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409
src/main.cpp
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409
src/main.cpp
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#include <Arduino.h>
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#include <Wire.h>
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#include <Adafruit_SHT31.h>
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#include "config.h"
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#include "csv_logger.h"
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#include "tca9548a.h"
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#include "thermal_controller.h"
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Tca9548a mux(TCA9548A_ADDRESS);
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Adafruit_SHT31 sht31;
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ThermalController thermal;
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SensorReading sensors[SENSOR_COUNT];
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uint32_t lastSensorReadMs = 0;
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uint32_t lastControlMs = 0;
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uint32_t lastReportMs = 0;
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char serialLine[48];
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uint8_t serialLineLen = 0;
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bool csvLogEnabled = LOG_CSV_DEFAULT;
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bool readSensorOnChannel(uint8_t channel, SensorReading &out) {
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if (!mux.selectChannel(channel)) {
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out.valid = false;
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return false;
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}
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if (!sht31.begin(SHT31_ADDRESS)) {
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out.valid = false;
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return false;
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}
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const float temp = sht31.readTemperature();
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const float humidity = sht31.readHumidity();
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if (isnan(temp) || isnan(humidity)) {
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out.valid = false;
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return false;
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}
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out.temperatureC = temp;
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out.humidityPct = humidity;
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out.valid = true;
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return true;
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}
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void readAllSensors() {
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for (uint8_t i = 0; i < SENSOR_COUNT; ++i) {
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readSensorOnChannel(SENSOR_CHANNELS[i], sensors[i]);
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}
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mux.disableAll();
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}
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float averageValidTemperature() {
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float sum = 0.0f;
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uint8_t count = 0;
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for (uint8_t i = 0; i < SENSOR_COUNT; ++i) {
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if (sensors[i].valid) {
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sum += sensors[i].temperatureC;
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++count;
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}
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}
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return count > 0 ? sum / static_cast<float>(count) : NAN;
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}
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float minValidTemperature() {
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float minTemp = INFINITY;
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for (uint8_t i = 0; i < SENSOR_COUNT; ++i) {
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if (sensors[i].valid && sensors[i].temperatureC < minTemp) {
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minTemp = sensors[i].temperatureC;
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}
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}
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return minTemp < INFINITY ? minTemp : NAN;
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}
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float maxValidTemperature() {
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float maxTemp = -INFINITY;
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for (uint8_t i = 0; i < SENSOR_COUNT; ++i) {
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if (sensors[i].valid && sensors[i].temperatureC > maxTemp) {
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maxTemp = sensors[i].temperatureC;
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}
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}
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return maxTemp > -INFINITY ? maxTemp : NAN;
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}
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float cornerTemperatureSpread() {
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const float minTemp = minValidTemperature();
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const float maxTemp = maxValidTemperature();
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if (isnan(minTemp) || isnan(maxTemp)) {
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return NAN;
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}
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return maxTemp - minTemp;
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}
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void printStatus(float avgTemp, float minTemp, float maxTemp) {
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Serial.print(F("target="));
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if (thermal.isIdle()) {
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Serial.print(F("idle"));
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} else {
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Serial.print(thermal.target(), 1);
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}
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Serial.print(F("C cutoff="));
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if (thermal.isIdle()) {
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Serial.print(F("n/a"));
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} else {
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Serial.print(thermal.cutoffThreshold(), 1);
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}
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Serial.print(F("C avg="));
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Serial.print(avgTemp, 2);
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Serial.print(F("C min="));
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Serial.print(minTemp, 2);
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Serial.print(F("C max="));
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Serial.print(maxTemp, 2);
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Serial.print(F("C spread="));
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Serial.print(thermal.cornerSpread(), 2);
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Serial.print(F("C heatlim="));
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Serial.print(thermal.heaterAllowance(), 0);
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Serial.print(F("% heater="));
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Serial.print(thermal.heaterDutyPercent(), 1);
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Serial.print(F("% fan="));
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Serial.print((thermal.fanPwm() * 100) / 255);
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if (thermal.isIdle() && thermal.isFanOff()) {
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Serial.print(F("(off)"));
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} else if (thermal.isIdleCooling()) {
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Serial.print(F("(cooldown)"));
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}
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Serial.print(F(" cutoff="));
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Serial.print(thermal.isCutoffActive() ? F("YES") : F("no"));
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Serial.print(F(" failsafe="));
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Serial.print(thermal.isFailSafeActive() ? F("YES") : F("no"));
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Serial.print(F(" mode="));
