#ifndef PLUNGER_H #define PLUNGER_H #include "config.h" #include #include #include #include #include "components/DELTA_VFD.h" #include "components/Joystick.h" #include "components/POT.h" #include "enums.h" #include "modbus/NetworkComponent.h" #include "profiles/IPlungerEvents.h" #include "PlungerSettings.h" // Forward declaration for the debug flag extern const bool debug_states; // Component Constants #define PLUNGER_COMPONENT_ID 760 #define PLUNGER_COMPONENT_NAME "Plunger" // Speed Presets (in Hz units for DELTA_VFD) #define PLUNGER_SPEED_SLOW_HZ 15 // 10.00 Hz #define PLUNGER_SPEED_MEDIUM_HZ 20 // 25.00 Hz #define PLUNGER_SPEED_FAST_HZ 35 #define PLUNGER_SPEED_MAX_HZ 45 // Post-flow settings #define PLUNGER_POST_FLOW_DURATION_MS 1000 // Duration of active post-flow (pressing) #define PLUNGER_POST_FLOW_SPEED_HZ 5 // Speed during post-flow pressing #define PLUNGER_CURRENT_POST_FLOW_MA 1200 // Current at or above this value indicates post-flow jam #define PLUNGER_POST_FLOW_STOPPING_WAIT_MS 1500 // Wait time after initial stop before starting post-flow press #define PLUNGER_POST_FLOW_COMPLETE_WAIT_MS 1500 // Wait time after post-flow press before returning to IDLE #define PLUNGER_DEFAULT_ENABLE_POST_FLOW true // Added for clarity if PlungerSettings uses it // New constants for Filling #define PLUNGER_FILL_JOYSTICK_HOLD_DURATION_MS 2500 // Time to hold joystick LEFT to start fill #define PLUNGER_SPEED_FILL_PLUNGE_HZ PLUNGER_SPEED_MEDIUM_HZ // Speed for plunging phase of filling #define PLUNGER_SPEED_FILL_HOME_HZ PLUNGER_SPEED_SLOW_HZ // Speed for homing phase of filling #define PLUNGER_FILL_PLUNGED_WAIT_DURATION_MS 1000 // Wait duration after plunging #define PLUNGER_FILL_HOMED_WAIT_DURATION_MS 1500 // Wait duration after homing // Speed POT Configuration for Plunging (multiplier for MEDIUM speed) // POT value 0-100. Example: 0 maps to 0.5x, 50 maps to 1.0x, 100 maps to 1.5x MEDIUM speed. // Fixed Current Thresholds (mA) #define PLUNGER_CURRENT_IDLE_LOWER_MA 300 #define PLUNGER_CURRENT_IDLE_UPPER_MA 500 #define PLUNGER_CURRENT_PLUNGING_LOWER_MA 500 #define PLUNGER_CURRENT_PLUNGING_UPPER_MA 700 #define PLUNGER_CURRENT_JAM_THRESHOLD_MA 700 // Current at or above this value indicates a jam #define PLUNGER_JAMMED_DURATION_HOMING_MS 10 #define PLUNGER_JAMMED_DURATION_MS 1400 #define PLUNGER_VFD_READ_INTERVAL_MS 200 // #define ENABLE_AUTO 1 // Set to 0 to disable joystick-activated auto homing/plunging -- REMOVED #define PLUNGER_AUTO_MODE_HOLD_DURATION_MS 2000 // Time joystick must be held for auto mode #define PLUNGER_MAX_UNIVERSAL_JAM_TIME_MS 5000 // Max time current can be high before a universal jam // New constants for Record/Replay #define PLUNGER_RECORD_HOLD_DURATION_MS 2000 // Min time joystick must be held RIGHT to enter RECORD mode #define PLUNGER_MAX_RECORD_DURATION_MS 20000 // Max duration for the plunging phase of recording #define PLUNGER_DEFAULT_REPLAY_DURATION_MS 4500 // Default duration for replay if not recorded/set // New constant for default max operation time #define PLUNGER_DEFAULT_MAX_OPERATION_DURATION_MS 60*1000*1 // 1 minute // Modbus Configuration #define PLUNGER_MB_BASE_ADDRESS COMPONENT_KEY_PLUNGER // Using component ID as base #define PLUNGER_MB_STATE_OFFSET 0 #define PLUNGER_MB_COMMAND_OFFSET 1 #define PLUNGER_MB_BLOCK_COUNT 3 // m_enabled, m_state, m_command #define PLUNGER_MAX_RUN_TIME_MEDIUM_SPEED_MS 15000 // Max runtime at medium speed enum class E_PlungerCommand : short { NO_COMMAND = 0, CMD_HOME = 1, CMD_PLUNGE = 2, CMD_STOP = 3, CMD_INFO = 4, CMD_FILL = 5, CMD_REPLAY = 6 }; // Plunger States enum class PlungerState : uint8_t { IDLE, HOMING_MANUAL, // Joystick held DOWN, VFD reversing, monitoring for auto-mode hold time HOMING_AUTO, // Auto-homing after joystick hold, VFD reversing PLUNGING_MANUAL, // Joystick held UP, VFD forwarding, monitoring for auto-mode hold time PLUNGING_AUTO, // Auto-plunging after joystick hold, VFD forwarding STOPPING, // Transition state to stop VFD JAMMED, RESETTING_JAM, // State to handle reset after jam RECORD, // New state for recording plunge duration REPLAY, // New state for replaying recorded plunge FILLING, POST_FLOW, }; enum class FillState : uint8_t { NONE, PLUNGING, // Actively plunging down PLUNGED, // Plunge event (jam/max_duration) occurred, waiting for min plunge time HOMING, // Actively homing up HOMED // Homing complete }; enum class PostFlowState : uint8_t { NONE, POST_FLOW_STOPPING, // Stopping VFD, and wait at least 1500ms POST_FLOW_STARTING, // Starting VFD, set post-flow speed, and run for post-flow duration POST_FLOW_COMPLETE // Stop VFD, and wait before resuming normal operation (e.g. IDLE) }; class Plunger : public NetworkComponent { public: enum E_MB_Offset { MB_OFS_STATE = E_NVC_USER + 0, MB_OFS_COMMAND = E_NVC_USER + 