Files
maxxfan-controller/main/maxxfan-controller.c

1013 lines
40 KiB
C
Executable File

#include <stdio.h>
#include <string.h>
#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"
#include "esp_log.h"
#include "esp_http_server.h"
#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
#include "config.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;
// Task handles for watchdog
static TaskHandle_t main_task_handle = NULL;
// Compact HTML web page for control
static const char* html_page =
"<!DOCTYPE html><html><head><title>Maxxfan</title><meta name=\"viewport\" content=\"width=device-width,initial-scale=1\"><style>"
"body{font-family:Arial;margin:20px;background:#f0f0f0}.container{max-width:500px;margin:0 auto;background:white;padding:20px;border-radius:8px}"
"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}.on{background:#2196F3;color:white}"
".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}"
"</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>"
"<p>Target: <span id=\"target\">0</span>%</p><p>State: <span id=\"state\">IDLE</span></p>"
"<p>Last ON: <span id=\"lastOn\">EXHAUST @ 50%</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><h3>Fan Control</h3><button class=\"off\" onclick=\"setFan('off',0)\">OFF</button>"
"<button class=\"on\" onclick=\"setFan('on',0)\">ON (Resume Last)</button>"
"<button class=\"exhaust\" onclick=\"setFan('exhaust',50)\">Exhaust 50%</button>"
"<button class=\"intake\" onclick=\"setFan('intake',50)\">Intake 50%</button></div>"
"<div><h3>Speed Control</h3><label>Speed: <span id=\"speedValue\">50</span>%</label>"
"<input type=\"range\" id=\"speedSlider\" class=\"slider\" min=\"0\" max=\"100\" value=\"50\" oninput=\"updateSpeed(this.value)\">"
"<button class=\"exhaust\" onclick=\"setFanSpeed('exhaust')\">Set Exhaust</button>"
"<button class=\"intake\" onclick=\"setFanSpeed('intake')\">Set Intake</button></div></div>"
"<script>let currentSpeed=50,updateInterval=null,errorCount=0;"
"function updateSpeed(v){currentSpeed=parseInt(v);document.getElementById('speedValue').textContent=v}"
"function showError(m){document.getElementById('errorStatus').innerHTML='Error: '+m;document.getElementById('errorStatus').style.display='block';"
"document.getElementById('connectionStatus').textContent='Error'}"
"function hideError(){document.getElementById('errorStatus').style.display='none';"
"document.getElementById('connectionStatus').textContent='Connected';errorCount=0}"
"function setFan(mode,speed){if(mode==='on'){fetch('/fan',{method:'POST',headers:{'Content-Type':'application/json'},"
"body:JSON.stringify({mode:'on',speed:0})})"
".then(r=>{if(!r.ok)throw new Error('HTTP '+r.status);return r.json()})"
".then(d=>{updateStatus(d);hideError()}).catch(e=>{console.error(e);showError(e.message)});return;}"
"currentSpeed=speed;document.getElementById('speedSlider').value=speed;"
"document.getElementById('speedValue').textContent=speed;fetch('/fan',{method:'POST',"
"headers:{'Content-Type':'application/json'},body:JSON.stringify({mode:mode,speed:parseInt(speed)})})"
".then(r=>{if(!r.ok)throw new Error('HTTP '+r.status);return r.json()})"
".then(d=>{updateStatus(d);hideError()}).catch(e=>{console.error(e);showError(e.message)})}"
"function setFanSpeed(mode){fetch('/fan',{method:'POST',headers:{'Content-Type':'application/json'},"
"body:JSON.stringify({mode:mode,speed:parseInt(currentSpeed)})})"
".then(r=>{if(!r.ok)throw new Error('HTTP '+r.status);return r.json()})"
