SMD Reflow Hot Plate (new version)

/**************************************************************************
 SMD Hot Plate

 2022-09-09 John Bradnam (jbrad2089@gmail.com)
   V1: Create program for ATtiny1614
   V2: Added PID code from electronoobs
       Added Ambient temperature support
   v3: Upgraded CPU to ATtiny3224
       Removed Ambient temperature sensor
       Fan only switches on for cooling

 --------------------------------------------------------------------------
 Arduino IDE:
 --------------------------------------------------------------------------
  BOARD: ATtiny1614/1604/814/804/414/404/214/204
  Chip: ATtiny1614
  Clock Speed: 20MHz
  millis()/micros(): "Enabled (default timer)"
  Programmer: jtag2updi (megaTinyCore)

  ATTiny1614 Pins mapped to Ardunio Pins
 
              +--------+
          VCC + 1   14 + GND
  (SS)  0 PA4 + 2   13 + PA3 10 (SCK)
        1 PA5 + 3   12 + PA2 9  (MISO)
  (DAC) 2 PA6 + 4   11 + PA1 8  (MOSI)
        3 PA7 + 5   10 + PA0 11 (UPDI)
  (RXD) 4 PB3 + 6    9 + PB0 7  (SCL)
  (TXD) 5 PB2 + 7    8 + PB1 6  (SDA)
              +--------+
  
 **************************************************************************/


#include <Adafruit_GFX.h>    // Core graphics library
#include <Adafruit_ST7735.h> // Hardware-specific library
#include <SPI.h>
#include <thermistor.h>      //http://electronoobs.com/eng_arduino_thermistor.php

#define TFT_SCK 10    //PA3
#define TFT_MISO 9    //PA2
#define TFT_MOSI 8    //PA1
#define TFT_CS 0      //PA4
#define TFT_DC 4      //PB3
#define TFT_RST -1    //Not connected

#define TEMP_PIN 3    //PA7
#define HEAT_PIN 1    //PA5
#define FAN_PIN 5     //PB2
#define SWITCHES 6    //PB1
#define SPEAKER 7     //PB0

enum SWITCH {NONE, SELECT, START};
enum MODE {STOP, RUN, PAUSE};

#define EPSILON 2                 //Degrees from required to current before reacting
thermistor therm(TEMP_PIN,0);     //PA7 has 3950 Thermistor

Adafruit_ST7735 tft = Adafruit_ST7735(TFT_CS, TFT_DC, TFT_RST);

#define STATUS_VALUE_X 4
#define TEMP_VALUE_X 64
#define TIME_VALUE_X 124
#define PROMPT_Y 116

#define GRAPH_X_MIN 22
#define GRAPH_X_DIV 8
#define GRAPH_X_GAP 15
#define GRAPH_X_TEXT 0
#define GRAPH_X_MAX (GRAPH_X_MIN + (GRAPH_X_DIV * GRAPH_X_GAP))
#define GRAPH_Y_MIN 92
#define GRAPH_Y_DIV 6
#define GRAPH_Y_GAP 15
#define GRAPH_Y_TEXT (GRAPH_Y_MIN + 5)
#define GRAPH_Y_MAX (GRAPH_Y_MIN - (GRAPH_Y_DIV * GRAPH_Y_GAP))

#define TABLES_IN_DATA_SPACE

typedef struct {
  int temp;     //Temperature to reach
  int period;   //Seconds to reach temperature
} TARGET;

#define NUMBER_OF_PERIODS 6
#ifdef TABLES_IN_DATA_SPACE
  const TARGET plot1[NUMBER_OF_PERIODS] = {{150,90},{150,180},{240,240},{240,260},{0,420},{0,0}};
  const TARGET plot2[NUMBER_OF_PERIODS] = {{150,50},{180,140},{240,175},{240,185},{120,250},{0,350}};
  const TARGET plot3[NUMBER_OF_PERIODS] = {{150,60},{200,120},{250,160},{250,190},{0,260},{0,0}};
#else
  const TARGET plot1[NUMBER_OF_PERIODS] PROGMEM = {{150,90},{150,180},{240,240},{240,260},{0,420},{0,0}};
  const TARGET plot2[NUMBER_OF_PERIODS] PROGMEM = {{150,50},{180,140},{240,175},{240,185},{120,250},{0,350}};
  const TARGET plot3[NUMBER_OF_PERIODS] PROGMEM = {{150,60},{200,120},{250,160},{250,190},{0,260},{0,0}};
#endif


