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remove fan-controls

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alex
2026-07-08 16:11:57 +02:00
parent 8182b9efd2
commit 2fe53d5a8a
8 changed files with 114 additions and 118 deletions
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14
include/config.h
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@@ -29,16 +29,12 @@ static const float TARGET_MAX_C = 80.0f;
static const float EMERGENCY_MAX_TEMP_C = 70.0f;
static const float CORNER_STOP_MARGIN_C = 3.0f;
// Dual PI — heat on avg, mix on spread (no D term)
// Heat PI on average temp (no D term)
static const float HEAT_PI_KP = 4.0f;
static const float HEAT_PI_KI = 0.05f;
static const float MIX_PI_KP = 40.0f;
static const float MIX_PI_KI = 2.0f;
static const float SPREAD_TARGET_C = 0.5f;
static const float HEAT_UP_BAND_C = 8.0f;
// Mix PI only at/above target; below target use minimum stir only (no mix PI).
// Cap mix fan — high airflow often increases spread / heat loss rather than fixing it.
static const uint8_t FAN_MIX_MAX_PWM = 140;
// Fixed circulation fan (~70%, fanchars winner); override with "fan <pwm>" when regulating
static const uint8_t FAN_STIR_PWM = 178;
// Legacy aliases for autotuner relay math only
static const float PID_KP = HEAT_PI_KP;
@@ -81,7 +77,7 @@ static const uint32_t AUTOTUNE_RELAY_PERIOD_MAX_MS = 2400000UL;
static const float FANCHARS_MAX_CORNER_C = 60.0f;
static const float FANCHARS_COOL_AVG_C = 40.0f;
static const float FANCHARS_PRECOOL_MARGIN_C = 2.0f;
static const float FANCHARS_HEATER_PCT = 85.0f;
static const float FANCHARS_HEATER_PCT = 100.0f;
// Coarse sweep order: 30%, 100%, 60%, 80% fan
static const uint8_t FANCHARS_COARSE_PWM[] = {77, 255, 153, 204};
static const uint8_t FANCHARS_COARSE_COUNT =

2
include/pid_autotuner.h
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@@ -271,7 +271,7 @@ private:
Serial.print(resultKp_, 3);
Serial.print(F(" Ki="));
Serial.println(resultKi_, 4);
Serial.println(F(" tune mix PI separately: mixpi <Kp> <Ki>"));
Serial.println(F(" tune heat PI: pid save after autotune"));
}
void fail(const __FlashStringHelper *reason) {

2
include/settings_store.h
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@@ -12,7 +12,7 @@ static const int SETTINGS_EEPROM_ADDR = 16;
struct SettingsData {
uint16_t magic = 0;
float targetC = TARGET_TEMP_C;
uint8_t stirFanPwm = 0; // 0 = use FAN_IDLE_PWM (~30%)
uint8_t stirFanPwm = 0; // 0 = use FAN_STIR_PWM from config
};
inline uint8_t settingsChecksum(const SettingsData &data) {

