reflow/reflowctl/reflowctl.ino

#define START_STATE 0
#define PREHEAT_STATE 1
#define RAMP_UP_STATE 2
#define TAL_FIRST_STATE 3
#define PEAK_STATE 4
#define TAL_SECOND_STATE 5
#define RAMP_DOWN_STATE 6
#define END_STATE 7
#define ERROR_STATE 8

// error conditions
#define E_DT_MIN 1 // temperatur dt too small
#define E_DT_MAX 2 // temperatur dt too big
#define E_TIME_MAX 4 // reflow process does take too long
#define E_TL_TOO_LONG 8 // package was roasted
#define E_TP_TOO_LONG 16 // package was roasted

// system time, timestamps and temperatures from sensors
__attribute__((__unused__)) static unsigned int time = 0; // profile seconds
__attribute__((__unused__)) static unsigned int temperatur = 25; // actual oven temp
__attribute__((__unused__)) static unsigned int last_temperatur = 25; // last oven temp
__attribute__((__unused__)) static int actual_dt = 0; // actual difference from last to actual temperatur


// profile temperatures
__attribute__((__unused__)) static unsigned int Ts_min = 150; // °C
__attribute__((__unused__)) static unsigned int Ts_max = 200; // °C
__attribute__((__unused__)) static unsigned int Tl = 217; // 217°C
__attribute__((__unused__)) static unsigned int Tp = 260; // 245-260°C
__attribute__((__unused__)) static unsigned int time_max = 480; // 8*60s max


// profile temp per second rates
__attribute__((__unused__)) static unsigned int ramp_up_rate_min = 0; // not used yet
__attribute__((__unused__)) static unsigned int ramp_up_rate_max = 50; // 3°C/s
__attribute__((__unused__)) static unsigned int ramp_down_max = 6; // 6°C/s max
__attribute__((__unused__)) static unsigned int ramp_down_min = 2; // 2°C/s max


// profile temp durations
__attribute__((__unused__)) static unsigned int Ts_duration = 100; // 60-180s
__attribute__((__unused__)) static unsigned int Tl_duration = 100; // 60-150s
__attribute__((__unused__)) static unsigned int Tp_duration = 30; // 20-40s


// timestamps of event beginnings/ends
__attribute__((__unused__)) static unsigned int Ts_min_time = 0;
__attribute__((__unused__)) static unsigned int Ts_max_time = 0;
__attribute__((__unused__)) static unsigned int Tl_time_start = 0;
__attribute__((__unused__)) static unsigned int Tl_time_end = 0;
__attribute__((__unused__)) static unsigned int Tp_time_start = 0;
__attribute__((__unused__)) static unsigned int Tp_time_end = 0;


// thermostat
__attribute__((__unused__)) static unsigned int set_min = 0;
__attribute__((__unused__)) static unsigned int set_max = 0;
__attribute__((__unused__)) static int set_dt_min = 0;
__attribute__((__unused__)) static int set_dt_max = 0;


// state machine
__attribute__((__unused__)) static byte state;
__attribute__((__unused__)) static boolean is_oven_heating = false;
__attribute__((__unused__)) static byte error_condition = 0;

// ui stuff
__attribute__((__unused__)) static boolean led_on = false;

void setup() {
  Serial.begin(9600);
  delay(2000);
  set_start_state();

}


static void control_oven() {
  if (temperatur < set_min && (!is_oven_heating)) {
    is_oven_heating = true;
    Serial.println("Oven turned on");
  }
  else if (temperatur > set_max && is_oven_heating) {
    is_oven_heating = false;
    Serial.println("Oven turned off");
  }
}


static void 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;
}


static void get_temp() {
  last_temperatur = temperatur;
  temperatur = int(float(analogRead(2)) * 0.2929);
  actual_dt = temperatur - last_temperatur;
}


static void check_dt() {
  if (actual_dt > set_dt_max) {
    error_condition |= E_DT_MAX;
  }
  if (actual_dt < set_dt_min) {
    error_condition |= E_DT_MIN;
  }
}

