added firmware section

2026-05-18 21:55:20 +02:00
parent 6e62cb7b57
commit 68cb57af28
16 changed files with 22474 additions and 21132 deletions
--- a/Flow_Controller.kicad_pcb
+++ b/Flow_Controller.kicad_pcb
@@ -68,8 +68,8 @@
 		(allow_soldermask_bridges_in_footprints no)
 		(tenting front back)
 		(pcbplotparams
-			(layerselection 0x00000000_00000000_55555555_5755f5ff)
-			(plot_on_all_layers_selection 0x00000000_00000000_00000000_00000000)
+			(layerselection 0x00000000_00000000_55555555_555555d0)
+			(plot_on_all_layers_selection 0x00000000_00000000_00000000_02008000)
 			(disableapertmacros no)
 			(usegerberextensions no)
 			(usegerberattributes yes)
@@ -100,9 +100,9 @@
 			(sketchdnponfab yes)
 			(crossoutdnponfab yes)
 			(subtractmaskfromsilk no)
-			(outputformat 1)
+			(outputformat 5)
 			(mirror no)
-			(drillshape 1)
+			(drillshape 0)
 			(scaleselection 1)
 			(outputdirectory "")
 		)
@@ -4029,19 +4029,6 @@
 			(justify bottom mirror)
 		)
 	)
-	(gr_text "SENSOR"
-		(at 34.544 40.767 0)
-		(layer "F.SilkS")
-		(uuid "3274ea7c-b64f-4229-b4b2-adc8cbdd17a6")
-		(effects
-			(font
-				(size 0.8128 0.8128)
-				(thickness 0.1524)
-				(bold yes)
-			)
-			(justify left bottom)
-		)
-	)
 	(gr_text "GND"
 		(at 34.544 43.053 0)
 		(layer "F.SilkS")
@@ -4068,6 +4055,19 @@
 			(justify left bottom)
 		)
 	)
+	(gr_text "SENSOR"
+		(at 34.65 40.55 0)
+		(layer "F.SilkS")
+		(uuid "3274ea7c-b64f-4229-b4b2-adc8cbdd17a6")
+		(effects
+			(font
+				(size 0.8128 0.8128)
+				(thickness 0.1524)
+				(bold yes)
+			)
+			(justify left bottom)
+		)
+	)
 	(gr_text "ALARM CNC"
 		(at 41.5 13.547 0)
 		(layer "F.SilkS")
@@ -4120,10 +4120,10 @@
 			(justify right bottom)
 		)
 	)
-	(gr_text "VCC"
-		(at 35.977 8.128 90)
+	(gr_text "GND"
+		(at 35.9 8.2 90)
 		(layer "F.SilkS")
-		(uuid "28f438a7-b55b-414b-95c5-54379ad95405")
+		(uuid "4dca8764-21dc-4b40-8815-cb83450a8ad1")
 		(effects
 			(font
 				(size 0.8128 0.8128)
@@ -4133,10 +4133,10 @@
 			(justify right bottom)
 		)
 	)
-	(gr_text "GND"
-		(at 38.481 8.128 90)
+	(gr_text "VCC"
+		(at 38.55 8.15 90)
 		(layer "F.SilkS")
-		(uuid "4dca8764-21dc-4b40-8815-cb83450a8ad1")
+		(uuid "28f438a7-b55b-414b-95c5-54379ad95405")
 		(effects
 			(font
 				(size 0.8128 0.8128)
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-				(xy 4.856153 32.160499) (xy 4.856156 32.1605) (xy 4.856158 32.1605) (xy 5.013842 32.1605) (xy 6.215106 32.1605)
+				(xy 3.040602 30.554172) (xy 3.040609 30.554185) (xy 3.12821 30.685288) (xy 3.128213 30.685292) (xy 4.313211 31.870289)
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+				(xy 4.701503 32.129737) (xy 4.856153 32.160499) (xy 4.856156 32.1605) (xy 4.856158 32.1605) (xy 6.215106 32.1605)
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--- a/Flow_Controller.kicad_prl
+++ b/Flow_Controller.kicad_prl
@@ -23,8 +23,8 @@
      "lockedItems": false,
      "otherItems": false,
      "pads": false,
-      "text": false,
-      "tracks": true,
+      "text": true,
+      "tracks": false,
      "vias": false,
      "zones": false
    },
--- a/Flow_Controller.kicad_pro
+++ b/Flow_Controller.kicad_pro
@@ -585,12 +585,24 @@
          "label": "Datasheet",
          "name": "Datasheet",
          "show": true
+        },
+        {
+          "group_by": false,
+          "label": "Description",
+          "name": "Description",
+          "show": false
+        },
+        {
+          "group_by": false,
+          "label": "#",
+          "name": "${ITEM_NUMBER}",
+          "show": false
        }
      ],
      "filter_string": "",
      "group_symbols": true,
      "include_excluded_from_bom": true,
-      "name": "Default Editing",
+      "name": "",
      "sort_asc": true,
      "sort_field": "Reference"
    },
--- a/Readme.md
+++ b/Readme.md
@@ -17,7 +17,7 @@ Designed in **KiCad v9**.
