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fixed entry-exit height difference bug for Multistage Experiment

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Hunter David Halloran
2026-02-09 12:57:40 -05:00
parent 09886e2e04
commit 1bddb4b58f
9 changed files with 2801 additions and 67 deletions
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%c -Wno-frame-address -std=gnu99 -Wno-old-style-declaration -Os -mlongcalls -ffunction-sections -fdata-sections -Wno-error=unused-function -Wno-error=unused-variable -Wno-error=deprecated-declarations -Wno-unused-parameter -Wno-sign-compare -ggdb -freorder-blocks -Wwrite-strings -fstack-protector -fstrict-volatile-bitfields -Wno-error=unused-but-set-variable -fno-jump-tables -fno-tree-switch-conversion -MMD
%cpp -Wno-frame-address -std=gnu++11 -fexceptions -fno-rtti -Os -mlongcalls -ffunction-sections -fdata-sections -Wno-error=unused-function -Wno-error=unused-variable -Wno-error=deprecated-declarations -Wno-unused-parameter -Wno-sign-compare -ggdb -freorder-blocks -Wwrite-strings -fstack-protector -fstrict-volatile-bitfields -Wno-error=unused-but-set-variable -fno-jump-tables -fno-tree-switch-conversion -MMD
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-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/fir/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/add/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/sub/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/mul/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/addc/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/mulc/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/math/sqrt/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/matrix/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/fft/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/dct/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/conv/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/common/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/kalman/ekf/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/espressif__esp-dsp/modules/kalman/ekf_imu13states/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/include/fb_gfx/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/tools/sdk/esp32/dio_qspi/include
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/cores/esp32
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/variants/esp32
-I/Users/hdh20267/.platformio/lib/AsyncMqttClient-esphome/src
-I/Users/hdh20267/.platformio/lib/AsyncTCP-esphome/src
-I/Users/hdh20267/.platformio/lib/Crypto
-I/Users/hdh20267/.platformio/lib/Dsmr/src
-I/Users/hdh20267/.platformio/lib/ESP32-audioI2S/src
-I/Users/hdh20267/.platformio/lib/ESPAsyncWebServer-esphome/src
-I/Users/hdh20267/.platformio/lib/FastLED
-I/Users/hdh20267/.platformio/lib/HaierProtocol/include
-I/Users/hdh20267/.platformio/lib/HaierProtocol/src
-I/Users/hdh20267/.platformio/lib/HeatpumpIR
-I/Users/hdh20267/.platformio/lib/IRremoteESP8266/src
-I/Users/hdh20267/.platformio/lib/Improv/src
-I/Users/hdh20267/.platformio/lib/MideaUART/include
-I/Users/hdh20267/.platformio/lib/MideaUART/src
-I/Users/hdh20267/.platformio/lib/NeoPixelBus/src
-I/Users/hdh20267/.platformio/lib/TM1651
-I/Users/hdh20267/.platformio/lib/TinyGPSPlus/src
-I/Users/hdh20267/.platformio/lib/arduino-MLX90393
-I/Users/hdh20267/.platformio/lib/esp_wireguard/include
-I/Users/hdh20267/.platformio/lib/esp_wireguard/src
-I/Users/hdh20267/.platformio/lib/libsodium/libsodium/src/libsodium/include
-I/Users/hdh20267/.platformio/lib/libsodium/libsodium/src/libsodium
-I/Users/hdh20267/.platformio/lib/libsodium/libsodium/src/libsodium/include/sodium
-I/Users/hdh20267/.platformio/lib/libsodium/port_include
-I/Users/hdh20267/.platformio/lib/noise-c/include
-I/Users/hdh20267/.platformio/lib/noise-c/src
-I/Users/hdh20267/.platformio/lib/noise-c@0.1.1/include
-I/Users/hdh20267/.platformio/lib/noise-c@0.1.1/src
-I/Users/hdh20267/.platformio/lib/qr-code-generator-library/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/ArduinoOTA/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/AsyncUDP/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/BLE/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/BluetoothSerial/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/DNSServer/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/EEPROM/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/ESP32/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/ESPmDNS/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/Ethernet/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/FFat/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/FS/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/HTTPClient/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/HTTPUpdate/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/HTTPUpdateServer/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/I2S/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/Insights/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/LittleFS/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/NetBIOS/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/Preferences/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/RainMaker/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/SD/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/SD_MMC/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/SPI/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/SPIFFS/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/SimpleBLE/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/Ticker/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/USB/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/Update/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/WebServer/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/WiFiClientSecure/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/WiFiProv/src
-I/Users/hdh20267/.platformio/packages/framework-arduinoespressif32/libraries/Wire/src
-I/Users/hdh20267/.platformio/packages/toolchain-xtensa-esp32/xtensa-esp32-elf/include/c++/8.4.0
-I/Users/hdh20267/.platformio/packages/toolchain-xtensa-esp32/xtensa-esp32-elf/include/c++/8.4.0/xtensa-esp32-elf
-I/Users/hdh20267/.platformio/packages/toolchain-xtensa-esp32/lib/gcc/xtensa-esp32-elf/8.4.0/include
-I/Users/hdh20267/.platformio/packages/toolchain-xtensa-esp32/lib/gcc/xtensa-esp32-elf/8.4.0/include-fixed
-I/Users/hdh20267/.platformio/packages/toolchain-xtensa-esp32/xtensa-esp32-elf/include
-DPLATFORMIO=60116
-DARDUINO_ESP32_DEV
-DHAVE_CONFIG_H
-DMBEDTLS_CONFIG_FILE="mbedtls/esp_config.h"
-DUNITY_INCLUDE_CONFIG_H
-DWITH_POSIX
-D_GNU_SOURCE
-DIDF_VER="v4.4.6-dirty"
-DESP_PLATFORM
-D_POSIX_READER_WRITER_LOCKS
-DARDUINO_ARCH_ESP32
-DESP32
-DF_CPU=240000000L
-DARDUINO=10812
-DARDUINO_VARIANT="esp32"
-DARDUINO_BOARD="Espressif ESP32 Dev Module"
-DARDUINO_PARTITION_default

