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Refactor motor control

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This commit is contained in:
Stephen Minakian
2025-07-09 17:29:27 -06:00
parent 15f8d41656
commit f3fb4f4ac8
4 changed files with 670 additions and 443 deletions
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532
main/maxxfan-controller.c
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@ -3,7 +3,6 @@
#include "freertos/FreeRTOS.h"
#include "freertos/task.h"
#include "freertos/event_groups.h"
#include "freertos/timers.h"
#include "esp_system.h"
#include "esp_wifi.h"
#include "esp_event.h"
@ -12,66 +11,16 @@
#include "esp_task_wdt.h"
#include "nvs_flash.h"
#include "nvs.h"
#include "driver/gpio.h"
#include "driver/ledc.h"
#include "cJSON.h"
// Project configuration
// Project modules
#include "config.h"
#include "motor_control.h"
// WiFi event group
static EventGroupHandle_t s_wifi_event_group;
static int s_retry_num = 0;
// Motor control
typedef enum {
MOTOR_OFF,
MOTOR_EXHAUST,
MOTOR_INTAKE
} 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 {
motor_mode_t mode;
motor_mode_t pending_mode; // Mode to switch to after cooldown
int target_speed;
int pending_speed; // Speed to set after cooldown
int current_speed;
motor_state_enum_t state;
bool ramping;
TimerHandle_t ramp_timer;
TimerHandle_t cooldown_timer;
uint32_t cooldown_remaining_ms; // For status reporting
// State preservation
motor_mode_t last_on_mode; // Last non-OFF mode for ON button
int last_on_speed; // Last non-zero speed for ON button
bool user_turned_off; // Track if user manually turned off
} motor_state_t;
static motor_state_t motor_state = {
.mode = MOTOR_OFF,
.pending_mode = MOTOR_OFF,
.target_speed = 0,
.pending_speed = 0,
.current_speed = 0,
.state = MOTOR_STATE_IDLE,
.ramping = false,
.ramp_timer = NULL,
.cooldown_timer = NULL,
.cooldown_remaining_ms = 0,
.last_on_mode = MOTOR_EXHAUST, // Default to exhaust for ON button
.last_on_speed = 50, // Default to 50% for ON button
.user_turned_off = false
};
// HTTP server handle
static httpd_handle_t server = NULL;
@ -136,14 +85,9 @@ static const char* html_page =
"document.addEventListener('DOMContentLoaded',function(){getStatus();startUpdates()})</script></body></html>";
// Forward declarations
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 start_motor_operation(motor_mode_t mode, int speed_percent);
static esp_err_t save_motor_state_to_nvs(void);
static esp_err_t load_motor_state_from_nvs(void);
static bool is_watchdog_reset(void);
static void save_last_on_state(motor_mode_t mode, int speed);
// Initialize watchdog timer
void init_watchdog(void) {
@ -194,29 +138,36 @@ static esp_err_t save_motor_state_to_nvs(void) {
return err;
}
// Get current motor state
const motor_state_t* state = motor_get_state();
motor_mode_t last_on_mode;
int last_on_speed;
motor_get_last_on_state(&last_on_mode, &last_on_speed);
bool user_turned_off = motor_get_user_turned_off();
ESP_LOGI(SYSTEM_TAG, "=== SAVING STATE TO NVS ===");
ESP_LOGI(SYSTEM_TAG, "Mode: %d, Speed: %d%%, Last ON: %d@%d%%, User OFF: %s",
motor_state.mode, motor_state.target_speed,
motor_state.last_on_mode, motor_state.last_on_speed,
