[ONOFF] Add overcurrent protection (#1426)

Add a function that switches OFF the actuator if the current measured is more than MAX_CURRENT_ACTUATOR

main/ZactuatorONOFF.ino

@@ -29,13 +29,19 @@
 #include "User_config.h"
 
 #ifdef ZactuatorONOFF
-unsigned long timeinttemp = 0;
 
 void setupONOFF() {
+#  ifdef MAX_CURRENT_ACTUATOR
+  xTaskCreate(overLimitCurrent, "overLimitCurrent", 2500, NULL, 10, NULL);
+#  endif
+#  ifdef MAX_TEMP_ACTUATOR
+  xTaskCreate(overLimitTemp, "overLimitTemp", 2500, NULL, 10, NULL);
+#  endif
   pinMode(ACTUATOR_ONOFF_GPIO, OUTPUT);
 #  ifdef ACTUATOR_ONOFF_DEFAULT
   digitalWrite(ACTUATOR_ONOFF_GPIO, ACTUATOR_ONOFF_DEFAULT);
 #  endif
+  Log.trace(F("ZactuatorONOFF setup done" CR));
 }
 
 #  if jsonReceiving
@@ -106,9 +112,9 @@ void MQTTtoONOFF(char* topicOri, char* datacallback) {
 
 //Check regularly temperature of the ESP32 board and switch OFF the relay if temperature is more than MAX_TEMP_ACTUATOR
 #  ifdef MAX_TEMP_ACTUATOR
-void OverHeatingRelayOFF() {
+void overLimitTemp(void* pvParameters) {
 #    if defined(ESP32) && !defined(NO_INT_TEMP_READING)
-  if (millis() > (timeinttemp + TimeBetweenReadingIntTemp)) {
+  for (;;) {
     static float previousInternalTempc = 0;
     float internalTempc = intTemperatureRead();
     Log.trace(F("Internal temperature of the ESP32 %F" CR), internalTempc);
@@ -116,14 +122,40 @@ void OverHeatingRelayOFF() {
     if (internalTempc > MAX_TEMP_ACTUATOR && previousInternalTempc > MAX_TEMP_ACTUATOR && digitalRead(ACTUATOR_ONOFF_GPIO) == ACTUATOR_ON) {
       Log.error(F("[ActuatorONOFF] OverTemperature detected ( %F > %F ) switching OFF Actuator" CR), internalTempc, MAX_TEMP_ACTUATOR);
       ActuatorTrigger();
+      for (int i = 0; i < 30; i++) {
+        ErrorIndicatorON();
+        vTaskDelay(200);
+        ErrorIndicatorOFF();
+        vTaskDelay(200);
+      }
     }
     previousInternalTempc = internalTempc;
-    timeinttemp = millis();
+    vTaskDelay(TimeBetweenReadingIntTemp);
   }
 #    endif
 }
-#  else
-void OverHeatingRelayOFF() {}
+#  endif
+
+// Check regularly current the relay and switch it OFF if the current is more than MAX_CURRENT_ACTUATOR
+#  ifdef MAX_CURRENT_ACTUATOR
+void overLimitCurrent(void* pvParameters) {
+  for (;;) {
+    float current = getRN8209current();
+    Log.trace(F("RN8209 Current %F" CR), current);
+    // We switch OFF the actuator if the current of the RN8209 is more than MAX_CURRENT_ACTUATOR.
+    if (current > MAX_CURRENT_ACTUATOR && digitalRead(ACTUATOR_ONOFF_GPIO) == ACTUATOR_ON) {
+      Log.error(F("[ActuatorONOFF] OverCurrent detected ( %F > %F ) switching OFF Actuator" CR), current, MAX_CURRENT_ACTUATOR);
+      ActuatorTrigger();
+      for (int i = 0; i < 30; i++) {
+        ErrorIndicatorON();
+        vTaskDelay(200);
+        ErrorIndicatorOFF();
+        vTaskDelay(200);
+      }
+    }
+    vTaskDelay(TimeBetweenReadingCurrent);
+  }
+}
 #  endif
 
 /*

main/ZsensorRN8209.ino

@@ -35,6 +35,23 @@ extern "C" bool init_8209c_interface();
 
 StaticJsonDocument<JSON_MSG_BUFFER> doc;
 