19
.clangd Normal file
View File

@@ -0,0 +1,19 @@
CompileFlags:
Add:
[
-mlong-calls,
-DSSIZE_MAX,
-DLWIP_NO_UNISTD_H=1,
-Dssize_t=long,
-D_SSIZE_T_DECLARED,
]
Remove:
[
-fno-tree-switch-conversion,
-f*,
-mtext-section-literals,
-mlongcalls,
-fstrict-volatile-bitfields,
-free,
-fipa-pta,
]

4
.gitignore vendored
View File

@@ -1,5 +1,7 @@
.pio .pio/
.vscode/.browse.c_cpp.db* .vscode/.browse.c_cpp.db*
.vscode/c_cpp_properties.json .vscode/c_cpp_properties.json
.vscode/launch.json .vscode/launch.json
.vscode/ipch .vscode/ipch
build/
.cache/

3
CMakeLists.txt Normal file
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@@ -0,0 +1,3 @@
cmake_minimum_required(VERSION 3.16.0)
include($ENV{IDF_PATH}/tools/cmake/project.cmake)
project(usda-platformio)

440
compile_commands.json Normal file
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File diff suppressed because one or more lines are too long

2
platformio.ini
View File

@@ -17,4 +17,6 @@ lib_deps =
PubSubClient PubSubClient
ArduinoJson ArduinoJson
RotaryEncoder RotaryEncoder
ArduinoOTA
ESPmDNS

1866
sdkconfig.esp32 Normal file
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File diff suppressed because it is too large Load Diff

6
src/CMakeLists.txt Normal file
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@@ -0,0 +1,6 @@
# This file was automatically generated for projects
# without default 'CMakeLists.txt' file.
FILE(GLOB_RECURSE app_sources ${CMAKE_SOURCE_DIR}/src/*.*)
idf_component_register(SRCS ${app_sources})

