kiln-controller-max31856/lib/oven.py

655 wiersze
22 KiB
Python

import threading
import time
import random
import datetime
import logging
import json
import config
import os
log = logging.getLogger(__name__)
class DupFilter(object):
def __init__(self):
self.msgs = set()
def filter(self, record):
rv = record.msg not in self.msgs
self.msgs.add(record.msg)
return rv
class Duplogger():
def __init__(self):
self.log = logging.getLogger("%s.dupfree" % (__name__))
dup_filter = DupFilter()
self.log.addFilter(dup_filter)
def logref(self):
return self.log
duplog = Duplogger().logref()
class Output(object):
def __init__(self):
self.active = False
self.load_libs()
def load_libs(self):
try:
import RPi.GPIO as GPIO
GPIO.setmode(GPIO.BCM)
GPIO.setwarnings(False)
GPIO.setup(config.gpio_heat, GPIO.OUT)
self.active = True
self.GPIO = GPIO
except:
msg = "Could not initialize GPIOs, oven operation will only be simulated!"
log.warning(msg)
self.active = False
def heat(self,sleepfor):
self.GPIO.output(config.gpio_heat, self.GPIO.HIGH)
time.sleep(sleepfor)
def cool(self,sleepfor):
'''no active cooling, so sleep'''
self.GPIO.output(config.gpio_heat, self.GPIO.LOW)
time.sleep(sleepfor)
# FIX - Board class needs to be completely removed
class Board(object):
def __init__(self):
self.name = None
self.active = False
self.temp_sensor = None
self.gpio_active = False
self.load_libs()
self.create_temp_sensor()
self.temp_sensor.start()
def load_libs(self):
if config.max31855:
try:
#from max31855 import MAX31855, MAX31855Error
self.name='MAX31855'
self.active = True
log.info("import %s " % (self.name))
except ImportError:
msg = "max31855 config set, but import failed"
log.warning(msg)
if config.max31856:
try:
#from max31856 import MAX31856, MAX31856Error
self.name='MAX31856'
self.active = True
log.info("import %s " % (self.name))
except ImportError:
msg = "max31856 config set, but import failed"
log.warning(msg)
def create_temp_sensor(self):
if config.simulate == True:
self.temp_sensor = TempSensorSimulate()
else:
self.temp_sensor = TempSensorReal()
class BoardSimulated(object):
def __init__(self):
self.temp_sensor = TempSensorSimulated()
class TempSensor(threading.Thread):
def __init__(self):
threading.Thread.__init__(self)
self.daemon = True
self.temperature = 0
self.bad_percent = 0
self.time_step = config.sensor_time_wait
self.noConnection = self.shortToGround = self.shortToVCC = self.unknownError = False
class TempSensorSimulated(TempSensor):
'''not much here, just need to be able to set the temperature'''
def __init__(self):
TempSensor.__init__(self)
class TempSensorReal(TempSensor):
'''real temperature sensor thread that takes N measurements
during the time_step'''
def __init__(self):
TempSensor.__init__(self)
self.sleeptime = self.time_step / float(config.temperature_average_samples)
self.bad_count = 0
self.ok_count = 0
self.bad_stamp = 0
if config.max31855:
log.info("init MAX31855")
from max31855 import MAX31855, MAX31855Error
self.thermocouple = MAX31855(config.gpio_sensor_cs,
config.gpio_sensor_clock,
config.gpio_sensor_data,
config.temp_scale)
if config.max31856:
log.info("init MAX31856")
from max31856 import MAX31856
software_spi = { 'cs': config.gpio_sensor_cs,
'clk': config.gpio_sensor_clock,
'do': config.gpio_sensor_data,
'di': config.gpio_sensor_di }
self.thermocouple = MAX31856(tc_type=config.thermocouple_type,
software_spi = software_spi,
units = config.temp_scale,
ac_freq_50hz = config.ac_freq_50hz,
)
def run(self):
'''use a moving average of config.temperature_average_samples across the time_step'''
temps = []
while True:
# reset error counter if time is up
if (time.time() - self.bad_stamp) > (self.time_step * 2):
if self.bad_count + self.ok_count:
self.bad_percent = (self.bad_count / (self.bad_count + self.ok_count)) * 100
else:
self.bad_percent = 0
self.bad_count = 0
self.ok_count = 0
self.bad_stamp = time.time()
temp = self.thermocouple.get()
self.noConnection = self.thermocouple.noConnection
self.shortToGround = self.thermocouple.shortToGround
self.shortToVCC = self.thermocouple.shortToVCC
self.unknownError = self.thermocouple.unknownError
is_bad_value = self.noConnection | self.unknownError
if not config.ignore_tc_short_errors:
is_bad_value |= self.shortToGround | self.shortToVCC
if not is_bad_value:
temps.append(temp)
if len(temps) > config.temperature_average_samples:
del temps[0]
self.ok_count += 1
else:
log.error("Problem reading temp N/C:%s GND:%s VCC:%s ???:%s" % (self.noConnection,self.shortToGround,self.shortToVCC,self.unknownError))
self.bad_count += 1
if len(temps):
self.temperature = self.get_avg_temp(temps)
time.sleep(self.sleeptime)
def get_avg_temp(self, temps, chop=25):
'''
strip off chop percent from the beginning and end of the sorted temps
then return the average of what is left
'''
chop = chop / 100
temps = sorted(temps)
total = len(temps)
items = int(total*chop)
temps = temps[items:total-items]
return sum(temps) / len(temps)
class Oven(threading.Thread):
'''parent oven class. this has all the common code
