Brine Automation Dashboard

/* ESP32 FreeRTOS multi-core sketch Core 0: WiFi + WebServer + LCD + Proximity + Conveyor Core 1: Button + Flow aggregation + Pump control */ #include #include #include #include #include #include "freertos/FreeRTOS.h" #include "freertos/task.h" #include "freertos/semphr.h" // ========== HARDWARE PINS ========== #define RELAY_PIN 13 // Pump / valve relay (activated by button/pump task) #define BUTTON_PIN 19 // Physical start button (INPUT_PULLUP) #define FLOW_SENSOR_PIN 35 // Flow sensor (ISR increments pulse count) #define CONVEYOR_PIN 32 // Conveyor relay (ON/OFF via proximity on core0) #define PROX_PIN 33 // Proximity sensor (INPUT_PULLUP; LOW = detected) #define I2C_ADDR 0x27 // LCD I2C address // ========== GLOBALS & PERFS ========== LiquidCrystal_I2C lcd(I2C_ADDR, 16, 2); Preferences prefs; WebServer server(80); const char* ssid = "ESP32_Auto"; const char* password = "12345678"; IPAddress local_IP(192, 168, 10, 1); IPAddress gateway(192, 168, 10, 1); IPAddress subnet(255, 255, 255, 0); #define PREF_NAMESPACE "esp32auto" #define KEY_MODE "mode" #define KEY_TIME "time" #define KEY_LITER "liter" #define KEY_PPL "ppl" #define KEY_CONV "conv" // defaults volatile int modeSetting = 1; volatile unsigned long mode1Seconds = 5; volatile float mode2Liters = 10.0; volatile float pulsesPerLiter = 12; // our value 71.5125 volatile unsigned long conveyorSeconds = 3; // flow variables volatile unsigned long pulseCount = 0; // incremented in ISR float totalLiters = 0.0; // aggregated once a second (protected by mutex) unsigned long lastFlowCalc = 0; // mutex to protect totalLiters SemaphoreHandle_t xLitMutex = NULL; // pump/sequence flags (Core1) volatile bool pumpRunning = false; // conveyor state (Core0) volatile bool conveyorRunning = false; unsigned long conveyorStartMillis = 0; unsigned long conveyorDurationMs = 0; // button debounce state (Core1) const unsigned long BUTTON_DEBOUNCE_MS = 50; unsigned long lastButtonDebounceMillis = 0; int lastButtonStable = HIGH; // proximity debounce (Core0) const unsigned long PROX_DEBOUNCE_MS = 50; unsigned long lastProxDebounceMillis = 0; int lastProxStable = HIGH; // HTML page (same UI as earlier) const char* htmlPage = R"rawliteral( Brine Automation Dashboard

ESP32 Automation

Current Mode: Loading...

Select Mode:

Seconds:

Conveyor Time (sec):