243
src/main.cpp
View File

@@ -5,40 +5,46 @@
#include <RotaryEncoder.h> #include <RotaryEncoder.h>
#include <EEPROM.h> #include <EEPROM.h>
const uint8_t bottom_dir_pin = 5, top_dir_pin = 18; const uint8_t bottom_dir_pin = 5, top_dir_pin = 18;
const uint8_t bottom_step_pin = 4, top_step_pin = 17; const uint8_t bottom_step_pin = 4, top_step_pin = 17;
const uint8_t bottom_en_pin = 12, top_en_pin = 16; const uint8_t bottom_en_pin = 12, top_en_pin = 16;
const uint8_t encoder_a = 19, encoder_b = 21; const uint8_t encoder_a = 19, encoder_b = 21;
#define EEPROM_SIZE 18 #define EEPROM_SIZE 18
#define EEPROM_BOTTOM_POS_ADDR 0 #define EEPROM_BOTTOM_POS_ADDR 0 // 0..3
#define EEPROM_TOP_POS_ADDR 4 #define EEPROM_TOP_POS_ADDR 4 // 4..7
#define EEPROM_FLAG_ADDR 8 #define EEPROM_FLAG_ADDR 8
#define EEPROM_BOTTOM_MOVING_FLAG_ADDR 9 #define EEPROM_BOTTOM_MOVING_FLAG_ADDR 9
#define EEPROM_TOP_MOVING_FLAG_ADDR 10 #define EEPROM_TOP_MOVING_FLAG_ADDR 10
#define EEPROM_TOP_BOTTOM_DIFF_ADDR 11 #define EEPROM_TOP_BOTTOM_DIFF_ADDR 11 // 11..14 (4 bytes)
#define HOMING_FLAG 0x01 #define HOMING_FLAG 0x01
#define NORMAL_FLAG 0x00 #define NORMAL_FLAG 0x00
#define MOVING_FLAG_SET 0xAA #define MOVING_FLAG_SET 0xAA
#define MOVING_FLAG_CLEAR 0x00 #define MOVING_FLAG_CLEAR 0x00
const char *ssid = "IOT-pecan"; const char *ssid = "IOT-pecan";
const char *password = "aaaaaaaa"; const char *password = "aaaaaaaa";
const char *mqttServer = "192.168.1.110"; const char *mqttServer = "192.168.1.110";
const int mqttPort = 1883; const int mqttPort = 1883;
const char *mqttHeightTopic = "/jc/height";
const char *mqttAngleTopic = "/jc/angle";
const char *mqttStopTopic = "/jc/stop";
const char *mqttHomingFlagTopic = "/jc/homing_mode";
const char *mqttDebugTopic = "/jc/debug";
const char *mqttStatusTopic = "/jc/status";
const char *mqttHeightLogTopic = "/jc/height/log"; const char *mqttHeightTopic = "/jc/height";
const char *mqttAngleLogTopic = "/jc/angle/log"; const char *mqttAngleTopic = "/jc/angle";
const char *mqttRPMLogTopic = "/jc/rpm/log"; const char *mqttStopTopic = "/jc/stop";
const char *mqttHomingFlagTopic = "/jc/homing_mode";
const char *mqttDebugTopic = "/jc/debug";
const char *mqttStatusTopic = "/jc/status";
const char *mqttHeightLogTopic = "/jc/height/log";
const char *mqttAngleLogTopic = "/jc/angle/log";
const char *mqttRPMLogTopic = "/jc/rpm/log";
const int steps_per_thou = 22; const int steps_per_thou = 22;
// Mechanical limits in steps (negative = more closed)
static const long POS_MAX_STEPS = 0;
static const long POS_MIN_STEPS = -1665L * steps_per_thou;
FastAccelStepperEngine engine = FastAccelStepperEngine(); FastAccelStepperEngine engine = FastAccelStepperEngine();
FastAccelStepper *bottom_stepper = nullptr; FastAccelStepper *bottom_stepper = nullptr;
FastAccelStepper *top_stepper = nullptr; FastAccelStepper *top_stepper = nullptr;
@@ -48,58 +54,116 @@ RotaryEncoder encoder(encoder_a, encoder_b);
WiFiClient wifiClient; WiFiClient wifiClient;
PubSubClient mqttClient(wifiClient); PubSubClient mqttClient(wifiClient);
// Commanded goals
volatile long bottom_step_goal = 0, top_step_goal = 0; volatile long bottom_step_goal = 0, top_step_goal = 0;
// Commanded "crush" meaning: MIN(bottom, top) == crush_min_steps
volatile long crush_min_steps = 0;
// Angle difference (top - bottom) in steps
volatile long top_angle_difference_steps = 0;
volatile bool bottom_step_done = true, top_step_done = true; volatile bool bottom_step_done = true, top_step_done = true;