92
include/thermal_controller.h
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@@ -15,7 +15,6 @@ public:
ThermalController()
: heatPi_(HEAT_PI_KP, HEAT_PI_KI, 0.0f, 0.0f, 100.0f),
mixPi_(MIX_PI_KP, MIX_PI_KI, 0.0f, 0.0f, 255.0f),
autotuner_(),
fanchars_(),
targetTempC_(TARGET_TEMP_C),
@@ -24,10 +23,12 @@ public:
cornerSpreadC_(0.0f),
lastMaxTempC_(0.0f),
regulatingFanPwm_(0),
stirFanPwm_(FAN_IDLE_PWM),
stirFanPwm_(FAN_STIR_PWM),
fanManualPwm_(0),
fanPwm_(0),
tuningLoaded_(false),
fanIdleOverride_(false),
fanManualActive_(false),
sensorWarmValid_(false),
cutoffActive_(false),
failSafeActive_(true),
@@ -38,9 +39,7 @@ public:
heaterBlock_(HeaterBlock::None),
fanTestActive_(false),
fanTestPwm_(0),
fanTestEndMs_(0) {
mixPi_.setSetpoint(0.0f);
}
fanTestEndMs_(0) {}
void begin() {
pinMode(FAN_PIN, OUTPUT);
@@ -50,7 +49,6 @@ public:
heatPi_.setSetpoint(targetTempC_);
heatPi_.reset();
mixPi_.reset();
heaterCycleStartMs_ = millis();
lastHeaterUpdateMs_ = 0;
failSafeActive_ = true;
@@ -83,44 +81,22 @@ public:
void applyTuning(const TuningData &data) {
heatPi_.setTunings(data.heatKp, data.heatKi, 0.0f);
mixPi_.setTunings(data.mixKp, data.mixKi, 0.0f);
tuningLoaded_ = true;
}
void clearTuning() {
tuningLoaded_ = false;
heatPi_.setTunings(HEAT_PI_KP, HEAT_PI_KI, 0.0f);
mixPi_.setTunings(MIX_PI_KP, MIX_PI_KI, 0.0f);
tuningClear();
heatPi_.reset();
mixPi_.reset();
Serial.println(F("PI reset to defaults"));
}
void setMixTunings(float kp, float ki) {
mixPi_.setTunings(kp, ki, 0.0f);
mixPi_.reset();
Serial.print(F("Mix PI Kp="));
Serial.print(kp, 3);
Serial.print(F(" Ki="));
Serial.println(ki, 4);
}
void resetMixTunings() {
mixPi_.setTunings(MIX_PI_KP, MIX_PI_KI, 0.0f);
mixPi_.reset();
Serial.println(F("Mix PI reset to defaults"));
}
void printTuning() const {
Serial.print(F("Heat PI Kp="));
Serial.print(heatPi_.kp(), 3);
Serial.print(F(" Ki="));
Serial.print(heatPi_.ki(), 4);
Serial.print(F(" Mix PI Kp="));
Serial.print(mixPi_.kp(), 3);
Serial.print(F(" Ki="));
Serial.print(mixPi_.ki(), 4);
Serial.print(F(" tuned="));
Serial.println(tuningLoaded_ ? F("yes") : F("no"));
}
@@ -130,8 +106,6 @@ public:
data.magic = TUNING_MAGIC;
data.heatKp = heatPi_.kp();
data.heatKi = heatPi_.ki();
data.mixKp = mixPi_.kp();
data.mixKi = mixPi_.ki();
tuningSave(data);
tuningLoaded_ = true;
Serial.println(F("Saved PI to EEPROM"));
@@ -139,8 +113,6 @@ public:
float heatKp() const { return heatPi_.kp(); }
float heatKi() const { return heatPi_.ki(); }
float mixKp() const { return mixPi_.kp(); }
float mixKi() const { return mixPi_.ki(); }
bool isTuningLoaded() const { return tuningLoaded_; }
@@ -150,7 +122,6 @@ public:
}
cutoffActive_ = false;
heatPi_.reset();
mixPi_.reset();
return autotuner_.start(setpointC);
}
@@ -175,7 +146,6 @@ public:
stopFanTest();
cutoffActive_ = false;
heatPi_.reset();
mixPi_.reset();
setTarget(0.0f, false);
return fanchars_.start(maxCornerC, avgTempC);
}
@@ -204,6 +174,32 @@ public:
uint8_t stirFanPwm() const { return stirFanPwm_; }
bool isFanManualOverride() const { return fanManualActive_ && !isIdle(); }
bool setRegulatingFanManual(uint8_t pwm) {
if (isIdle()) {
return false;
}
fanManualPwm_ = pwm;