static void print_debug() {
  Serial.print("Time: ");
  Serial.print(time);
  Serial.print(", temperatur: ");
  Serial.print(temperatur);
  Serial.print(", last_temperatur: ");
  Serial.print(last_temperatur);
  Serial.print(", state: ");
  Serial.print(state);
  Serial.print(", Error: ");
  Serial.println(error_condition);
}

boolean check_max_duration() {
  if (time > time_max) {
    error_condition |= E_TIME_MAX;
    return false;
  }
}

boolean check_Tl_duration() {
  if (time - Tl_time_start > Tp_duration) {
    error_condition |= E_TL_TOO_LONG;
    return false;
  }
}

boolean check_Tp_duration() {
  if (time - Tp_time_start > Tp_duration) {
    error_condition |= E_TP_TOO_LONG;
    return false;
  }
}

static void set_start_state() {
  state = START_STATE;
  get_temp();
  last_temperatur = temperatur;
  set_temp(Tp-5, Tp, 0, ramp_up_rate_max);
}


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


static void set_ramp_up_state() {
  Serial.println("Changed state to RAMP_UP_STATE");
  state++;
}


static void set_tal_first_state() {
  Serial.println("Changed state to TAL_FIRST_STATE");
  state++;
}


static void set_peak_state() {
  Serial.println("Changed state to PEAK_STATE");
  state++;
}


static void set_tal_second_state() {
  Serial.println("Changed state to TAL_SECOND_STATE");
  set_temp(25, 25, -3, -6);
  state++;
}


static void set_ramp_down_state() {
  Serial.println("Changed state to RAMP_DOWN_STATE");
  state++;
}


static void set_end_state() {
  Serial.println("Changed state to END_STATE");
  state++;
}


void set_error_state() {
  if (state != ERROR_STATE) {
    Serial.println("Changed state to ERROR_STATE");
    set_temp(0, 0, 0, 0);
    state = ERROR_STATE;
  }
}


static void handle_start_state() {
  if (temperatur > Ts_min) {
    Ts_min_time = time;
    set_preheat_state();
  }
}


static void handle_preheat_state() {
  if (temperatur > Ts_max) {
    Ts_max_time = time;
    set_ramp_up_state();
  }
}


static void handle_ramp_up_state() {
  if (temperatur > Tl) {
    Tl_time_start = time;
    set_tal_first_state();
  }
}


static void handle_tal_first_state() {
  check_Tl_duration();
  if (temperatur > Tp - 5) {
    Tp_time_start = time;
    set_peak_state();
  }
}


static void handle_peak_state() {
  check_Tl_duration();
  check_Tp_duration();
  if (time - Tp_time_start > Tp_duration) {
    Tp_time_end = time;
    set_tal_second_state();
   }
}


static void handle_tal_second_state() {
  check_Tl_duration();
  if (temperatur < Tl) {
    set_ramp_down_state();
  }
}

static void handle_ramp_down_state() {
  if (temperatur < Ts_min) {
    set_end_state();
  }
}


static void handle_end_state() {
  while(true) {
    continue;
  }
}


static void handle_error_state() {
  if (led_on) {
    digitalWrite(13, LOW);
    led_on = false;
  }
  else {
    digitalWrite(13, HIGH);
    led_on = true;
  }
  if (error_condition & E_DT_MIN)
    Serial.println("Error: delta °K/second too low");
  if (error_condition & E_DT_MAX)
    Serial.println("Error: delta °K/second too big");
  if (error_condition & E_TIME_MAX)
    Serial.println("Error: reflow process does take too long");
  if (error_condition & E_TL_TOO_LONG)
    Serial.println("Error: temperatur above liquidus was too long");
  if (error_condition & E_TP_TOO_LONG)
    Serial.println("Error: peak temperature duration was too long");
}


void loop() {
  time = millis() / 1000;
  get_temp();
  check_dt();
  check_max_duration();

  if (error_condition) {
    set_error_state();
  }
  else {
    print_debug();
  }


  switch (state) {
      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();
  delay(1000);
}