motor_state.user_turned_off ? "YES" : "NO");
state->mode, state->target_speed,
last_on_mode, last_on_speed,
user_turned_off ? "YES" : "NO");
// Save current motor state
err = nvs_set_u8(nvs_handle, NVS_KEY_MODE, (uint8_t)motor_state.mode);
err = nvs_set_u8(nvs_handle, NVS_KEY_MODE, (uint8_t)state->mode);
if (err == ESP_OK) {
err = nvs_set_u8(nvs_handle, NVS_KEY_SPEED, (uint8_t)motor_state.target_speed);
err = nvs_set_u8(nvs_handle, NVS_KEY_SPEED, (uint8_t)state->target_speed);
}
// Save last ON state
if (err == ESP_OK) {
err = nvs_set_u8(nvs_handle, NVS_KEY_LAST_ON_MODE, (uint8_t)motor_state.last_on_mode);
err = nvs_set_u8(nvs_handle, NVS_KEY_LAST_ON_MODE, (uint8_t)last_on_mode);
}
if (err == ESP_OK) {
err = nvs_set_u8(nvs_handle, NVS_KEY_LAST_ON_SPEED, (uint8_t)motor_state.last_on_speed);
err = nvs_set_u8(nvs_handle, NVS_KEY_LAST_ON_SPEED, (uint8_t)last_on_speed);
}
// Save power state (whether user turned off manually)
if (err == ESP_OK) {
err = nvs_set_u8(nvs_handle, NVS_KEY_POWER_STATE, motor_state.user_turned_off ? 1 : 0);
err = nvs_set_u8(nvs_handle, NVS_KEY_POWER_STATE, user_turned_off ? 1 : 0);
}
if (err == ESP_OK) {
@ -266,13 +217,13 @@ static esp_err_t load_motor_state_from_nvs(void) {
if (stored_last_mode < MOTOR_EXHAUST || stored_last_mode > MOTOR_INTAKE) stored_last_mode = MOTOR_EXHAUST;
if (!IS_VALID_SPEED(stored_last_speed)) stored_last_speed = 50;
motor_state.last_on_mode = (motor_mode_t)stored_last_mode;
motor_state.last_on_speed = stored_last_speed;
motor_state.user_turned_off = (stored_power_state == 1);
// Set the last ON state in motor control module
motor_set_last_on_state((motor_mode_t)stored_last_mode, stored_last_speed);
motor_set_user_turned_off(stored_power_state == 1);
ESP_LOGI(SYSTEM_TAG, "Loaded state from NVS - Mode: %d, Speed: %d%%, Last ON: %d@%d%%, User OFF: %s",
stored_mode, stored_speed, motor_state.last_on_mode, motor_state.last_on_speed,
motor_state.user_turned_off ? "YES" : "NO");
stored_mode, stored_speed, stored_last_mode, stored_last_speed,
stored_power_state ? "YES" : "NO");
// Check reset reason to decide whether to restore state
bool was_watchdog_reset = is_watchdog_reset();
@ -293,34 +244,28 @@ static esp_err_t load_motor_state_from_nvs(void) {
reset_reason == ESP_RST_SDIO ? "SDIO" : "UNKNOWN");
ESP_LOGI(SYSTEM_TAG, "Watchdog reset: %s", was_watchdog_reset ? "YES" : "NO");
ESP_LOGI(SYSTEM_TAG, "Stored mode: %d, speed: %d", stored_mode, stored_speed);
ESP_LOGI(SYSTEM_TAG, "User turned off: %s", motor_state.user_turned_off ? "YES" : "NO");
ESP_LOGI(SYSTEM_TAG, "User turned off: %s", stored_power_state ? "YES" : "NO");
ESP_LOGI(SYSTEM_TAG, "====================");
// Store the restored state for potential motor restoration
if (was_watchdog_reset) {
// True watchdog reset (TASK_WDT or INT_WDT) - don't restore state, start fresh
ESP_LOGI(SYSTEM_TAG, "⚠️ TRUE watchdog reset detected - starting in OFF state for safety");
motor_state.mode = MOTOR_OFF;
motor_state.target_speed = 0;
motor_state.current_speed = 0;
motor_state.user_turned_off = false; // Reset user off flag
} else if (motor_state.user_turned_off) {
// Motor module is already initialized in OFF state, no action needed