 3. [Panel Design and GCode](#panel-design-and-gcode)
 4. [Microcontroller Pin Mapping](#microcontroller-pin-mapping)
 5. [Firmware Logic](#firmware-logic)
-6. [Development & Programming](#development--programming)
+6. [Firmware Build & Flashing](#firmware-build--flashing)

 ## Features
 * **Microcontroller:** WCH CH32V003J4M6 (RISC-V).
@@ -36,24 +36,28 @@ Designed in **KiCad v9**.
 The [scripts](scripts) folder contains a guide to panelize the board (`Flow_Controller_Panel.kicad_pcb`) and howto generate gcode.

 ## Microcontroller Pin Mapping (Per Schematic)
-| Pin | Schematic Net | Function |
-| :--- | :--- | :--- |
-| 1 | `FLOW_PULSE_MCU` | Input: Pulse counter from Flow Sensor (via RC Filter) |
-| 2 | `GND` | System Ground (VSS) |
-| 3 | `ALARM_TRIGGER` | Output: Drives the Gate of the 2N7002 MOSFET |
-| 4 | `+5V` | System Power (VDD) |
-| 5 | `I2C_SDA` | I2C Data (OLED Display) |
-| 6 | `I2C_SCL` | I2C Clock (OLED Display) |
-| 7 | `BUTTON_ADC` | ADC Input: 2-Button Resistor Ladder |
-| 8 | `SWIO` | WCH-LinkE Programming Interface |
+| Pin | Schematic Net | Function | MCU Port (SOP8) |
+| :--- | :--- | :--- | :--- |
+| 1 | `FLOW_PULSE_MCU` | Input: Pulse counter from Flow Sensor | PD6 |
+| 2 | `GND` | System Ground (VSS) | VSS |
+| 3 | `ALARM_TRIGGER` | Output: Drives the Gate of the 2N7002 | PA2 |
+| 4 | `+5V` | System Power (VDD) | VDD |
+| 5 | `I2C_SDA` | I2C Data (OLED Display) | PC1 |
+| 6 | `I2C_SCL` | I2C Clock (OLED Display) | PC2 |
+| 7 | `BUTTON_ADC` | ADC Input: 2-Button Resistor Ladder | PC4 |
+| 8 | `SWIO` | WCH-LinkE Programming Interface | PD1 |

 ## Firmware Logic (Overview)
-1. **Interrupts:** Pin 1 counts falling edges from the flow sensor. Flow (L/min) is calculated every second.
+1. **Interrupts:** Pin 1 (PD6) counts falling edges from the flow sensor. Flow (L/min) is calculated every second.
 2. **Failsafe:** If `Current_Flow >= Threshold`, Pin 3 is driven **HIGH** (MOSFET ON, CNC OK). If `Current_Flow < Threshold`, Pin 3 is driven **LOW** (MOSFET OFF, CNC Alarm).