1, }; Plunger(Component* owner, DELTA_VFD* vfd, Joystick* joystick, POT* speedPot, POT* torquePot); ~Plunger() override = default; short setup() override; short loop() override; short info() override; short debug() override; short init(); short reset(); short mb_tcp_read(MB_Registers* reg) override; short mb_tcp_write(MB_Registers* reg, short networkValue) override; // Public commands for serial/external control short cmd_plunge(); short cmd_home(); short cmd_stop(); short cmd_fill(); short cmd_save_settings(); short cmd_load_default_settings(); short cmd_replay(); // Auto mode control void setAutoModeEnabled(bool enabled); bool isAutoModeEnabled() const; short cmd_enableAutoMode(); short cmd_disableAutoMode(); // Event delegate void setEventsDelegate(IPlungerEvents* delegate) { _eventsDelegate = delegate; } // Persistence related methods (now for REST exposure) void getSettingsJson(JsonDocument& doc) const; bool updateSettingsFromJson(const JsonObject& json); bool loadDefaultSettings(const char* defaultPath = "/plunger_default.json", const char* operationalPath = "/plunger.json"); private: DELTA_VFD* _vfd; Joystick* _joystick; POT* _speedPot; POT* _torquePot; FillState _currentFillState; // Re-added PostFlowState _currentPostFlowState; // For managing sub-states of POST_FLOW Joystick::E_POSITION _lastJoystickDirection; uint16_t _currentSpeedPotValue; // 0-100 uint16_t _currentTorquePotValue; // 0-100, for torque/jam sensitivity float _calculatedPlungingSpeedHz; // Calculated speed for plunging (0.01Hz units) NetworkValue m_state; NetworkValue m_command; unsigned long _lastStateChangeTimeMs; unsigned long _jammedStartTimeMs; unsigned long _lastVfdReadTimeMs; unsigned long _joystickHoldStartTimeMs; // Timer for joystick hold duration unsigned long _operationStartTimeMs; // Start time of current plunge/home operation (used for fill plunge phase) unsigned long _currentMaxOperationTimeMs; // Calculated max duration for current operation (used for fill plunge phase) unsigned long _lastDiagnosticLogTimeMs; // Timer for the 5-second diagnostic log in _checkVfdForJam unsigned long _lastImmediateStopCheckTimeMs; // Timer for the 1-second immediate high-current stop check bool _joystickReleasedSinceAutoStart; // True if joystick released to center after auto mode started bool _autoModeEnabled; // True if joystick/command auto modes are enabled // Record and Replay members Ticker _joystickRecordHoldTimer; Ticker _replayPlungeTimer; Ticker _joystickFillHoldTimer; // Timer for joystick LEFT hold to start filling unsigned long _recordedPlungeDurationMs; unsigned long _recordModeStartTimeMs; // To time the actual plunge during recording // Filling members Ticker _fillSubStateTimer; // Timer for fill sub-state durations unsigned long _fillOperationStartTimeMs; // Start time of the overall fill operation unsigned long _postFlowStartTimeMs; // Start time of the active post-flow pressing phase // Post-flow sub-state timer Ticker _postFlowSubStateTimer; // Settings PlungerSettings _settings; // Timer for state logging unsigned long _lastStateLogTimeMs; // Event delegate IPlungerEvents* _eventsDelegate; // Helper methods void _handleIdleState(); void _handleHomingManualState(); void _handleHomingAutoState(); void _handlePlungingManualState(); void _handlePlungingAutoState(); void _handleStoppingState(); void _handleJammedState(); void _handleResettingJamState(); void _handleRecordState(); void _handleReplayState(); void _handleFillingState(); void _handlePostFlowState(); // Declaration for the new state handler // Static relay callbacks for Ticker static void _joystickRecordHoldTimerRelay(Plunger* pThis); static void _replayPlungeTimerRelay(Plunger* pThis); static void _fillSubStateTimerRelay(Plunger* pThis); // Added for fill timer static void _joystickFillHoldTimerRelay(Plunger* pThis); // Relay for fill joystick hold static void _postFlowSubStateTimerRelay(Plunger* pThis); // Relay for post-flow sub-state timer // Actual timer event handlers void _onJoystickRecordHoldTimeout(); void _onReplayPlungeTimeout(); void _onFillSubStateTimeout(); // Added for fill timer void _onJoystickFillHoldTimeout(); // Handler for fill joystick hold void _onPostFlowSubStateTimeout(); // Handler for post-flow sub-state timer void _updatePotValues(); void _checkVfdForJam(); void _transitionToState(PlungerState newState); // VFD interaction wrappers void _vfdStartForward(uint16_t frequencyCentiHz); void _vfdStartReverse(uint16_t frequencyCentiHz); void _vfdStop(); void _vfdResetJam(); // Event firing void _fireEvent(PlungerEvent event, int16_t val = 0); }; const char *_plungerStateToString(PlungerState state); const char *_fillStateToString(FillState state); // Ensure this declaration is present const char *_postFlowStateToString(PostFlowState state); // Declaration for PostFlowState to string #endif // PLUNGER_H