reflow/oven_control.cpp

#include "oven_control.h"
#include <DFR_Key.h>
#include <LiquidCrystal.h>
#include "profile.h"

//Pin assignments for SainSmart LCD Keypad Shield
LiquidCrystal lcd(8, 9, 4, 5, 6, 7);
DFR_Key keypad;
Profile profile;

OvenCtl::OvenCtl() {

  time = 0;
  temperature = 1;
  last_temperature = 1;
  actual_dt = 0.f;


  // timestamps of event beginnings/ends
  Ts_time_start = 0;
  Ts_time_end = 0;
  Tl_time_start = 0;
  Tl_time_end = 0;
  Tp_time_start = 0;
  Tp_time_end = 0;

  // thermostat
  set_min = 0;
  set_max = 0;
  set_dt_min = 0;
  set_dt_max = 0;

  op_state = OP_CONFIG;
  profile_state = START_STATE;
  error_condition = 0;
  is_oven_heating = false;

  actual_hysteresis = ramp_up_hysteresis = 1.0; // s
  ramp_down_hysteresis = 1.0; // s

  // ui stuff
  disable_checks = false;
  lcd.begin(16, 2);
}

void OvenCtl::reset() {
  digitalWrite(7, LOW);
}


void OvenCtl::send_state() {
  Serial.write(time & 0xff);
  Serial.write((time>>8) & 0xff);
  Serial.write(temperature & 0xff);
  Serial.write((temperature >> 8) & 0xff);
  Serial.write(last_temperature & 0xff);
  Serial.write((last_temperature >> 8) & 0xff);
  Serial.write(profile_state & 0xff);
  Serial.write((profile_state >> 8) & 0xff);
  Serial.write(error_condition & 0xff);
  Serial.write((error_condition >> 8) & 0xff);
  Serial.write(is_oven_heating);
  Serial.flush();
}

void OvenCtl::send_config() {
  int tmp;
  for (int i=0;i < PI_END; i++)
  {
    tmp = profile.data[i];
    Serial.write(tmp & 0xff);
    Serial.write((tmp >> 8 ) & 0xff);
  }
  Serial.flush();
}


void OvenCtl::recv_config() {

}


void OvenCtl::dispatch_input_config(int cmd) {
  if (cmd == 255)
    send_config();
  else if (cmd == 254)
    recv_config();
  else if (cmd == 250)
    reset();
  else if (cmd == 253)
    ;
}

void OvenCtl::handle_stand_alone_state() {
    time++;
    get_temp();
    check_dt();
}

void OvenCtl::handle_remote_state() {
  time++;
  get_temp();
  check_dt();
}




/**
 * handles input, dispatching state dependend modes to state handlers
 *
 *
 */
void OvenCtl::loop() {
  int cmd = -1;

  switch (op_state) {
    case OP_CONFIG:
//       if (profile.handle_config_state())
//         set_start_state();
      break;
    case OP_STAND_ALONE:
//       if (profile.handle_config_state())
//         set_start_state();
//       break;
    case OP_REMOTE:
//       if (profile.handle_config_state())
//         set_start_state();
      break;
  }

//   if (error_condition != 0) {
//     set_error_state();
//   }

  if (Serial.available() > 0) {
    cmd = Serial.read();
    if (cmd == 255)
      send_config();
    else if (cmd == 254)
      send_state();
    else if (cmd == 253)
      recv_config();
    else if (cmd == 252)
      reset();
//     else if (cmd == 251)
//       set_start_state();
  }



  control_oven();
  if (profile_state > 0) {
    print_status();
    delay(1000);
  }
}



void OvenCtl::print_status() {
  if (error_condition == 0) {
    String tmp("T: ");
    if (time < 10)
      tmp += "00";
    else if (time < 100)
      tmp += "0";
    tmp += time;
    tmp += " Tmp: ";
    if (temperature < 10)
      tmp += "00";
    else if (temperature < 100)
      tmp += "0";
    tmp += temperature;
    lcd.setCursor(0, 0);
    lcd.print(tmp);

    tmp = "Profile: ";
    tmp += profile_state;
    tmp += "/";
    tmp += END_STATE;
    lcd.setCursor(0, 1);
    lcd.print(tmp);
    lcd.setCursor(13, 1);
    if (is_oven_heating)
      lcd.print("on ");
    else
      lcd.print("off");
  }
  else {
    lcd.clear();
    lcd.print("Error:");
    lcd.setCursor(0, 1);
    if (error_condition & E_DT_MIN)
      lcd.print("K/s too low");
    if (error_condition & E_DT_MAX)
      lcd.print("K/s too high");
    if (error_condition & E_TIME_MAX)
      lcd.print("reflow too long");
    if (error_condition & E_TS_TOO_SHORT)
      lcd.print("ts too short");
    if (error_condition & E_TS_TOO_LONG)
      lcd.print("ts too long");
    if (error_condition & E_TL_TOO_SHORT)
      lcd.print("tal too short");
    if (error_condition & E_TL_TOO_LONG)
      lcd.print("tal too long");
    if (error_condition & E_TP_TOO_LONG)
      lcd.print("peak too short");
    if (error_condition & E_TP_TOO_SHORT)
      lcd.print("peak too long");
  }
}


void OvenCtl::control_oven() {
  if (temperature <= set_min + actual_hysteresis && !is_oven_heating) {
    is_oven_heating = true;
//     Serial.println("Oven turned on");
  }
  else if (temperature >= set_min + actual_hysteresis && is_oven_heating) {
    is_oven_heating = false;
  }
}


void OvenCtl::set_temp(int min, int max, int dt_min, int dt_max) {
  set_min = min;
  set_max = max;
  set_dt_min = dt_min;
  set_dt_max = dt_max;
}


void OvenCtl::get_temp() {
  last_temperature = temperature;
  temperature = int(float(analogRead(2)) * 0.2929);
  actual_dt = float(temperature) - last_temperature;
}

void OvenCtl::check_dt() {
  if (disable_checks)
    return;
  if (actual_dt > set_dt_max) {
    error_condition |= E_DT_MAX;
  }
  if (actual_dt < set_dt_min) {
    error_condition |= E_DT_MIN;
  }
}