bb7cdddc6c
Fix bug where display is stuck when countdown stopped via reset button Add functionality to stop countdown via turning auto-cut switch off Fix display priority issues with using 2 boolean variables and a delay before counting
499 lines
19 KiB
C++
499 lines
19 KiB
C++
#include "control.hpp"
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//========================
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//===== init encoder =====
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//========================
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QueueHandle_t init_encoder(rotary_encoder_info_t * info){
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// esp32-rotary-encoder requires that the GPIO ISR service is installed before calling rotary_encoder_register()
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ESP_ERROR_CHECK(gpio_install_isr_service(0));
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// Initialise the rotary encoder device with the GPIOs for A and B signals
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ESP_ERROR_CHECK(rotary_encoder_init(info, ROT_ENC_A_GPIO, ROT_ENC_B_GPIO));
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ESP_ERROR_CHECK(rotary_encoder_enable_half_steps(info, ENABLE_HALF_STEPS));
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#ifdef FLIP_DIRECTION
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ESP_ERROR_CHECK(rotary_encoder_flip_direction(info));
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#endif
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// Create a queue for events from the rotary encoder driver.
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// Tasks can read from this queue to receive up to date position information.
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QueueHandle_t event_queue = rotary_encoder_create_queue();
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ESP_ERROR_CHECK(rotary_encoder_set_queue(info, event_queue));
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return event_queue;
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}
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//====================
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//==== variables =====
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//====================
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static const char *TAG = "control"; //tag for logging
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const char* systemStateStr[6] = {"COUNTING", "WINDING_START", "WINDING", "TARGET_REACHED", "CUTTING", "MANUAL"};
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systemState_t controlState = systemState_t::COUNTING;
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uint32_t timestamp_changedState = 0;
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char buf_disp[20]; //both displays
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char buf_disp1[10];// 8 digits + decimal point + \0
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char buf_disp2[10];// 8 digits + decimal point + \0
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char buf_tmp[15];
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rotary_encoder_info_t encoder; //encoder device/info
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QueueHandle_t encoder_queue = NULL; //encoder event queue
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rotary_encoder_state_t encoderState;
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int lengthNow = 0; //length measured in mm
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int lengthTarget = 3000; //target length in mm
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int lengthRemaining = 0; //(target - now) length needed for reaching the target
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int potiRead = 0; //voltage read from adc
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uint32_t timestamp_motorStarted = 0; //timestamp winding started
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//encoder test / calibration
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int lengthBeeped = 0; //only beep once per meter during encoder test
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//automatic cut
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int cut_msRemaining = 0;
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uint32_t timestamp_cut_lastBeep = 0;
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uint32_t autoCut_delayMs = 3000; //TODO add this to config
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bool autoCutEnabled = false; //store state of toggle switch (no hotswitch)
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bool autoCutWaiting = false; //currently waiting (for display)
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//===== change State =====
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//function for changing the controlState with log output
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void changeState (systemState_t stateNew) {
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//only proceed when state actually changed
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if (controlState == stateNew){
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return; //already at target state -> nothing to do
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}
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//log change
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ESP_LOGW(TAG, "changed state from %s to %s", systemStateStr[(int)controlState], systemStateStr[(int)stateNew]);
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//change state
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controlState = stateNew;
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//update timestamp
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timestamp_changedState = esp_log_timestamp();
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}
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//===== handle Stop Condition =====
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//function that checks whether start button is released or target is reached (used in multiple states)
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//returns true when stopped, false when no action
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bool handleStopCondition(handledDisplay * displayTop, handledDisplay * displayBot){
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//--- stop conditions ---
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//stop conditions that are checked in any mode
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//target reached
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if (lengthRemaining <= 0 ) {
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changeState(systemState_t::TARGET_REACHED);
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vfd_setState(false);
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displayTop->blink(1, 0, 1000, " S0LL ");
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displayBot->blink(1, 0, 1000, "ERREICHT");
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buzzer.beep(2, 100, 100);
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//store current state once at change to TARGET_REACHED
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//(prevent unwanted cut when enabling while already TARGET_REACHED state)
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autoCutEnabled = SW_AUTO_CUT.state;
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return true;
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}
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//start button released
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else if (SW_START.state == false) {
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changeState(systemState_t::COUNTING);
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vfd_setState(false);
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displayTop->blink(2, 900, 1000, "- STOP -");
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displayBot->blink(2, 900, 1000, " TASTER ");
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buzzer.beep(3, 200, 100);
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return true;
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} else {
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return false;
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}
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}
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//===== set dynamic speed level =====
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//function that sets the vfd speed level dynamicly depending on the remaining distance
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//closer to target -> slower
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void setDynSpeedLvl(uint8_t lvlMax = 3){
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uint8_t lvl;
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//define speed level according to difference
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if (lengthRemaining < 20) {
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lvl = 0;
