Electronics
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RailroadSwitch
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Code Issues 1 Pull Requests Releases Activity

Fixed #1: Unstable on/off positions 

Fixed #2: Unit sleeps when adjusting positions
Fixed #3: No capacitor on input side of voltage regulator
Fixed #4: Add 3rd potentiometer for speed setting?
This commit is contained in:
Mark van Renswoude 2019-01-03 23:16:44 +01:00
parent 7be7190477
commit fa53deb9d0
4 changed files with 1040 additions and 574 deletions
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974
kicad/RailroadSwitch/RailroadSwitch.kicad_pcb
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File diff suppressed because it is too large Load Diff

92
kicad/RailroadSwitch/RailroadSwitch.net
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@ -1,7 +1,7 @@
(export (version D)
(design
(source P:\Electronics\RailroadSwitch\kicad\RailroadSwitch\RailroadSwitch.sch)
(date "1-1-2019 19:51:10")
(date "3-1-2019 19:49:40")
(tool "Eeschema (5.0.1)-3")
(sheet (number 1) (name /) (tstamps /)
(title_block
@ -76,7 +76,28 @@
(datasheet http://www.st.com/content/ccc/resource/technical/document/datasheet/41/4f/b3/b0/12/d4/47/88/CD00000444.pdf/files/CD00000444.pdf/jcr:content/translations/en.CD00000444.pdf)
(libsource (lib Regulator_Linear) (part L7805) (description "Positive 1.5A 35V Linear Regulator, Fixed Output 5V, TO-220/TO-263/TO-252"))
(sheetpath (names /) (tstamps /))
(tstamp 5C2CDA60)))
(tstamp 5C2CDA60))
(comp (ref C2)
(value 22pF)
(footprint Capacitors_SMD:C_1206)
(datasheet ~)
(libsource (lib Device) (part C) (description "Unpolarized capacitor"))
(sheetpath (names /) (tstamps /))
(tstamp 5C2E5A00))
(comp (ref RV3)
(value 10k)
(footprint Potentiometers:Potentiometer_Triwood_RM-065)
(datasheet ~)
(libsource (lib Device) (part R_POT) (description Potentiometer))
(sheetpath (names /) (tstamps /))
(tstamp 5C2EE588))
(comp (ref C3)
(value 470uF)
(footprint Capacitors_ThroughHole:CP_Radial_D6.3mm_P2.50mm)
(datasheet ~)
(libsource (lib Device) (part C) (description "Unpolarized capacitor"))
(sheetpath (names /) (tstamps /))
(tstamp 5C2EF195)))
(libparts
(libpart (lib Connector) (part Conn_01x02_Male)
(description "Generic connector, single row, 01x02, script generated (kicad-library-utils/schlib/autogen/connector/)")
@ -202,40 +223,47 @@
(library (logical Switch)
(uri "C:\\Program Files\\KiCad\\share\\kicad\\library/Switch.lib")))
(nets
(net (code 1) (name "Net-(J1-Pad3)")
(node (ref J1) (pin 3))
(node (ref U1) (pin 5)))
(net (code 2) (name GND)
(node (ref RV2) (pin 1))
(node (ref RV1) (pin 1))
(node (ref U2) (pin 2))
(node (ref C1) (pin 2))
(node (ref SW1) (pin 2))
(node (ref J2) (pin 1))
(net (code 1) (name GND)
(node (ref J1) (pin 1))
(node (ref U1) (pin 4)))
(net (code 3) (name "Net-(SW1-Pad1)")
(node (ref SW1) (pin 1))
(node (ref U1) (pin 6)))
(net (code 4) (name "Net-(RV2-Pad2)")
(node (ref U1) (pin 3))
(node (ref RV2) (pin 2)))
(net (code 5) (name "Net-(RV1-Pad2)")
(node (ref U1) (pin 7))
(node (ref RV1) (pin 2)))
(net (code 6) (name +12V)
(node (ref U2) (pin 1))
(node (ref J2) (pin 2)))
(net (code 7) (name "Net-(U1-Pad2)")