".then(d=>{updateStatus(d);hideError()}).catch(e=>{console.error(e);showError(e.message)})}"
"function updateStatus(data){document.getElementById('mode').textContent=data.mode.toUpperCase();"
"document.getElementById('speed').textContent=data.current_speed;"
"document.getElementById('target').textContent=data.target_speed;"
"document.getElementById('state').textContent=data.state.toUpperCase();"
"if(data.last_on_mode&&data.last_on_speed){document.getElementById('lastOn').textContent=data.last_on_mode.toUpperCase()+' @ '+data.last_on_speed+'%';}"
"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()})"
".then(d=>{updateStatus(d);hideError()}).catch(e=>{errorCount++;if(errorCount>=3)showError('Connection lost')})}"
"function startUpdates(){if(updateInterval)clearInterval(updateInterval);updateInterval=setInterval(getStatus,1000)}"
"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) {
ESP_LOGI(SYSTEM_TAG, "Setting up watchdog monitoring...");
// Get current task handle and add to watchdog
main_task_handle = xTaskGetCurrentTaskHandle();
esp_err_t result = esp_task_wdt_add(main_task_handle);
if (result == ESP_OK) {
ESP_LOGI(SYSTEM_TAG, "Main task added to watchdog monitoring");
} else if (result == ESP_ERR_INVALID_ARG) {
ESP_LOGI(SYSTEM_TAG, "Task already monitored by watchdog");
} else {
ESP_LOGW(SYSTEM_TAG, "Watchdog not available: %s", esp_err_to_name(result));
main_task_handle = NULL; // Disable watchdog feeding
}
}
// Feed the watchdog
void feed_watchdog(void) {
if (main_task_handle != NULL) {
esp_err_t result = esp_task_wdt_reset();
if (result != ESP_OK) {
MOTOR_LOGD(SYSTEM_TAG, "Watchdog reset failed: %s", esp_err_to_name(result));
}
}
}
// Check if this was a watchdog reset
static bool is_watchdog_reset(void) {
esp_reset_reason_t reset_reason = esp_reset_reason();
// Only consider TASK_WDT and INT_WDT as true watchdog resets
// ESP_RST_WDT can be triggered by power disconnection, so we exclude it
return (reset_reason == ESP_RST_TASK_WDT ||
reset_reason == ESP_RST_INT_WDT);
}
// Save motor state to NVS
static esp_err_t save_motor_state_to_nvs(void) {
nvs_handle_t nvs_handle;
esp_err_t err;
err = nvs_open(NVS_NAMESPACE, NVS_READWRITE, &nvs_handle);
if (err != ESP_OK) {
ESP_LOGE(SYSTEM_TAG, "Error opening NVS handle: %s", esp_err_to_name(err));
return err;
}
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");
// Save current motor state
err = nvs_set_u8(nvs_handle, NVS_KEY_MODE, (uint8_t)motor_state.mode);
if (err == ESP_OK) {
err = nvs_set_u8(nvs_handle, NVS_KEY_SPEED, (uint8_t)motor_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);
}
if (err == ESP_OK) {
err = nvs_set_u8(nvs_handle, NVS_KEY_LAST_ON_SPEED, (uint8_t)motor_state.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);
}
if (err == ESP_OK) {
err = nvs_commit(nvs_handle);
if (err == ESP_OK) {
ESP_LOGI(SYSTEM_TAG, "✓ Motor state successfully saved to NVS");
} else {
ESP_LOGE(SYSTEM_TAG, "✗ NVS commit failed: %s", esp_err_to_name(err));
}
} else {
ESP_LOGE(SYSTEM_TAG, "✗ Error saving to NVS: %s", esp_err_to_name(err));
}
ESP_LOGI(SYSTEM_TAG, "===========================");
nvs_close(nvs_handle);
return err;
}
// Load motor state from NVS
static esp_err_t load_motor_state_from_nvs(void) {
nvs_handle_t nvs_handle;
esp_err_t err;
err = nvs_open(NVS_NAMESPACE, NVS_READONLY, &nvs_handle);
if (err != ESP_OK) {
ESP_LOGI(SYSTEM_TAG, "NVS not found, using default state");
return ESP_ERR_NVS_NOT_FOUND;