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} else if (lengthRemaining < 200) {
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lvl = 1;
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} else if (lengthRemaining < 600) {
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lvl = 2;
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} else { //more than last step remaining
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lvl = 3;
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}
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//limit to max lvl
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if (lvl > lvlMax){
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lvl = lvlMax;
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}
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//update vfd speed level
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vfd_setSpeedLevel(lvl);
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}
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//========================
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//===== control task =====
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//========================
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void task_control(void *pvParameter)
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{
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//initialize encoder
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encoder_queue = init_encoder(&encoder);
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//initialize display
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max7219_t two7SegDisplays = display_init();
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//create two separate handled display instances
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handledDisplay displayTop(two7SegDisplays, 0);
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handledDisplay displayBot(two7SegDisplays, 8);
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//--- display welcome msg ---
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//display welcome message on two 7 segment displays
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//currently show name and date and scrolling 'hello'
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display_ShowWelcomeMsg(two7SegDisplays);
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//================
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//===== loop =====
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//================
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while(1){
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vTaskDelay(10 / portTICK_PERIOD_MS);
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//-----------------------------
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//------ handle switches ------
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//-----------------------------
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//run handle functions for all switches
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SW_START.handle();
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SW_RESET.handle();
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SW_SET.handle();
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SW_PRESET1.handle();
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SW_PRESET2.handle();
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SW_PRESET3.handle();
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SW_CUT.handle();
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SW_AUTO_CUT.handle();
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//---------------------------
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//------ handle cutter ------
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//---------------------------
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cutter_handle();
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//----------------------------
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//------ rotary encoder ------
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//----------------------------
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// Poll current position and direction
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rotary_encoder_get_state(&encoder, &encoderState);
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//--- calculate distance ---
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//lengthNow = (float)encoderState.position * (MEASURING_ROLL_DIAMETER * PI) / 600; //TODO dont calculate constant factor every time FIXME: ROUNDING ISSUE float-int?
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lengthNow = (float)encoderState.position * 1000 / STEPS_PER_METER;
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//---------------------------
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//--------- buttons ---------
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//---------------------------
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//TODO: ADD PRESET SWITCHES HERE
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//--- RESET switch ---
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if (SW_RESET.risingEdge) {
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rotary_encoder_reset(&encoder);
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lengthNow = 0;
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buzzer.beep(1, 700, 100);
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//TODO: stop cutter with reset switch?
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//cutter_stop();
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}
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//--- CUT switch ---
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//start cut cycle immediately
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if (SW_CUT.risingEdge) {
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cutter_start();
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buzzer.beep(1, 70, 50);
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}
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//--- beep at AUTO_CUT toggle ---
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if (SW_AUTO_CUT.risingEdge){
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buzzer.beep(2, 100, 50);
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} else if (SW_AUTO_CUT.fallingEdge) {
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buzzer.beep(1, 400, 50);
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}
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//--- manual mode ---
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//switch to manual motor control (2 buttons + poti)
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if ( SW_PRESET2.state && (SW_PRESET1.state || SW_PRESET3.state) && controlState != systemState_t::MANUAL ) {
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//enable manual control
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changeState(systemState_t::MANUAL);
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buzzer.beep(3, 100, 60);
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}
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//--- set custom target length ---
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//set target length to poti position when SET switch is pressed
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if (SW_SET.state == true) {
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//read adc
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potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
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//scale to target length range
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int lengthTargetNew = (float)potiRead / 4095 * 30000;
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//apply hysteresis and round to whole meters //TODO optimize this
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if (lengthTargetNew % 1000 < 200) { //round down if less than .2 meter
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ESP_LOGD(TAG, "Poti input = %d -> rounding down", lengthTargetNew);
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lengthTargetNew = (lengthTargetNew/1000 ) * 1000; //round down
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} else if (lengthTargetNew % 1000 > 800 ) { //round up if more than .8 meter
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ESP_LOGD(TAG, "Poti input = %d -> rounding up", lengthTargetNew);
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lengthTargetNew = (lengthTargetNew/1000 + 1) * 1000; //round up
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} else {
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ESP_LOGD(TAG, "Poti input = %d -> hysteresis", lengthTargetNew);
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lengthTargetNew = lengthTarget;
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}
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//update target length and beep when effectively changed
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if (lengthTargetNew != lengthTarget) {
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//TODO update lengthTarget only at button release?