volatile bool bottom_step_sent = false, top_step_sent = false; volatile bool bottom_step_sent = false, top_step_sent = false;
volatile bool stop = false; volatile bool stop = false;
bool system_locked = false; bool system_locked = false;
void writePositionToEEPROM(int addr, long pos) static void mqttDebugf(const char *fmt, long v) {
{ char buf[128];
EEPROM.write(addr, (pos >> 24) & 0xFF); snprintf(buf, sizeof(buf), fmt, v);
EEPROM.write(addr + 1, (pos >> 16) & 0xFF); mqttClient.publish(mqttDebugTopic, buf);
EEPROM.write(addr + 2, (pos >> 8) & 0xFF);
EEPROM.write(addr + 3, pos & 0xFF);
} }
long readPositionFromEEPROM(int addr) static void writePositionToEEPROM(int addr, long pos)
{ {
long pos = ((long)EEPROM.read(addr) << 24) | EEPROM.write(addr, (pos >> 24) & 0xFF);
EEPROM.write(addr + 1, (pos >> 16) & 0xFF);
EEPROM.write(addr + 2, (pos >> 8) & 0xFF);
EEPROM.write(addr + 3, (pos ) & 0xFF);
}
static long readPositionFromEEPROM(int addr)
{
long pos = ((long)EEPROM.read(addr) << 24) |
((long)EEPROM.read(addr + 1) << 16) | ((long)EEPROM.read(addr + 1) << 16) |
((long)EEPROM.read(addr + 2) << 8) | ((long)EEPROM.read(addr + 2) << 8) |
(long)EEPROM.read(addr + 3); ((long)EEPROM.read(addr + 3));
return pos; return pos;
} }
volatile long top_angle_difference_steps = readPositionFromEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR); static inline long clampLong(long v, long lo, long hi) {
if (v < lo) return lo;
if (v > hi) return hi;
return v;
}
// Recompute bottom_step_goal and top_step_goal so that:
// min(bottom, top) == crush_min_steps
// top - bottom == top_angle_difference_steps (as much as limits allow)
//
// After clamping, we update crush_min_steps to the achieved min so later angle
// changes don't "resurrect" an impossible crush target.
static void recomputeGoalsFromCrushAndDiff()
{
long diff = top_angle_difference_steps;
long bottomGoal, topGoal;
// Ensure crush_min_steps is within physical limits first.
crush_min_steps = clampLong(crush_min_steps, POS_MIN_STEPS, POS_MAX_STEPS);
if (diff >= 0) {
// bottom is the min (more crushed)
bottomGoal = crush_min_steps;
topGoal = crush_min_steps + diff;
} else {
// top is the min (more crushed)
topGoal = crush_min_steps;
bottomGoal = crush_min_steps - diff; // subtract negative => add magnitude
}
// Clamp both to physical limits (this can distort diff near bounds).
bottomGoal = clampLong(bottomGoal, POS_MIN_STEPS, POS_MAX_STEPS);
topGoal = clampLong(topGoal, POS_MIN_STEPS, POS_MAX_STEPS);
bottom_step_goal = bottomGoal;
top_step_goal = topGoal;
// Update crush_min_steps to what we can actually achieve.
crush_min_steps = (bottomGoal < topGoal) ? bottomGoal : topGoal;
bottom_step_done = false; bottom_step_sent = false;
top_step_done = false; top_step_sent = false;
}
void callback(char *topic, byte *payload, unsigned int length) void callback(char *topic, byte *payload, unsigned int length)
{ {
String topic_str = String(topic); String topic_str(topic);
String payload_str = ""; String payload_str;
for (unsigned int i = 0; i < length; i++) payload_str.reserve(length);
payload_str += (char)payload[i]; for (unsigned int i = 0; i < length; i++) payload_str += (char)payload[i];
int value = payload_str.toInt();
long value = payload_str.toInt();
if (topic_str == mqttHeightTopic && !system_locked) if (topic_str == mqttHeightTopic && !system_locked)
{ {