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if (thermal.isAutotuning()) {
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Serial.print(F("autotune"));
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} else if (thermal.isAdaptive()) {
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Serial.print(F("learned"));
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} else {
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Serial.print(F("manual"));
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}
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Serial.print(F(" sensors=["));
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for (uint8_t i = 0; i < SENSOR_COUNT; ++i) {
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if (i > 0) {
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Serial.print(F(", "));
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}
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Serial.print(F("ch"));
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Serial.print(SENSOR_CHANNELS[i]);
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Serial.print(F(":"));
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if (sensors[i].valid) {
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Serial.print(sensors[i].temperatureC, 1);
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Serial.print(F("C/"));
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Serial.print(sensors[i].humidityPct, 0);
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Serial.print(F("%"));
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} else {
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Serial.print(F("ERR"));
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}
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}
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Serial.println(F("]"));
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}
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void printHelp() {
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Serial.println(F("Commands:"));
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Serial.println(F(" target <C> set target (0 = idle)"));
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Serial.println(F(" fan off cancel idle fan override (auto-off below 40C)"));
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Serial.println(F(" fan on idle fan 30% (optional, auto-off below 40C)"));
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Serial.println(F(" autotune [C] learn PID (default: 40C when idle)"));
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Serial.println(F(" autotune stop"));
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Serial.println(F(" pid show PID / adaptive status"));
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Serial.println(F(" pid default reset to factory PID"));
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Serial.println(F(" status print current readings"));
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Serial.println(F(" log on|off CSV data stream"));
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Serial.println(F(" help show this message"));
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}
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void refreshThermalSensorMax() {
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const float maxTemp = maxValidTemperature();
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if (!isnan(maxTemp)) {
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thermal.noteSensorMax(maxTemp);
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}
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}
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void processSerialLine(const char *line) {
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while (*line == ' ' || *line == '\t') {
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++line;
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}
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if (*line == '\0') {
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return;
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}
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if (strncmp(line, "target ", 7) == 0) {
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const float targetC = atof(line + 7);
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if (targetC < TARGET_MIN_C || targetC > TARGET_MAX_C) {
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Serial.print(F("ERR target must be "));
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Serial.print(TARGET_MIN_C, 0);
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Serial.print(F("-"));
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Serial.print(TARGET_MAX_C, 0);
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Serial.println(F(" C"));
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return;
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}
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refreshThermalSensorMax();
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thermal.setTarget(targetC);
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if (targetC <= 0.0f) {
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Serial.println(F("OK idle — heater off, fan auto-off when max < 40C"));
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} else {
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Serial.print(F("OK target="));
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Serial.print(targetC, 1);
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Serial.print(F("C cutoff="));
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Serial.print(thermal.cutoffThreshold(), 1);
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Serial.println(F("C"));
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}
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return;
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}
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if (strcmp(line, "fan off") == 0) {
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refreshThermalSensorMax();
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if (!thermal.setFanOff()) {
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Serial.println(F("ERR fan off requires target 0 first (send: target 0)"));
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return;
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}
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if (thermal.isIdleCooling()) {
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Serial.println(F("OK cooling — fans stay on until max < 40C"));
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} else {
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Serial.println(F("OK fans off"));
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}
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return;
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}
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if (strcmp(line, "fan on") == 0) {
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refreshThermalSensorMax();
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if (!thermal.isIdle()) {
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Serial.println(F("ERR fan on only when target is 0"));
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return;
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}
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if (thermal.isIdleCooling()) {
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Serial.println(F("ERR fan on blocked — still cooling (max >= 40C)"));
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return;
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}
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thermal.setFanIdle();
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Serial.println(F("OK fans at idle 30%"));
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return;
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}
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if (strcmp(line, "status") == 0) {
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const float avgTemp = averageValidTemperature();
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const float minTemp = minValidTemperature();
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const float maxTemp = maxValidTemperature();
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if (!isnan(avgTemp) && !isnan(minTemp) && !isnan(maxTemp)) {
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printStatus(avgTemp, minTemp, maxTemp);
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} else {
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Serial.println(F("WARN: no valid sensor readings"));
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}
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return;
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}
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if (strncmp(line, "autotune", 8) == 0) {
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if (strcmp(line, "autotune stop") == 0) {
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thermal.stopAutotune();
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Serial.println(F("OK autotune cancelled"));
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return;