} else if (stored_power_state) {
// User manually turned off - stay off
ESP_LOGI(SYSTEM_TAG, "🔒 User had turned off manually - staying OFF");
motor_state.mode = MOTOR_OFF;
motor_state.target_speed = 0;
motor_state.current_speed = 0;
// Motor module is already initialized in OFF state, no action needed
} else if (stored_mode != MOTOR_OFF && stored_speed > 0) {
// Normal power loss or general WDT (which can be power-related) - restore previous state
ESP_LOGI(SYSTEM_TAG, "🔋 Power restored - will resume previous state: %s @ %d%%",
stored_mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE", stored_speed);
motor_state.mode = (motor_mode_t)stored_mode;
motor_state.target_speed = stored_speed;
motor_state.current_speed = 0; // Always start ramping from 0
// Set the motor to the restored state (will be applied after initialization)
motor_set_speed((motor_mode_t)stored_mode, stored_speed);
} else {
ESP_LOGI(SYSTEM_TAG, "❌ No valid state to restore (mode=%d, speed=%d)", stored_mode, stored_speed);
motor_state.mode = MOTOR_OFF;
motor_state.target_speed = 0;
motor_state.current_speed = 0;
// Motor module is already initialized in OFF state, no action needed
}
} else {
ESP_LOGI(SYSTEM_TAG, "No saved state found, using defaults");
@ -331,16 +276,6 @@ static esp_err_t load_motor_state_from_nvs(void) {
return err;
}
// Save the last ON state (for ON button functionality)
static void save_last_on_state(motor_mode_t mode, int speed) {
if (mode != MOTOR_OFF && speed > 0) {
motor_state.last_on_mode = mode;
motor_state.last_on_speed = speed;
ESP_LOGI(SYSTEM_TAG, "Last ON state updated: %s @ %d%%",
mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE", speed);
}
}
// WiFi event handler
static void event_handler(void* arg, esp_event_base_t event_base,
int32_t event_id, void* event_data)
@ -364,305 +299,6 @@ static void event_handler(void* arg, esp_event_base_t event_base,
}
}
void configure_gpio_pins(void)
{
ESP_LOGI(SYSTEM_TAG, "Configuring GPIO pins...");
uint64_t pin_mask = (1ULL << LED_PIN) |
(1ULL << MOTOR_R_EN) |
(1ULL << MOTOR_L_EN);
gpio_config_t io_conf = {
.pin_bit_mask = pin_mask,
.mode = GPIO_MODE_OUTPUT,
.pull_up_en = GPIO_PULLUP_DISABLE,
.pull_down_en = GPIO_PULLDOWN_DISABLE,
.intr_type = GPIO_INTR_DISABLE
};
gpio_config(&io_conf);
gpio_set_level(LED_PIN, 0);
gpio_set_level(MOTOR_R_EN, 0);
gpio_set_level(MOTOR_L_EN, 0);
ESP_LOGI(SYSTEM_TAG, "GPIO pins configured");
}
void configure_pwm(void)
{
ESP_LOGI(SYSTEM_TAG, "Configuring PWM...");
ledc_timer_config_t timer_conf = {
.speed_mode = PWM_SPEED_MODE,
.timer_num = PWM_TIMER,
.duty_resolution = PWM_RESOLUTION,
.freq_hz = PWM_FREQUENCY,
.clk_cfg = LEDC_AUTO_CLK
};
ledc_timer_config(&timer_conf);
ledc_channel_config_t channel_conf = {
.channel = PWM_R_CHANNEL,
.duty = 0,
.gpio_num = PWM_R_PIN,
.speed_mode = PWM_SPEED_MODE,
.hpoint = 0,
.timer_sel = PWM_TIMER
};
ledc_channel_config(&channel_conf);
channel_conf.channel = PWM_L_CHANNEL;
channel_conf.gpio_num = PWM_L_PIN;
ledc_channel_config(&channel_conf);
ESP_LOGI(SYSTEM_TAG, "PWM configured");
}
// Apply PWM to motor based on current mode and speed
static void apply_motor_pwm(int speed_percent) {