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lengthTarget = lengthTargetNew;
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ESP_LOGI(TAG, "Changed target length to %d mm", lengthTarget);
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buzzer.beep(1, 25, 10);
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}
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}
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//beep start and end of editing
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if (SW_SET.risingEdge) {
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buzzer.beep(1, 70, 50);
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}
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if (SW_SET.fallingEdge) {
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buzzer.beep(2, 70, 50);
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displayBot.blink(2, 100, 100, "S0LL ");
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}
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//--- target length presets ---
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if (controlState != systemState_t::MANUAL) { //dont apply preset length while controlling motor with preset buttons
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if (SW_PRESET1.risingEdge){
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lengthTarget = 1000;
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buzzer.beep(lengthTarget/1000, 25, 30);
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displayBot.blink(3, 100, 100, "S0LL ");
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}
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else if (SW_PRESET2.risingEdge) {
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lengthTarget = 5000;
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buzzer.beep(lengthTarget/1000, 25, 30);
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displayBot.blink(2, 100, 100, "S0LL ");
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}
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else if (SW_PRESET3.risingEdge) {
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lengthTarget = 10000;
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buzzer.beep(lengthTarget/1000, 25, 30);
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displayBot.blink(2, 100, 100, "S0LL ");
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}
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}
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//---------------------------
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//--------- control ---------
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//---------------------------
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//calculate length difference
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lengthRemaining = lengthTarget - lengthNow;
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//--- statemachine ---
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switch (controlState) {
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case systemState_t::COUNTING: //no motor action
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vfd_setState(false);
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//TODO check stop condition before starting - prevents motor from starting 2 cycles when
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//--- start winding to length ---
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if (SW_START.risingEdge) {
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changeState(systemState_t::WINDING_START);
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//TODO apply dynamic speed here too (if started when already very close)
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vfd_setSpeedLevel(1); //start at low speed
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vfd_setState(true); //start motor
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timestamp_motorStarted = esp_log_timestamp(); //save time started
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buzzer.beep(1, 100, 0);
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}
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break;
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case systemState_t::WINDING_START: //wind slow for certain time
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//set vfd speed depending on remaining distance
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setDynSpeedLvl(1); //limit to speed lvl 1 (force slow start)
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if (esp_log_timestamp() - timestamp_motorStarted > 3000) {
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changeState(systemState_t::WINDING);
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}
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handleStopCondition(&displayTop, &displayBot); //stops if button released or target reached
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//TODO: cancel when there was no cable movement during start time?
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break;
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case systemState_t::WINDING: //wind fast, slow down when close
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//set vfd speed depending on remaining distance
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setDynSpeedLvl(); //slow down when close to target
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handleStopCondition(&displayTop, &displayBot); //stops if button released or target reached
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//TODO: cancel when there is no cable movement anymore e.g. empty / timeout?
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break;
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case systemState_t::TARGET_REACHED:
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vfd_setState(false);
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//switch to counting state when no longer at or above target length
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if ( lengthRemaining > 10 ) { //FIXME: require reset switch to be able to restart? or evaluate a tolerance here?
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changeState(systemState_t::COUNTING);
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autoCutWaiting = false;
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}
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//handle delayed cutting if automatic cut is enabled
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else if ( (autoCutEnabled == true)
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&& (esp_log_timestamp() - timestamp_changedState > 300) ){ //wait for dislay msg "reached" to finish
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autoCutWaiting = true; //display countdown
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cut_msRemaining = autoCut_delayMs - (esp_log_timestamp() - timestamp_changedState);
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//- beep countdown -
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//time passed since last beep > time remaining / 10
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if ( (esp_log_timestamp() - timestamp_cut_lastBeep) > (cut_msRemaining / 6)
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&& (esp_log_timestamp() - timestamp_cut_lastBeep) > 50 ){ //dont trigger beeps faster than beep time
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buzzer.beep(1, 50, 0);
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timestamp_cut_lastBeep = esp_log_timestamp();
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}
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//- cancel countdown with AUTO_CUT off -
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if (!SW_AUTO_CUT.state) { //note: stop button also works
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autoCutWaiting = false;
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autoCutEnabled = false;
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}
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//- trigger cut if delay passed -
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else if (cut_msRemaining <= 0){
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cut_msRemaining = 0; //prevent negative number on display
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cutter_start();
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changeState(systemState_t::CUTTING);
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autoCutWaiting = false;
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}
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}
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//show msg when trying to start, but target is reached
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if (SW_START.risingEdge){
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buzzer.beep(3, 40, 30);
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displayTop.blink(2, 600, 800, " S0LL ");
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displayBot.blink(2, 600, 800, "ERREICHT");
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}
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break;
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case systemState_t::CUTTING:
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//exit if finished cutting
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if (cutter_isRunning() == false){
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//TODO stop if start buttons released?
