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10 sec cooldown when switch direction

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This commit is contained in:
Stephen Minakian
2025-07-09 13:10:54 -06:00
parent 343c664d83
commit 27802237f8
1 changed files with 189 additions and 58 deletions
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235
main/maxxfan-controller.c
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@ -37,6 +37,7 @@
#define RAMP_STEP_MS 150 // Time between ramp steps (milliseconds) #define RAMP_STEP_MS 150 // Time between ramp steps (milliseconds)
#define RAMP_STEP_SIZE 5 // PWM duty change per step (0-255) #define RAMP_STEP_SIZE 5 // PWM duty change per step (0-255)
#define MIN_MOTOR_SPEED 10 // Minimum speed to overcome motor inertia #define MIN_MOTOR_SPEED 10 // Minimum speed to overcome motor inertia
#define DIRECTION_CHANGE_COOLDOWN_MS 10000 // 10 seconds cooldown for direction changes
// Watchdog configuration // Watchdog configuration
#define WATCHDOG_TIMEOUT_S 10 // Watchdog timeout in seconds #define WATCHDOG_TIMEOUT_S 10 // Watchdog timeout in seconds
@ -57,20 +58,38 @@ typedef enum {
MOTOR_INTAKE MOTOR_INTAKE
} motor_mode_t; } motor_mode_t;
typedef enum {
MOTOR_STATE_IDLE, // Motor is off or running normally
MOTOR_STATE_RAMPING, // Motor is ramping up/down
MOTOR_STATE_STOPPING, // Motor is stopping for direction change
MOTOR_STATE_COOLDOWN, // Motor is in cooldown period
MOTOR_STATE_RESTARTING // Motor is restarting after cooldown
} motor_state_enum_t;
typedef struct { typedef struct {
motor_mode_t mode; motor_mode_t mode;
motor_mode_t pending_mode; // Mode to switch to after cooldown
int target_speed; int target_speed;
int pending_speed; // Speed to set after cooldown
int current_speed; int current_speed;
motor_state_enum_t state;
bool ramping; bool ramping;
TimerHandle_t ramp_timer; TimerHandle_t ramp_timer;
TimerHandle_t cooldown_timer;
uint32_t cooldown_remaining_ms; // For status reporting
} motor_state_t; } motor_state_t;
static motor_state_t motor_state = { static motor_state_t motor_state = {
.mode = MOTOR_OFF, .mode = MOTOR_OFF,
.pending_mode = MOTOR_OFF,
.target_speed = 0, .target_speed = 0,
.pending_speed = 0,
.current_speed = 0, .current_speed = 0,
.state = MOTOR_STATE_IDLE,
.ramping = false, .ramping = false,
.ramp_timer = NULL .ramp_timer = NULL,
.cooldown_timer = NULL,
.cooldown_remaining_ms = 0
}; };
// HTTP server handle // HTTP server handle
@ -86,10 +105,13 @@ static const char* html_page =
"h1{color:#333;text-align:center;margin:0 0 20px}button{padding:12px 20px;margin:5px;border:none;border-radius:4px;cursor:pointer;font-size:14px}" "h1{color:#333;text-align:center;margin:0 0 20px}button{padding:12px 20px;margin:5px;border:none;border-radius:4px;cursor:pointer;font-size:14px}"
".off{background:#f44336;color:white}.exhaust{background:#ff9800;color:white}.intake{background:#4CAF50;color:white}" ".off{background:#f44336;color:white}.exhaust{background:#ff9800;color:white}.intake{background:#4CAF50;color:white}"
".status{background:#e3f2fd;padding:15px;border-radius:4px;margin:15px 0}.ramping{background:#fff3e0;padding:8px;margin:8px 0;display:none}" ".status{background:#e3f2fd;padding:15px;border-radius:4px;margin:15px 0}.ramping{background:#fff3e0;padding:8px;margin:8px 0;display:none}"
".cooldown{background:#ffebee;padding:8px;margin:8px 0;color:#c62828;display:none}"
".error{background:#ffebee;padding:8px;margin:8px 0;color:#c62828;display:none}.slider{width:100%;height:30px;margin:10px 0}" ".error{background:#ffebee;padding:8px;margin:8px 0;color:#c62828;display:none}.slider{width:100%;height:30px;margin:10px 0}"
"</style></head><body><div class=\"container\"><h1>Maxxfan Controller</h1>" "</style></head><body><div class=\"container\"><h1>Maxxfan Controller</h1>"