fanManualActive_ = true;
return true;
}
void clearRegulatingFanManual() {
fanManualActive_ = false;
}
bool setStirFanPwm(uint8_t pwm, bool persist = true) {
if (pwm == 0) {
return false;
}
stirFanPwm_ = pwm;
if (persist) {
settingsSaveStirFan(pwm);
}
return true;
}
void logFanCharacterizeIfDue(const float *sensorTemps, const bool *sensorValid, uint8_t sensorCount,
float avgTempC, float minTempC, float maxTempC, float spreadC,
uint32_t nowMs) {
@@ -239,12 +235,10 @@ public:
data.magic = TUNING_MAGIC;
data.heatKp = autotuner_.resultKp();
data.heatKi = autotuner_.resultKi();
data.mixKp = mixPi_.kp();
data.mixKi = mixPi_.ki();
tuningSave(data);
tuningLoaded_ = true;
autotuner_.reset();
Serial.println(F("Saved heat PI to EEPROM (mix PI unchanged)"));
Serial.println(F("Saved heat PI to EEPROM"));
return true;
}
@@ -252,7 +246,7 @@ public:
targetTempC_ = targetC;
heatPi_.setSetpoint(targetC);
heatPi_.reset();
mixPi_.reset();
fanManualActive_ = false;
cutoffActive_ = false;
if (targetC > 0.0f) {
fanIdleOverride_ = false;
@@ -390,7 +384,6 @@ public:
forceHeaterOff();
cutoffActive_ = false;
heatPi_.reset();
mixPi_.reset();
lastHeaterUpdateMs_ = nowMs;
applyFan(nowMs);
return;
@@ -408,7 +401,6 @@ public:
forceHeaterOff();
applyFan(millis());
heatPi_.reset();
mixPi_.reset();
autotuner_.abort();
fanchars_.abort();
}
@@ -485,14 +477,12 @@ private:
regulatingFanPwm_ = FAN_MAX_PWM;
heaterBlock_ = HeaterBlock::Cutoff;
heatPi_.reset();
mixPi_.reset();
return;
}
if (cutoffActive_ && maxTempC < EMERGENCY_MAX_TEMP_C - 5.0f) {
cutoffActive_ = false;
heatPi_.reset();
mixPi_.reset();
}
if (cutoffActive_) {
@@ -523,17 +513,7 @@ private:
}
heaterDutyPercent_ = applyHeaterRamp(duty, avgTempC, nowMs);
uint8_t fanPwm = stirFanPwm_;
if (avgTempC < targetTempC_) {
mixPi_.reset();
} else {
const float mixInput = SPREAD_TARGET_C - cornerSpreadC_;
float fanOut = mixPi_.compute(mixInput, nowMs);
fanPwm = static_cast<uint8_t>(fanOut + 0.5f);
if (fanPwm > FAN_MIX_MAX_PWM) {
fanPwm = FAN_MIX_MAX_PWM;
}
}
const uint8_t fanPwm = fanManualActive_ ? fanManualPwm_ : stirFanPwm_;
regulatingFanPwm_ = fanWithMinStir(avgTempC, fanPwm);
}
@@ -541,9 +521,6 @@ private:
if (avgTempC < IDLE_AUTO_FAN_OFF_TEMP_C) {
return 0;
}
if (pwm < stirFanPwm_) {
return stirFanPwm_;
}
return pwm;
}
@@ -665,7 +642,6 @@ private:
}
PidController heatPi_;
PidController mixPi_;
PidAutotuner autotuner_;
FanCharacterize fanchars_;
float targetTempC_;
@@ -675,9 +651,11 @@ private:
float lastMaxTempC_;
uint8_t regulatingFanPwm_;
uint8_t stirFanPwm_;
uint8_t fanManualPwm_;
uint8_t fanPwm_;
bool tuningLoaded_;
bool fanIdleOverride_;
bool fanManualActive_;
bool sensorWarmValid_;
bool cutoffActive_;
bool failSafeActive_;

4
include/tuning_store.h
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@@ -5,15 +5,13 @@
#include "config.h"
static const uint16_t TUNING_MAGIC = 0xDA7B;
static const uint16_t TUNING_MAGIC = 0xDA7C;
static const int TUNING_EEPROM_ADDR = 0;
struct TuningData {
uint16_t magic = 0;
float heatKp = HEAT_PI_KP;
float heatKi = HEAT_PI_KI;
float mixKp = MIX_PI_KP;
float mixKi = MIX_PI_KI;
};
inline uint8_t tuningChecksum(const TuningData &data) {