espmega-pro-ecu-genrator/src/GasolineGenerator.cpp

#include "GasolineGenerator.hpp"

GasolineGenerator::GasolineGenerator()
{
}

/**
 * @brief Initialize the Gasoline Generator.
 *
 * @note This does not start the generator, it only initializes the input and output cards,
 *
 * @param inputCard The digital input card used for monitoring the generator state
 * @param outputCard The digital output card used for controlling the generator components
 * @param config The configuration settings for the generator, pins are of input and output cards specified earlier.
 */
void GasolineGenerator::initialize(DigitalInputCard *inputCard, DigitalOutputCard *outputCard, const GasolineGeneratorConfig &config)
{
    this->config = &config;
    this->inputCard = inputCard;
    this->outputCard = outputCard;

    // Initialize all outputs to safe state
    setIgnitionSystem(false);
    setStarter(false);
    setCarburetorValve(false); // Close for startup    // Set debounce time for power output sensor if enabled
    if (config.usePowerOutputSensor)
    {
        this->inputCard->setDebounceTime(config.powerOutputSensorPin, POWER_SENSOR_DEBOUNCE_MS);
    }

    // Set debounce time for toggle pin if enabled
    if (config.useTogglePin)
    {
        this->inputCard->setDebounceTime(config.togglePin, POWER_SENSOR_DEBOUNCE_MS);
    }

    // Register input change callback
    this->inputCard->registerCallback([this](uint8_t pin, bool state)
                                      { this->handleInputChanges(pin, state); });

    state = GeneratorState::STOPPED;
}

/**
 * @brief Main loop for the Gasoline Generator.
 * * This function should be called periodically to handle the generator state machine.
 */
void GasolineGenerator::loop()
{
    unsigned long currentTime = (xTaskGetTickCount() * 1000) / configTICK_RATE_HZ;

    switch (state)
    {
    case GeneratorState::STARTING:
        handleStartupSequence(currentTime);
        break;

    case GeneratorState::RUNNING:        // Monitor engine status and handle any issues
        if (config->usePowerOutputSensor)
        {
            bool hasPowerOutput = inputCard->digitalRead(config->powerOutputSensorPin);
            if (!hasPowerOutput)
            {
                // Engine stopped unexpectedly - no power output detected
                isEngineRunning = false;
                shutdown();
            }
        }
        break;

    case GeneratorState::SHUTTING_DOWN:
        // Complete shutdown sequence
        state = GeneratorState::STOPPED;
        break;

    case GeneratorState::STOPPED:
    default:
        // Nothing to do in stopped state
        break;
    }
}

/**
 * @brief Start the gasoline generator.
 *
 * This function initiates the startup sequence for the generator.
 * It will close the carburetor valve, power up the ignition system,
 * and engage the starter relay to start the engine.
 */
void GasolineGenerator::start()
{
    if (state != GeneratorState::STOPPED)
    {
        return; // Already starting or running
    }

    state = GeneratorState::STARTING;
    startupStartTime = (xTaskGetTickCount() * 1000) / configTICK_RATE_HZ;
    ignitionStartTime = 0;
    isEngineRunning = false;
    starterEngaged = false;

    // Step 1: Close carburetor valve for rich mixture
    setCarburetorValve(false);

    // Step 2: Power up ignition system
    setIgnitionSystem(true);
    ignitionStartTime = (xTaskGetTickCount() * 1000) / configTICK_RATE_HZ;
}

/**
 * @brief Shutdown the gasoline generator.
 *
 * This function stops the generator by turning off all systems,
 * including the starter, ignition system, and carburetor valve.
 */
void GasolineGenerator::shutdown()
{
    // Turn off all systems
    setStarter(false);
    setIgnitionSystem(false);
    setCarburetorValve(false); // Close carburetor valve

    state = GeneratorState::STOPPED;
    isEngineRunning = false;
}

/**
 * @brief Set the carburetor valve state.
 *
 * @param open If true, opens the carburetor valve; if false, closes it.
 * The actual pin state is reversed based on the configuration.
 */
void GasolineGenerator::setCarburetorValve(bool open)
{
    bool pinState = config->carburetorValveReverse ? !open : open;
    outputCard->digitalWrite(config->carburetorValvePin, pinState);
}