value -= 1875 - 210; // Convert incoming "height" into steps. Keeping your original offset logic.
// (If this is wrong, it's wrong consistently, at least.)
value -= (1875 - 210);
value *= steps_per_thou; value *= steps_per_thou;
stop = false; stop = false;
bottom_step_goal = value;
bottom_step_done = false; crush_min_steps = value;
bottom_step_sent = false; recomputeGoalsFromCrushAndDiff();
top_step_goal = value + top_angle_difference_steps;
top_step_done = false;
top_step_sent = false;
} }
else if (topic_str == mqttAngleTopic && !system_locked) else if (topic_str == mqttAngleTopic && !system_locked)
{ {
stop = false; stop = false;
// value is in thou, convert to steps
top_angle_difference_steps = value * steps_per_thou; top_angle_difference_steps = value * steps_per_thou;
top_step_goal = bottom_step_goal + top_angle_difference_steps; recomputeGoalsFromCrushAndDiff();
top_step_done = false;
top_step_sent = false;
} }
else if (topic_str == mqttStopTopic && !system_locked) else if (topic_str == mqttStopTopic && !system_locked)
{ {
@@ -119,23 +183,14 @@ void callback(char *topic, byte *payload, unsigned int length)
} }
EEPROM.commit(); EEPROM.commit();
} }
if (top_step_goal < -1665 * steps_per_thou)
top_step_goal = -1665 * steps_per_thou;
if (bottom_step_goal < -1665 * steps_per_thou)
bottom_step_goal = -1665 * steps_per_thou;
if (top_step_goal > 0)
top_step_goal = 0;
if (bottom_step_goal > 0)
bottom_step_goal = 0;
} }
void reconnect() void reconnect()
{ {
while (!mqttClient.connected()) while (!mqttClient.connected())
{ {
if (WiFi.status() != WL_CONNECTED) if (WiFi.status() != WL_CONNECTED) WiFi.reconnect();
WiFi.reconnect();
Serial.println("Attempting MQTT connection..."); Serial.println("Attempting MQTT connection...");
if (mqttClient.connect("ESP32Client")) if (mqttClient.connect("ESP32Client"))
{ {
@@ -160,9 +215,13 @@ long last_publish_time = 0;
void setup() void setup()
{ {
Serial.begin(9600); Serial.begin(9600);
EEPROM.begin(EEPROM_SIZE); EEPROM.begin(EEPROM_SIZE);
engine.init(); engine.init();
// Now it's legal to read EEPROM-backed values.
top_angle_difference_steps = readPositionFromEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR);
WiFi.begin(ssid, password); WiFi.begin(ssid, password);
while (WiFi.status() != WL_CONNECTED) while (WiFi.status() != WL_CONNECTED)
{ {
@@ -174,13 +233,24 @@ void setup()
mqttClient.setServer(mqttServer, mqttPort); mqttClient.setServer(mqttServer, mqttPort);
mqttClient.setCallback(callback); mqttClient.setCallback(callback);
// Establish MQTT connection before any publish attempts.
reconnect();
uint8_t startupFlag = EEPROM.read(EEPROM_FLAG_ADDR); uint8_t startupFlag = EEPROM.read(EEPROM_FLAG_ADDR);
Serial.print("Startup flag: "); Serial.print("Startup flag: ");
Serial.println(startupFlag); Serial.println(startupFlag);
if (startupFlag == HOMING_FLAG) {
top_angle_difference_steps = 0;
writePositionToEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR, 0);
EEPROM.commit();
mqttClient.publish(mqttDebugTopic, "HOMING: angle diff reset to 0");
}
uint8_t bottomMovingFlag = EEPROM.read(EEPROM_BOTTOM_MOVING_FLAG_ADDR); uint8_t bottomMovingFlag = EEPROM.read(EEPROM_BOTTOM_MOVING_FLAG_ADDR);
uint8_t topMovingFlag = EEPROM.read(EEPROM_TOP_MOVING_FLAG_ADDR); uint8_t topMovingFlag = EEPROM.read(EEPROM_TOP_MOVING_FLAG_ADDR);
if (startupFlag != HOMING_FLAG && (bottomMovingFlag != MOVING_FLAG_CLEAR || topMovingFlag != MOVING_FLAG_CLEAR))
if (startupFlag != HOMING_FLAG &&
