Chiller works

This commit is contained in:
eddyem
2019-01-25 16:54:43 +03:00
parent 32905c1981
commit 89b3809993
11 changed files with 704 additions and 193 deletions

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@@ -20,10 +20,58 @@
#define HARDWARE_H
#include "stm32f0.h"
// measure flow sensor data each 5 seconds
#define FLOW_RATE_MS 4999
extern uint16_t flow_rate, flow_cntr;
// measure flow sensor data each 1 second
#define FLOW_RATE_MS (999)
// previous as string constant
#define FLOWRATESTR "1"
// each TMEASURE_MS ms calculate temperatures & check them
#define TMEASURE_MS (1000)
// each TCHECK_MS ms check cooler state and regulate temperature
#define TCHECK_MS (10000)
/*
temperature limits and tolerances
*/
// tolerance: +-1.5degrC
#define TEMP_TOLERANCE (15)
// dT tolerance: +-0.5degrC
#define DT_TOLERANCE (5)
// maximal heater temperature - 80degrC; normal - <60
#define MAX_HEATER_T (800)
#define NORMAL_HEATER_T (600)
// maximal output temperature - 45degrC; minimal - 10
#define MAX_OUTPUT_T (450)
#define MIN_OUTPUT_T (100)
// temperature working values: from 15 to 30degrC
#define OUTPUT_T_H (300)
#define OUTPUT_T_L (150)
/*
other limits & tolerances
*/
// minimal flow rate - 0.2l per minute
#define MIN_FLOW_RATE (20)
// normal flow rate
#define NORMAL_FLOW_RATE (30)
// minimal PWM values when motors should work
#define MIN_PUMP_PWM (90)
#define MIN_COOLER_PWM (90)
// PWM setters and getters
#define SET_COOLER_PWM(N) do{TIM14->CCR1 = (uint32_t)N;}while(0)
#define GET_COOLER_PWM() (uint16_t)(TIM14->CCR1)
#define SET_HEATER_PWM(N) do{TIM16->CCR1 = (uint32_t)N;}while(0)
#define GET_HEATER_PWM() (uint16_t)(TIM16->CCR1)
#define SET_PUMP_PWM(N) do{TIM17->CCR1 = (uint32_t)N;}while(0)
#define GET_PUMP_PWM() (uint16_t)(TIM17->CCR1)
// ext. alarm states
#define ALARM_ON() pin_set(GPIOF, 2)
#define ALARM_OFF() pin_clear(GPIOF, 2)
#define ALARM_STATE() pin_read(GPIOF, 2)
extern volatile uint16_t flow_rate, flow_cntr;
extern volatile uint32_t Tms;
void hw_setup(void);

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@@ -1,4 +1,4 @@
update=Чт 20 дек 2018 22:32:48
update=Ср 16 янв 2019 16:46:34
version=1
last_client=kicad
[pcbnew]

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@@ -18,33 +18,53 @@
* Foundation, Inc., 51 Franklin Street, Fifth Floor, Boston,
* MA 02110-1301, USA.
