arduino-filament-dryer/include/fan_step_response.h

#pragma once

#include <Arduino.h>

#include "config.h"

class FanStepResponse {
public:
  enum class Phase : uint8_t { Idle, Preheat, Baseline, StepHold, Done, Failed };

  FanStepResponse()
      : phase_(Phase::Idle),
        targetC_(STEPRESP_DEFAULT_TEMP_C),
        heaterPct_(STEPRESP_DEFAULT_HEATER_PCT),
        stepIndex_(0),
        sessionStartMs_(0),
        phaseStartMs_(0),
        lastLogMs_(0),
        lastAvgC_(0.0f) {}

  Phase phase() const { return phase_; }

  bool isActive() const {
    return phase_ == Phase::Preheat || phase_ == Phase::Baseline || phase_ == Phase::StepHold;
  }

  uint32_t elapsedMs(uint32_t nowMs) const {
    if (sessionStartMs_ == 0) {
      return 0;
    }
    return nowMs - sessionStartMs_;
  }

  uint8_t stepIndex() const { return stepIndex_; }

  uint8_t stepCount() const { return STEPRESP_FAN_STEP_COUNT; }

  float targetC() const { return targetC_; }

  float heaterPct() const { return heaterPct_; }

  uint8_t currentFanPwm() const {
    if (stepIndex_ >= STEPRESP_FAN_STEP_COUNT) {
      return 0;
    }
    return STEPRESP_FAN_STEPS[stepIndex_];
  }

  const char *phaseName() const {
    switch (phase_) {
    case Phase::Preheat:
      return "preheat";
    case Phase::Baseline:
      return "baseline";
    case Phase::StepHold:
      return "step";
    default:
      return "";
    }
  }

  bool start(float targetC, float heaterPct) {
    if (targetC < 25.0f || targetC > TARGET_MAX_C) {
      return false;
    }
    if (heaterPct < STEPRESP_MIN_HEATER_PCT || heaterPct > STEPRESP_MAX_HEATER_PCT) {
      return false;
    }

    targetC_ = targetC;
    heaterPct_ = heaterPct;
    stepIndex_ = 0;
    sessionStartMs_ = millis();
    phaseStartMs_ = sessionStartMs_;
    lastLogMs_ = 0;
    lastAvgC_ = 0.0f;
    phase_ = Phase::Preheat;

    Serial.print(F("stepresp: preheat to "));
    Serial.print(targetC_ - STEPRESP_PREHEAT_BAND_C, 1);
    Serial.print(F("-"));
    Serial.print(targetC_, 1);
    Serial.print(F("C avg, heater="));
    Serial.print(heaterPct_, 0);
    Serial.println(F("% fan=0"));
    return true;
  }

  void abort() {
    if (isActive()) {
      Serial.println(F("stepresp: cancelled"));
    }
    phase_ = Phase::Idle;
    sessionStartMs_ = 0;
  }

  void reset() {
    phase_ = Phase::Idle;
    sessionStartMs_ = 0;
  }

  bool update(float avgTempC, float maxTempC, float spreadC, uint32_t nowMs, float &heaterDutyOut,
              uint8_t &fanPwmOut) {
    heaterDutyOut = 0.0f;
    fanPwmOut = 0;

    if (phase_ == Phase::Idle || phase_ == Phase::Done || phase_ == Phase::Failed) {
      return false;
    }

    if (maxTempC >= EMERGENCY_MAX_TEMP_C) {
      fail(F("stepresp: abort — max sensor at safety limit"));
      return false;
    }

    if (phase_ == Phase::Preheat) {
      fanPwmOut = 0;
      if (nowMs - phaseStartMs_ > STEPRESP_PREHEAT_TIMEOUT_MS) {
        fail(F("stepresp: abort — preheat timeout"));
        return false;
      }
      if (avgTempC >= targetC_ - STEPRESP_PREHEAT_BAND_C) {
        enterBaseline(nowMs);
      } else {
        heaterDutyOut = heaterPct_;
      }
      return true;
    }

    heaterDutyOut = heaterPct_;
    fanPwmOut = currentFanPwm();

    if (phase_ == Phase::Baseline) {
      if (nowMs - phaseStartMs_ >= STEPRESP_BASELINE_MS) {
        advanceStep(nowMs);
      }
      return true;
    }