for either a real or simulated oven'''
def __init__(self):
threading.Thread.__init__(self)
self.daemon = True
self.temperature = 0
self.time_step = config.sensor_time_wait
self.reset()
def reset(self):
self.cost = 0
self.state = "IDLE"
self.profile = None
self.start_time = 0
self.runtime = 0
self.totaltime = 0
self.target = 0
self.heat = 0
self.pid = PID(ki=config.pid_ki, kd=config.pid_kd, kp=config.pid_kp)
def run_profile(self, profile, startat=0):
self.reset()
if self.board.temp_sensor.noConnection:
log.info("Refusing to start profile - thermocouple not connected")
return
if self.board.temp_sensor.shortToGround:
log.info("Refusing to start profile - thermocouple short to ground")
return
if self.board.temp_sensor.shortToVCC:
log.info("Refusing to start profile - thermocouple short to VCC")
return
if self.board.temp_sensor.unknownError:
log.info("Refusing to start profile - thermocouple unknown error")
return
self.startat = startat * 60
self.runtime = self.startat
self.start_time = datetime.datetime.now() - datetime.timedelta(seconds=self.startat)
self.profile = profile
self.totaltime = profile.get_duration()
self.state = "RUNNING"
log.info("Running schedule %s starting at %d minutes" % (profile.name,startat))
log.info("Starting")
def abort_run(self):
self.reset()
self.save_automatic_restart_state()
def kiln_must_catch_up(self):
'''shift the whole schedule forward in time by one time_step
to wait for the kiln to catch up'''
if config.kiln_must_catch_up == True:
temp = self.board.temp_sensor.temperature + \
config.thermocouple_offset
# kiln too cold, wait for it to heat up
if self.target - temp > config.pid_control_window:
log.info("kiln must catch up, too cold, shifting schedule")
self.start_time = datetime.datetime.now() - datetime.timedelta(milliseconds = self.runtime * 1000)
# kiln too hot, wait for it to cool down
if temp - self.target > config.pid_control_window:
log.info("kiln must catch up, too hot, shifting schedule")
self.start_time = datetime.datetime.now() - datetime.timedelta(milliseconds = self.runtime * 1000)
def update_runtime(self):
runtime_delta = datetime.datetime.now() - self.start_time
if runtime_delta.total_seconds() < 0:
runtime_delta = datetime.timedelta(0)
self.runtime = runtime_delta.total_seconds()
def update_target_temp(self):
self.target = self.profile.get_target_temperature(self.runtime)
def reset_if_emergency(self):
'''reset if the temperature is way TOO HOT, or other critical errors detected'''
if (self.board.temp_sensor.temperature + config.thermocouple_offset >=
config.emergency_shutoff_temp):
log.info("emergency!!! temperature too high")
if config.ignore_temp_too_high == False:
self.abort_run()
if self.board.temp_sensor.noConnection:
log.info("emergency!!! lost connection to thermocouple")
if config.ignore_lost_connection_tc == False:
self.abort_run()
if self.board.temp_sensor.unknownError:
log.info("emergency!!! unknown thermocouple error")
if config.ignore_unknown_tc_error == False:
self.abort_run()
if self.board.temp_sensor.bad_percent > 30:
log.info("emergency!!! too many errors in a short period")
if config.ignore_too_many_tc_errors == False:
self.abort_run()
def reset_if_schedule_ended(self):
if self.runtime > self.totaltime:
log.info("schedule ended, shutting down")
log.info("total cost = %s%.2f" % (config.currency_type,self.cost))
self.abort_run()
def update_cost(self):
if self.heat:
cost = (config.kwh_rate * config.kw_elements) * ((self.heat)/3600)
else:
cost = 0
self.cost = self.cost + cost
def get_state(self):
temp = 0
try:
temp = self.board.temp_sensor.temperature + config.thermocouple_offset
except AttributeError as error:
# this happens at start-up with a simulated oven
temp = 0
pass
state = {
'cost': self.cost,
'runtime': self.runtime,
'temperature': temp,
'target': self.target,
'state': self.state,
'heat': self.heat,
'totaltime': self.totaltime,
'kwh_rate': config.kwh_rate,
'currency_type': config.currency_type,
'profile': self.profile.name if self.profile else None,
'pidstats': self.pid.pidstats,
}
return state
def save_state(self):
with open(config.automatic_restart_state_file, 'w', encoding='utf-8') as f:
json.dump(self.get_state(), f, ensure_ascii=False, indent=4)
def state_file_is_old(self):
'''returns True is state files is older than 15 mins default
False if younger
True if state file cannot be opened or does not exist
'''
if os.path.isfile(config.automatic_restart_state_file):
state_age = os.path.getmtime(config.automatic_restart_state_file)
now = time.time()
minutes = (now - state_age)/60
if(minutes <= config.automatic_restart_window):
return False
return True
def save_automatic_restart_state(self):
# only save state if the feature is enabled
if not config.automatic_restarts == True:
return False
self.save_state()
def should_i_automatic_restart(self):
# only automatic restart if the feature is enabled
if not config.automatic_restarts == True:
return False
if self.state_file_is_old():
duplog.info("automatic restart not possible. state file does not exist or is too old.")