*/
#include <string.h> // memcpy
#include "stm32f0.h"
#include "hardware.h"
#include "usart.h"
#include "adc.h"
#include "protocol.h"
#include "mainloop.h"
volatile uint32_t Tms = 0;
uint16_t flow_rate = 0; // flow sensor rate
uint16_t flow_cntr = 0; // flow sensor trigger counter
volatile uint16_t flow_rate = 0; // flow sensor rate
volatile uint16_t flow_cntr = 0; // flow sensor trigger counter
// this variable is global as user need to clear it in protocol.c
uint8_t crit_error = 0; // got critical error, need user acknowledgement
// Called when systick fires
void sys_tick_handler(void){
++Tms;
}
static void print_state(uint8_t state){
if(state == ST_OK){
put_string("OK\n");
return;
}
if(state & ST_CRITICAL) put_string("CRIT"); // add prefix "CRIT" for critical states
if(!(state & ST_OK)){ // something changed
if(state & ST_OFF) put_string("OFF");
else{
if(state & ST_FASTER) put_string("FASTER");
else put_string("SLOWER");
}
}
put_char('\n');
}
int main(void){
uint32_t lastTflow = 0;
uint32_t lastTflow = 0; // last flow measurement time
chiller_state ost = {ST_OK, ST_OK, ST_OK, ST_OK}, *st; // old & current chiller states
char *txt;
hw_setup();
SysTick_Config(6000, 1);
usart1_send_blocking("Chiller controller v0.1\n", 0);
SEND_BLK("Chiller controller v0.1\n");
if(RCC->CSR & RCC_CSR_IWDGRSTF){ // watchdog reset occured
usart1_send("WDGRESET=1\n", 0);
SEND_BLK("WDGRESET=1");
}
if(RCC->CSR & RCC_CSR_SFTRSTF){ // software reset occured
usart1_send("SOFTRESET=1\n", 0);
SEND_BLK("SOFTRESET=1");
}
RCC->CSR |= RCC_CSR_RMVF; // remove reset flags
while (1){
@@ -53,6 +73,7 @@ int main(void){
lastTflow = Tms;
flow_rate = flow_cntr;
flow_cntr = 0;
if(crit_error) SEND("CRITICAL=1\n");
}
if(usart1_getline(&txt)){ // usart1 received command, process it
txt = process_command(txt);
@@ -62,5 +83,29 @@ int main(void){
IWDG->KR = IWDG_REFRESH;
}
}
IWDG->KR = IWDG_REFRESH;
//usart1_sendbuf();
st = mainloop();
// process state values
if(st->common_state != ST_OK){
if(st->common_state & ST_CRITICAL) crit_error = 1;
put_string("STATE=");
print_state(st->common_state);
}
// other states
if(st->pump_state != ST_OK){
put_string("PUMP=");
print_state(st->pump_state);
}
if(st->cooler_state != ST_OK){
put_string("COOLER=");
print_state(st->cooler_state);
}
if(st->heater_state != ST_OK){
put_string("HEATER=");
print_state(st->heater_state);
}
memcpy(&ost, st, sizeof(chiller_state));
usart1_sendbuf();
}
}

319
F0-nolib/Chiller/mainloop.c Normal file
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@@ -0,0 +1,319 @@
/*
* This file is part of the Chiller project.
* Copyright 2019 Edward V. Emelianov <edward.emelianoff@gmail.com>.
*
* This program is free software: you can redistribute it and/or modify
* it under the terms of the GNU General Public License as published by
* the Free Software Foundation, either version 3 of the License, or
* (at your option) any later version.
*
* This program is distributed in the hope that it will be useful,
* but WITHOUT ANY WARRANTY; without even the implied warranty of
* MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
* GNU General Public License for more details.
*
* You should have received a copy of the GNU General Public License
* along with this program. If not, see <http://www.gnu.org/licenses/>.
*/
#include "mainloop.h"
#include "hardware.h"
#include "adc.h"
int16_t Tset = 200; // temperature setpoint
int16_t NTCval[4] = {0,};
// common status for all functions from this file; pointer to this variable return @mainloop
static chiller_state retstatus = {
.common_state = ST_OK,
.heater_state = ST_OK,
.cooler_state = ST_OK,
.pump_state = ST_OK
};
/* error bit fields: */
// chiller_error==0 - no errors
#define CE_NOERROR (0)
// heater error (overheating)
#define CE_HEATER (1<<0)