// Clamp speed to valid range using config macro
speed_percent = CLAMP_SPEED(speed_percent);
uint32_t duty = SPEED_TO_DUTY(speed_percent);
if (motor_state.mode == MOTOR_OFF || speed_percent == 0) {
gpio_set_level(LED_PIN, 0);
gpio_set_level(MOTOR_R_EN, 0);
gpio_set_level(MOTOR_L_EN, 0);
ledc_set_duty(PWM_SPEED_MODE, PWM_R_CHANNEL, 0);
ledc_set_duty(PWM_SPEED_MODE, PWM_L_CHANNEL, 0);
ledc_update_duty(PWM_SPEED_MODE, PWM_R_CHANNEL);
ledc_update_duty(PWM_SPEED_MODE, PWM_L_CHANNEL);
} else if (motor_state.mode == MOTOR_EXHAUST) {
gpio_set_level(LED_PIN, 1);
gpio_set_level(MOTOR_R_EN, 1);
gpio_set_level(MOTOR_L_EN, 1);
ledc_set_duty(PWM_SPEED_MODE, PWM_R_CHANNEL, duty);
ledc_set_duty(PWM_SPEED_MODE, PWM_L_CHANNEL, 0);
ledc_update_duty(PWM_SPEED_MODE, PWM_R_CHANNEL);
ledc_update_duty(PWM_SPEED_MODE, PWM_L_CHANNEL);
} else if (motor_state.mode == MOTOR_INTAKE) {
gpio_set_level(LED_PIN, 1);
gpio_set_level(MOTOR_R_EN, 1);
gpio_set_level(MOTOR_L_EN, 1);
ledc_set_duty(PWM_SPEED_MODE, PWM_R_CHANNEL, 0);
ledc_set_duty(PWM_SPEED_MODE, PWM_L_CHANNEL, duty);
ledc_update_duty(PWM_SPEED_MODE, PWM_R_CHANNEL);
ledc_update_duty(PWM_SPEED_MODE, PWM_L_CHANNEL);
}
}
// Motor ramp timer callback
static void motor_ramp_timer_callback(TimerHandle_t xTimer) {
if (motor_state.state != MOTOR_STATE_RAMPING) {
return;
}
int speed_diff = motor_state.target_speed - motor_state.current_speed;
if (abs(speed_diff) <= RAMP_STEP_SIZE) {
// Close enough to target, finish ramping
motor_state.current_speed = motor_state.target_speed;
motor_state.ramping = false;
motor_state.state = MOTOR_STATE_IDLE;
// Stop the timer
xTimerStop(motor_state.ramp_timer, 0);
ESP_LOGI(SYSTEM_TAG, "Ramping complete - Final speed: %d%%", motor_state.current_speed);
} else {
// Continue ramping
if (speed_diff > 0) {
motor_state.current_speed += RAMP_STEP_SIZE;
} else {
motor_state.current_speed -= RAMP_STEP_SIZE;
}
MOTOR_LOGD(SYSTEM_TAG, "Ramping: %d%% (target: %d%%)", motor_state.current_speed, motor_state.target_speed);
}
apply_motor_pwm(motor_state.current_speed);
}
// Motor cooldown timer callback
static void motor_cooldown_timer_callback(TimerHandle_t xTimer) {
ESP_LOGI(SYSTEM_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 >= STATUS_UPDATE_INTERVAL_MS) {
motor_state.cooldown_remaining_ms -= STATUS_UPDATE_INTERVAL_MS;
} else {
motor_state.cooldown_remaining_ms = 0;
}
}
}
// Start motor operation (internal function)
static void start_motor_operation(motor_mode_t mode, int speed_percent) {
// Clamp speed using config macro
speed_percent = CLAMP_SPEED(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(SYSTEM_TAG, "Motor stopped immediately");
} else {
// Save last ON state for future ON button use
save_last_on_state(mode, speed_percent);
// 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(SYSTEM_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;
}
}
// Save state to NVS after any change
save_motor_state_to_nvs();
}
// Initialize motor ramping system
void init_motor_ramping(void) {
motor_state.ramp_timer = xTimerCreate(
"MotorRampTimer", // Timer name
pdMS_TO_TICKS(RAMP_STEP_MS), // Timer period
pdTRUE, // Auto-reload
(void*)0, // Timer ID
motor_ramp_timer_callback // Callback function