+// GetCurrent function for critical operation like overcurrent protection
+float getRN8209current() {
+  uint8_t ret = rn8209c_read_emu_status();
+  if (ret) {
+    int32_t current;
+    uint32_t temp_current = 0;
+    rn8209c_read_current(phase_A, &temp_current);
+    if (ret == 1) {
+      current = temp_current;
+    } else {
+      current = (int32_t)temp_current * (-1);
+    }
+    return current / 10000.0;
+  }
+  return 0;
+}
+
 void rn8209_loop(void* mode) {
   if (!ProcessLock) {
     uint32_t voltage;
@@ -78,6 +95,7 @@ void setupRN8209() {
   set_user_param(cal);
   init_8209c_interface();
   xTaskCreate(rn8209_loop, "rn8209_loop", RN8209_TASK_STACK_SIZE, NULL, RN8209_TASK_PRIO, NULL);
+  Log.trace(F("ZsensorRN8209 setup done " CR));
 }
 
 #endif // ZsensorRN8209

main/config_ONOFF.h

@@ -47,11 +47,18 @@ extern void MQTTtoONOFF(char* topicOri, JsonObject& RFdata);
 //#  define ACTUATOR_BUTTON_TRIGGER_LEVEL LOW // 0 or 1, set to the level which to detect a button press to change the actuator state.
 #endif
 #ifndef MAX_TEMP_ACTUATOR
-//#  define MAX_TEMP_ACTUATOR         70 // Temperature that will trigger the relay to go OFF
+//#  define MAX_TEMP_ACTUATOR         70.0 // Temperature that will trigger the relay to go OFF
 #endif
+#ifndef MAX_CURRENT_ACTUATOR
+//#  define MAX_CURRENT_ACTUATOR         15.0 // Current that will trigger the relay to go OFF
+#endif
+
 #ifndef TimeBetweenReadingIntTemp
 #  define TimeBetweenReadingIntTemp 5000 // Time interval between internal temp measurement to switch off the relay if MAX_TEMP_ACTUATOR is reached
 #endif
+#ifndef TimeBetweenReadingCurrent
+#  define TimeBetweenReadingCurrent 1000 // Time interval between internal temp measurement to switch off the relay if MAX_TEMP_ACTUATOR is reached
+#endif
 /*-------------------PIN DEFINITIONS----------------------*/
 // default pin, if not set into the MQTT json
 #ifndef ACTUATOR_ONOFF_GPIO

main/main.ino

@@ -692,6 +692,19 @@ void setup() {
   Log.notice(F("OpenMQTTGateway Version: " OMG_VERSION CR));
 #  endif
 
+/*
+ The 2 modules below are not connection dependent so start them before the connectivity functions
+ Note that the ONOFF module need to start after the RN8209 so that the overCurrent task is launched after the setup of the sensor
+*/
+#  ifdef ZsensorRN8209
+  setupRN8209();
+  modules.add(ZsensorRN8209);
+#  endif
+#  ifdef ZactuatorONOFF
+  setupONOFF();
+  modules.add(ZactuatorONOFF);
+#  endif
+
   String s = WiFi.macAddress();
 #  ifdef USE_MAC_AS_GATEWAY_NAME
   sprintf(gateway_name, "%.2s%.2s%.2s%.2s%.2s%.2s",
@@ -757,10 +770,6 @@ void setup() {
 
   delay(1500);
 
-#ifdef ZactuatorONOFF
-  setupONOFF();
-  modules.add(ZactuatorONOFF);
-#endif
 #ifdef ZsensorBME280
   setupZsensorBME280();
   modules.add(ZsensorBME280);
@@ -898,10 +907,6 @@ void setup() {
 #  endif
 #  define ACTIVE_RECEIVER ACTIVE_RTL
 #endif
-#ifdef ZsensorRN8209
-  setupRN8209();
-  modules.add(ZsensorRN8209);
-#endif
 #if defined(ZgatewayRTL_433) || defined(ZgatewayRF) || defined(ZgatewayPilight) || defined(ZgatewayRF2)
 #  ifdef DEFAULT_RECEIVER // Allow defining of default receiver as a compiler directive
   activeReceiver = DEFAULT_RECEIVER;
@@ -1587,9 +1592,6 @@ void loop() {
 #ifdef ZactuatorFASTLED
       FASTLEDLoop();
 #endif
-#ifdef ZactuatorONOFF
-      OverHeatingRelayOFF();
-#endif
 #ifdef ZactuatorPWM
       PWMLoop();
 #endif