}
uint8_t stored_mode = 0;
uint8_t stored_speed = 0;
uint8_t stored_last_mode = 1; // Default to MOTOR_EXHAUST
uint8_t stored_last_speed = 50;
uint8_t stored_power_state = 0;
// Load current motor state
err = nvs_get_u8(nvs_handle, NVS_KEY_MODE, &stored_mode);
if (err == ESP_OK) {
nvs_get_u8(nvs_handle, NVS_KEY_SPEED, &stored_speed);
nvs_get_u8(nvs_handle, NVS_KEY_LAST_ON_MODE, &stored_last_mode);
nvs_get_u8(nvs_handle, NVS_KEY_LAST_ON_SPEED, &stored_last_speed);
nvs_get_u8(nvs_handle, NVS_KEY_POWER_STATE, &stored_power_state);
// Validate ranges using config macros
if (stored_mode > MOTOR_INTAKE) stored_mode = MOTOR_OFF;
if (!IS_VALID_SPEED(stored_speed)) stored_speed = 0;
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);
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");
// Check reset reason to decide whether to restore state
bool was_watchdog_reset = is_watchdog_reset();
esp_reset_reason_t reset_reason = esp_reset_reason();
ESP_LOGI(SYSTEM_TAG, "=== RESET ANALYSIS ===");
ESP_LOGI(SYSTEM_TAG, "Reset reason: %d", reset_reason);
ESP_LOGI(SYSTEM_TAG, "Reset reason name: %s",
reset_reason == ESP_RST_POWERON ? "POWERON" :
reset_reason == ESP_RST_EXT ? "EXTERNAL" :
reset_reason == ESP_RST_SW ? "SOFTWARE" :
reset_reason == ESP_RST_PANIC ? "PANIC" :
reset_reason == ESP_RST_INT_WDT ? "INT_WDT" :
reset_reason == ESP_RST_TASK_WDT ? "TASK_WDT" :
reset_reason == ESP_RST_WDT ? "WDT" :
reset_reason == ESP_RST_DEEPSLEEP ? "DEEPSLEEP" :
reset_reason == ESP_RST_BROWNOUT ? "BROWNOUT" :
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, "====================");
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) {
// 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;
} 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
} 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;
}
} else {
ESP_LOGI(SYSTEM_TAG, "No saved state found, using defaults");
err = ESP_ERR_NVS_NOT_FOUND;
}
nvs_close(nvs_handle);
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)
{
if (event_base == WIFI_EVENT && event_id == WIFI_EVENT_STA_START) {
esp_wifi_connect();
} else if (event_base == WIFI_EVENT && event_id == WIFI_EVENT_STA_DISCONNECTED) {
if (s_retry_num < WIFI_MAXIMUM_RETRY) {
esp_wifi_connect();
s_retry_num++;
ESP_LOGI(SYSTEM_TAG, "retry to connect to the AP");
} else {
xEventGroupSetBits(s_wifi_event_group, WIFI_FAIL_BIT);
}
ESP_LOGI(SYSTEM_TAG, "connect to the AP fail");
} else if (event_base == IP_EVENT && event_id == IP_EVENT_STA_GOT_IP) {
ip_event_got_ip_t* event = (ip_event_got_ip_t*) event_data;
ESP_LOGI(SYSTEM_TAG, "got ip:" IPSTR, IP2STR(&event->ip_info.ip));
s_retry_num = 0;
xEventGroupSetBits(s_wifi_event_group, WIFI_CONNECTED_BIT);
}
}
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", "*");
httpd_resp_set_hdr(req, "Access-Control-Allow-Methods", "GET, POST, OPTIONS");
httpd_resp_set_hdr(req, "Access-Control-Allow-Headers", "Content-Type, Accept");
httpd_resp_set_hdr(req, "Cache-Control", "no-cache");
}
// HTTP handler for the main web page
static esp_err_t root_get_handler(httpd_req_t *req)
{
set_cors_headers(req);
httpd_resp_set_type(req, "text/html");
httpd_resp_send(req, html_page, HTTPD_RESP_USE_STRLEN);
return ESP_OK;
}
// HTTP handler for fan status (GET /status)
static esp_err_t status_get_handler(httpd_req_t *req)
{
// Update cooldown time before reporting
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");
set_cors_headers(req);
httpd_resp_set_type(req, "application/json");