);
motor_state.cooldown_timer = xTimerCreate(
"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(SYSTEM_TAG, "Failed to create motor timers");
} else {
ESP_LOGI(SYSTEM_TAG, "Motor control system initialized with direction change safety");
}
}
void set_motor_speed(motor_mode_t mode, int speed_percent)
{
// Clamp speed to valid range using config macro
speed_percent = CLAMP_SPEED(speed_percent);
ESP_LOGI(SYSTEM_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);
// Track if user manually turned off
if (mode == MOTOR_OFF && motor_state.mode != MOTOR_OFF) {
motor_state.user_turned_off = true;
ESP_LOGI(SYSTEM_TAG, "User manually turned OFF - will stay off after restart");
} else if (mode != MOTOR_OFF) {
motor_state.user_turned_off = false;
ESP_LOGI(SYSTEM_TAG, "Motor turned ON - will resume after power loss");
}
// 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(SYSTEM_TAG, "Motor in cooldown - command queued for execution");
save_motor_state_to_nvs(); // Save the pending state
return;
}
// Check if this is a direction change that requires cooldown using config macro
bool requires_cooldown = false;
if (motor_state.current_speed > 0 && motor_state.mode != MOTOR_OFF) {
requires_cooldown = IS_DIRECTION_CHANGE(motor_state.mode, mode);
}
if (requires_cooldown) {
ESP_LOGI(SYSTEM_TAG, "Direction change detected - initiating safety cooldown sequence");
// Stop any current ramping
if (motor_state.ramping) {
xTimerStop(motor_state.ramp_timer, 0);
motor_state.ramping = false;
}
// Stop the motor immediately
motor_state.mode = MOTOR_OFF;
motor_state.current_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);
// Store the pending command
motor_state.pending_mode = mode;
motor_state.pending_speed = speed_percent;
// Start cooldown timer
xTimerStart(motor_state.cooldown_timer, 0);
ESP_LOGI(SYSTEM_TAG, "Motor stopped for direction change - %d second cooldown started",
DIRECTION_CHANGE_COOLDOWN_MS / 1000);
// Save state including pending command
save_motor_state_to_nvs();
} else {
// No direction change required, proceed normally
// Stop any current ramping
if (motor_state.ramping) {
xTimerStop(motor_state.ramp_timer, 0);
motor_state.ramping = false;
}
// Stop cooldown timer if running
if (motor_state.state == MOTOR_STATE_COOLDOWN) {
xTimerStop(motor_state.cooldown_timer, 0);
motor_state.cooldown_remaining_ms = 0;
}
start_motor_operation(mode, speed_percent);
}
}
// Helper function to set CORS headers
static void set_cors_headers(httpd_req_t *req) {
httpd_resp_set_hdr(req, "Access-Control-Allow-Origin", "*");
@ -684,11 +320,17 @@ static esp_err_t root_get_handler(httpd_req_t *req)
static esp_err_t status_get_handler(httpd_req_t *req)
{
// Update cooldown time before reporting
update_cooldown_time();
motor_update_cooldown_time();
ESP_LOGI(SYSTEM_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.state, motor_state.ramping ? "YES" : "NO");
// Get current motor state
const motor_state_t* state = motor_get_state();
motor_mode_t last_on_mode;
int last_on_speed;
motor_get_last_on_state(&last_on_mode, &last_on_speed);
ESP_LOGI(SYSTEM_TAG, "Status request - Mode: %s, Current: %d%%, Target: %d%%, State: %s, Ramping: %s",