#define NUMBER_OF_PLOTS 3
const TARGET* plots[NUMBER_OF_PLOTS] = {plot1, plot2, plot3};

volatile unsigned int minutes;  // In minutes
volatile unsigned int seconds;  // In seconds
volatile bool updateDisplay;    // Force display update
int currentPlot;                // Currently selected heating plot
float temperature;              // Current temperature
float ambient = 50.0;           // ambient temperature min
float cool = 45.0;              // Cool down temperature min
volatile MODE currentMode;      // Current mode
char buf[16];                   // Used to format strings

/////////////////////PID VARIABLES///////////////////////
#define PID_REFRESH_RATE 50
#define MIN_PID_VALUE 0
#define MAX_PID_VALUE 255       //Max PID value. You can change this. 
uint32_t pidTimeout = 0;        //Used to hold next PID period

float Kp = 4;                   //Mine was 2 - How fast the system responds (too high cause overshoot)
float Ki = 0.0025;              //Mine was 0.0025 - How fast the steady state error is removed
float Kd = 9;                   //Mine was 9 - How far into the future to predict the rate of change
float PID_Output = 0;
float PID_P, PID_I, PID_D;
float PID_ERROR, PREV_ERROR;
/////////////////////////////////////////////////////////

//---------------------------------------------------
// Hardware setup
void setup(void) 
{
  pinMode(TEMP_PIN, INPUT);
  pinMode(HEAT_PIN, OUTPUT);
  digitalWrite(HEAT_PIN, LOW);
  pinMode(FAN_PIN, OUTPUT);
  analogWrite(FAN_PIN, 0);
  pinMode(SWITCHES, INPUT);
  pinMode(SPEAKER, OUTPUT);
  digitalWrite(SPEAKER, LOW);

  // If your TFT's plastic wrap has a Black Tab, use the following:
  tft.initR(INITR_BLACKTAB);   // initialize a ST7735S chip, black tab
  // If your TFT's plastic wrap has a Red Tab, use the following:
  //tft.initR(INITR_REDTAB);   // initialize a ST7735R chip, red tab
  // If your TFT's plastic wrap has a Green Tab, use the following:
  //tft.initR(INITR_GREENTAB); // initialize a ST7735R chip, green tab
  
  currentMode = STOP;
  minutes = 0;
  seconds = 0;
  RTCSetup();
  updateDisplay = true;

  tft.setTextWrap(false); // Allow text to run off right edge
  tft.fillScreen(ST7735_BLACK);
  tft.setRotation(3);
  tft.setTextSize(1);
  tft.setTextColor(ST7735_WHITE, ST7735_BLACK);

  drawGraphFrame();

  updateDisplay = true;
  currentPlot = 0;
  plotGraph(currentPlot);
}

//---------------------------------------------------
// Primary loop
void loop(void) 
{
  if (millis() > pidTimeout)
  {
    pidTimeout = millis() + PID_REFRESH_RATE; 
    temperature = therm.analog2temp();
    if (currentMode == RUN || currentMode == PAUSE)
    {
      int s = minutes * 60 + seconds;
      int t = timeToTemperature(currentPlot, s);
      if (s != 0 && t == 0)
      {
        digitalWrite(FAN_PIN, HIGH);
        if (temperature <= cool)
        {
          //Finished
          digitalWrite(HEAT_PIN, LOW);
          digitalWrite(FAN_PIN, LOW);
          currentMode = STOP;
          digitalWrite(SPEAKER, HIGH);
          delay(2000);
          digitalWrite(SPEAKER, LOW);
        }
      }
      else
      {
        //Calculate PID
        PID_ERROR = t - temperature;
        PID_P = Kp*PID_ERROR;
        PID_I = PID_I+(Ki*PID_ERROR);      
        PID_D = Kd * (PID_ERROR-PREV_ERROR);
        PID_Output = max(min(PID_P + PID_I + PID_D, MAX_PID_VALUE), MIN_PID_VALUE);
        analogWrite(HEAT_PIN, PID_Output);  //Change the Duty Cycle applied to the SSR
        PREV_ERROR = PID_ERROR;

        //switch on fan if not heating
        digitalWrite(FAN_PIN, (temperature >= ambient && PID_Output == MIN_PID_VALUE) ? HIGH : LOW);
      }
    }
    else
    {
      //switch on fan while paused or stopped if temp more than cool down
      digitalWrite(FAN_PIN, (temperature >= ambient) ? HIGH : LOW);
    }
  }
  
  if (updateDisplay)
  {
    updateDisplay = false;