"<div class=\"status\"><h4>Status</h4><p>Mode: <span id=\"mode\">OFF</span></p><p>Speed: <span id=\"speed\">0</span>%</p>" "<div class=\"status\"><h4>Status</h4><p>Mode: <span id=\"mode\">OFF</span></p><p>Speed: <span id=\"speed\">0</span>%</p>"
"<p>Target: <span id=\"target\">0</span>%</p><div id=\"rampStatus\" class=\"ramping\">Ramping...</div>" "<p>Target: <span id=\"target\">0</span>%</p><p>State: <span id=\"state\">IDLE</span></p>"
"<div id=\"rampStatus\" class=\"ramping\">Ramping...</div>"
"<div id=\"cooldownStatus\" class=\"cooldown\">Direction change cooldown: <span id=\"cooldownTime\">0</span>s</div>"
"<div id=\"errorStatus\" class=\"error\">Error</div><small id=\"connectionStatus\">Connecting...</small></div>" "<div id=\"errorStatus\" class=\"error\">Error</div><small id=\"connectionStatus\">Connecting...</small></div>"
"<div><h3>Fan Control</h3><button class=\"off\" onclick=\"setFan('off',0)\">OFF</button>" "<div><h3>Fan Control</h3><button class=\"off\" onclick=\"setFan('off',0)\">OFF</button>"
"<button class=\"exhaust\" onclick=\"setFan('exhaust',50)\">Exhaust 50%</button>" "<button class=\"exhaust\" onclick=\"setFan('exhaust',50)\">Exhaust 50%</button>"
@ -116,7 +138,11 @@ static const char* html_page =
"function updateStatus(data){document.getElementById('mode').textContent=data.mode.toUpperCase();" "function updateStatus(data){document.getElementById('mode').textContent=data.mode.toUpperCase();"
"document.getElementById('speed').textContent=data.current_speed;" "document.getElementById('speed').textContent=data.current_speed;"
"document.getElementById('target').textContent=data.target_speed;" "document.getElementById('target').textContent=data.target_speed;"
"document.getElementById('rampStatus').style.display=data.ramping?'block':'none'}" "document.getElementById('state').textContent=data.state.toUpperCase();"
"document.getElementById('rampStatus').style.display=data.ramping?'block':'none';"
"let cooldownDiv=document.getElementById('cooldownStatus');"
"if(data.cooldown_remaining>0){cooldownDiv.style.display='block';"
"document.getElementById('cooldownTime').textContent=Math.ceil(data.cooldown_remaining/1000);}else{cooldownDiv.style.display='none';}}"
"function getStatus(){fetch('/status').then(r=>{if(!r.ok)throw new Error('HTTP '+r.status);return r.json()})" "function getStatus(){fetch('/status').then(r=>{if(!r.ok)throw new Error('HTTP '+r.status);return r.json()})"
".then(d=>{updateStatus(d);hideError()}).catch(e=>{errorCount++;if(errorCount>=3)showError('Connection lost')})}" ".then(d=>{updateStatus(d);hideError()}).catch(e=>{errorCount++;if(errorCount>=3)showError('Connection lost')})}"
"function startUpdates(){if(updateInterval)clearInterval(updateInterval);updateInterval=setInterval(getStatus,1000)}" "function startUpdates(){if(updateInterval)clearInterval(updateInterval);updateInterval=setInterval(getStatus,1000)}"
@ -124,7 +150,9 @@ static const char* html_page =
// Forward declarations // Forward declarations
static void motor_ramp_timer_callback(TimerHandle_t xTimer); static void motor_ramp_timer_callback(TimerHandle_t xTimer);
static void motor_cooldown_timer_callback(TimerHandle_t xTimer);
static void apply_motor_pwm(int speed_percent); static void apply_motor_pwm(int speed_percent);
static void start_motor_operation(motor_mode_t mode, int speed_percent);
// Initialize watchdog timer // Initialize watchdog timer
void init_watchdog(void) { void init_watchdog(void) {
@ -270,7 +298,7 @@ static void apply_motor_pwm(int speed_percent) {
// Motor ramp timer callback // Motor ramp timer callback
static void motor_ramp_timer_callback(TimerHandle_t xTimer) { static void motor_ramp_timer_callback(TimerHandle_t xTimer) {
if (!motor_state.ramping) { if (motor_state.state != MOTOR_STATE_RAMPING) {
return; return;
} }
@ -280,6 +308,7 @@ static void motor_ramp_timer_callback(TimerHandle_t xTimer) {
// Close enough to target, finish ramping // Close enough to target, finish ramping
motor_state.current_speed = motor_state.target_speed; motor_state.current_speed = motor_state.target_speed;