    if (phase_ == Phase::StepHold) {
      if (nowMs - phaseStartMs_ >= STEPRESP_STEP_HOLD_MS) {
        if (stepIndex_ + 1 >= STEPRESP_FAN_STEP_COUNT) {
          finish(nowMs, avgTempC, spreadC);
        } else {
          ++stepIndex_;
          enterStepHold(nowMs, true);
        }
      }
      return true;
    }

    return false;
  }

  void logIfDue(const float *sensorTemps, const bool *sensorValid, uint8_t sensorCount,
                float avgTempC, float minTempC, float maxTempC, float spreadC, uint32_t nowMs) {
    if (!isActive()) {
      return;
    }
    if (lastLogMs_ != 0 && nowMs - lastLogMs_ < STEPRESP_LOG_INTERVAL_MS) {
      return;
    }
    lastLogMs_ = nowMs;
    lastAvgC_ = avgTempC;

    Serial.print(F("sr,"));
    Serial.print(nowMs);
    Serial.print(',');
    Serial.print(phaseName());
    Serial.print(',');
    Serial.print(stepIndex_);
    Serial.print('/');
    Serial.print(STEPRESP_FAN_STEP_COUNT);
    Serial.print(',');
    Serial.print(heaterPct_, 0);
    Serial.print(',');
    Serial.print(currentFanPwm());
    Serial.print(',');
    Serial.print(avgTempC, 2);
    Serial.print(',');
    Serial.print(minTempC, 2);
    Serial.print(',');
    Serial.print(maxTempC, 2);
    Serial.print(',');
    Serial.print(spreadC, 2);

    for (uint8_t i = 0; i < sensorCount; ++i) {
      Serial.print(',');
      if (sensorValid[i]) {
        Serial.print(sensorTemps[i], 2);
      }
    }

    Serial.println();
  }

private:
  void enterBaseline(uint32_t nowMs) {
    phase_ = Phase::Baseline;
    phaseStartMs_ = nowMs;
    stepIndex_ = 0;
    Serial.print(F("stepresp: baseline fan="));
    Serial.print(currentFanPwm());
    Serial.print(F(" for "));
    Serial.print(STEPRESP_BASELINE_MS / 1000UL);
    Serial.println(F("s"));
  }

  void enterStepHold(uint32_t nowMs, bool isStep) {
    phase_ = Phase::StepHold;
    phaseStartMs_ = nowMs;
    Serial.print(F("stepresp: "));
    if (isStep) {
      Serial.print(F("step "));
    }
    Serial.print(stepIndex_ + 1);
    Serial.print(F("/"));
    Serial.print(STEPRESP_FAN_STEP_COUNT);
    Serial.print(F(" fan="));
    Serial.print(currentFanPwm());
    Serial.print(F(" ("));
    Serial.print((currentFanPwm() * 100) / 255);
    Serial.print(F("%) hold "));
    Serial.print(STEPRESP_STEP_HOLD_MS / 1000UL);
    Serial.println(F("s"));
  }

  void advanceStep(uint32_t nowMs) {
    if (STEPRESP_FAN_STEP_COUNT <= 1) {
      finish(nowMs, lastAvgC_, 0.0f);
      return;
    }
    stepIndex_ = 1;
    enterStepHold(nowMs, true);
  }

  void finish(uint32_t nowMs, float avgTempC, float spreadC) {
    phase_ = Phase::Done;
    Serial.print(F("stepresp: done in "));
    Serial.print((nowMs - sessionStartMs_) / 1000UL);
    Serial.println(F("s"));
    Serial.print(F("  target="));
    Serial.print(targetC_, 1);
    Serial.print(F("C heater="));
    Serial.print(heaterPct_, 0);
    Serial.print(F("% final avg="));
    Serial.print(avgTempC, 1);
    Serial.print(F("C spread="));
    Serial.print(spreadC, 1);
    Serial.println(F("C"));
    Serial.println(F("  parse sr,... lines for step response (fan PWM vs temp)"));
  }

  void fail(const __FlashStringHelper *reason) {
    Serial.println(reason);
    phase_ = Phase::Failed;
    sessionStartMs_ = 0;
  }

  Phase phase_;
  float targetC_;
  float heaterPct_;
  uint8_t stepIndex_;
  uint32_t sessionStartMs_;
  uint32_t phaseStartMs_;
  uint32_t lastLogMs_;
  float lastAvgC_;
};