    //Status
    tft.setTextColor(ST7735_YELLOW, ST7735_BLACK);
    tft.setCursor(STATUS_VALUE_X, PROMPT_Y);
    switch(currentMode)
    {
      case STOP: strcpy(buf,"STOPPED"); break;
      case RUN: strcpy(buf,"RUNNING"); break;
      case PAUSE: strcpy(buf,"PAUSED"); break;
    }
    spadr(buf,9);
    tft.print(buf);
    
    //Temperature
    //temperature = therm.analog2temp();
    tft.setCursor(TEMP_VALUE_X, PROMPT_Y);
    dtostrf(temperature, 3, 1, buf);
    strcat(buf," C");
    spadr(buf,7);
    tft.print(buf);
    if (currentMode != STOP)
    {
      plotCurrentTemperature(temperature, minutes * 60 + seconds);
    }

    //Time
    tft.setCursor(TIME_VALUE_X, PROMPT_Y);
    sprintf(buf,"%02d:%02d",minutes,seconds);
    spadr(buf,5);
    tft.print(buf);
  }

  SWITCH sw = readSwitches(true);
  if (currentMode == STOP || currentMode == PAUSE)
  {
    switch(sw)
    {
      case SELECT:
        if (currentMode == PAUSE)
        {
          currentMode = STOP;   //Stop if paused
          minutes = 0;
          seconds = 0;
          digitalWrite(HEAT_PIN, LOW);
        }
        else
        {
          currentPlot++;
          if (currentPlot == NUMBER_OF_PLOTS)
          {
            currentPlot = 0;
          }
        }
        tft.fillScreen(ST7735_BLACK);
        drawGraphFrame();
        plotGraph(currentPlot);
        updateDisplay = true;
        break;
  
      case START:
        if (currentMode == STOP)
        {
          minutes = 0;
          seconds = 0;
          tft.fillScreen(ST7735_BLACK);
          drawGraphFrame();
          plotGraph(currentPlot);
        }
        currentMode = RUN;
        updateDisplay = true;
        break;

      case NONE:
        break;
    }
  }
  else if (sw == START)
  {
    //Currently running
    currentMode = PAUSE;
    updateDisplay = true;
  }
  delay(100);
}

//---------------------------------------------------------------------
// Real-Time Clock Setup
void RTCSetup() 
{
  // Initialize RTC
  while (RTC.STATUS > 0);                           // Wait until registers synchronized

  //Use the internal oscillator
  RTC.CLKSEL = RTC_CLKSEL_INT32K_gc;                    // 32.768kHz Internal Oscillator  
  
  RTC.PITINTCTRL = RTC_PI_bm;                           //Periodic Interrupt: enabled
  RTC.PITCTRLA = RTC_PERIOD_CYC32768_gc | RTC_PITEN_bm; //RTC Clock Cycles 32768, resulting in 32.768kHz/32768 = 1Hz and enable
}

//---------------------------------------------------------------------
//RTC interrupt occurs every second
ISR(RTC_PIT_vect)
{
  if (currentMode == RUN)
  {
    if (seconds < 59)
    {
      seconds++;
    }
    else
    {
      seconds = 0;
      minutes++;
    }
  }
  updateDisplay = true;
  RTC.PITINTFLAGS = RTC_PI_bm;          //Clear flag by writing '1'
}

//---------------------------------------------------------------------
//Read current switches state
// - wait - True to wait for button released if pressed
// - Returns NONE, START or SELECT
SWITCH readSwitches(bool wait)
{
  SWITCH sw = NONE;
  int value = analogRead(SWITCHES);
  if (value < 1000)
  {
    delay(10);    //debounce
    if (value == analogRead(SWITCHES))
    {
      sw = (value < 100) ? START : SELECT;
      if (wait)
      {
        //wait for release
        while (analogRead(SWITCHES) < 1000)
        {
          delay(50);
        }
      }
    }
  }
  return sw;
}