// output was too hot
#define CE_OUTHOT (1<<1)
// output was too cool
#define CE_OUTCOOL (1<<2)
// no flow sensor pulses detected
#define CE_NOFLOW (1<<3)
// error code explaining why alarm is working
static uint8_t chiller_error;
static inline void increase_pump_pwm(){
uint16_t pwm = GET_PUMP_PWM();
if(pwm < 246){
SET_PUMP_PWM(pwm+10);
retstatus.pump_state = ST_FASTER;
}
}
static inline void decrease_pump_pwm(){
uint16_t pwm = GET_PUMP_PWM();
if(pwm > MIN_PUMP_PWM+9){
SET_PUMP_PWM(pwm-10);
retstatus.pump_state = 0; // "ST_SLOWER"
}
}
/**
* @brief binsrch - binary search for new good value
* @param oldval - previuos value
* @param curval - current value
* @param dir - direction (1 - increase, 0 - decrease)
* @return new value
*/
static inline uint16_t binsrch(uint16_t oldval, uint16_t curval, uint8_t dir){
if(oldval == curval){
if(dir) oldval = 256;
else oldval = 0;
}else{
if(dir){ // increase
if(oldval == 0) oldval = 256;
else if(oldval < curval){
oldval = 2*curval - oldval;
}
}else{ // decrease
if(curval == 0) oldval = 0;
else if(oldval > curval){
oldval = 2*curval - oldval;
}
}
}
oldval = (oldval + curval) / 2;
if(oldval > 255) oldval = 0;
return oldval;
}
// change PWM according to dir (1->up, 0->down)
static void change_heater_pwm(uint8_t dir){
static uint16_t oldpwm = 0;
uint16_t pwm = binsrch(oldpwm, GET_HEATER_PWM(), dir);
if(pwm != GET_HEATER_PWM()){
oldpwm = GET_HEATER_PWM();
SET_HEATER_PWM(pwm);
if(dir){ // up
retstatus.heater_state = ST_FASTER;
}else{ // down
if(pwm == 0) retstatus.heater_state = ST_OFF;
else retstatus.heater_state = 0; // "ST_SLOWER"
}
}
}
static void change_cooler_pwm(uint8_t dir){
uint16_t pwm = GET_COOLER_PWM();
if(dir){ // up
if(pwm < 224) SET_COOLER_PWM(pwm + 32);
else SET_COOLER_PWM(255);
if(pwm != GET_COOLER_PWM())
retstatus.cooler_state = ST_FASTER;
}else{ // down
if(pwm > MIN_COOLER_PWM + 31) SET_COOLER_PWM(pwm - 32);
else SET_COOLER_PWM(0);
if(pwm != GET_COOLER_PWM())
retstatus.cooler_state = GET_COOLER_PWM() ? 0 : ST_OFF; // "ST_SLOWER" / ST_OFF
}
}
/**
* @brief get_critical - check device for critical errors
* @return 1 if critical error occured
*/
static inline uint8_t get_critical(){
uint8_t ret = 0;
// critical state: heater can burn out!
// turn off heater & make signal
if(HEATER_TEMPERATURE > MAX_HEATER_T){
// change heater state to CRIT_HOFF
retstatus.heater_state = ST_CRITICAL;
if(GET_HEATER_PWM()){
SET_HEATER_PWM(0);
retstatus.heater_state |= ST_OFF;
}
chiller_error |= CE_HEATER;
ret = 1;
}
// very hot output: turn off heater, turn on cooler & make signal
if(OUTPUT_TEMPERATURE > MAX_OUTPUT_T){
// change chiller state to CRIT_HOT
retstatus.common_state = ST_CRITICAL;
if(GET_HEATER_PWM()){
SET_HEATER_PWM(0);
retstatus.heater_state = ST_OFF;
}
if(GET_COOLER_PWM() < 255){
SET_COOLER_PWM(255);
retstatus.cooler_state = ST_FASTER;
}
// if water @input is also too hot, turn pump to max speed
if(INPUT_TEMPERATURE > MAX_OUTPUT_T){
increase_pump_pwm();
}
chiller_error |= CE_OUTHOT;
ret = 1;
}
// very cool output: turn on heater (max power), turn off cooler & make signal
if(OUTPUT_TEMPERATURE < MIN_OUTPUT_T){
retstatus.common_state = ST_CRITICAL|ST_FASTER;
if(GET_HEATER_PWM() < 255){
SET_HEATER_PWM(255);
retstatus.heater_state = ST_FASTER;
}
if(GET_COOLER_PWM()){
SET_COOLER_PWM(0);
retstatus.cooler_state = ST_OFF;
}
chiller_error |= CE_OUTCOOL;
ret = 1;
}
// check flow rate & pump working
if(GET_PUMP_PWM() >= MIN_PUMP_PWM){ // pump working
if(flow_rate < MIN_FLOW_RATE){ // check pump
// change chiller state to CRIT_NOFLOW
retstatus.common_state = ST_CRITICAL|ST_OK;
// increase pump speed
//increase_pump_pwm();
retstatus.pump_state = ST_CRITICAL;
chiller_error |= CE_NOFLOW;
ret = 1;
}
}else{
// turn ON pump if PWM < minimal
// (pump should be never off!)