return False
with open(config.automatic_restart_state_file) as infile:
d = json.load(infile)
if d["state"] != "RUNNING":
duplog.info("automatic restart not possible. state = %s" % (d["state"]))
return False
return True
def automatic_restart(self):
with open(config.automatic_restart_state_file) as infile: d = json.load(infile)
startat = d["runtime"]/60
filename = "%s.json" % (d["profile"])
profile_path = os.path.abspath(os.path.join(os.path.dirname( __file__ ), '..', 'storage','profiles',filename))
log.info("automatically restarting profile = %s at minute = %d" % (profile_path,startat))
with open(profile_path) as infile:
profile_json = json.dumps(json.load(infile))
profile = Profile(profile_json)
self.run_profile(profile,startat=startat)
self.cost = d["cost"]
time.sleep(1)
self.ovenwatcher.record(profile)
def set_ovenwatcher(self,watcher):
log.info("ovenwatcher set in oven class")
self.ovenwatcher = watcher
def run(self):
while True:
if self.state == "IDLE":
if self.should_i_automatic_restart() == True:
self.automatic_restart()
time.sleep(1)
continue
if self.state == "RUNNING":
self.update_cost()
self.save_automatic_restart_state()
self.kiln_must_catch_up()
self.update_runtime()
self.update_target_temp()
self.heat_then_cool()
self.reset_if_emergency()
self.reset_if_schedule_ended()
class SimulatedOven(Oven):
def __init__(self):
self.board = BoardSimulated()
self.t_env = config.sim_t_env
self.c_heat = config.sim_c_heat
self.c_oven = config.sim_c_oven
self.p_heat = config.sim_p_heat
self.R_o_nocool = config.sim_R_o_nocool
self.R_ho_noair = config.sim_R_ho_noair
self.R_ho = self.R_ho_noair
# set temps to the temp of the surrounding environment
self.t = self.t_env # deg C temp of oven
self.t_h = self.t_env #deg C temp of heating element
super().__init__()
# start thread
self.start()
log.info("SimulatedOven started")
def heating_energy(self,pid):
# using pid here simulates the element being on for
# only part of the time_step
self.Q_h = self.p_heat * self.time_step * pid
def temp_changes(self):
#temperature change of heat element by heating
self.t_h += self.Q_h / self.c_heat
#energy flux heat_el -> oven
self.p_ho = (self.t_h - self.t) / self.R_ho
#temperature change of oven and heating element
self.t += self.p_ho * self.time_step / self.c_oven
self.t_h -= self.p_ho * self.time_step / self.c_heat
#temperature change of oven by cooling to environment
self.p_env = (self.t - self.t_env) / self.R_o_nocool
self.t -= self.p_env * self.time_step / self.c_oven
self.temperature = self.t
self.board.temp_sensor.temperature = self.t
def heat_then_cool(self):
pid = self.pid.compute(self.target,
self.board.temp_sensor.temperature +
config.thermocouple_offset)
heat_on = float(self.time_step * pid)
heat_off = float(self.time_step * (1 - pid))
self.heating_energy(pid)
self.temp_changes()
# self.heat is for the front end to display if the heat is on
self.heat = 0.0
if heat_on > 0:
self.heat = heat_on
log.info("simulation: -> %dW heater: %.0f -> %dW oven: %.0f -> %dW env" % (int(self.p_heat * pid),
self.t_h,
int(self.p_ho),
self.t,
int(self.p_env)))
time_left = self.totaltime - self.runtime
try:
log.info("temp=%.2f, target=%.2f, error=%.2f, pid=%.2f, p=%.2f, i=%.2f, d=%.2f, heat_on=%.2f, heat_off=%.2f, run_time=%d, total_time=%d, time_left=%d" %
(self.pid.pidstats['ispoint'],
self.pid.pidstats['setpoint'],
self.pid.pidstats['err'],
self.pid.pidstats['pid'],
self.pid.pidstats['p'],
self.pid.pidstats['i'],
self.pid.pidstats['d'],
heat_on,
heat_off,
self.runtime,
self.totaltime,
time_left))
except KeyError:
