reflow/libs/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 = 0;
  last_temperature = 0;
  actual_dt = 0;
  // 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;

  state = 0;
  error_condition = 0;
  is_oven_heating = false;

  // ui stuff
  led_on = false;
  disable_checks = false;
  lcd = &_lcd;
  keypad = &_keypad;
  profile = &_profile;
  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(state & 0xff);
  Serial.write((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::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::recv_config() {

}

void OvenCtl::handle_states() {
  int cmd = -1;

  if (state > 0)
  {
    time++;
    get_temp();
    check_dt();
  }

  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();
  }

  switch (state) {
      case CONFIG_STATE:
        if (profile->handle_config_state(lcd, keypad))
          set_start_state();
        break;
      case START_STATE:
        handle_start_state();
        break;
      case PREHEAT_STATE:
        handle_preheat_state();
        break;
      case RAMP_UP_STATE:
        handle_ramp_up_state();
        break;
      case TAL_FIRST_STATE:
        handle_tal_first_state();
        break;
      case PEAK_STATE:
        handle_peak_state();
        break;
      case TAL_SECOND_STATE:
        Tl_time_end = time;
        handle_tal_second_state();
        break;
      case RAMP_DOWN_STATE:
        handle_ramp_down_state();
        break;
      case END_STATE:
        handle_end_state();
        break;
      case ERROR_STATE:
        handle_error_state();
        break;
      default:
        break;
  }

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

void OvenCtl::check_max_duration() {
  if (disable_checks)
    return;
  if (time > profile->data[PI_TIME_MAX]) {
    error_condition |= E_TIME_MAX;
  }
}

void OvenCtl::check_Ts_duration_min() {
  if (disable_checks)
    return;
  Tl_time_end = time;
  if (time - Tl_time_start < profile->data[PI_TL_DURATION_MIN]) {
    error_condition |= E_TL_TOO_SHORT;
  }
}

void OvenCtl::check_Ts_duration_max() {
  if (disable_checks)
    return;
  if (time - Ts_time_start > profile->data[PI_TL_DURATION_MAX]) {
    error_condition |= E_TS_TOO_LONG;
  }
}


void OvenCtl::check_Tl_duration_min() {
  if (disable_checks)
    return;
  Tl_time_end = time;
  if (time - Tl_time_start < profile->data[PI_TL_DURATION_MIN]) {
    error_condition |= E_TL_TOO_SHORT;
  }
}

void OvenCtl::check_Tl_duration_max() {
  if (disable_checks)
    return;
  if (time - Tl_time_start > profile->data[PI_TL_DURATION_MAX]) {
    error_condition |= E_TL_TOO_LONG;
  }
}

void OvenCtl::check_Tp_duration_min() {
  Tp_time_end = time;
  if (time - Tp_time_start < profile->data[PI_TP_DURATION_MIN]) {
    error_condition |= E_TP_TOO_SHORT;
  }
}

void OvenCtl::check_Tp_duration_max() {
  if (disable_checks)
    return;
  if (time - Tp_time_start > profile->data[PI_TP_DURATION_MAX]) {
    error_condition |= E_TP_TOO_LONG;
  }
}

void OvenCtl::set_config_state() {
  profile->print_config_state_0(lcd);
}

void OvenCtl::set_start_state() {
  led_on = false;
  digitalWrite(13, LOW);
  error_condition = 0;
  state = START_STATE;
  get_temp();
  last_temperature = temperature;
  actual_dt = temperature - last_temperature;
  set_temp(profile->data[PI_TP]-5, profile->data[PI_TP], 0, profile->data[PI_RAMP_UP_MAX]);
  lcd->clear();
}


void OvenCtl::set_preheat_state() {
//   Serial.println("Changing state to PREHEAT_STATE");
  state++;
}


void OvenCtl::set_ramp_up_state() {
  state++;
}


void OvenCtl::set_tal_first_state() {
  state++;
}


void OvenCtl::set_peak_state() {
  state++;
}


void OvenCtl::set_tal_second_state() {
  set_temp(0, 25, -3, -6);
  state++;
}


void OvenCtl::set_ramp_down_state() {
  state++;
}


void OvenCtl::set_end_state() {
  state++;
}


void OvenCtl::set_error_state() {
  if (state != ERROR_STATE) {
    set_temp(0, 0, 0, 0);
    state = ERROR_STATE;
  }
}


void OvenCtl::handle_config_state() {
  if (profile->handle_config_state(lcd, keypad))
    state++;
}

void OvenCtl::handle_start_state() {
  check_max_duration();
  if (temperature > profile->data[PI_TS_MIN]) {
    Ts_time_start = time;
    set_preheat_state();
  }
}


void OvenCtl::handle_preheat_state() {
  check_Ts_duration_max();
  check_max_duration();
  if (temperature > profile->data[PI_TS_MAX]) {
    check_Ts_duration_min();
    set_ramp_up_state();
  }
}


void OvenCtl::handle_ramp_up_state() {
  check_max_duration();
  if (temperature > profile->data[PI_TL]) {
    Tl_time_start = time;
    set_tal_first_state();
  }
}


void OvenCtl::handle_tal_first_state() {
  check_max_duration();
  check_Tl_duration_max();
  if (temperature > profile->data[PI_TP] - 5) {
    Tp_time_start = time;
    set_peak_state();
  }
}


void OvenCtl::handle_peak_state() {
  check_Tl_duration_max();
  check_Tp_duration_max();
  if (time - Tp_time_start > profile->data[PI_TP_DURATION_MAX]) {
    check_Tp_duration_min();
    set_tal_second_state();
   }
}


void OvenCtl::handle_tal_second_state() {
  check_Tl_duration_max();
  if (temperature < profile->data[PI_TL]) {
    check_Tl_duration_min();
    set_ramp_down_state();
  }
}

void OvenCtl::handle_ramp_down_state() {
  if (temperature < profile->data[PI_TS_MIN]) {
    set_end_state();
  }
}


void OvenCtl::handle_end_state() {
}


void OvenCtl::handle_error_state() {
  if (led_on) {
    digitalWrite(13, LOW);
    led_on = false;
  }
  else {
    digitalWrite(13, HIGH);
    led_on = true;
  }
}