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";
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;
}
const char* last_on_mode_str = "exhaust";
if (motor_state.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_AddStringToObject(json, "state", state_str);
cJSON_AddBoolToObject(json, "ramping", motor_state.ramping);
cJSON_AddNumberToObject(json, "cooldown_remaining", motor_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);
// 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);
if (json_string) {
httpd_resp_send(req, json_string, strlen(json_string));
free(json_string);
} else {
httpd_resp_send_err(req, HTTPD_500_INTERNAL_SERVER_ERROR, "JSON creation failed");
}
cJSON_Delete(json);
return ESP_OK;
}
// HTTP handler for fan control (POST /fan)
static esp_err_t fan_post_handler(httpd_req_t *req)
{
char buf[MAX_JSON_BUFFER_SIZE];
int ret, remaining = req->content_len;
if (remaining >= sizeof(buf)) {
httpd_resp_send_err(req, HTTPD_400_BAD_REQUEST, "Content too long");
return ESP_FAIL;
}
ret = httpd_req_recv(req, buf, remaining);
if (ret <= 0) {
if (ret == HTTPD_SOCK_ERR_TIMEOUT) {
httpd_resp_send_err(req, HTTPD_408_REQ_TIMEOUT, "Request timeout");
}
return ESP_FAIL;
}
buf[ret] = '\0';
ESP_LOGI(SYSTEM_TAG, "Received POST data: %s", buf);
cJSON *json = cJSON_Parse(buf);
if (json == NULL) {
ESP_LOGE(SYSTEM_TAG, "JSON parsing failed");
httpd_resp_send_err(req, HTTPD_400_BAD_REQUEST, "Invalid JSON");
return ESP_FAIL;
}
cJSON *mode_json = cJSON_GetObjectItem(json, "mode");
cJSON *speed_json = cJSON_GetObjectItem(json, "speed");
if (!cJSON_IsString(mode_json) || (!cJSON_IsNumber(speed_json) && !cJSON_IsString(speed_json))) {
ESP_LOGE(SYSTEM_TAG, "JSON parsing failed - mode: %s, speed: %s",
mode_json ? (cJSON_IsString(mode_json) ? mode_json->valuestring : "not_string") : "null",
speed_json ? (cJSON_IsNumber(speed_json) ? "number" : (cJSON_IsString(speed_json) ? speed_json->valuestring : "not_number_or_string")) : "null");
cJSON_Delete(json);
httpd_resp_send_err(req, HTTPD_400_BAD_REQUEST, "Missing mode or speed");
return ESP_FAIL;
}
const char* mode_str = mode_json->valuestring;
int speed;
// Handle both number and string speed values
if (cJSON_IsNumber(speed_json)) {
speed = (int)speed_json->valuedouble;
} else if (cJSON_IsString(speed_json)) {
speed = atoi(speed_json->valuestring);
} else {
speed = 0;
}
motor_mode_t mode = MOTOR_OFF;
// 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);
} else if (strcmp(mode_str, "exhaust") == 0) {
mode = MOTOR_EXHAUST;
} else if (strcmp(mode_str, "intake") == 0) {
mode = MOTOR_INTAKE;
}
ESP_LOGI(SYSTEM_TAG, "HTTP Request: mode=%s, speed=%d", mode_str, speed);
set_motor_speed(mode, speed);
cJSON_Delete(json);
// Send response with updated status
return status_get_handler(req);
}
// HTTP handler for OPTIONS requests (CORS preflight)
static esp_err_t options_handler(httpd_req_t *req)
{
set_cors_headers(req);
httpd_resp_set_status(req, "200 OK");
httpd_resp_send(req, NULL, 0);
return ESP_OK;
}
// Start HTTP server
static httpd_handle_t start_webserver(void)
{
httpd_config_t config = HTTPD_DEFAULT_CONFIG();
config.server_port = HTTP_SERVER_PORT;
config.max_uri_handlers = HTTP_MAX_URI_HANDLERS;
config.recv_wait_timeout = HTTP_RECV_TIMEOUT_SEC;
config.send_wait_timeout = HTTP_SEND_TIMEOUT_SEC;
ESP_LOGI(SYSTEM_TAG, "Starting server on port: '%d'", config.server_port);
if (httpd_start(&server, &config) == ESP_OK) {