motor_mode_to_string(state->mode), state->current_speed, state->target_speed,
motor_state_to_string(state->state), state->ramping ? "YES" : "NO");
set_cors_headers(req);
httpd_resp_set_type(req, "application/json");
@ -696,11 +338,11 @@ static esp_err_t status_get_handler(httpd_req_t *req)
cJSON *json = cJSON_CreateObject();
const char* mode_str = "off";
if (motor_state.mode == MOTOR_EXHAUST) mode_str = "exhaust";
else if (motor_state.mode == MOTOR_INTAKE) mode_str = "intake";
if (state->mode == MOTOR_EXHAUST) mode_str = "exhaust";
else if (state->mode == MOTOR_INTAKE) mode_str = "intake";
const char* state_str = "idle";
switch (motor_state.state) {
switch (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;
@ -709,25 +351,25 @@ static esp_err_t status_get_handler(httpd_req_t *req)
}
const char* last_on_mode_str = "exhaust";
if (motor_state.last_on_mode == MOTOR_INTAKE) last_on_mode_str = "intake";
if (last_on_mode == MOTOR_INTAKE) last_on_mode_str = "intake";
cJSON_AddStringToObject(json, "mode", mode_str);
cJSON_AddNumberToObject(json, "current_speed", motor_state.current_speed);
cJSON_AddNumberToObject(json, "target_speed", motor_state.target_speed);
cJSON_AddNumberToObject(json, "current_speed", state->current_speed);
cJSON_AddNumberToObject(json, "target_speed", state->target_speed);
cJSON_AddStringToObject(json, "state", state_str);
cJSON_AddBoolToObject(json, "ramping", motor_state.ramping);
cJSON_AddNumberToObject(json, "cooldown_remaining", motor_state.cooldown_remaining_ms);
cJSON_AddBoolToObject(json, "ramping", state->ramping);
cJSON_AddNumberToObject(json, "cooldown_remaining", state->cooldown_remaining_ms);
cJSON_AddStringToObject(json, "last_on_mode", last_on_mode_str);
cJSON_AddNumberToObject(json, "last_on_speed", motor_state.last_on_speed);
cJSON_AddNumberToObject(json, "last_on_speed", last_on_speed);
// Add pending command info if in cooldown
if (motor_state.state == MOTOR_STATE_COOLDOWN) {
if (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";
if (state->pending_mode == MOTOR_EXHAUST) pending_mode_str = "exhaust";
else if (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);
cJSON_AddNumberToObject(json, "pending_speed", state->pending_speed);
}
char *json_string = cJSON_Print(json);
@ -799,10 +441,14 @@ static esp_err_t fan_post_handler(httpd_req_t *req)
// Handle special "ON" command - resume last settings
if (strcmp(mode_str, "on") == 0) {
mode = motor_state.last_on_mode;
speed = motor_state.last_on_speed;
ESP_LOGI(SYSTEM_TAG, "ON button pressed - resuming %s @ %d%%",
mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE", speed);
ESP_LOGI(SYSTEM_TAG, "ON button pressed - resuming last state");
motor_resume_last_state();
// Save state after ON button
save_motor_state_to_nvs();
cJSON_Delete(json);
return status_get_handler(req);
} else if (strcmp(mode_str, "exhaust") == 0) {
mode = MOTOR_EXHAUST;
} else if (strcmp(mode_str, "intake") == 0) {
@ -810,7 +456,10 @@ static esp_err_t fan_post_handler(httpd_req_t *req)
}
ESP_LOGI(SYSTEM_TAG, "HTTP Request: mode=%s, speed=%d", mode_str, speed);
set_motor_speed(mode, speed);
motor_set_speed(mode, speed);
// Save state after any motor command