(node (ref U1) (pin 2)))
(net (code 8) (name +5V)
(node (ref C3) (pin 1))
(node (ref U1) (pin 4))
(node (ref RV2) (pin 1))
(node (ref C1) (pin 2))
(node (ref RV3) (pin 1))
(node (ref SW1) (pin 2))
(node (ref RV1) (pin 1))
(node (ref C2) (pin 2))
(node (ref U2) (pin 2))
(node (ref J2) (pin 1)))
(net (code 2) (name +5V)
(node (ref R1) (pin 1))
(node (ref C1) (pin 1))
(node (ref RV1) (pin 3))
(node (ref RV2) (pin 3))
(node (ref J1) (pin 2))
(node (ref RV3) (pin 3))
(node (ref C3) (pin 2))
(node (ref U2) (pin 3))
(node (ref R1) (pin 1))
(node (ref C1) (pin 1))
(node (ref U1) (pin 8)))
(net (code 9) (name "Net-(R1-Pad2)")
(net (code 3) (name +12V)
(node (ref J2) (pin 2))
(node (ref C2) (pin 1))
(node (ref U2) (pin 1)))
(net (code 4) (name "Net-(J1-Pad3)")
(node (ref U1) (pin 5))
(node (ref J1) (pin 3)))
(net (code 5) (name "Net-(RV3-Pad2)")
(node (ref U1) (pin 2))
(node (ref RV3) (pin 2)))
(net (code 6) (name "Net-(RV2-Pad2)")
(node (ref RV2) (pin 2))
(node (ref U1) (pin 3)))
(net (code 7) (name "Net-(R1-Pad2)")
(node (ref R1) (pin 2))
(node (ref U1) (pin 1)))))
(node (ref U1) (pin 1)))
(net (code 8) (name "Net-(RV1-Pad2)")
(node (ref U1) (pin 7))
(node (ref RV1) (pin 2)))
(net (code 9) (name "Net-(SW1-Pad1)")
(node (ref U1) (pin 6))
(node (ref SW1) (pin 1)))))

444
kicad/RailroadSwitch/RailroadSwitch.sch
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@ -65,332 +65,406 @@ Wire Wire Line
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F 3 "~" H 4350 2400 50 0001 C CNN
1 4350 2400
1 0 0 -1
$EndComp
Wire Wire Line
4350 2250 4350 2100
Connection ~ 4350 2100
Wire Wire Line
4350 2100 4550 2100
Wire Wire Line
4350 2550 4850 2550
Connection ~ 4850 2550
Wire Wire Line
4850 2550 4850 2750
Wire Wire Line
5900 4450 6450 4450
Wire Wire Line
6450 4450 6450 4900
Wire Wire Line
6450 4900 6500 4900
$Comp
L Device:R_POT RV3
U 1 1 5C2EE588
P 7300 4900
F 0 "RV3" H 7231 4854 50 0000 R CNN
F 1 "10k" H 7231 4945 50 0000 R CNN
F 2 "Potentiometers:Potentiometer_Triwood_RM-065" H 7300 4900 50 0001 C CNN
F 3 "~" H 7300 4900 50 0001 C CNN
1 7300 4900
-1 0 0 1
$EndComp
$Comp
L power:+5V #PWR01
U 1 1 5C2EE618
P 7300 4750
F 0 "#PWR01" H 7300 4600 50 0001 C CNN
F 1 "+5V" H 7315 4923 50 0000 C CNN
F 2 "" H 7300 4750 50 0001 C CNN
F 3 "" H 7300 4750 50 0001 C CNN
1 7300 4750
1 0 0 -1
$EndComp
$Comp
L power:GND #PWR019
U 1 1 5C2EE639
P 7300 5050
F 0 "#PWR019" H 7300 4800 50 0001 C CNN
F 1 "GND" H 7305 4877 50 0000 C CNN
F 2 "" H 7300 5050 50 0001 C CNN
F 3 "" H 7300 5050 50 0001 C CNN
1 7300 5050
1 0 0 -1
$EndComp
Wire Wire Line
5900 4350 7050 4350
Wire Wire Line
7050 4350 7050 4900
Wire Wire Line
7050 4900 7150 4900
$Comp
L Device:C C3
U 1 1 5C2EF195
P 6100 3050
F 0 "C3" H 6215 3096 50 0000 L CNN
F 1 "470uF" H 6215 3005 50 0000 L CNN
F 2 "Capacitors_ThroughHole:CP_Radial_D6.3mm_P2.50mm" H 6138 2900 50 0001 C CNN
F 3 "~" H 6100 3050 50 0001 C CNN
1 6100 3050
1 0 0 -1
$EndComp
Connection ~ 6100 3200
Wire Wire Line
6100 3200 5950 3200
Wire Wire Line
5950 2900 6100 2900
Wire Wire Line
6100 2900 6450 2900
Wire Wire Line
6450 2900 6450 3100
Connection ~ 6100 2900
$EndSCHEMATC

104
src/main.cpp
View File

@ -12,36 +12,42 @@
Wiring:
+---u---+
10k R to +5V -| 1 8 |- +5V