(bottomMovingFlag != MOVING_FLAG_CLEAR || topMovingFlag != MOVING_FLAG_CLEAR))
{ {
system_locked = true; system_locked = true;
mqttClient.publish(mqttDebugTopic, "FAULT: NEEDS HOMING RESET"); mqttClient.publish(mqttDebugTopic, "FAULT: NEEDS HOMING RESET");
@@ -196,6 +266,7 @@ void setup()
bottom_stepper->setEnablePin(bottom_en_pin, false); bottom_stepper->setEnablePin(bottom_en_pin, false);
bottom_stepper->setSpeedInHz(1000); bottom_stepper->setSpeedInHz(1000);
bottom_stepper->setAcceleration(250); bottom_stepper->setAcceleration(250);
if (startupFlag == HOMING_FLAG) if (startupFlag == HOMING_FLAG)
{ {
Serial.println("Starting in homing mode (bottom)"); Serial.println("Starting in homing mode (bottom)");
@@ -210,9 +281,13 @@ void setup()
{ {
bottom_stepper->setCurrentPosition(readPositionFromEEPROM(EEPROM_BOTTOM_POS_ADDR)); bottom_stepper->setCurrentPosition(readPositionFromEEPROM(EEPROM_BOTTOM_POS_ADDR));
mqttClient.publish(mqttDebugTopic, "Started in NORMAL mode"); mqttClient.publish(mqttDebugTopic, "Started in NORMAL mode");
mqttClient.publish(mqttDebugTopic, "Bottom stepper loaded %d position from EEPROM", bottom_stepper->getCurrentPosition()); mqttDebugf("Bottom stepper loaded %ld position from EEPROM", bottom_stepper->getCurrentPosition());
} }
} }
else
{
mqttClient.publish(mqttDebugTopic, "ERROR: bottom_stepper init failed");
}
top_stepper = engine.stepperConnectToPin(top_step_pin); top_stepper = engine.stepperConnectToPin(top_step_pin);
if (top_stepper) if (top_stepper)
@@ -221,6 +296,7 @@ void setup()
top_stepper->setEnablePin(top_en_pin, false); top_stepper->setEnablePin(top_en_pin, false);
top_stepper->setSpeedInHz(1000); top_stepper->setSpeedInHz(1000);
top_stepper->setAcceleration(250); top_stepper->setAcceleration(250);
if (startupFlag == HOMING_FLAG) if (startupFlag == HOMING_FLAG)
{ {
Serial.println("Starting in homing mode (top)"); Serial.println("Starting in homing mode (top)");
@@ -232,15 +308,30 @@ void setup()
else else
{ {
top_stepper->setCurrentPosition(readPositionFromEEPROM(EEPROM_TOP_POS_ADDR)); top_stepper->setCurrentPosition(readPositionFromEEPROM(EEPROM_TOP_POS_ADDR));
mqttClient.publish(mqttDebugTopic, "Top stepper loaded %d position from EEPROM", top_stepper->getCurrentPosition()); mqttDebugf("Top stepper loaded %ld position from EEPROM", top_stepper->getCurrentPosition());
} }
} }
else
{
mqttClient.publish(mqttDebugTopic, "ERROR: top_stepper init failed");
}
// Initialize crush_min_steps to current achieved minimum so angle changes don't jump.
if (bottom_stepper && top_stepper) {
long b = bottom_stepper->getCurrentPosition();
long t = top_stepper->getCurrentPosition();
crush_min_steps = (b < t) ? b : t;
} else {
crush_min_steps = 0;
}
// Ensure goals are consistent with stored diff at startup.
recomputeGoalsFromCrushAndDiff();
} }
void loop() void loop()
{ {
if (!mqttClient.connected()) if (!mqttClient.connected()) reconnect();
reconnect();
mqttClient.loop(); mqttClient.loop();
encoder.tick(); encoder.tick();
@@ -248,11 +339,23 @@ void loop()
if (millis() - last_publish_time > 1000) if (millis() - last_publish_time > 1000)
{ {
last_publish_time = millis(); last_publish_time = millis();
mqttClient.publish(mqttHeightLogTopic, String(1665 + bottom_stepper->getCurrentPosition() / steps_per_thou).c_str());
mqttClient.publish(mqttAngleLogTopic, String((top_stepper->getCurrentPosition() - bottom_stepper->getCurrentPosition()) / steps_per_thou).c_str()); if (bottom_stepper && top_stepper) {
