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reflow
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almost done

This commit is contained in:
Stefan Kögl 2012-10-03 20:09:27 +02:00
parent c04dcaa2e1
commit b1060ab9f4
1 changed files with 172 additions and 102 deletions
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272
reflowctl/reflowctl.ino
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@ -10,23 +10,25 @@
#define ERROR_STATE 8
// error conditions
#define E_RAMPUP 1 // oven heats up too fast
#define E_RAMPDOWN_TOO_FAST 2 // oven cools down too fast
#define E_RAMPDOWN_TOO_SLOW 3 // oven cools down too slow
#define E_DT_MIN 1 // temperatur dt too small
#define E_DT_MAX 2 // temperatur dt too big
#define E_TIME_MAX 4 // reflow process does take too long
#define E_PEAK_TOO_LONG 5 // package was roasted
#define E_PEAK_TOO_LONG 8 // package was roasted
unsigned int time = 0; // profile seconds
unsigned int temperatur = 25; // actual oven temp
unsigned int last_temperatur = 25;
unsigned int actual_dt = 0;
// profile stuff
unsigned int Ts_max = 200; // °C
unsigned int Ts_min = 150; // °C
unsigned int Ts_max = 200; // °C
unsigned int Tp = 260; // 245-260°C
unsigned int rampup_rate = 50; // 3°C/s
unsigned int preheat_duration = 100; // 60-180s
unsigned int Tl = 217; // 217°C
unsigned int Tl_duration = 100; // 60-150s
unsigned int peak_duration = 30; // 20-40s
@ -43,6 +45,7 @@ unsigned int Tp_time_end = 0;
unsigned int error_condition = 0;
boolean is_oven_heating = false;
boolean led_on = false;
byte state = START_STATE;
@ -52,77 +55,121 @@ int hysteresis = 0;
int set_min = 0;
int set_max = 0;
int set_dt_min = 0;
int set_dt_max = 0;
void setup() {
Serial.begin(9600);
get_temp();
last_temperatur = temperatur;
control_oven(Tp, Tp);
delay(2000);
set_start_state();
}
void set_temp(int min, int max) {
set_min = min;
set_max = max;
}
void control_oven() {
if (temperatur < set_min) {
if (temperatur < set_min && (!is_oven_heating)) {
is_oven_heating = true;
Serial.println("Oven turned on");
}
else if (temperatur < set_max) {
else if (temperatur > set_max && is_oven_heating) {
is_oven_heating = false;
Serial.println("Oven turned off");
}
}
void set_temp(int min, int max, int dt_min, int dt_max) {
set_min = min;
set_max = max;
set_dt_min = dt_min;
set_dt_max = dt_max;
}
void get_temp() {
// simulating an +1K/s rampup oven
last_temperatur = temperatur;
temperatur = int(float(analogRead(analogPin)) * 0.2929);
actual_dt = temperatur - last_temperatur;
}
void check_rampup_rate() {
if (temperatur - last_temperatur > rampup_rate) {
error_condition = E_RAMPUP;
control_oven(false);
void check_dt() {
if (actual_dt > set_dt_max) {
error_condition |= E_DT_MAX;
}
else
control_oven(true);
}
boolean check_rampdown_rate() {
unsigned int dt = temperatur - last_temperatur;
if (dt > rampdown_max) {
error_condition = E_RAMPDOWN_TOO_FAST;
return false;
}
if (dt < rampdown_min) {
error_condition = E_RAMPDOWN_TOO_SLOW;
return false;
}
return true;
}
boolean check_max_duration() {
if (time > time_max) {
error_condition = E_TIME_MAX;
return false;
if (actual_dt < set_dt_min) {
error_condition |= E_DT_MIN;
}
}
void print_debug() {
Serial.print("Time: ");
Serial.print(time);
Serial.print(", temperatur: ");
Serial.print(temperatur);
Serial.print(", last_temperatur: ");
Serial.print(last_temperatur);
Serial.print(", state: ");
Serial.print(state);
Serial.print(", Error: ");
Serial.println(error_condition);
}
// boolean check_max_duration() {
// if (time > time_max) {
// error_condition = E_TIME_MAX;
// return false;
// }
// }
/*
boolean check_Tl_duration() {
if (time > time_max) {
error_condition = E_TIME_MAX;
return false;
}
}*/
void set_start_state() {
get_temp();
last_temperatur = temperatur;
set_temp(Tp-5, Tp, 0, rampup_rate);
}
void set_preheat_state() {
}
void set_ramp_up_state() {
}