motor_state.ramping = false; motor_state.ramping = false;
motor_state.state = MOTOR_STATE_IDLE;
// Stop the timer // Stop the timer
xTimerStop(motor_state.ramp_timer, 0); xTimerStop(motor_state.ramp_timer, 0);
@ -293,14 +322,70 @@ static void motor_ramp_timer_callback(TimerHandle_t xTimer) {
motor_state.current_speed -= RAMP_STEP_SIZE; motor_state.current_speed -= RAMP_STEP_SIZE;
} }
ESP_LOGD(TAG, "Ramping: %d%% -> %d%% (target: %d%%)", ESP_LOGD(TAG, "Ramping: %d%% (target: %d%%)", motor_state.current_speed, motor_state.target_speed);
motor_state.current_speed - (speed_diff > 0 ? RAMP_STEP_SIZE : -RAMP_STEP_SIZE),
motor_state.current_speed, motor_state.target_speed);
} }
apply_motor_pwm(motor_state.current_speed); apply_motor_pwm(motor_state.current_speed);
} }
// Motor cooldown timer callback
static void motor_cooldown_timer_callback(TimerHandle_t xTimer) {
ESP_LOGI(TAG, "Cooldown complete - Starting motor in %s mode at %d%%",
motor_state.pending_mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE",
motor_state.pending_speed);
// Reset cooldown tracking
motor_state.cooldown_remaining_ms = 0;
// Start the motor in the pending mode
start_motor_operation(motor_state.pending_mode, motor_state.pending_speed);
}
// Update cooldown remaining time (called periodically)
static void update_cooldown_time(void) {
if (motor_state.state == MOTOR_STATE_COOLDOWN && motor_state.cooldown_remaining_ms > 0) {
if (motor_state.cooldown_remaining_ms >= 1000) {
motor_state.cooldown_remaining_ms -= 1000;
} else {
motor_state.cooldown_remaining_ms = 0;
}
}
}
// Start motor operation (internal function)
static void start_motor_operation(motor_mode_t mode, int speed_percent) {
motor_state.mode = mode;
motor_state.target_speed = speed_percent;
motor_state.state = MOTOR_STATE_RAMPING;
motor_state.ramping = true;
if (mode == MOTOR_OFF || speed_percent == 0) {
// Immediate stop
motor_state.current_speed = 0;
motor_state.target_speed = 0;
motor_state.state = MOTOR_STATE_IDLE;
motor_state.ramping = false;
apply_motor_pwm(0);
ESP_LOGI(TAG, "Motor stopped immediately");
} else {
// Start from minimum speed if currently off
if (motor_state.current_speed == 0) {
int start_speed = (speed_percent < MIN_MOTOR_SPEED) ? speed_percent : MIN_MOTOR_SPEED;
motor_state.current_speed = start_speed;
apply_motor_pwm(start_speed);
ESP_LOGI(TAG, "Motor starting at %d%%, ramping to %d%%", start_speed, speed_percent);
}
// Start ramping if needed
if (motor_state.current_speed != motor_state.target_speed) {
xTimerStart(motor_state.ramp_timer, 0);
} else {
motor_state.state = MOTOR_STATE_IDLE;
motor_state.ramping = false;
}
}
}
// Initialize motor ramping system // Initialize motor ramping system
void init_motor_ramping(void) { void init_motor_ramping(void) {
motor_state.ramp_timer = xTimerCreate( motor_state.ramp_timer = xTimerCreate(
@ -311,10 +396,18 @@ void init_motor_ramping(void) {
motor_ramp_timer_callback // Callback function motor_ramp_timer_callback // Callback function
); );
if (motor_state.ramp_timer == NULL) { motor_state.cooldown_timer = xTimerCreate(
ESP_LOGE(TAG, "Failed to create motor ramp timer"); "MotorCooldownTimer", // Timer name
pdMS_TO_TICKS(DIRECTION_CHANGE_COOLDOWN_MS), // Timer period
pdFALSE, // One-shot
(void*)0, // Timer ID
motor_cooldown_timer_callback // Callback function
);
if (motor_state.ramp_timer == NULL || motor_state.cooldown_timer == NULL) {
ESP_LOGE(TAG, "Failed to create motor timers");
} else { } else {
ESP_LOGI(TAG, "Motor ramping system initialized"); ESP_LOGI(TAG, "Motor control system initialized with direction change safety");
} }
} }
@ -323,59 +416,72 @@ void set_motor_speed(motor_mode_t mode, int speed_percent)
if (speed_percent < 0) speed_percent = 0; if (speed_percent < 0) speed_percent = 0;
if (speed_percent > 100) speed_percent = 100; if (speed_percent > 100) speed_percent = 100;