mqttClient.publish(mqttHeightLogTopic,
String(1665 + bottom_stepper->getCurrentPosition() / steps_per_thou).c_str());
mqttClient.publish(mqttAngleLogTopic,
String((top_stepper->getCurrentPosition() - bottom_stepper->getCurrentPosition()) / steps_per_thou).c_str());
}
mqttClient.publish(mqttRPMLogTopic, String(encoder.getRPM()).c_str()); mqttClient.publish(mqttRPMLogTopic, String(encoder.getRPM()).c_str());
} }
if (!bottom_stepper || !top_stepper) {
// If steppers didn't init, don't crash the MCU trying anyway.
return;
}
if (system_locked) if (system_locked)
{ {
bottom_stepper->disableOutputs(); bottom_stepper->disableOutputs();
@@ -271,7 +374,8 @@ void loop()
top_stepper->enableOutputs(); top_stepper->enableOutputs();
} }
if (bottom_stepper->getCurrentPosition() != bottom_step_goal && !bottom_step_done && !bottom_step_sent) if (bottom_stepper->getCurrentPosition() != bottom_step_goal &&
!bottom_step_done && !bottom_step_sent)
{ {
bottom_stepper->moveTo(bottom_step_goal); bottom_stepper->moveTo(bottom_step_goal);
bottom_step_sent = true; bottom_step_sent = true;
@@ -280,7 +384,8 @@ void loop()
Serial.println("Moving bottom stepper"); Serial.println("Moving bottom stepper");
} }
if (top_stepper->getCurrentPosition() != top_step_goal && !top_step_done && !top_step_sent) if (top_stepper->getCurrentPosition() != top_step_goal &&
!top_step_done && !top_step_sent)
{ {
top_stepper->moveTo(top_step_goal); top_stepper->moveTo(top_step_goal);
top_step_sent = true; top_step_sent = true;
@@ -289,25 +394,31 @@ void loop()
Serial.println("Moving top stepper"); Serial.println("Moving top stepper");
} }
if (bottom_stepper->getCurrentPosition() == bottom_step_goal && !bottom_step_done && bottom_step_sent) if (bottom_stepper->getCurrentPosition() == bottom_step_goal &&
!bottom_step_done && bottom_step_sent)
{ {
bottom_step_done = true; bottom_step_done = true;
bottom_step_sent = false; bottom_step_sent = false;
writePositionToEEPROM(EEPROM_BOTTOM_POS_ADDR, bottom_stepper->getCurrentPosition()); writePositionToEEPROM(EEPROM_BOTTOM_POS_ADDR, bottom_stepper->getCurrentPosition());
writePositionToEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR, top_angle_difference_steps); writePositionToEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR, top_angle_difference_steps);
EEPROM.write(EEPROM_BOTTOM_MOVING_FLAG_ADDR, MOVING_FLAG_CLEAR); EEPROM.write(EEPROM_BOTTOM_MOVING_FLAG_ADDR, MOVING_FLAG_CLEAR);
EEPROM.commit(); EEPROM.commit();
Serial.println("Bottom stepper done"); Serial.println("Bottom stepper done");
} }
if (top_stepper->getCurrentPosition() == top_step_goal && !top_step_done && top_step_sent) if (top_stepper->getCurrentPosition() == top_step_goal &&
!top_step_done && top_step_sent)
{ {
top_step_done = true; top_step_done = true;
top_step_sent = false; top_step_sent = false;
writePositionToEEPROM(EEPROM_TOP_POS_ADDR, top_stepper->getCurrentPosition()); writePositionToEEPROM(EEPROM_TOP_POS_ADDR, top_stepper->getCurrentPosition());
writePositionToEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR, top_angle_difference_steps); writePositionToEEPROM(EEPROM_TOP_BOTTOM_DIFF_ADDR, top_angle_difference_steps);
EEPROM.write(EEPROM_TOP_MOVING_FLAG_ADDR, MOVING_FLAG_CLEAR); EEPROM.write(EEPROM_TOP_MOVING_FLAG_ADDR, MOVING_FLAG_CLEAR);
EEPROM.commit(); EEPROM.commit();
Serial.println("Top stepper done"); Serial.println("Top stepper done");
} }
} }