Robotic Curtain Control

curtain.ino

// Stage Curtain Control System
//
// A Hall Effect Sensor is used to count the rotations of the drive motor. Two relays are used to power the motor on in either direction.
// Input is provided by an Up, and Down button operating on 12v DC.
// Input may be added later using WiFi, or Schedules.
//
// Author: Jason Hejna (jason.hejna@gmail.com)
// Author: Mukesh Ramani

//void count_motor_rotation(void);

SYSTEM_MODE(MANUAL);

// Define Relay Pins
int RELAY1 = D3;
int RELAY2 = D4;
//int RELAY3 = D5;
//int RELAY4 = D6;

// Define Hall Effect Pin
int HALLEFFECT = A2;

// Buttons
int UPBUTTON = D5;
int upButton;
int DOWNBUTTON = D6;
int downButton;

bool upState = false;
bool downState = false;

bool isRunning = false;

// Constants
int min_position = -5;
int max_position = 5;

// Declare Variables
int error_state = false;
int rotation_count;
int active_rotation_count;
int hallSensor = 0;
int hallState0 = 0;
int hallState1 = 0;
int hallState2 = 0;
int curtainUpDownState = -1;

// EEPROM
int addr = 25;
uint16_t initValue;
bool eeprom_write_needed = false;

ApplicationWatchdog wd(20000, System.reset);

// Serial Logging Library
//SerialLogHandler logHandler;

// Timer for detecting if Hall Effect sensor fails to detect motor rotation
//void sensor_fail_detected() {
//  Log.info("Hall Effect Sensor fail");
//  error_state = true;
//}
//
//// Interupt Timer for detecting Hall Effect sensor failure
//Timer sensor_check_timer(3000, sensor_fail_detected);
//void fall_off_timer() {
//  if (!sensor_check_timer.isActive()) {
//    sensor_check_timer.reset();
//  }
//}


void setup() {
    // connect to particle cloud
    Particle.connect();
    
    //Initilize the relay control pins as output
    pinMode(RELAY1, OUTPUT);
    pinMode(RELAY2, OUTPUT);
    //pinMode(RELAY3, OUTPUT);
    //pinMode(RELAY4, OUTPUT);
    // Initialize all relays to an OFF state
    digitalWrite(RELAY1, LOW);
    digitalWrite(RELAY2, LOW);
    //digitalWrite(RELAY3, LOW);
    //digitalWrite(RELAY4, LOW);
    //EEPROM.put(addr, 0);
    // Check EEPROM
    EEPROM.get(addr, initValue);
    if (initValue == 0xFFFF) {
      // EEPROM was empty -> initialize value
      // Assume first run and set value to 0
      // Note: recalibration required if condition met
      rotation_count = 0;
      EEPROM.put(addr, rotation_count);
      //Log.info("EEPROM is empty");
    }
    else {
      // Load rotation_count from EEPROM into memory
      EEPROM.get(addr, rotation_count);
      //Log.info("EEPROM is populated %d", rotation_count);
    }
    
    active_rotation_count = rotation_count;
    Particle.variable("active_rotation_count", active_rotation_count);
   
    // Initialize Hall Effect Sensor
    pinMode(HALLEFFECT, INPUT);
    //attachInterrupt(HALLEFFECT, count_motor_rotation, CHANGE);
    
    // Initialize Push Buttons
    pinMode(UPBUTTON, INPUT);
    pinMode(DOWNBUTTON, INPUT);
}

void loop() {
    
  // Read button values
  upButton = digitalRead(UPBUTTON);
  if (upButton) {
      if (!isRunning) {
        isRunning = true;
        System.disableUpdates();
        noInterrupts();
        curtainUpDownState = 1;
        upState = true;
      }
  }
  downButton = digitalRead(DOWNBUTTON);
  if (downButton) {
      if (!isRunning) {
        isRunning = true;
        System.disableUpdates();
        noInterrupts();
        curtainUpDownState = -1;
        downState = true;
      }
  }
  
  //if (errorState) {
  //  digitalWrite(RELAY1, LOW);
  //  digitalWrite(RELAY2, LOW);
  //}
  if (upState && downState) {
    // Error: motor cannot travel in two directions
    digitalWrite(RELAY1, LOW);
    digitalWrite(RELAY2, LOW);
    upState = false;
    downState = false;
  }
  else if(upState && rotation_count <= max_position) {
    digitalWrite(RELAY1, HIGH);
    digitalWrite(RELAY2, LOW);
    // Add timeout if no rotation is detected after n seconds
    //fall_off_timer();
  }
  else if(downState && rotation_count >= min_position) {
    digitalWrite(RELAY1, LOW);
    digitalWrite(RELAY2, HIGH);
    // Add timeout if no rotation is detected after n seconds
    //fall_off_timer();
  }
  else {
    digitalWrite(RELAY1, LOW);
    digitalWrite(RELAY2, LOW);
    upState = false;
    downState = false;
    interrupts();
    System.enableUpdates();
    Particle.process();
    // backup eeprom
    if (eeprom_write_needed) {
      // TODO: run in timeout function
      eeprom_write_needed = false;
      EEPROM.put(addr, rotation_count);
      active_rotation_count = rotation_count;
      isRunning = false;
    }
  }
  
  // Keep running count of motor rotation
  count_motor_rotation();
}

void count_motor_rotation() {
  // capture Hall Effect to count motor shaft rotations
  hallState0 = hallSensor;      // Assign value before loop
  hallSensor = digitalRead(HALLEFFECT);  // 0 is on, 1 is off
  hallState1 = hallSensor;      // Assign value after read
  if (hallState0 == 1 && hallState1 == 0 && hallState2 == 1) {
    // should be off, on, and off again to trigger an increment
    rotation_count += curtainUpDownState;
    eeprom_write_needed = true;
    //Log.info("rotations count %d", rotation_count);
    //sensor_check_timer.stop();
  }
  hallState2 = hallSensor;           // Assign value after check
}