SET_PUMP_PWM(MIN_PUMP_PWM);
retstatus.pump_state = ST_FASTER;
}
return ret;
}
/**
* @brief check_alarm - check device status and turn off alarm if it is on
*/
static inline void check_alarm(){
if(!ALARM_STATE()) return;
// check errors & turn alarm OFF if there's no critical situations
if(chiller_error == CE_NOERROR){
// turn off alarm if there's no more errors
ALARM_OFF();
}else{
if(chiller_error & CE_HEATER){ // clear CE_HEATER if heater T is normal
if(HEATER_TEMPERATURE < NORMAL_HEATER_T){
chiller_error &= ~CE_HEATER;
}
}
if(chiller_error & CE_OUTHOT){ // clear CE_OUTHOT if Tout is normal
if(OUTPUT_TEMPERATURE < OUTPUT_T_H){
chiller_error &= ~CE_OUTHOT;
}
}
if(chiller_error & CE_OUTCOOL){ // clear CE_OUTCOOL if Tout is normal
if(OUTPUT_TEMPERATURE > OUTPUT_T_L){
chiller_error &= ~CE_OUTCOOL;
}
}
if(chiller_error & CE_NOFLOW){ // clear CE_NOFLOW if there's flow pulses
if(flow_rate > NORMAL_FLOW_RATE){
chiller_error &= ~CE_NOFLOW;
}
}
}
}
static inline void checkOutT(){
// check that T is between limits
int8_t hc = 0; // need heating or cooling?
if(OUTPUT_TEMPERATURE > Tset + TEMP_TOLERANCE) hc = -1; // need cooling
else if(OUTPUT_TEMPERATURE < Tset - TEMP_TOLERANCE) hc = 1; // need heating
if(hc){// out of limits -> check
if(hc > 0){ // need heating: turn off cooler & turn on heater
if(GET_COOLER_PWM()){
SET_COOLER_PWM(0);
retstatus.cooler_state = ST_OFF;
}
if(GET_HEATER_PWM() < 255){
SET_HEATER_PWM(255);
retstatus.heater_state = ST_FASTER;
}else{
// bad situation: need MORE heating!
}
}else{ // need cooling: turn off heater & turn on cooler
if(GET_HEATER_PWM()){
SET_HEATER_PWM(0);
retstatus.heater_state = ST_OFF;
}
if(GET_COOLER_PWM() < 255){
SET_COOLER_PWM(255);
retstatus.cooler_state = ST_FASTER;
}else{
// bad situation: need MORE cooling!
}
}
}else{ // T inside borders -> correct heating/cooling speed
// Tout > Tset -> heater PWM up & cooler PWM down
// else -> vice versa
uint8_t ht = 2; // don't need heater/cooler change
if(OUTPUT_TEMPERATURE < Tset - DT_TOLERANCE) ht = 1; // need heating
else if(OUTPUT_TEMPERATURE > Tset + DT_TOLERANCE) ht = 0; // need cooling
if(ht != 2){
change_heater_pwm(ht);
change_cooler_pwm(!ht);
}
}
// if all OK, make pump slower
if(retstatus.pump_state == ST_OK){
decrease_pump_pwm();
}
}
/**
* @brief mainloop - the main chiller loop
* by timer check current states & change them
*/
chiller_state *mainloop(){
static uint32_t lastTmeas = 0xffff; // Temperatures measurement time
static uint32_t lastTchk = 0xffff; // last state checking time
retstatus.common_state = ST_OK;
retstatus.heater_state = ST_OK;
retstatus.cooler_state = ST_OK;
retstatus.pump_state = ST_OK;
// 1. Get temperatures and check critical situations
if(Tms - lastTmeas < TMEASURE_MS) return &retstatus;
lastTmeas = Tms;
for(int i = 0; i < 4; ++i) // refresh NTC values
NTCval[i] = getNTC(i);
uint8_t alrm = get_critical();
// check cooler
if(GET_COOLER_PWM() > MIN_COOLER_PWM){ // cooler working
// air temperature is very hot - cooler useless
if(AIR_TEMPERATURE > OUTPUT_TEMPERATURE + TEMP_TOLERANCE){
// change cooler state to OFF
if(GET_COOLER_PWM()){
SET_COOLER_PWM(0);
retstatus.cooler_state = ST_OFF;
}
}
}else{
if(GET_COOLER_PWM()){
SET_COOLER_PWM(0);
retstatus.cooler_state = ST_OFF;
}
}
// check alarm
if(alrm){
ALARM_ON();
return &retstatus;
}
// there wasn't critical cases in this iteration, go further
check_alarm();
// Now check thermal data and decide what to do
if(Tms - lastTchk < TCHECK_MS) return &retstatus;
lastTchk = Tms;
checkOutT();
return &retstatus;
}

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@@ -0,0 +1,55 @@
/*
* This file is part of the Chiller project.