-3. **UI:** ADC reads Pin 7 to detect button presses for adjusting the threshold.
+3. **UI:** ADC reads Pin 7 (PC4) to detect button presses for adjusting the threshold.
 4. **Storage:** User-defined threshold is saved to MCU flash memory.

-## Development & Programming
-To flash the CH32V003, you will need a **WCH-LinkE** programmer connected to the 3-pin SWIO header `J1` (+5V, SWIO, GND).
-
+## Firmware Build & Flashing
+The firmware is written in C using the lightweight `ch32fun` framework. All source files and toolchain documentation are located in the `firmware` folder.

+**Step-by-step Setup:**
+1. Follow the setup guide in [`firmware/Readme.md`](firmware/Readme.md) to install the RISC-V GCC toolchain and `minichlink`.
+2. Connect your **WCH-LinkE** programmer to the 3-pin SWIO header `J1` (+5V, SWIO, GND).
+3. Run `make` to compile the firmware.
+4. Run `make flash` to upload the code to the CH32V003 microcontroller.
--- a/firmware/.gitignore
+++ b/firmware/.gitignore
@@ -0,0 +1,15 @@
+# Compiled binaries
+*.elf
+*.bin
+*.hex
+
+# Build artifacts and memory maps
+*.map
+*.o
+*.d
+*.lst
+
+# Specifically ignore the output files for our target
+main.elf
+main.bin
+main.map
--- a/firmware/Makefile
+++ b/firmware/Makefile
@@ -0,0 +1,12 @@
+all : flash
+
+TARGET:=main
+TARGET_MCU:=CH32V003
+
+# Path based on your error output
+CH32FUN:=/home/martin/ch32fun/ch32fun
+
+include $(CH32FUN)/ch32fun.mk
+
+flash : cv_flash
+clean : cv_clean
--- a/firmware/Readme.md
+++ b/firmware/Readme.md
@@ -0,0 +1,80 @@
+# CH32V003 Firmware & Linux Development Setup
+
+This folder contains the firmware source code for the CNC Water Flow Controller, built using the [ch32fun](https://github.com/cnlohr/ch32fun) framework. 
+
+Below is the guide to set up the build environment, compile, and flash the CH32V003 series on Linux using CLI tools.
+
+*Tested on: Ubuntu Linux, CH32V003J4M6 (8-pin)*
+
+---
+
+## 1. Install toolchain
+
+Download xPack RISC-V GCC:
+[https://github.com/xpack-dev-tools/riscv-none-elf-gcc-xpack/releases](https://github.com/xpack-dev-tools/riscv-none-elf-gcc-xpack/releases)
+
+Extract it:
+```bash
+mkdir -p ~/toolchains
+tar -xzf xpack-riscv-none-elf-gcc-*-linux-x64.tar.gz -C ~/toolchains
+```
+
+Activate it (add this to your ~/.bashrc for permanence):
+```Bash
+export TOOLCHAIN=$HOME/toolchains/xpack-riscv-none-elf-gcc-* # Update e.g.: xpack-riscv-none-elf-gcc-15.2.0-1
+export PATH=$TOOLCHAIN/bin:$PATH
+```
+
+Verify the installation:
+```Bash
+riscv-none-elf-gcc --version
+```
+
+## 2. Install Flashing Tool (minichlink)
+Clone the ch32fun repository and build minichlink:
+```Bash
+git clone https://github.com/cnlohr/ch32fun ~/ch32fun
+cd ~/ch32fun/minichlink
+make
+sudo mv minichlink /usr/local/bin/
+```
+
+## 3. Build the Firmware
+Navigate to this firmware directory where the Makefile and main.c are located. Make sure the CH32FUN path in the Makefile points to where you cloned ch32fun.
+```Bash
+cd Flow-Controller/firmware
+make clean
+make
+```
+This will generate main.bin and main.elf.