)rawliteral"; // ========== PREFERENCES ========== void saveSettings() { prefs.begin(PREF_NAMESPACE, false); prefs.putInt(KEY_MODE, (int)modeSetting); prefs.putULong(KEY_TIME, mode1Seconds); prefs.putFloat(KEY_LITER, mode2Liters); prefs.putFloat(KEY_PPL, pulsesPerLiter); prefs.putULong(KEY_CONV, conveyorSeconds); prefs.end(); Serial.printf("Saved settings: mode=%d time=%lu liter=%.2f conv=%lu ppl=%.2f\n", (int)modeSetting, mode1Seconds, mode2Liters, conveyorSeconds, pulsesPerLiter); } void loadSettings() { prefs.begin(PREF_NAMESPACE, true); modeSetting = prefs.getInt(KEY_MODE, 1); mode1Seconds = prefs.getULong(KEY_TIME, 5); mode2Liters = prefs.getFloat(KEY_LITER, 10.0); pulsesPerLiter = prefs.getFloat(KEY_PPL, 71.5125); conveyorSeconds = prefs.getULong(KEY_CONV, 3); prefs.end(); Serial.printf("Loaded settings: mode=%d time=%lu liter=%.2f conv=%lu ppl=%.2f\n", (int)modeSetting, mode1Seconds, mode2Liters, conveyorSeconds, pulsesPerLiter); } // ========== FLOW ISR & AGGREGATION ========== void IRAM_ATTR flowISR() { pulseCount++; } // Called periodically on Core1 to aggregate pulses into liters into totalLiters void aggregateFlow() { unsigned long now = millis(); if (now - lastFlowCalc >= 1000UL) { // every 1 second noInterrupts(); unsigned long pulses = pulseCount; pulseCount = 0; interrupts(); float litersThisSec = (float)pulses / pulsesPerLiter; // protect totalLiters if (xLitMutex != NULL && xSemaphoreTake(xLitMutex, (TickType_t)10) == pdTRUE) { totalLiters += litersThisSec; xSemaphoreGive(xLitMutex); } else { // fallback (shouldn't happen often) totalLiters += litersThisSec; } Serial.printf("Flow agg: pulses=%lu +%.4f L total=%.4f\n", pulses, litersThisSec, totalLiters); lastFlowCalc = now; } } // ========== WEB HANDLERS ========== void handleRoot() { server.send(200, "text/html", htmlPage); } void handleStatus() { float safeLit = 0.0; if (xLitMutex != NULL && xSemaphoreTake(xLitMutex, (TickType_t)10) == pdTRUE) { safeLit = totalLiters; xSemaphoreGive(xLitMutex); } else { safeLit = totalLiters; } String json = "{\"mode\":" + String((int)modeSetting) + ",\"time\":" + String(mode1Seconds) + ",\"liter\":" + String(mode2Liters) + ",\"conv\":" + String(conveyorSeconds) + ",\"flow\":" + String(safeLit) + "}"; server.send(200, "application/json", json); } void handleSave() { String body = server.arg("plain"); DynamicJsonDocument doc(512); DeserializationError err = deserializeJson(doc, body); if (err) { server.send(400, "application/json", "{\"ok\":false, \"error\":\"bad json\"}"); return; } if (doc.containsKey("mode")) modeSetting = doc["mode"].as(); if (doc.containsKey("time")) mode1Seconds = doc["time"].as(); if (doc.containsKey("liter")) mode2Liters = doc["liter"].as(); if (doc.containsKey("conv")) conveyorSeconds = doc["conv"].as(); saveSettings(); server.send(200, "application/json", "{\"ok\":true}"); } // ========== TASKS ========== // Core0: Web + LCD + Proximity & Conveyor void TaskCore0(void* pv) { (void)pv; Serial.println("TaskCore0 starting on core " + String(xPortGetCoreID())); // setup AP and server WiFi.softAP(ssid, password); WiFi.softAPConfig(local_IP, gateway, subnet); Serial.print("AP IP: "); Serial.println(WiFi.softAPIP()); #if defined(WEB_SERVER_ENABLE_CORS) server.enableCORS(true); #endif server.on("/", handleRoot); server.on("/status", handleStatus); server.on("/save", HTTP_POST, handleSave); server.begin(); Serial.println("Web server started (Core0)."); unsigned long lastLCD = 0; const unsigned long LCD_INTERVAL = 700; for (;;) { // handle web clients frequently server.handleClient(); // Proximity debounce & control conveyor (INPUT_PULLUP; LOW = detected) int prox = digitalRead(PROX_PIN); if (prox != lastProxStable) { lastProxDebounceMillis = millis(); lastProxStable = prox; } else { if ((millis() - lastProxDebounceMillis) > PROX_DEBOUNCE_MS) { // stable if (prox == LOW) { // detection if (!conveyorRunning) { conveyorRunning = true; conveyorStartMillis = millis(); conveyorDurationMs = conveyorSeconds * 1000UL; digitalWrite(CONVEYOR_PIN, HIGH); Serial.printf("Proximity detected -> Conveyor ON for %lu ms\n", conveyorDurationMs); } } // If prox is HIGH we do nothing special: conveyor will auto-stop after duration } } // conveyor timing (non-blocking) if (conveyorRunning) { if (millis() - conveyorStartMillis >= conveyorDurationMs) { conveyorRunning = false; digitalWrite(CONVEYOR_PIN, LOW); Serial.println("Conveyor auto-stopped (Core0)."); } } // LCD update: read totalLiters safely if (millis() - lastLCD >= LCD_INTERVAL) { float safeLit = 0.0; if (xLitMutex != NULL && xSemaphoreTake(xLitMutex, (TickType_t)10) == pdTRUE) { safeLit = totalLiters; xSemaphoreGive(xLitMutex); } else { safeLit = totalLiters; } // Update LCD content lcd.clear(); switch (modeSetting) { case 1: lcd.print("Mode1: Time "); lcd.setCursor(0, 1); lcd.print("Time:"); lcd.print(mode1Seconds); lcd.print("s "); break; case 2: lcd.print("Mode2: Volume"); lcd.setCursor(0, 1); lcd.print(safeLit, 2); lcd.print("/"); lcd.print(mode2Liters); lcd.print("L"); break; default: lcd.print("Mode3 Disabled"); lcd.setCursor(0, 1); lcd.print("Conv:"); lcd.print(conveyorSeconds); break; } lastLCD = millis(); } vTaskDelay(pdMS_TO_TICKS(40)); // yield } } // Core1: Flow aggregation and Pump control + Button handling TaskHandle_t pumpTaskHandle = NULL; void PumpTask(void* pv) { (void)pv; Serial.println("PumpTask starting on core " + String(xPortGetCoreID())); for (;;) { // Wait to be notified by the Button task when a start is requested // ulTaskNotifyTake blocks until a notification arrives (or timeout) uint32_t notified = ulTaskNotifyTake(pdTRUE, portMAX_DELAY); // clear on receive if (notified > 0) { // If mode disabled ignore if (modeSetting == 3) { Serial.println("PumpTask: mode disabled -> ignoring start"); continue; } if (pumpRunning) { Serial.println("PumpTask: pump already running -> ignoring"); continue; } // Start pump according to mode if (modeSetting == 1) { // Time based pumpRunning = true; digitalWrite(RELAY_PIN, HIGH); Serial.printf("PumpTask: time-based run for %lu s\n", mode1Seconds); unsigned long start = millis(); while (millis() - start < mode1Seconds * 1000UL) { aggregateFlow(); // keep aggregating flow during pump vTaskDelay(pdMS_TO_TICKS(200)); } digitalWrite(RELAY_PIN, LOW); pumpRunning = false; Serial.println("PumpTask: time run finished."); } else if (modeSetting == 2) { // Volume based pumpRunning = true; // Reset flow counters safely if (xLitMutex != NULL && xSemaphoreTake(xLitMutex, (TickType_t)10) == pdTRUE) { totalLiters = 0.0; xSemaphoreGive(xLitMutex); } else { totalLiters = 0.0; } noInterrupts(); pulseCount = 0; interrupts(); digitalWrite(RELAY_PIN, HIGH); unsigned long startMillis = millis(); Serial.printf("PumpTask: volume-based target %.2f L\n", mode2Liters); while (true) { aggregateFlow(); float safeLit = 0.0; if (xLitMutex != NULL && xSemaphoreTake(xLitMutex, (TickType_t)10) == pdTRUE) { safeLit = totalLiters; xSemaphoreGive(xLitMutex); } else { safeLit = totalLiters; } if (safeLit >= mode2Liters) { Serial.printf("PumpTask: target reached %.3f L\n", safeLit); break; } // safety timeout (10 min) if (millis() - startMillis > 10UL * 60UL * 1000UL) { Serial.println("PumpTask: timeout waiting for volume -> abort"); break; } vTaskDelay(pdMS_TO_TICKS(250)); } digitalWrite(RELAY_PIN, LOW); pumpRunning = false; Serial.println("PumpTask: volume run finished."); } // modes } } } void ButtonTask(void* pv) { (void)pv; Serial.println("ButtonTask starting on core " + String(xPortGetCoreID())); int lastStable = HIGH; lastButtonStable = HIGH; for (;;) { int b = digitalRead(BUTTON_PIN); if (b != lastStable) { lastButtonDebounceMillis = millis(); lastStable = b; } else { if ((millis() - lastButtonDebounceMillis) > BUTTON_DEBOUNCE_MS) { // falling edge detection static int prevState = HIGH; if (b == LOW && prevState == HIGH) { Serial.println("ButtonTask: button pressed -> notify pump"); // Notify (unblock) PumpTask if (pumpTaskHandle != NULL) { xTaskNotifyGive(pumpTaskHandle); } } prevState = b; } } // also aggregate flow here regularly aggregateFlow(); vTaskDelay(pdMS_TO_TICKS(40)); } } // ========== SETUP & LOOP ========== void setup() { Serial.begin(115200); delay(50); // pins pinMode(RELAY_PIN, OUTPUT); pinMode(CONVEYOR_PIN, OUTPUT); pinMode(BUTTON_PIN, INPUT_PULLUP); pinMode(FLOW_SENSOR_PIN, INPUT_PULLUP); pinMode(PROX_PIN, INPUT_PULLUP); digitalWrite(RELAY_PIN, LOW); digitalWrite(CONVEYOR_PIN, LOW); attachInterrupt(digitalPinToInterrupt(FLOW_SENSOR_PIN), flowISR, RISING); // lcd lcd.init(); lcd.backlight(); // mutex xLitMutex = xSemaphoreCreateMutex(); // load settings loadSettings(); // create tasks pinned to cores BaseType_t r0 = xTaskCreatePinnedToCore(TaskCore0, "TaskCore0", 8192, NULL, 1, NULL, 0); // Core 0 BaseType_t rPump = xTaskCreatePinnedToCore(PumpTask, "PumpTask", 8192, NULL, 2, &pumpTaskHandle, 1); // Core 1 BaseType_t rButton = xTaskCreatePinnedToCore(ButtonTask, "ButtonTask", 4096, NULL, 2, NULL, 1); // Core 1 if (r0 != pdPASS || rPump != pdPASS || rButton != pdPASS) { Serial.println("Task creation failed!"); } else { Serial.println("Tasks created successfully."); } } void loop() { // Empty - tasks do the work vTaskDelay(pdMS_TO_TICKS(1000)); }