ESP_LOGI(SYSTEM_TAG, "Registering URI handlers");
// Root handler
httpd_uri_t root = {
.uri = "/",
.method = HTTP_GET,
.handler = root_get_handler,
.user_ctx = NULL
};
httpd_register_uri_handler(server, &root);
// Status handler
httpd_uri_t status = {
.uri = "/status",
.method = HTTP_GET,
.handler = status_get_handler,
.user_ctx = NULL
};
httpd_register_uri_handler(server, &status);
// Fan control handler
httpd_uri_t fan = {
.uri = "/fan",
.method = HTTP_POST,
.handler = fan_post_handler,
.user_ctx = NULL
};
httpd_register_uri_handler(server, &fan);
// OPTIONS handler for CORS preflight
httpd_uri_t options_status = {
.uri = "/status",
.method = HTTP_OPTIONS,
.handler = options_handler,
.user_ctx = NULL
};
httpd_register_uri_handler(server, &options_status);
httpd_uri_t options_fan = {
.uri = "/fan",
.method = HTTP_OPTIONS,
.handler = options_handler,
.user_ctx = NULL
};
httpd_register_uri_handler(server, &options_fan);
return server;
}
ESP_LOGI(SYSTEM_TAG, "Error starting server!");
return NULL;
}
void wifi_init_sta(void)
{
s_wifi_event_group = xEventGroupCreate();
ESP_ERROR_CHECK(esp_netif_init());
ESP_ERROR_CHECK(esp_event_loop_create_default());
esp_netif_create_default_wifi_sta();
wifi_init_config_t cfg = WIFI_INIT_CONFIG_DEFAULT();
ESP_ERROR_CHECK(esp_wifi_init(&cfg));
esp_event_handler_instance_t instance_any_id;
esp_event_handler_instance_t instance_got_ip;
ESP_ERROR_CHECK(esp_event_handler_instance_register(WIFI_EVENT,
ESP_EVENT_ANY_ID,
&event_handler,
NULL,
&instance_any_id));
ESP_ERROR_CHECK(esp_event_handler_instance_register(IP_EVENT,
IP_EVENT_STA_GOT_IP,
&event_handler,
NULL,
&instance_got_ip));
wifi_config_t wifi_config = {
.sta = {
.ssid = WIFI_SSID,
.password = WIFI_PASS,
.threshold.authmode = WIFI_AUTH_WPA2_PSK,
.pmf_cfg = {
.capable = true,
.required = false
},
},
};
ESP_ERROR_CHECK(esp_wifi_set_mode(WIFI_MODE_STA));
ESP_ERROR_CHECK(esp_wifi_set_config(WIFI_IF_STA, &wifi_config));
ESP_ERROR_CHECK(esp_wifi_start());
ESP_LOGI(SYSTEM_TAG, "wifi_init_sta finished.");
EventBits_t bits = xEventGroupWaitBits(s_wifi_event_group,
WIFI_CONNECTED_BIT | WIFI_FAIL_BIT,
pdFALSE,
pdFALSE,
portMAX_DELAY);
if (bits & WIFI_CONNECTED_BIT) {
ESP_LOGI(SYSTEM_TAG, "connected to ap SSID:%s", WIFI_SSID);
} else if (bits & WIFI_FAIL_BIT) {
ESP_LOGI(SYSTEM_TAG, "Failed to connect to SSID:%s", WIFI_SSID);
} else {
ESP_LOGE(SYSTEM_TAG, "UNEXPECTED EVENT");
}
}
void app_main(void)
{
ESP_LOGI(SYSTEM_TAG, "Starting Maxxfan HTTP Controller with State Preservation!");
// Initialize NVS
esp_err_t ret = nvs_flash_init();
if (ret == ESP_ERR_NVS_NO_FREE_PAGES || ret == ESP_ERR_NVS_NEW_VERSION_FOUND) {
ESP_ERROR_CHECK(nvs_flash_erase());
ret = nvs_flash_init();
}
ESP_ERROR_CHECK(ret);
// Initialize watchdog timer
init_watchdog();
// Configure hardware
configure_gpio_pins();
configure_pwm();
// Initialize motor ramping system
init_motor_ramping();
// Load saved state from NVS
ESP_LOGI(SYSTEM_TAG, "Loading saved state...");
load_motor_state_from_nvs();
ESP_LOGI(SYSTEM_TAG, "Connecting to WiFi network: %s", WIFI_SSID);
wifi_init_sta();
// 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);
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");
} else {
ESP_LOGI(SYSTEM_TAG, "No motor state to restore - staying OFF");
}
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, "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
while (1) {
feed_watchdog();
vTaskDelay(pdMS_TO_TICKS(WATCHDOG_FEED_INTERVAL_MS));
}
}