ESP_LOGI(TAG, "Motor command: %s - Speed: %d%% (Current mode: %s, Current speed: %d%%, State: %d)",
mode == MOTOR_OFF ? "OFF" : (mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE"),
speed_percent,
motor_state.mode == MOTOR_OFF ? "OFF" : (motor_state.mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE"),
motor_state.current_speed,
motor_state.state);
// If we're in cooldown, update the pending command
if (motor_state.state == MOTOR_STATE_COOLDOWN) {
motor_state.pending_mode = mode;
motor_state.pending_speed = speed_percent;
ESP_LOGI(TAG, "Motor in cooldown - command queued for execution");
return;
}
// Check if this is a direction change that requires cooldown
bool requires_cooldown = false;
if (motor_state.current_speed > 0 && motor_state.mode != MOTOR_OFF) {
if ((motor_state.mode == MOTOR_EXHAUST && mode == MOTOR_INTAKE) ||
(motor_state.mode == MOTOR_INTAKE && mode == MOTOR_EXHAUST)) {
requires_cooldown = true;
}
}
if (requires_cooldown) {
ESP_LOGI(TAG, "Direction change detected - initiating safety cooldown sequence");
// Stop any current ramping // Stop any current ramping
if (motor_state.ramping) { if (motor_state.ramping) {
xTimerStop(motor_state.ramp_timer, 0); xTimerStop(motor_state.ramp_timer, 0);
motor_state.ramping = false; motor_state.ramping = false;
} }
motor_mode_t previous_mode = motor_state.mode; // Stop the motor immediately
motor_state.mode = mode; motor_state.mode = MOTOR_OFF;
motor_state.target_speed = speed_percent;
ESP_LOGI(TAG, "Motor command: %s - Target: %d%% (Current: %d%%)",
mode == MOTOR_OFF ? "OFF" : (mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE"),
speed_percent, motor_state.current_speed);
// Handle different scenarios
if (mode == MOTOR_OFF || speed_percent == 0) {
// Immediate stop
motor_state.current_speed = 0; motor_state.current_speed = 0;
motor_state.target_speed = 0; motor_state.target_speed = 0;
motor_state.state = MOTOR_STATE_COOLDOWN;
motor_state.cooldown_remaining_ms = DIRECTION_CHANGE_COOLDOWN_MS;
apply_motor_pwm(0); apply_motor_pwm(0);
ESP_LOGI(TAG, "Motor stopped immediately");
} else if (previous_mode == MOTOR_OFF || motor_state.current_speed == 0) { // Store the pending command
// Starting from stop - apply minimum speed first, then ramp motor_state.pending_mode = mode;
int start_speed = (speed_percent < MIN_MOTOR_SPEED) ? speed_percent : MIN_MOTOR_SPEED; motor_state.pending_speed = speed_percent;
motor_state.current_speed = start_speed;
apply_motor_pwm(start_speed);
if (speed_percent > start_speed) { // Start cooldown timer
// Start ramping to target xTimerStart(motor_state.cooldown_timer, 0);
motor_state.ramping = true;
xTimerStart(motor_state.ramp_timer, 0); ESP_LOGI(TAG, "Motor stopped for direction change - %d second cooldown started",
ESP_LOGI(TAG, "Motor starting at %d%%, ramping to %d%%", start_speed, speed_percent); DIRECTION_CHANGE_COOLDOWN_MS / 1000);
} else { } else {
ESP_LOGI(TAG, "Motor started at %d%% (no ramping needed)", start_speed); // No direction change required, proceed normally
// Stop any current ramping
if (motor_state.ramping) {
xTimerStop(motor_state.ramp_timer, 0);
motor_state.ramping = false;
} }
} else if (previous_mode != mode) { // Stop cooldown timer if running
// Direction change - ramp down to minimum, change direction, then ramp up if (motor_state.state == MOTOR_STATE_COOLDOWN) {
motor_state.target_speed = MIN_MOTOR_SPEED; xTimerStop(motor_state.cooldown_timer, 0);
motor_state.ramping = true; motor_state.cooldown_remaining_ms = 0;
xTimerStart(motor_state.ramp_timer, 0); }
ESP_LOGI(TAG, "Direction change - ramping down first");
// Note: In a real implementation, you might want to implement a state machine start_motor_operation(mode, speed_percent);
// to handle the direction change sequence properly
} else {
// Same mode, just speed change - ramp to new speed
motor_state.ramping = true;
xTimerStart(motor_state.ramp_timer, 0);