+
+## 4. Flash Firmware
+Connect your WCH-LinkE programmer to the board's J1 header:
+| Signal | Programmer | MCU Header (J1) |
+| :--- | :--- | :--- |
+| SWIO | SWDIO | Pin 3 (SWIO) |
+| GND | GND | Pin 2 (GND) |
+| 5V | 3.3V | Pin 1 (+3.3V) |
+Flash the compiled binary:
+```Bash
+make flash
+```
+or manually: 
+```bash
+minichlink -w main.bin flash
+```
+
+## 5. Logs
+See logs on the SWIO pin:
+```Bash
+minichlink -T
+```
+
+## 6. Unbricking
+If you accidentally misconfigure the SWIO pin and lock yourself out, you can use the CH32V003 Unbrick CLI tool:
+```Bash
+git clone https://github.com/shakir-abdo/ch32v003-unbrick.git
+cd ch32v003-unbrick
+npm install
+./unbrick.js
+```
--- a/firmware/funconfig.h
+++ b/firmware/funconfig.h
@@ -0,0 +1,13 @@
+#ifndef _FUNCONFIG_H
+#define _FUNCONFIG_H
+
+#define CH32V003 1
+
+// Default system clock to 48MHz
+#define FUNCONF_SYSTEM_CORE_CLOCK 48000000
+
+// support "printf-over-single-wire" at about 400kBaud on the SWIO pin (PD1)
+#define FUNCONF_USE_DEBUGPRINTF 1
+#define FUNCONF_USE_UARTPRINTF  0
+
+#endif // _FUNCONFIG_H
--- a/firmware/main.c
+++ b/firmware/main.c
@@ -0,0 +1,169 @@
+#include "ch32fun.h"
+#include <stdio.h>
+
+// ==========================================
+// PIN CONFIGURATION (CH32V003J4M6 - SOP8)
+// ==========================================
+// Package Pin 1: PD6 (FLOW_PULSE_MCU) -> EXTI Input
+// Package Pin 3: PA2 (ALARM_TRIGGER)  -> GPIO Output
+// Package Pin 5: PC1 (I2C_SDA)        -> Bitbang or HW I2C
+// Package Pin 6: PC2 (I2C_SCL)        -> Bitbang or HW I2C
+// Package Pin 7: PC4 (BUTTON_ADC)     -> ADC Channel 2 Input
+// Package Pin 8: PD1 (SWIO) -> Programming & Logging
+
+#define FLOW_PIN      6 // PD6 = bit 6 of GPIOD
+#define ALARM_PIN     2 // PA2 = bit 2 of GPIOA
+#define BUTTON_PIN    4 // PC4 = bit 4 of GPIOC
+
+// Constants
+#define FLOW_CONVERSION_FACTOR 5.5  // L/min = Hz / 5.5 (Adjust for ZJ-S401)
+
+#define ADC_UP_BTN_MAX     200  // Button 1 range: 50..200  (center ~93)
+#define ADC_UP_BTN_MIN      20
+#define ADC_DOWN_BTN_MAX    15  // Button 2 range: 0..15    (should read ~0)
+
+#define DEBOUNCE_DELAY_MS   200
+
+// Globals
+volatile uint32_t pulse_count = 0;
+uint32_t flow_rate_ml_min = 0;    // Stored in mL/min for integer precision
+uint32_t threshold_ml_min = 2000; // Default: 2.0 L/min
+uint8_t  alarm_active = 0;        // Track state to prevent log spam (0 = OK, 1 = ALARM)
+
+// ==========================================
+// INTERRUPT HANDLER (Flow Sensor Pulses)
+// ==========================================
+void EXTI7_0_IRQHandler(void) __attribute__((interrupt));
+void EXTI7_0_IRQHandler(void) {
+    if (EXTI->INTFR & (1 << FLOW_PIN)) {
+        pulse_count++;
+        EXTI->INTFR = (1 << FLOW_PIN); // Clear interrupt flag
+    }
+}
+
+// ==========================================
+// HARDWARE INITIALIZATION
+// ==========================================