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changeState(systemState_t::COUNTING);
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//TODO reset automatically or wait for manual reset?
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rotary_encoder_reset(&encoder);
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lengthNow = 0;
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buzzer.beep(1, 700, 100);
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}
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break;
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case systemState_t::MANUAL: //manually control motor via preset buttons + poti
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//read poti value
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potiRead = gpio_readAdc(ADC_CHANNEL_POTI); //0-4095
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//scale poti to speed levels 0-3
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uint8_t level = round( (float)potiRead / 4095 * 3 );
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//exit manual mode if preset2 released
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if ( SW_PRESET2.state == false ) {
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changeState(systemState_t::COUNTING);
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buzzer.beep(1, 1000, 100);
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}
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//P2 + P1 -> turn left
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else if ( SW_PRESET1.state && !SW_PRESET3.state ) {
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vfd_setSpeedLevel(level); //TODO: use poti input for level
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vfd_setState(true, REV);
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sprintf(buf_disp2, "[--%02i ", level);
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// 123 45 678
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}
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//P2 + P3 -> turn right
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else if ( SW_PRESET3.state && !SW_PRESET1.state ) {
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vfd_setSpeedLevel(level); //TODO: use poti input for level
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vfd_setState(true, FWD);
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sprintf(buf_disp2, " %02i--]", level);
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}
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//no valid switch combination -> turn off motor
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else {
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vfd_setState(false);
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sprintf(buf_disp2, " %02i ", level);
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}
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}
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//--------------------------
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//------ encoder test ------
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//--------------------------
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#ifdef ENCODER_TEST
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//run display handle functions
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displayTop.handle();
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displayBot.handle();
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//-- show encoder steps on display1 ---
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sprintf(buf_disp1, "EN %05d", encoderState.position); //count
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displayTop.showString(buf_disp1);
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//--- show converted distance on display2 ---
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sprintf(buf_disp2, "Met %5.3f", (float)lengthNow/1000); //m
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displayBot.showString(buf_disp2);
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//--- beep every 1m ---
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//note: only works precicely in forward/positive direction
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if (lengthNow % 1000 < 50) { //with tolerance in case of missed exact value
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if (fabs(lengthNow - lengthBeeped) >= 900) { //dont beep multiple times at same meter
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//TODO: add case for reverse direction. currently beeps 0.1 too early
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buzzer.beep(1, 400, 100 );
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lengthBeeped = lengthNow;
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}
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}
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#else
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//--------------------------
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//-------- display1 --------
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//--------------------------
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//run handle function
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displayTop.handle();
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//indicate upcoming cut when pending
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if (autoCutWaiting == true){
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displayTop.blinkStrings(" CUT 1N ", " ", 70, 30);
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}
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//otherwise show current position
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else {
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sprintf(buf_tmp, "1ST %5.4f", (float)lengthNow/1000);
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// 123456789
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//limit length to 8 digits + decimal point (drop decimal places when it does not fit)
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sprintf(buf_disp1, "%.9s", buf_tmp);
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displayTop.showString(buf_disp1);
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}
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//--------------------------
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//-------- display2 --------
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//--------------------------
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//run handle function
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displayBot.handle();
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//setting target length: blink target length
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if (SW_SET.state == true) {
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sprintf(buf_tmp, "S0LL%5.3f", (float)lengthTarget/1000);
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displayBot.blinkStrings(buf_tmp, "S0LL ", 300, 100);
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}
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//manual state: blink "manual"
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else if (controlState == systemState_t::MANUAL) {
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displayBot.blinkStrings(" MANUAL ", buf_disp2, 400, 800);
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}
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//notify that cutter is active
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else if (cutter_isRunning()) {
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displayBot.blinkStrings("CUTTING]", "CUTTING[", 100, 100);
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}
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//show ms countdown to cut when pending
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else if (autoCutWaiting == true) {
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sprintf(buf_disp2, " %04d ", cut_msRemaining);
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//displayBot.showString(buf_disp2); //TODO:blink "erreicht" overrides this. for now using blink as workaround
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displayBot.blinkStrings(buf_disp2, buf_disp2, 100, 100);
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}
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//otherwise show target length
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else {
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//sprintf(buf_disp2, "%06.1f cm", (float)lengthTarget/10); //cm
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sprintf(buf_tmp, "S0LL%5.3f", (float)lengthTarget/1000); //m
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// 1234 5678
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displayBot.showString(buf_tmp);
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}
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#endif
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//TODO: blink disp2 when set button pressed
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//TODO: blink disp2 when preset button pressed (exept manual mode)
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//TODO: write "MAN CTL" to disp2 when in manual mode
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//TODO: display or blink "REACHED" when reached state and start pressed
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}
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}
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