ESP_LOGI(TAG, "Speed change - ramping from %d%% to %d%%",
motor_state.current_speed, speed_percent);
} }
} }
@ -399,9 +505,12 @@ static esp_err_t root_get_handler(httpd_req_t *req)
// HTTP handler for fan status (GET /status) // HTTP handler for fan status (GET /status)
static esp_err_t status_get_handler(httpd_req_t *req) static esp_err_t status_get_handler(httpd_req_t *req)
{ {
ESP_LOGI(TAG, "Status request - Mode: %d, Current: %d%%, Target: %d%%, Ramping: %s", // Update cooldown time before reporting
update_cooldown_time();
ESP_LOGI(TAG, "Status request - Mode: %d, Current: %d%%, Target: %d%%, State: %d, Ramping: %s",
motor_state.mode, motor_state.current_speed, motor_state.target_speed, motor_state.mode, motor_state.current_speed, motor_state.target_speed,
motor_state.ramping ? "YES" : "NO"); motor_state.state, motor_state.ramping ? "YES" : "NO");
set_cors_headers(req); set_cors_headers(req);
httpd_resp_set_type(req, "application/json"); httpd_resp_set_type(req, "application/json");
@ -412,10 +521,31 @@ static esp_err_t status_get_handler(httpd_req_t *req)
if (motor_state.mode == MOTOR_EXHAUST) mode_str = "exhaust"; if (motor_state.mode == MOTOR_EXHAUST) mode_str = "exhaust";
else if (motor_state.mode == MOTOR_INTAKE) mode_str = "intake"; else if (motor_state.mode == MOTOR_INTAKE) mode_str = "intake";
const char* state_str = "idle";
switch (motor_state.state) {
case MOTOR_STATE_RAMPING: state_str = "ramping"; break;
case MOTOR_STATE_STOPPING: state_str = "stopping"; break;
case MOTOR_STATE_COOLDOWN: state_str = "cooldown"; break;
case MOTOR_STATE_RESTARTING: state_str = "restarting"; break;
default: state_str = "idle"; break;
}
cJSON_AddStringToObject(json, "mode", mode_str); cJSON_AddStringToObject(json, "mode", mode_str);
cJSON_AddNumberToObject(json, "current_speed", motor_state.current_speed); cJSON_AddNumberToObject(json, "current_speed", motor_state.current_speed);
cJSON_AddNumberToObject(json, "target_speed", motor_state.target_speed); cJSON_AddNumberToObject(json, "target_speed", motor_state.target_speed);
cJSON_AddStringToObject(json, "state", state_str);
cJSON_AddBoolToObject(json, "ramping", motor_state.ramping); cJSON_AddBoolToObject(json, "ramping", motor_state.ramping);
cJSON_AddNumberToObject(json, "cooldown_remaining", motor_state.cooldown_remaining_ms);
// Add pending command info if in cooldown
if (motor_state.state == MOTOR_STATE_COOLDOWN) {
const char* pending_mode_str = "off";
if (motor_state.pending_mode == MOTOR_EXHAUST) pending_mode_str = "exhaust";
else if (motor_state.pending_mode == MOTOR_INTAKE) pending_mode_str = "intake";
cJSON_AddStringToObject(json, "pending_mode", pending_mode_str);
cJSON_AddNumberToObject(json, "pending_speed", motor_state.pending_speed);
}
char *json_string = cJSON_Print(json); char *json_string = cJSON_Print(json);
if (json_string) { if (json_string) {
@ -638,7 +768,7 @@ void main_task(void *pvParameters) {
void app_main(void) void app_main(void)
{ {
ESP_LOGI(TAG, "Starting Maxxfan HTTP Controller with improvements!"); ESP_LOGI(TAG, "Starting Maxxfan HTTP Controller with Direction Change Safety!");
// Initialize NVS // Initialize NVS
esp_err_t ret = nvs_flash_init(); esp_err_t ret = nvs_flash_init();
@ -665,7 +795,8 @@ void app_main(void)
start_webserver(); start_webserver();
ESP_LOGI(TAG, "=== Enhanced Maxxfan Controller Ready! ==="); ESP_LOGI(TAG, "=== Enhanced Maxxfan Controller Ready! ===");
ESP_LOGI(TAG, "Features: Motor Ramping, Optimized Performance, Real-time Updates"); ESP_LOGI(TAG, "Features: Motor Ramping, Direction Change Safety, Real-time Updates");
ESP_LOGI(TAG, "Safety: 10-second cooldown for direction changes");
ESP_LOGI(TAG, "Open your browser and go to: http://[ESP32_IP_ADDRESS]"); ESP_LOGI(TAG, "Open your browser and go to: http://[ESP32_IP_ADDRESS]");
ESP_LOGI(TAG, "Check the monitor output above for your IP address"); ESP_LOGI(TAG, "Check the monitor output above for your IP address");