* Copyright 2019 Edward V. Emelianov <edward.emelianoff@gmail.com>.
*
* This program is free software: you can redistribute it and/or modify
* it under the terms of the GNU General Public License as published by
* the Free Software Foundation, either version 3 of the License, or
* (at your option) any later version.
*
* This program is distributed in the hope that it will be useful,
* but WITHOUT ANY WARRANTY; without even the implied warranty of
* MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
* GNU General Public License for more details.
*
* You should have received a copy of the GNU General Public License
* along with this program. If not, see <http://www.gnu.org/licenses/>.
*/
#include "stm32f0.h"
// temperature setpoint
extern int16_t Tset;
// temperatures of NTC
extern int16_t NTCval[4];
// meaning of each array member: in/out, heater and air
#define TI_IDX (0)
#define TO_IDX (1)
#define TH_IDX (2)
#define TA_IDX (3)
#define INPUT_TEMPERATURE NTCval[TI_IDX]
#define OUTPUT_TEMPERATURE NTCval[TO_IDX]
#define HEATER_TEMPERATURE NTCval[TH_IDX]
#define AIR_TEMPERATURE NTCval[TA_IDX]
/* status bits */
// ==1 if no changes
#define ST_OK (1<<0)
// (ST_OK=0) == 1 if moving faster (or hotter), 0 if slower (or cooler)
#define ST_FASTER (1<<1)
// turn OFF
#define ST_OFF (1<<2)
// critical error
#define ST_CRITICAL (1<<7)
/* chiller status codes */
typedef struct{
uint8_t common_state; // common state != ST_OK if some other states changed
uint8_t heater_state;
uint8_t cooler_state;
uint8_t pump_state;
} chiller_state;
chiller_state *mainloop();

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@@ -19,6 +19,9 @@
#include "protocol.h"
#include "usart.h"
#include "adc.h"
#include "mainloop.h"
extern uint8_t crit_error;
#ifdef EBUG
/**
@@ -71,16 +74,14 @@ static void debugging_proc(const char *command){
static void get_ntc(const char *str){
uint8_t N = *str - '0';
if(N > 3) return;
int16_t NTC = getNTC(N);
put_string("NTC");
put_char(*str);
put_char('=');
put_int(NTC);
put_int(NTCval[N]);
}
#define SEND(x) usart1_send_blocking(x, 0)
#define STR(a) XSTR(a)
#define XSTR(a) #a
#define STR(a) XSTR(a)
#define XSTR(a) #a
/**
* @brief process_command - command parser
* @param command - command text (all inside [] without spaces)
@@ -93,20 +94,22 @@ char *process_command(const char *command){
usart1_sendbuf(); // send buffer (if it is already filled)
switch(*ptr++){
case '?': // help
SEND(
SEND_BLK(
"Ax - alarm on(1)/off(0)\n"
"Cx - cooler PWM\n"
"F - get flow sensor rate for " STR(FLOW_RATE_MS) "ms\n"
"CLR- clear critical error\n"
"F - get flow sensor rate for " FLOWRATESTR "s (5880 pulses per liter)\n"
"Hx - heater PWM\n"
"L - check water level\n"
"L - check water level\n"
"Px - pump PWM\n"
"R - reset\n"
"Tx - get NTC temp\n"
"t - get MCU temp\n"
"V - get Vdd"
"R - reset\n"
"Sx - change temperature setpoint\n"
"Tx - get NTC[x] temperature\n"
"t - get MCU temperature (approx.)\n"
