#include #include static const uint8_t GAUGE_COUNT = 2; // For now: commands come over USB serial #define CMD_PORT Serial #define DEBUG_PORT Serial struct GaugePins { uint8_t dirPin; uint8_t stepPin; int8_t enablePin; // -1 if unused bool dirInverted; bool stepActiveHigh; bool enableActiveLow; }; GaugePins gaugePins[GAUGE_COUNT] = { // dir, step, en, dirInv, stepHigh, enActiveLow {50, 51, -1, false, true, true}, // Gauge 0 {8, 9, -1, true, true, true}, // Gauge 1 }; enum HomingState : uint8_t { HS_IDLE, HS_START, HS_BACKING, HS_SETTLE, HS_DONE }; struct Gauge { long currentPos = 0; long targetPos = 0; long minPos = 0; long maxPos = 3610; // adjust to your usable travel long homingBackoffSteps = 3700; // should exceed reverse travel slightly float velocity = 0.0f; float maxSpeed = 8000.0f; float accel = 9000.0f; float homingSpeed = 500.0f; float stepAccumulator = 0.0f; unsigned long lastUpdateMicros = 0; bool enabled = true; bool homed = false; HomingState homingState = HS_IDLE; long homingStepsRemaining = 0; unsigned long homingLastStepMicros = 0; unsigned long homingStateStartMs = 0; bool sweepEnabled = false; bool sweepTowardMax = true; }; Gauge gauges[GAUGE_COUNT]; String rxLine; void sendReply(const String& s) { CMD_PORT.println(s); } float absf(float x) { return (x < 0.0f) ? -x : x; } void setEnable(uint8_t id, bool en) { if (id >= GAUGE_COUNT) return; gauges[id].enabled = en; int8_t pin = gaugePins[id].enablePin; if (pin < 0) return; bool level = gaugePins[id].enableActiveLow ? !en : en; digitalWrite(pin, level ? HIGH : LOW); } void setDir(uint8_t id, bool forward) { bool level = gaugePins[id].dirInverted ? !forward : forward; digitalWrite(gaugePins[id].dirPin, level ? HIGH : LOW); } void pulseStep(uint8_t id) { bool active = gaugePins[id].stepActiveHigh; digitalWrite(gaugePins[id].stepPin, active ? HIGH : LOW); delayMicroseconds(4); digitalWrite(gaugePins[id].stepPin, active ? LOW : HIGH); } void doStep(uint8_t id, int dir, bool allowPastMin = false) { Gauge& g = gauges[id]; if (!g.enabled) return; if (dir > 0) { if (g.currentPos >= g.maxPos) return; setDir(id, true); pulseStep(id); g.currentPos++; } else if (dir < 0) { if (!allowPastMin && g.currentPos <= g.minPos) return; setDir(id, false); pulseStep(id); g.currentPos--; } } void requestHome(uint8_t id) { if (id >= GAUGE_COUNT) return; Gauge& g = gauges[id]; g.homingState = HS_START; g.homed = false; g.velocity = 0.0f; g.stepAccumulator = 0.0f; g.sweepEnabled = false; } void requestHomeAll() { for (uint8_t i = 0; i < GAUGE_COUNT; i++) { requestHome(i); } } void updateHoming(uint8_t id) { Gauge& g = gauges[id]; unsigned long nowUs = micros(); unsigned long nowMs = millis(); switch (g.homingState) { case HS_IDLE: return; case HS_START: g.velocity = 0.0f; g.stepAccumulator = 0.0f; g.homingStepsRemaining = g.homingBackoffSteps; g.homingLastStepMicros = nowUs; g.homingState = HS_BACKING; break; case HS_BACKING: { float intervalUs = 1000000.0f / g.homingSpeed; if ((nowUs - g.homingLastStepMicros) >= intervalUs) { g.homingLastStepMicros = nowUs; if (g.homingStepsRemaining > 0) { doStep(id, -1, true); g.homingStepsRemaining--; } else { g.homingState = HS_SETTLE; g.homingStateStartMs = nowMs; } } break; } case HS_SETTLE: if (nowMs - g.homingStateStartMs >= 100) { g.currentPos = 0; g.targetPos = 0; g.velocity = 0.0f; g.stepAccumulator = 0.0f; g.homed = true; g.homingState = HS_DONE; DEBUG_PORT.print("HOMED "); DEBUG_PORT.println(id); } break; case HS_DONE: g.homingState = HS_IDLE; break; } } void updateSweepTarget(uint8_t id) { Gauge& g = gauges[id]; if (!g.sweepEnabled || !g.homed || g.homingState != HS_IDLE) return; if (g.sweepTowardMax) { g.targetPos = g.maxPos; if (g.currentPos >= g.maxPos && absf(g.velocity) < 1.0f) { g.sweepTowardMax = false; g.targetPos = g.minPos; } } else { g.targetPos = g.minPos; if (g.currentPos <= g.minPos && absf(g.velocity) < 1.0f) { g.sweepTowardMax = true; g.targetPos = g.maxPos; } } } void updateGauge(uint8_t id) { Gauge& g = gauges[id]; if (g.homingState != HS_IDLE) { updateHoming(id); return; } if (!g.homed) return; if (g.sweepEnabled) { updateSweepTarget(id); } unsigned long now = micros(); if (g.lastUpdateMicros == 0) { g.lastUpdateMicros = now; return; } float dt = (now - g.lastUpdateMicros) / 1000000.0f; g.lastUpdateMicros = now; if (dt <= 0.0f || dt > 0.1f) return; long error = g.targetPos - g.currentPos; if (error == 0 && absf(g.velocity) < 0.01f) { g.velocity = 0.0f; g.stepAccumulator = 0.0f; return; } float dir = (error > 0) ? 1.0f : (error < 0 ? -1.0f : 0.0f); float brakingDistance = (g.velocity * g.velocity) / (2.0f * g.accel + 0.0001f); if ((float)labs(error) <= brakingDistance) { if (g.velocity > 0.0f) { g.velocity -= g.accel * dt; if (g.velocity < 0.0f) g.velocity = 0.0f; } else if (g.velocity < 0.0f) { g.velocity += g.accel * dt; if (g.velocity > 0.0f) g.velocity = 0.0f; } } else { g.velocity += dir * g.accel * dt; if (g.velocity > g.maxSpeed) g.velocity = g.maxSpeed; if (g.velocity < -g.maxSpeed) g.velocity = -g.maxSpeed; } if (fabs(g.velocity) < 0.01f && error != 0) { g.velocity = dir * 5.0f; } g.stepAccumulator += g.velocity * dt; while (g.stepAccumulator >= 1.0f) { if (g.currentPos == g.targetPos) { g.stepAccumulator = 0.0f; g.velocity = 0.0f; break; } doStep(id, +1, false); g.stepAccumulator -= 1.0f; if (g.currentPos >= g.maxPos) { g.currentPos = g.maxPos; g.targetPos = g.maxPos; g.velocity = 0.0f; g.stepAccumulator = 0.0f; break; } } while (g.stepAccumulator <= -1.0f) { if (g.currentPos == g.targetPos) { g.stepAccumulator = 0.0f; g.velocity = 0.0f; break; } doStep(id, -1, false); g.stepAccumulator += 1.0f; if (g.currentPos <= g.minPos) { g.currentPos = g.minPos; g.targetPos = g.minPos; g.velocity = 0.0f; g.stepAccumulator = 0.0f; break; } } } bool parseSet(const String& line) { int id; long pos; if (sscanf(line.c_str(), "SET %d %ld", &id, &pos) == 2) { if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } Gauge& g = gauges[id]; pos = constrain(pos, g.minPos, g.maxPos); g.targetPos = pos; g.sweepEnabled = false; sendReply("OK"); return true; } return false; } bool parseSpeed(const String& line) { int firstSpace = line.indexOf(' '); int secondSpace = line.indexOf(' ', firstSpace + 1); if (firstSpace < 0 || secondSpace < 0) return false; if (line.substring(0, firstSpace) != "SPEED") return false; int id = line.substring(firstSpace + 1, secondSpace).toInt(); float speed = line.substring(secondSpace + 1).toFloat(); if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } if (speed <= 0.0f) { sendReply("ERR BAD_SPEED"); return true; } gauges[id].maxSpeed = speed; sendReply("OK"); return true; } bool parseAccel(const String& line) { int firstSpace = line.indexOf(' '); int secondSpace = line.indexOf(' ', firstSpace + 1); if (firstSpace < 0 || secondSpace < 0) return false; if (line.substring(0, firstSpace) != "ACCEL") return false; int id = line.substring(firstSpace + 1, secondSpace).toInt(); float accel = line.substring(secondSpace + 1).toFloat(); if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } if (accel <= 0.0f) { sendReply("ERR BAD_ACCEL"); return true; } gauges[id].accel = accel; sendReply("OK"); return true; } bool