//---------------------------------------------------------------------
// Draw grid and labels on X and Y axis
void drawGraphFrame()
{
  //5 red, 6 green, 5 blue
  #define ST7735_GRAY 0xC618 //0xC0C0C0
  for(int x = 0; x < GRAPH_X_DIV; x++)
  {
    tft.drawLine(GRAPH_X_MIN + (x * GRAPH_X_GAP), GRAPH_Y_MIN, GRAPH_X_MIN + (x * GRAPH_X_GAP), GRAPH_Y_MAX, ST7735_GRAY);
    if (x != 0)
    {
      tft.setTextColor(ST7735_WHITE, ST7735_BLACK);
      tft.setCursor(GRAPH_X_MIN + (x * GRAPH_X_GAP) - 2,GRAPH_Y_TEXT);
      if (x == (GRAPH_X_DIV - 1))
      {
        tft.print("(min)");
      }
      else
      {
        tft.print(x);
      }
    }
  }
  for(int y = 0; y < GRAPH_Y_DIV; y++)
  {
    tft.drawLine(GRAPH_X_MIN, GRAPH_Y_MIN - (y * GRAPH_Y_GAP), GRAPH_X_MAX, GRAPH_Y_MIN - (y * GRAPH_Y_GAP), ST7735_GRAY);
    if (y != 0)
    {
      tft.setTextColor(ST7735_WHITE, ST7735_BLACK);
      tft.setCursor(GRAPH_X_TEXT, GRAPH_Y_MIN - (y * GRAPH_Y_GAP) - 4);
      sprintf(buf,"%3d",y*50);
      tft.print(buf);
    }
  }
  tft.drawLine(GRAPH_X_MIN, GRAPH_Y_MIN, GRAPH_X_MIN, GRAPH_Y_MAX, ST7735_WHITE);
  tft.drawLine(GRAPH_X_MIN, GRAPH_Y_MIN, GRAPH_X_MAX, GRAPH_Y_MIN, ST7735_WHITE);
  tft.drawLine(GRAPH_X_MAX, GRAPH_Y_MIN, GRAPH_X_MAX, GRAPH_Y_MAX, ST7735_WHITE);
  tft.drawLine(GRAPH_X_MIN, GRAPH_Y_MIN - (GRAPH_Y_DIV * GRAPH_Y_GAP), GRAPH_X_MAX, GRAPH_Y_MAX, ST7735_WHITE);
}

//---------------------------------------------------------------------
//Plot current graph
// plot - Graph to plot
void plotGraph(int plot)
{
  const TARGET* p = plots[plot];
  int te, se;
  int ss = 0;
  int ts = 0;
  for (int i = 0; i < NUMBER_OF_PERIODS; i++)
  {
    #ifdef TABLES_IN_DATA_SPACE
      te = p->temp;
      se = p->period;
    #else
      te = pgm_read_word(&p->temp);
      se = pgm_read_word(&p->period);
    #endif
    if (te != 0 || se != 0 || i == 0)
    {
      tft.drawLine(toGraphX(ss),toGraphY(ts),toGraphX(se),toGraphY(te),ST7735_CYAN);
    }
    ts = te;
    ss = se;
    p++;
  }
}

//---------------------------------------------------------------------
//Convert a time in seconds to the X position on the graph
// x - time in seconds
// returns X position on graph
int toGraphX(int x)
{
  return (GRAPH_X_MIN + (x * GRAPH_X_GAP) / 60);
}

//---------------------------------------------------------------------
//Convert a temperature to the Y position on the graph
// y - temperature in degrees C
// returns Y position on graph
int toGraphY(int y)
{
  return (GRAPH_Y_MIN - (y * GRAPH_Y_GAP) / 50);
}

//---------------------------------------------------------------------
//Highlight the current temparture
// t - Current temperature
// s - Current time in seconds
void plotCurrentTemperature(float t, int s)
{
  tft.fillCircle(toGraphX(s),toGraphY(round(t)),1,ST7735_RED);
}      

//---------------------------------------------------------------------
//Highlight the expected temparture
// plot - Graph being plotted
// s - Current time in seconds
// Returns false when reached end
bool plotExpectedTemperature(int plot, int s)
{
  int t = timeToTemperature(plot, s);
  tft.fillCircle(toGraphX(s),toGraphY(t),1,ST7735_RED);
  return (s == 0 || t != 0);
}      

//---------------------------------------------------------------------
//Convert a time in seconds to a temperature
// plot - Graph being plotted
// s - Current time in seconds
// Returns temperature expected
int timeToTemperature(int plot, int s)
{
  const TARGET* p = plots[plot];
  long te, se;
  long ss = 0;
  long ts = 0;
  for (int i = 0; i < NUMBER_OF_PERIODS; i++)
  {
    #ifdef TABLES_IN_DATA_SPACE
      te = p->temp;
      se = p->period;
    #else
      te = pgm_read_word(&p->temp);
      se = pgm_read_word(&p->period);
    #endif
    if (te == 0 && se == 0)
    {
      return 0;
    }
    else if (s <= se)
    {
      //found target
      return ts + (((long)s - ss) * (te - ts)) / (se - ss);
    }
    ts = te;
    ss = se;
    p++;
  }
  return 0;
}

//---------------------------------------------------------------------
//Pad string right with spaces
// - p pointer to start of string
// - l length of final string
void spadr(char* p, int l)
{
  int k = strlen(p);
  int i = k;
  for(; i < l; i++)
  {
    p[i] = ' ';
  }
  p[i] = '\0';
}