fermentord/internal/controllers/hysteresis.go

package controllers

import (
	"sync"
	"time"

	"github.com/rs/zerolog/log"
)

// Hysteresis will only run when the ambient temperature is above the
// fermentation temperature. The compressor will run until the wort
// is cooled to FermentationTemperature, the chamber is cooled to
// MinChamberTemperature or the compressor has run for MaxCoolerRuntimeSecs.
// The compressor will run for min. MinCoolerRuntimeSecs before switching off,
// regardless of temperatures. Once turned off, the compressor will not be
// turned on before MinCoolerCooldownSecs has expired, regardless of temperatures.
type Hysteresis struct {
	config *Config

	// Current state.
	coolerState           bool
	lastCoolerStateChange time.Time
	C                     chan bool
	mutex                 *sync.Mutex

	name string

	// Current temperature readings.
	ambientTemperature float64
	chamberTemperature float64
	wortTemperature    float64
}

func NewHysteresis(name string) *Hysteresis {
	return &Hysteresis{
		C:     make(chan bool),
		name:  name,
		mutex: &sync.Mutex{},
	}
}

func (h *Hysteresis) SetConfig(newConfig *Config) {
	h.lock()
	h.config = newConfig
	h.unlock()
	h.update()
}

func (h *Hysteresis) UpdateAmbientTemperature(value float64) {
	h.lock()
	h.ambientTemperature = value
	h.unlock()
	h.update()
}

func (h *Hysteresis) UpdateChamberTemperature(value float64) {
	h.lock()
	h.chamberTemperature = value
	h.unlock()
	h.update()
}

func (h *Hysteresis) UpdateWortTemperature(value float64) {
	h.lock()
	h.wortTemperature = value
	h.unlock()
	h.update()
}

func (h *Hysteresis) lock() {
	h.mutex.Lock()
}

func (h *Hysteresis) unlock() {
	h.mutex.Unlock()
}

func (h *Hysteresis) GetCoolerState() bool {
	return h.coolerState
}

func (h *Hysteresis) setState(state bool) {
	h.lock()

	if state == h.coolerState {
		h.unlock()
		return
	}

	log.Debug().Bool("state", state).Msg("Setting state")
	h.coolerState = state
	h.lastCoolerStateChange = time.Now()
	h.unlock()

	h.C <- state
}

func (h *Hysteresis) update() {
	// Compressor runtime has highest priority.
	lastStateChangeAgeSecs := time.Since(h.lastCoolerStateChange).Seconds()
	if h.coolerState {
		// Keep the cooler running until min. runtime is reached.
		if lastStateChangeAgeSecs < h.config.MinCoolerRuntimeSecs {
			log.Debug().
				Str("name", h.name).
				Float64("runtime", lastStateChangeAgeSecs).
				Float64("min_runtime", h.config.MinCoolerRuntimeSecs).
				Bool("state", h.coolerState).
				Msg("Cooler kept running as it's runtime threshold is not yet reached.")
			return
		}

		// Stop the cooler if it's runtime exceeds max.
		if lastStateChangeAgeSecs > h.config.MaxCoolerRuntimeSecs {
			log.Info().
				Str("name", h.name).
				Float64("runtime", lastStateChangeAgeSecs).
				Float64("max_runtime", h.config.MaxCoolerRuntimeSecs).
				Bool("state", false).
				Msg("Cooler stopped as it's runtime exceeds max. threshold.")
			h.setState(false)
			return
		}
	} else {
		// Keep the cooler off until min. cooldown time is reached.
		if lastStateChangeAgeSecs < h.config.MinCoolerCooldownSecs {
			log.Debug().
				Str("name", h.name).
				Float64("runtime", lastStateChangeAgeSecs).
				Float64("min_cooldown", h.config.MinCoolerCooldownSecs).
				Bool("state", h.coolerState).
				Msg("Cooler kept off as it's cooldown time threshold is not yet reached.")
			return
		}
	}

	// Do not allow the cooler to run when the ambient temperature is below
	// the fermentation temperature.
	if h.ambientTemperature < h.config.FermentationTemperature {
		if h.coolerState {
			log.Info().
				Str("name", h.name).
				Float64("ambient_temp", h.ambientTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Msg("Turn off cooler as ambient temperature is less than fermentation temperature.")
			h.setState(false)
		} else {
			log.Debug().
				Str("name", h.name).
				Float64("ambient_temp", h.ambientTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Msg("Cooler kept off as ambient temperature is less than fermentation temperature.")
		}
		return
	}

	// Do not allow the cooler to run if the chamber temperature is below
	// minimum.
	if h.chamberTemperature <= h.config.MinChamberTemperature {
		if h.coolerState {
			log.Info().
				Str("name", h.name).
				Float64("chamber_temp", h.chamberTemperature).
				Float64("min_chamber_temp", h.config.MinChamberTemperature).
				Msg("Cooler turned off as chamber temperature dropped below threshold.")
			h.setState(false)
		} else {
			log.Debug().
				Str("name", h.name).
				Float64("ambient_temp", h.ambientTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Msg("Cooler kept off as chamber temperature is below threshold.")
		}
		return
	}

	// Keep the cooler stopped until the wort delta temperature reaches it's threshold.
	delta := h.wortTemperature - h.config.FermentationTemperature
	if h.coolerState {
		// Keep the cooler running until the wort reaches the desired temp.
		if delta <= 0 {
			// TODO Investigate how much the wort temp. drops below fermentation temp.
			// TODO A threshold may be needed.
			log.Info().
				Str("name", h.name).
				Float64("wort_temp", h.wortTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Float64("delta", delta).
				Float64("max_wort_delta", h.config.MaxWortDelta).
				Msg("Cooler stopped as wort is cooled down to fermentation temp.")
			h.setState(false)
			return
		} else {
			log.Debug().
				Str("name", h.name).
				Float64("wort_temp", h.wortTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Float64("delta", delta).
				Float64("max_wort_delta", h.config.MaxWortDelta).
				Msg("Cooler kept running as the wort has not yet reached fermentation temp.")
		}
	} else {
		// Start the cooler when delta exceeds threshold.
		if delta > h.config.MaxWortDelta {
			log.Info().
				Str("name", h.name).
				Float64("wort_temp", h.wortTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Float64("delta", delta).
				Float64("max_wort_delta", h.config.MaxWortDelta).
				Msg("Cooler started as wort delta exceeds threshold.")
			h.setState(true)
			return
		} else {
			log.Debug().
				Str("name", h.name).
				Float64("wort_temp", h.wortTemperature).
				Float64("fermentation_temp", h.config.FermentationTemperature).
				Float64("delta", delta).
				Float64("max_wort_delta", h.config.MaxWortDelta).
				Msg("Cooler kept off as delta does not yet exceed threshold.")
			// TODO If this is reached, then we can lower the delta as min. cooldown is reached.
			// TODO This is relevant for PID.
		}
	}
}