save_motor_state_to_nvs();
cJSON_Delete(json);
@ -962,14 +611,15 @@ void app_main(void)
// Initialize watchdog timer
init_watchdog();
// Configure hardware
configure_gpio_pins();
configure_pwm();
// Initialize motor control system
ESP_LOGI(SYSTEM_TAG, "Initializing motor control system...");
ret = motor_control_init();
if (ret != ESP_OK) {
ESP_LOGE(SYSTEM_TAG, "Failed to initialize motor control: %s", esp_err_to_name(ret));
return;
}
// Initialize motor ramping system
init_motor_ramping();
// Load saved state from NVS
// Load saved state from NVS and potentially restore motor state
ESP_LOGI(SYSTEM_TAG, "Loading saved state...");
load_motor_state_from_nvs();
@ -979,35 +629,35 @@ void app_main(void)
// Start HTTP server
start_webserver();
// Restore motor state if needed (after WiFi is connected and server is running)
ESP_LOGI(SYSTEM_TAG, "=== MOTOR STATE RESTORATION ===");
ESP_LOGI(SYSTEM_TAG, "Current motor state: mode=%d, target=%d%%, current=%d%%",
motor_state.mode, motor_state.target_speed, motor_state.current_speed);
// Report final motor state after initialization
const motor_state_t* final_state = motor_get_state();
ESP_LOGI(SYSTEM_TAG, "=== MOTOR STATE AFTER INITIALIZATION ===");
ESP_LOGI(SYSTEM_TAG, "Final motor state: mode=%s, target=%d%%, current=%d%%, state=%s",
motor_mode_to_string(final_state->mode), final_state->target_speed,
final_state->current_speed, motor_state_to_string(final_state->state));
if (motor_state.mode != MOTOR_OFF && motor_state.target_speed > 0) {
ESP_LOGI(SYSTEM_TAG, "Restoring motor state: %s @ %d%%",
motor_state.mode == MOTOR_EXHAUST ? "EXHAUST" : "INTAKE",
motor_state.target_speed);
// Start the motor with current settings
motor_state.current_speed = 0; // Start from 0 and ramp up
start_motor_operation(motor_state.mode, motor_state.target_speed);
ESP_LOGI(SYSTEM_TAG, "Motor restoration initiated");
if (final_state->mode != MOTOR_OFF && final_state->target_speed > 0) {
ESP_LOGI(SYSTEM_TAG, "Motor restored to: %s @ %d%%",
motor_mode_to_string(final_state->mode), final_state->target_speed);
} else {
ESP_LOGI(SYSTEM_TAG, "No motor state to restore - staying OFF");
ESP_LOGI(SYSTEM_TAG, "Motor remains OFF");
}
ESP_LOGI(SYSTEM_TAG, "===============================");
ESP_LOGI(SYSTEM_TAG, "=======================================");
ESP_LOGI(SYSTEM_TAG, "=== Enhanced Maxxfan Controller Ready! ===");
ESP_LOGI(SYSTEM_TAG, "Features: State Preservation, Direction Safety, Motor Ramping, ON Button");
ESP_LOGI(SYSTEM_TAG, "Safety: 10-second cooldown for direction changes");
ESP_LOGI(SYSTEM_TAG, "Safety: %d-second cooldown for direction changes", DIRECTION_CHANGE_COOLDOWN_MS / 1000);
ESP_LOGI(SYSTEM_TAG, "Memory: Remembers settings after power loss (except watchdog resets)");
ESP_LOGI(SYSTEM_TAG, "Open your browser and go to: http://[ESP32_IP_ADDRESS]");
ESP_LOGI(SYSTEM_TAG, "Check the monitor output above for your IP address");
// Main loop - reset watchdog periodically
// Main loop - reset watchdog periodically and update motor cooldown
while (1) {
feed_watchdog();
// Update motor cooldown time for status reporting
motor_update_cooldown_time();
vTaskDelay(pdMS_TO_TICKS(WATCHDOG_FEED_INTERVAL_MS));
}
}