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}
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float tuneTarget = thermal.target();
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if (line[8] == ' ') {
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tuneTarget = atof(line + 9);
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} else if (tuneTarget <= 0.0f) {
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tuneTarget = AUTOTUNE_DEFAULT_TEMP_C;
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}
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if (tuneTarget <= 0.0f || tuneTarget > TARGET_MAX_C) {
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Serial.println(F("ERR autotune temperature must be 25-80 C"));
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return;
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}
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thermal.setTarget(tuneTarget);
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if (!thermal.startAutotune(tuneTarget)) {
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Serial.println(F("ERR autotune already running"));
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return;
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}
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Serial.println(F("OK autotune started — keep chamber closed, wait ~10-20 min"));
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return;
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}
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if (strcmp(line, "pid") == 0 || strcmp(line, "pid show") == 0) {
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thermal.printTuning();
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return;
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}
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if (strcmp(line, "pid default") == 0) {
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thermal.clearTuning();
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return;
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}
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if (strcmp(line, "help") == 0) {
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printHelp();
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return;
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}
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if (strcmp(line, "log on") == 0) {
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csvLogEnabled = true;
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printCsvHeader();
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Serial.println(F("OK csv logging on"));
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return;
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}
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if (strcmp(line, "log off") == 0) {
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csvLogEnabled = false;
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Serial.println(F("OK csv logging off"));
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return;
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}
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if (strcmp(line, "log") == 0) {
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Serial.println(csvLogEnabled ? F("OK csv logging on") : F("OK csv logging off"));
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return;
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}
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Serial.println(F("ERR unknown command (try help)"));
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}
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void pollSerial() {
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while (Serial.available() > 0) {
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const char c = static_cast<char>(Serial.read());
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if (c == '\n' || c == '\r') {
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if (serialLineLen > 0) {
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serialLine[serialLineLen] = '\0';
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processSerialLine(serialLine);
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serialLineLen = 0;
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}
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} else if (serialLineLen < sizeof(serialLine) - 1) {
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serialLine[serialLineLen++] = c;
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}
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}
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}
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void setup() {
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// Claim outputs before anything else — fan on, heater off (fail-safe)
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thermal.begin();
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Serial.begin(115200);
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while (!Serial && millis() < 3000) {
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delay(10);
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}
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Wire.begin();
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if (!mux.begin()) {
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Serial.println(F("ERROR: TCA9548A not found on I2C bus"));
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} else {
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Serial.println(F("TCA9548A detected"));
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}
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Serial.print(F("Filament dryer ready. "));
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if (thermal.isIdle()) {
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Serial.println(F("Idle — send target <C> to start drying"));
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} else {
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Serial.print(F("Target "));
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Serial.print(thermal.target(), 1);
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Serial.print(F(" C, hard cutoff at "));
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Serial.print(thermal.cutoffThreshold(), 1);
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Serial.println(F(" C"));
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}
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printHelp();
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}
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void loop() {
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const uint32_t now = millis();
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pollSerial();
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if (now - lastSensorReadMs >= SENSOR_READ_INTERVAL_MS) {
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lastSensorReadMs = now;
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readAllSensors();
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}
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if (now - lastControlMs >= CONTROL_INTERVAL_MS) {
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lastControlMs = now;
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const float avgTemp = averageValidTemperature();
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const float maxTemp = maxValidTemperature();
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const float spread = cornerTemperatureSpread();
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if (!isnan(avgTemp) && !isnan(maxTemp) && !isnan(spread)) {
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thermal.update(avgTemp, maxTemp, spread, now);
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} else {
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thermal.enterFailSafe();
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Serial.println(F("WARN: no valid sensor readings — heater off"));
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}
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}
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if (now - lastReportMs >= SERIAL_REPORT_INTERVAL_MS) {
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lastReportMs = now;
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const float avgTemp = averageValidTemperature();
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const float minTemp = minValidTemperature();
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const float maxTemp = maxValidTemperature();
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if (!isnan(avgTemp) && !isnan(minTemp) && !isnan(maxTemp)) {
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printStatus(avgTemp, minTemp, maxTemp);
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if (csvLogEnabled) {
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printCsvRow(now, thermal, sensors, SENSOR_COUNT, avgTemp, minTemp, maxTemp);
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}
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}
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}
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}
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