NC -| 2 7 |- "Off" potentiometer
"On" potentiometer -| 3 6 |- On/Off switch (active low)
GND -| 4 5 |- Servo PWM signal
+-------+
+---u---+
10k R to +5V -| 1 8 |- +5V
"Speed" potentiometer (RV3) -| 2 7 |- "Off" potentiometer (RV1)
"On" potentiometer (RV2) -| 3 6 |- On/Off switch (active low)
GND -| 4 5 |- Servo PWM signal
+-------+
*/
static const uint8_t PinServo = 0;
static const uint8_t PinSwitch = 1;
static const uint8_t PinOffPosition = A1;
static const uint8_t PinOnPosition = A2;
static const uint8_t PinSpeed = A3;
static const float TransitionTime = 2000;
static const float TransitionTimeMin = 1;
static const float TransitionTimeMax = 5000;
static const uint16_t SleepTime = 10000;
static const uint16_t ServoMinPulse = 544;
static const uint16_t ServoMaxPulse = 2400;
static const uint16_t ServoPulseInterval = 20;
static const uint16_t ServoStabilizeDelay = 100;
int offPosition; // 0 - 180 degrees, read from "Off" potentiometer
int onPosition; // 0 - 180 degrees, read from "On" potentiometer
float speed; // Degrees per millisecond
int speed; // 0 - 1023, read from "Speed" potentiometer
float degreesPerMilli; // Degrees per millisecond
bool startOn; // If the switch was on when it was last flipped
bool lastOn; // If the switch was on when it was last flipped
int startPosition; // The position the servo was in when the switch was flipped
unsigned long startTime; // The last time the switch was flipped
unsigned long idleTime; // The last time anything happened
bool servoEnabled; // Whether or not pulses should be sent to the servo
int servoPosition; // The desired position of the servo
@ -55,10 +61,12 @@ SoftwareSerial debug(-1,3);
// Forward declarations
void pulseServo(unsigned long currentTime);
bool updateOnOffPositions();
bool updateSettings();
inline int getNewPosition(unsigned long currentTime, int targetPosition) __attribute__((always_inline));
void sleepUntilSwitch();
float floatMap(float x, float in_min, float in_max, float out_min, float out_max);
void setup()
{
@ -72,9 +80,13 @@ void setup()
pinMode(PinSwitch, INPUT_PULLUP);
pinMode(PinServo, OUTPUT);
updateOnOffPositions();
offPosition = -1;
onPosition = -1;
speed = -1;
startOn = false;
updateSettings();
lastOn = false;
startPosition = offPosition;
servoPosition = offPosition;
@ -97,15 +109,16 @@ void loop()
bool isOn = (digitalRead(PinSwitch) == LOW);
// If the switch changed, start from the last known position
if (isOn != startOn)
if (isOn != lastOn)
{
#ifdef DEBUG
debug.println("State changed");
#endif
startOn = isOn;
lastOn = isOn;
startPosition = servoPosition;
startTime = currentTime;
idleTime = startTime;
}
int targetPosition = isOn ? onPosition : offPosition;
@ -113,45 +126,52 @@ void loop()
{
servoPosition = getNewPosition(currentTime, targetPosition);
servoEnabled = true;
idleTime = currentTime;
}
else
else if (servoEnabled)
{
// Ensure we pulsed the last position
delay(20);
pulseServo(millis());
delay(20);
currentTime = millis();
delay(ServoPulseInterval);
pulseServo(currentTime);
delay(ServoPulseInterval);
// Stop sending pulses when we reach the destination, to prevent
// power consumption and possible buzzing
servoEnabled = false;
idleTime = currentTime;