"V - get Vdd"
);
#ifdef EBUG
SEND("d -> goto debug:\n"
SEND_BLK("d -> goto debug:\n"
"\tAx - get raw ADCx value\n"
"\tF - get flow_cntr\n"
"\tT - show raw T values\n"
@@ -115,17 +118,21 @@ char *process_command(const char *command){
#endif
break;
case 'A': // turn alarm on/off
if(*ptr == '1') pin_set(GPIOF, 2);
else if(*ptr == '0')pin_clear(GPIOF, 2);
if(*ptr == '1') ALARM_ON();
else if(*ptr == '0') ALARM_OFF();
put_string("ALRM=");
put_char(pin_read(GPIOF, 2) + '0');
put_char(ALARM_STATE() + '0');
break;
case 'C': // cooler PWM - TIM14CH1
case 'C': // "CLR" - clear critical error flag, 'C' - cooler PWM - TIM14CH1
if(ptr[0] == 'L' && ptr[1] == 'R' && ptr[2] == 0){
crit_error = 0;
return "CLRERR=1\n";
}
if(getnum(ptr, &N) && N > -1 && N < 256){
TIM14->CCR1 = N;
SET_COOLER_PWM(N);
}
put_string("COOLERPWM=");
put_int(TIM14->CCR1);
put_int(GET_COOLER_PWM());
break;
case 'F':
put_string("FLOWRATE=");
@@ -133,10 +140,10 @@ char *process_command(const char *command){
break;
case 'H': // heater PWM - TIM16CH1
if(getnum(ptr, &N) && N > -1 && N < 256){
TIM16->CCR1 = N;
SET_HEATER_PWM(N);
}
put_string("HEATERPWM=");
put_int(TIM16->CCR1);
put_int(GET_HEATER_PWM());
break;
case 'L': // water level
put_string("WATERLEVEL=");
@@ -144,14 +151,21 @@ char *process_command(const char *command){
break;
case 'P': // pump PWM - TIM17CH1
if(getnum(ptr, &N) && N > -1 && N < 256){
TIM17->CCR1 = N;
SET_PUMP_PWM(N);
}
put_string("PUMPPWM=");
put_int(TIM17->CCR1);
put_int(GET_PUMP_PWM());
break;
case 'R': // reset MCU
NVIC_SystemReset();
break;
case 'S':
if(getnum(ptr, &N) && N > OUTPUT_T_L + TEMP_TOLERANCE && N < OUTPUT_T_H - TEMP_TOLERANCE){
Tset = N;
}
put_string("TSET=");
put_int(Tset);
break;
case 'T': // get temperature of NTC(x)
get_ntc(ptr);
break;

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@@ -41,18 +41,17 @@ static char trbuf[UARTBUFSZ+1]; // auxiliary buffer for data transmission
static int trbufidx = 0;
int put_char(char c){
if(trbufidx > UARTBUFSZ - 1) return 1;
if(trbufidx >= UARTBUFSZ - 1){
if(ALL_OK != usart1_sendbuf()) return 1;
}
trbuf[trbufidx++] = c;
return 0;
}
// write zero-terminated string
int put_string(const char *str){
while(trbufidx < UARTBUFSZ - 1 && *str){
trbuf[trbufidx++] = *str++;
while(*str){
if(put_char(*str++)) return 1; //error! shouldn't be!!!
}
//error! shouldn't be!!!
if(*str) return 1; // buffer overfull
trbuf[trbufidx] = 0;
return 0; // all OK
}
/**

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@@ -37,6 +37,10 @@ typedef enum{
#define usart1ovr() (bufovr)
// send constant string
#define SEND_BLK(x) do{while(LINE_BUSY == usart1_send_blocking(x, sizeof(x)-1));}while(0)
#define SEND(x) do{while(LINE_BUSY == usart1_send(x, sizeof(x)-1));}while(0)
extern uint8_t bufovr;
void USART1_config();

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@@ -1,4 +1,4 @@
update=Вт 13 ноя 2018 22:27:32
update=Вс 06 янв 2019 17:11:01
version=1
last_client=kicad
[pcbnew]