pass
# we don't actually spend time heating & cooling during
# a simulation, so sleep.
time.sleep(self.time_step)
class RealOven(Oven):
def __init__(self):
self.board = Board()
self.output = Output()
self.reset()
# call parent init
Oven.__init__(self)
# start thread
self.start()
def reset(self):
super().reset()
self.output.cool(0)
def heat_then_cool(self):
pid = self.pid.compute(self.target,
self.board.temp_sensor.temperature +
config.thermocouple_offset)
heat_on = float(self.time_step * pid)
heat_off = float(self.time_step * (1 - pid))
# self.heat is for the front end to display if the heat is on
self.heat = 0.0
if heat_on > 0:
self.heat = 1.0
if heat_on:
self.output.heat(heat_on)
if heat_off:
self.output.cool(heat_off)
time_left = self.totaltime - self.runtime
try:
log.info("temp=%.2f, target=%.2f, error=%.2f, pid=%.2f, p=%.2f, i=%.2f, d=%.2f, heat_on=%.2f, heat_off=%.2f, run_time=%d, total_time=%d, time_left=%d" %
(self.pid.pidstats['ispoint'],
self.pid.pidstats['setpoint'],
self.pid.pidstats['err'],
self.pid.pidstats['pid'],
self.pid.pidstats['p'],
self.pid.pidstats['i'],
self.pid.pidstats['d'],
heat_on,
heat_off,
self.runtime,
self.totaltime,
time_left))
except KeyError:
pass
class Profile():
def __init__(self, json_data):
obj = json.loads(json_data)
self.name = obj["name"]
self.data = sorted(obj["data"])
def get_duration(self):
return max([t for (t, x) in self.data])
def get_surrounding_points(self, time):
if time > self.get_duration():
return (None, None)
prev_point = None
next_point = None
for i in range(len(self.data)):
if time < self.data[i][0]:
prev_point = self.data[i-1]
next_point = self.data[i]
break
return (prev_point, next_point)
def get_target_temperature(self, time):
if time > self.get_duration():
return 0
(prev_point, next_point) = self.get_surrounding_points(time)
incl = float(next_point[1] - prev_point[1]) / float(next_point[0] - prev_point[0])
temp = prev_point[1] + (time - prev_point[0]) * incl
return temp
class PID():
def __init__(self, ki=1, kp=1, kd=1):
self.ki = ki
self.kp = kp
self.kd = kd
self.lastNow = datetime.datetime.now()
self.iterm = 0
self.lastErr = 0
self.pidstats = {}
# FIX - this was using a really small window where the PID control
# takes effect from -1 to 1. I changed this to various numbers and
# settled on -50 to 50 and then divide by 50 at the end. This results
# in a larger PID control window and much more accurate control...
# instead of what used to be binary on/off control.
def compute(self, setpoint, ispoint):
now = datetime.datetime.now()
timeDelta = (now - self.lastNow).total_seconds()
window_size = 100
error = float(setpoint - ispoint)
# this removes the need for config.stop_integral_windup
# it turns the controller into a binary on/off switch
# any time it's outside the window defined by
# config.pid_control_window
icomp = 0
output = 0
out4logs = 0
dErr = 0
if error < (-1 * config.pid_control_window):
log.info("kiln outside pid control window, max cooling")
output = 0
# it is possible to set self.iterm=0 here and also below
# but I dont think its needed
elif error > (1 * config.pid_control_window):
log.info("kiln outside pid control window, max heating")
output = 1
else:
icomp = (error * timeDelta * (1/self.ki))
self.iterm += (error * timeDelta * (1/self.ki))
dErr = (error - self.lastErr) / timeDelta
output = self.kp * error + self.iterm + self.kd * dErr
output = sorted([-1 * window_size, output, window_size])[1]
out4logs = output
output = float(output / window_size)
self.lastErr = error
self.lastNow = now
# no active cooling
if output < 0:
output = 0
self.pidstats = {
'time': time.mktime(now.timetuple()),
'timeDelta': timeDelta,
'setpoint': setpoint,
'ispoint': ispoint,
'err': error,
'errDelta': dErr,
'p': self.kp * error,
'i': self.iterm,
'd': self.kd * dErr,
'kp': self.kp,
'ki': self.ki,
'kd': self.kd,
'pid': out4logs,
'out': output,
}
return output