parseEnable(const String& line) { int id, en; if (sscanf(line.c_str(), "ENABLE %d %d", &id, &en) == 2) { if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } setEnable(id, en != 0); sendReply("OK"); return true; } return false; } bool parseZero(const String& line) { int id; if (sscanf(line.c_str(), "ZERO %d", &id) == 1) { if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } Gauge& g = gauges[id]; g.currentPos = 0; g.targetPos = 0; g.velocity = 0.0f; g.stepAccumulator = 0.0f; g.homed = true; g.sweepEnabled = false; sendReply("OK"); return true; } return false; } bool parseHome(const String& line) { int id; if (sscanf(line.c_str(), "HOME %d", &id) == 1) { if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } requestHome(id); sendReply("OK"); return true; } if (line == "HOMEALL") { requestHomeAll(); sendReply("OK"); return true; } return false; } bool parseSweep(const String& line) { int firstSpace = line.indexOf(' '); int secondSpace = line.indexOf(' ', firstSpace + 1); int thirdSpace = line.indexOf(' ', secondSpace + 1); if (firstSpace < 0 || secondSpace < 0 || thirdSpace < 0) return false; if (line.substring(0, firstSpace) != "SWEEP") return false; int id = line.substring(firstSpace + 1, secondSpace).toInt(); float accel = line.substring(secondSpace + 1, thirdSpace).toFloat(); float speed = line.substring(thirdSpace + 1).toFloat(); if (id < 0 || id >= GAUGE_COUNT) { sendReply("ERR BAD_ID"); return true; } Gauge& g = gauges[id]; if (accel <= 0.0f || speed <= 0.0f) { g.sweepEnabled = false; g.velocity = 0.0f; g.stepAccumulator = 0.0f; sendReply("OK"); return true; } g.accel = accel; g.maxSpeed = speed; g.sweepEnabled = true; g.sweepTowardMax = true; g.targetPos = g.maxPos; sendReply("OK"); return true; } bool parsePosQuery(const String& line) { if (line == "POS?") { for (uint8_t i = 0; i < GAUGE_COUNT; i++) { CMD_PORT.print("POS "); CMD_PORT.print(i); CMD_PORT.print(' '); CMD_PORT.print(gauges[i].currentPos); CMD_PORT.print(' '); CMD_PORT.print(gauges[i].targetPos); CMD_PORT.print(' '); CMD_PORT.print(gauges[i].homed ? 1 : 0); CMD_PORT.print(' '); CMD_PORT.print((int)gauges[i].homingState); CMD_PORT.print(' '); CMD_PORT.println(gauges[i].sweepEnabled ? 1 : 0); } return true; } return false; } bool parsePing(const String& line) { if (line == "PING") { sendReply("PONG"); return true; } return false; } void processLine(const String& line) { if (parseSet(line)) return; if (parseSpeed(line)) return; if (parseAccel(line)) return; if (parseEnable(line)) return; if (parseZero(line)) return; if (parseHome(line)) return; if (parseSweep(line)) return; if (parsePosQuery(line)) return; if (parsePing(line)) return; sendReply("ERR BAD_CMD"); } void readCommands() { while (CMD_PORT.available()) { char c = (char)CMD_PORT.read(); if (c == '\n') { rxLine.trim(); if (rxLine.length() > 0) { processLine(rxLine); } rxLine = ""; } else if (c != '\r') { rxLine += c; if (rxLine.length() > 120) { rxLine = ""; } } } } void setup() { DEBUG_PORT.begin(115200); DEBUG_PORT.println("Gauge controller booting"); for (uint8_t i = 0; i < GAUGE_COUNT; i++) { pinMode(gaugePins[i].dirPin, OUTPUT); pinMode(gaugePins[i].stepPin, OUTPUT); digitalWrite(gaugePins[i].dirPin, LOW); digitalWrite(gaugePins[i].stepPin, gaugePins[i].stepActiveHigh ? LOW : HIGH); if (gaugePins[i].enablePin >= 0) { pinMode(gaugePins[i].enablePin, OUTPUT); setEnable(i, true); } gauges[i].lastUpdateMicros = micros(); } requestHomeAll(); DEBUG_PORT.println("READY"); sendReply("READY"); } void loop() { readCommands(); for (uint8_t i = 0; i < GAUGE_COUNT; i++) { updateGauge(i); } }