}
if (!servoEnabled)
// Don't update the settings while the servo is moving, as the
// voltage drop can cause fluctuating results
if (!servoEnabled && currentTime - idleTime >= ServoStabilizeDelay)
{
// Don't update the positions while the servo is moving, as the
// voltage drop can cause fluctuating results
if (updateOnOffPositions())
if (updateSettings())
{
// Immediately go to the new position
currentTime = millis();
servoPosition = isOn ? onPosition : offPosition;
delay(20);
pulseServo(millis());
delay(20);
delay(ServoPulseInterval);
pulseServo(currentTime);
delay(ServoPulseInterval);
idleTime = currentTime;
}
}
// Stay awake for a bit to allow changes to the on and off positions
// to take effect immediately
if (currentTime - startTime >= SleepTime)
if (currentTime - idleTime >= SleepTime)
sleepUntilSwitch();
}
void pulseServo(unsigned long currentTime)
{
if (currentTime - servoPulseTime < 20)
if (currentTime - servoPulseTime < ServoPulseInterval)
return;
int pulseWidth = map(servoPosition, 0, 180, ServoMinPulse, ServoMaxPulse);
@ -171,23 +191,27 @@ void pulseServo(unsigned long currentTime)
}
bool updateOnOffPositions()
bool updateSettings()
{
int newOffPosition = map(analogRead(PinOffPosition), 0, 1023, 0, 180);
int newOnPosition = map(analogRead(PinOnPosition), 0, 1023, 0, 180);
int newSpeed = analogRead(PinSpeed);
if (newOffPosition != offPosition || newOnPosition != onPosition)
if (newOffPosition != offPosition || newOnPosition != onPosition || newSpeed != speed)
{
offPosition = newOffPosition;
onPosition = newOnPosition;
speed = newSpeed;
speed = abs((float)(onPosition - offPosition)) / TransitionTime;
float transitionTime = floatMap(speed, 0, 1023, TransitionTimeMin, TransitionTimeMax);
degreesPerMilli = abs((float)(onPosition - offPosition)) / transitionTime;
#ifdef DEBUG
debug.println("Positions changed");
debug.print(" Off position: "); debug.println(offPosition);
debug.print(" On position : "); debug.println(onPosition);
debug.print(" Speed : "); debug.println(speed);
debug.print(" Off position : "); debug.println(offPosition);
debug.print(" On position : "); debug.println(onPosition);
debug.print(" Transition time: "); debug.println(transitionTime);
debug.print(" Degrees / milli: "); debug.println(degreesPerMilli);
#endif
return true;
@ -200,17 +224,17 @@ bool updateOnOffPositions()
int getNewPosition(unsigned long currentTime, int targetPosition)
{
int newPosition;
float timePassed = currentTime - startTime;
unsigned long timePassed = currentTime - startTime;
if (targetPosition > startPosition)
{
newPosition = startPosition + (timePassed * speed);
newPosition = startPosition + ((float)timePassed * degreesPerMilli);
if (newPosition > targetPosition)
newPosition = targetPosition;
}
else
{
newPosition = startPosition - (timePassed * speed);
newPosition = startPosition - ((float)timePassed * degreesPerMilli);
if (newPosition < targetPosition)
newPosition = targetPosition;
}
@ -266,4 +290,10 @@ void sleepUntilSwitch()
PCMSK = 0;
sleepEnd();
}
}
float floatMap(float x, float in_min, float in_max, float out_min, float out_max)
{
return (x - in_min) * (out_max - out_min) / (in_max - in_min) + out_min;
}