/**
 * @brief Set the ignition system state.
 *
 * @param enable If true, powers the ignition system; if false, turns it off.
 */
void GasolineGenerator::setIgnitionSystem(bool enable)
{
    outputCard->digitalWrite(config->ignitionSystemPowerRelayPin, enable);
}

/**
 * @brief Set the starter relay state.
 *
 * @param enable If true, engages the starter; if false, disengages it.
 */
void GasolineGenerator::setStarter(bool enable)
{
    outputCard->digitalWrite(config->starterRelayPin, enable);
    starterEngaged = enable;
}

/**
 * @brief Handle the startup sequence of the gasoline generator.
 *
 * This function manages the timing and state transitions during the startup process,
 * including engaging the starter and checking for successful engine start.
 *
 * @param currentTime The current time in milliseconds since system start.
 */
void GasolineGenerator::handleStartupSequence(unsigned long currentTime)
{
    // Step 3: After ignition delay, engage starter
    if (ignitionStartTime > 0 &&
        (currentTime - ignitionStartTime) >= IGNITION_DELAY_MS &&
        !starterEngaged)
    {

        setStarter(true);
    }    // Check if we have power output AND starter is off (engine is running independently)
    if (config->usePowerOutputSensor)
    {
        bool hasPowerOutput = inputCard->digitalRead(config->powerOutputSensorPin);
        if (hasPowerOutput && !starterEngaged && !isEngineRunning)
        {
            onEngineStarted();
        }
    }
    else
    {
        // No power sensor - fallback to time-based detection
        if ((currentTime - startupStartTime) >= (IGNITION_DELAY_MS + 3000) && !isEngineRunning)
        {
            onEngineStarted();
        }
    }

    // Timeout protection - stop starter after maximum duration
    if (ignitionStartTime > 0 &&
        (currentTime - ignitionStartTime) >= (IGNITION_DELAY_MS + STARTER_DURATION_MS))
    {

        setStarter(false);

        if (!isEngineRunning)
        {
            // Failed to start
            shutdown();
        }
    }
}

/**
 * @brief Callback function called when the engine has successfully started.
 *
 * This function is called when the engine starts successfully after engaging the starter.
 * It turns off the starter, opens the carburetor valve, and transitions to the RUNNING state.
 */
void GasolineGenerator::onEngineStarted()
{
    isEngineRunning = true;

    // Turn off starter
    setStarter(false);

    // Open carburetor valve for normal operation
    setCarburetorValve(true);

    state = GeneratorState::RUNNING;
}

/**
 * @brief Handle input changes from the digital input card.
 * 
 * This function processes changes in the state of input pins, particularly for the power output sensor
 * and toggle switch. It checks if the engine has started or stopped based on the power output sensor state,
 * and handles toggle switch presses to start/stop the generator.
 * 
 * @param pin The pin number that changed state.
 * @param state The new state of the pin (true for HIGH, false for LOW).
 */
void GasolineGenerator::handleInputChanges(uint8_t pin, bool state)
{
    // Handle power output sensor changes
    if (pin == config->powerOutputSensorPin)
    {
        if (state && this->state == GeneratorState::STARTING && !starterEngaged && !isEngineRunning)
        {
            // Power detected during startup with starter off - engine has started successfully
            onEngineStarted();
        }
        else if (!state && this->state == GeneratorState::RUNNING)
        {
            // Power lost during operation - engine may have stopped
            isEngineRunning = false;
            shutdown();
        }
    }
    
    // Handle toggle pin changes
    if (pin == config->togglePin && config->useTogglePin)
    {
        if (state) // Toggle switch pressed (rising edge)
        {
            if (this->state == GeneratorState::STOPPED)
            {
                // Start the generator
                start();
            }
            else if (this->state == GeneratorState::RUNNING)
            {
                // Stop the generator
                shutdown();
            }
            // Ignore toggle during STARTING and SHUTTING_DOWN states
        }
    }
}