference
|
|
lengthRemaining = lengthTarget - lengthNow + TARGET_LENGTH_OFFSET;
|
|
|
|
//--- statemachine ---
|
|
switch (controlState) {
|
|
case systemState_t::COUNTING: //no motor action
|
|
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)
|
|
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(); //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:
|
|
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
|
|
else if ( (autoCutEnabled)
|
|
&& (esp_log_timestamp() - timestamp_changedState > 300) ) { //wait for dislay msg "reached" to finish
|
|
changeState(systemState_t::AUTO_CUT_WAITING);
|
|
}
|
|
//show msg when trying to start, but target is reached
|
|
if (SW_START.risingEdge) {
|
|
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_changedState);
|
|
//- countdown stop conditions -
|
|
//stop with any button
|
|
if (!autoCutEnabled
|
|
|| SW_RESET.state || SW_CUT.state
|
|
|| SW_SET.state || SW_PRESET1.state
|
|
|| SW_PRESET2.state || SW_PRESET3.state) {//TODO: also stop when target not reached anymore?
|
|
changeState(systemState_t::COUNTING);
|
|
buzzer.beep(5, 100, 50);
|
|
}
|
|
//- trigger cut if delay passed -
|
|
else if (cut_msRemaining <= 0) {
|
|
cutter_start();
|
|
changeState(systemState_t::CUTTING);
|
|
}
|
|
//- beep countdown -
|
|
//time passed since last beep > time remaining / 6
|
|
else if ( (esp_log_timestamp() - timestamp_cut_lastBeep) > (cut_msRemaining / 6)
|
|
&& (esp_log_timestamp() - timestamp_cut_lastBeep) > 50 ) { //dont trigger beeps faster than beep time
|
|
buzzer.beep(1, 50, 0);
|
|
timestamp_cut_lastBeep = esp_log_timestamp();
|
|
}
|
|
break;
|
|
|
|
case systemState_t::CUTTING:
|
|
//exit when finished cutting
|
|
if (cutter_isRunning() == false) {
|
|
//TODO stop if start buttons released?
|
|
changeState(systemState_t::COUNTING);
|
|
//TODO reset automatically or wait for manual reset?
|
|
guide_moveToZero();
|
|
encoder_reset();
|
|
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);
|
|
}
|
|
}
|
|
|
|
|
|
|
|
//--------------------------
|
|
//------ encoder test ------
|
|
//--------------------------
|
|
#ifdef ENCODER_TEST
|
|
//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 1m ---
|
|
//note: only works precicely in forward/positive direction
|
|
if (lengthNow % 1000 < 50) { //with tolerance in case of missed exact value
|
|
if (fabs(lengthNow - lengthBeeped) >= 900) { //dont beep multiple times at same meter
|
|
//TODO: add case for reverse direction. currently beeps 0.1 too early
|
|
buzzer.beep(1, 400, 100 );
|
|
lengthBeeped = lengthNow;
|
|
}
|
|
}
|
|
#else
|
|
|
|
//--------------------------
|
|
//-------- display1 --------
|
|
//--------------------------
|
|
//run handle function
|
|
displayTop.handle();
|
|
//indicate upcoming cut when pending
|
|
if (controlState == systemState_t::AUTO_CUT_WAITING) {
|
|
displayTop.blinkStrings(" CUT 1N ", " ", 70, 30);
|
|
}
|
|
//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();
|
|
//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()) {
|
|
displayBot.blinkStrings("CUTTING]", "CUTTING[", 100, 100);
|
|
}
|
|
//show ms countdown to cut when pending
|
|
else if (controlState == systemState_t::AUTO_CUT_WAITING) {
|
|
sprintf(buf_disp2, " %04d ", cut_msRemaining);
|
|
//displayBot.showString(buf_disp2); //TODO:blink "erreicht" overrides this. for now using blink as workaround
|
|
displayBot.blinkStrings(buf_disp2, buf_disp2, 100, 100);
|
|
}
|
|
//otherwise show target length
|
|
else {
|
|
//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);
|
|
}
|
|
|
|
|
|
//----------------------------
|
|
//------- 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);
|
|
}
|
|
|
|
|
|
|
|
#endif
|
|
|
|
}
|
|
|
|
}
|