void set_tal_first_state() {
}
void set_peak_state() {
Serial.println("Changed state to PEAK_STATE");
}
void set_tal_second_state() {
Serial.println("Changed state to TAL_SECOND_STATE");
set_temp(25, 25, -3, -6);
state++;
}
void set_ramp_down_state() {
Serial.println("Changed state to RAMP_DOWN_STATE");
state++;
}
void set_end_state() {
state = END_STATE;
}
void set_error_state() {
if (state != ERROR_STATE) {
set_temp(0, 0, 0, 0);
state = ERROR_STATE;
}
}
void handle_start_state() {
Serial.println("START_STATE");
if (temperatur > Ts_min) {
Serial.println("Changing state to PREHEAT_STATE");
Ts_min_time = time;
@ -132,98 +179,121 @@ void handle_start_state() {
void handle_peak_state() {
Serial.println("PEAK_STATE");
if (temperatur > Tp)
control_oven(false);
else
control_oven(true);
if (time - Tp_time_start > peak_duration) {
Serial.println("Changed state to TAL_SECOND_STATE");
Tp_time_end = time;
void handle_preheat_state() {
Serial.println("PREHEAT_STATE");
if (temperatur > Ts_max) {
Serial.println("Changed state to RAMP_UP_STATE");
Ts_max_time = time;
state++;
}
}
void handle_rampup_state() {
Serial.println("RAMP_UP_STATE");
if (temperatur > Tl) {
Serial.println("Changed state to TAL_FIRST_STATE");
Tl_time_start = time;
state++;
}
}
void handle_tal_first_state() {
Serial.println("TAL_FIRST_STATE");
if (temperatur > Tp - 5) {
Serial.println("Changed state to PEAK_STATE");
Tp_time_start = time;
state++;
set_peak_state();
}
}
void handle_peak_state() {
Serial.println("PEAK_STATE");
if (time - Tp_time_start > peak_duration) {
Tp_time_end = time;
set_tal_second_state();
}
}
void handle_tal_second_state() {
if (temperatur < Tl) {
set_ramp_down_state();
}
}
void handle_ramp_down_state() {
if (temperatur < Ts_min) {
Serial.println("Changed state to END_STATE");
state++;
}
}
void handle_error_state() {
if (led_on) {
digitalWrite(13, LOW);
led_on = false;
}
else {
digitalWrite(13, HIGH);
led_on = true;
}
if (error_condition & E_DT_MIN)
Serial.print("Error: delta °K/second too low");
if (error_condition & E_DT_MAX)
Serial.print("Error: delta °K/second too big");
}
void loop() {
time = millis() / 1000;
get_temp();
Serial.print(time);
Serial.print(" ");
Serial.print(temperatur);
Serial.print(" ");
Serial.print(last_temperatur);
Serial.print(" ");
Serial.println(state);
check_dt();
if (error_condition) {
set_error_state();
}
else {
print_debug();
}
switch (state) {
case START_STATE:
Serial.println("START_STATE");
// going from room temp to preheat, nothing to check here
handle_start_state();
break;
case PREHEAT_STATE:
Serial.println("PREHEAT_STATE");
check_rampup_rate();
if (temperatur > Ts_max) {
Serial.println("Changed state to RAMP_UP_STATE");
Ts_max_time = time;
state++;
}
handle_preheat_state();
break;
case RAMP_UP_STATE:
Serial.println("RAMP_UP_STATE");
check_rampup_rate();
if (temperatur > Tl) {
Serial.println("Changed state to TAL_FIRST_STATE");
Tl_time_start = time;
state++;
}
handle_rampup_state();
break;
case TAL_FIRST_STATE:
Serial.println("TAL_FIRST_STATE");
check_rampup_rate();
if (temperatur > Tp - 5) {
Serial.println("Changed state to PEAK_STATE");
Tp_time_start = time;
state++;
}
handle_tal_first_state();
break;
case PEAK_STATE:
handle_peak_state();
break;
case TAL_SECOND_STATE:
Serial.println("TAL_SECOND_STATE");
if (temperatur < Tl) {
Serial.println("Changed state to RAMP_DOWN_STATE");
Tl_time_end = time;
state++;
}
Tl_time_end = time;
handle_tal_second_state();
break;
case RAMP_DOWN_STATE:
Serial.println("RAMP_DOWN_STATE");
if (temperatur < Ts_min) {
Serial.println("Changed state to END_STATE");
state++;
}
handle_ramp_down_state();
break;
case END_STATE:
Serial.println("END_STATE");
break;
case ERROR_STATE:
handle_error_state();
break;
default:
break;
}
control_oven();
delay(1000);
return;
error:
state = END_STATE;
Serial.print("Error: ");
Serial.println(error_condition);
}