reflow/reflowctl/reflowctl.ino

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#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
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#define RAMP_DOWN_STATE 6
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#define END_STATE 7
#define ERROR_STATE 8
// error conditions
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#define E_DT_MIN 1 // temperatur dt too small
#define E_DT_MAX 2 // temperatur dt too big
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#define E_TIME_MAX 4 // reflow process does take too long
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#define E_TL_TOO_LONG 8 // package was roasted
#define E_TP_TOO_LONG 16 // package was roasted
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// 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
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__attribute__((__unused__)) static int actual_dt = 0; // actual difference from last to actual temperatur
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// 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
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// 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
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// 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
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// 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;
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// 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;
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void setup() {
Serial.begin(9600);
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delay(2000);
set_start_state();
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}
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static void control_oven() {
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if (temperatur < set_min && (!is_oven_heating)) {
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is_oven_heating = true;
Serial.println("Oven turned on");
}
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else if (temperatur > set_max && is_oven_heating) {
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is_oven_heating = false;
Serial.println("Oven turned off");
}
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}
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static void set_temp(int min, int max, int dt_min, int dt_max) {
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set_min = min;
set_max = max;
set_dt_min = dt_min;
set_dt_max = dt_max;
}
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static void get_temp() {
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last_temperatur = temperatur;
temperatur = int(float(analogRead(2)) * 0.2929);
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actual_dt = temperatur - last_temperatur;
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}
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static void check_dt() {
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if (actual_dt > set_dt_max) {
error_condition |= E_DT_MAX;
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}
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if (actual_dt < set_dt_min) {
error_condition |= E_DT_MIN;
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}
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}
static void print_debug() {
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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);
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}
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static boolean check_max_duration() {
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if (time > time_max) {
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error_condition |= E_TIME_MAX;
return false;
}
}
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static boolean check_Tl_duration() {
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if (time - Tl_time_start > Tp_duration) {
error_condition |= E_TL_TOO_LONG;
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return false;
}
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}
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static boolean check_Tp_duration() {
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if (time - Tp_time_start > Tp_duration) {
error_condition |= E_TP_TOO_LONG;
return false;
}
}
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static void set_start_state() {
state = START_STATE;
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get_temp();
last_temperatur = temperatur;
set_temp(Tp-5, Tp, 0, ramp_up_rate_max);
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}
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static void set_preheat_state() {
Serial.println("Changing state to PREHEAT_STATE");
state++;
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}
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static void set_ramp_up_state() {
Serial.println("Changed state to RAMP_UP_STATE");
state++;
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}
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static void set_tal_first_state() {
Serial.println("Changed state to TAL_FIRST_STATE");
state++;
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}
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static void set_peak_state() {
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Serial.println("Changed state to PEAK_STATE");
state++;
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}
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static void set_tal_second_state() {
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Serial.println("Changed state to TAL_SECOND_STATE");
set_temp(25, 25, -3, -6);
state++;
}
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static void set_ramp_down_state() {
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Serial.println("Changed state to RAMP_DOWN_STATE");
state++;
}
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static void set_end_state() {
Serial.println("Changed state to END_STATE");
state++;
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}
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static void set_error_state() {
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if (state != ERROR_STATE) {
Serial.println("Changed state to ERROR_STATE");
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set_temp(0, 0, 0, 0);
state = ERROR_STATE;
}
}
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static void handle_start_state() {
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if (temperatur > Ts_min) {
Ts_min_time = time;
set_preheat_state();
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}
}
static void handle_preheat_state() {
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if (temperatur > Ts_max) {
Ts_max_time = time;
set_ramp_up_state();
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}
}
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static void handle_ramp_up_state() {
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if (temperatur > Tl) {
Tl_time_start = time;
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set_tal_first_state();
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}
}
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static void handle_tal_first_state() {
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check_Tl_duration();
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if (temperatur > Tp - 5) {
Tp_time_start = time;
set_peak_state();
}
}
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static void handle_peak_state() {
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check_Tl_duration();
check_Tp_duration();
if (time - Tp_time_start > Tp_duration) {
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Tp_time_end = time;
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set_tal_second_state();
}
}
static void handle_tal_second_state() {
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check_Tl_duration();
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if (temperatur < Tl) {
set_ramp_down_state();
}
}
static void handle_ramp_down_state() {
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if (temperatur < Ts_min) {
set_end_state();
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}
}
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static void handle_end_state() {
while(true) {
continue;
}
}
static void handle_error_state() {
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if (led_on) {
digitalWrite(13, LOW);
led_on = false;
}
else {
digitalWrite(13, HIGH);
led_on = true;
}
if (error_condition & E_DT_MIN)
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Serial.println("Error: delta °K/second too low");
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if (error_condition & E_DT_MAX)
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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");
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}
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void loop() {
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time = millis() / 1000;
get_temp();
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check_dt();
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check_max_duration();
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if (error_condition) {
set_error_state();
}
else {
print_debug();
}
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switch (state) {
case START_STATE:
handle_start_state();
break;
case PREHEAT_STATE:
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handle_preheat_state();
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break;
case RAMP_UP_STATE:
handle_ramp_up_state();
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break;
case TAL_FIRST_STATE:
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handle_tal_first_state();
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break;
case PEAK_STATE:
handle_peak_state();
break;
case TAL_SECOND_STATE:
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Tl_time_end = time;
handle_tal_second_state();
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break;
case RAMP_DOWN_STATE:
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handle_ramp_down_state();
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break;
case END_STATE:
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handle_end_state();
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break;
case ERROR_STATE:
handle_error_state();
break;
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default:
break;
}
control_oven();
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delay(1000);
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}
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