+void Init_Hardware(void) {
+    // 1. Enable Clocks for GPIOA, GPIOC, GPIOD, ADC, AFIO
+    RCC->APB2PCENR |= RCC_APB2Periph_GPIOA | RCC_APB2Periph_GPIOC | RCC_APB2Periph_GPIOD | RCC_APB2Periph_ADC1 | RCC_APB2Periph_AFIO;
+
+    // 2. Configure ALARM_TRIGGER Output (PA2) - Push-Pull
+    GPIOA->CFGLR &= ~(0xF << (4 * ALARM_PIN));
+    GPIOA->CFGLR |= (GPIO_Speed_10MHz | GPIO_CNF_OUT_PP) << (4 * ALARM_PIN);
+    GPIOA->BSHR = (1 << (16 + ALARM_PIN)); // Default to ALARM STATE (Low = MOSFET OFF)
+
+    // 3. Configure FLOW_PULSE_MCU Input (PD6) - Pull-up
+    GPIOD->CFGLR &= ~(0xF << (4 * FLOW_PIN));
+    GPIOD->CFGLR |= (GPIO_CNF_IN_PUPD) << (4 * FLOW_PIN);
+    GPIOD->BSHR = (1 << FLOW_PIN); // Enable pull-up
+
+    // Setup EXTI on PD6 (CH32V003 has single EXTICR, 2 bits per pin, Port D = 0b11)
+    AFIO->EXTICR |= (0b11 << (FLOW_PIN * 2));   // PD6: Port D=0b11, bits [13:12]
+    EXTI->INTENR |= (1 << FLOW_PIN);             // Enable EXTI interrupt on line 6
+    EXTI->FTENR  |= (1 << FLOW_PIN);             // Falling edge trigger
+    NVIC_EnableIRQ(EXTI7_0_IRQn);                // Enable interrupt in NVIC
+
+    // 4. Configure BUTTON_ADC Input (PC4 / AIN2) - Analog mode (no pull)
+    GPIOC->CFGLR &= ~(0xF << (4 * BUTTON_PIN));
+
+    // Setup ADC
+    ADC1->CTLR2 |= ADC_ADON;       // Turn on ADC
+    ADC1->RSQR3 = 2;               // PC4 is ADC Channel 2 (AIN2)
+    ADC1->SAMPTR2 = 7 << (3 * 2);  // Max sampling time for CH2
+
+    ADC1->CTLR2 |= ADC_RSTCAL;     // Reset & calibrate
+    while(ADC1->CTLR2 & ADC_RSTCAL);
+    ADC1->CTLR2 |= ADC_CAL;
+    while(ADC1->CTLR2 & ADC_CAL);
+}
+
+// ==========================================
+// HELPER FUNCTIONS
+// ==========================================
+uint16_t Read_ADC(void) {
+    ADC1->CTLR2 |= ADC_SWSTART;
+    while(!(ADC1->STATR & ADC_EOC));
+    return ADC1->RDATAR;
+}
+
+void Update_Display(uint32_t current_flow, uint32_t threshold) {
+    // TODO: Implement OLED I2C drawing here using ch32fun's I2C bitbang
+}
+
+// ==========================================
+// MAIN LOOP
+// ==========================================
+int main() {
+    SystemInit();
+    Init_Hardware();
+
+    printf("\r\n==================================\r\n");
+    printf(" CNC Flow Controller Initialized\r\n");
+    printf("==================================\r\n");
+    printf("[INFO] Active Threshold: %lu mL/min\r\n", threshold_ml_min);
+
+    uint32_t last_time = SysTick->CNT;
+    uint32_t last_button_time = 0;
+
+    while(1) {
+        uint32_t current_time = SysTick->CNT;
+        uint32_t ticks_per_sec = DELAY_US_TIME * 1000000; // = FUNCONF_SYSTEM_CORE_CLOCK
+
+        // --- 1. EVALUATE FLOW EVERY 1 SECOND ---
+        if ((current_time - last_time) >= ticks_per_sec) {
+            last_time = current_time;
+
+            // Copy and reset pulse count safely
+            NVIC_DisableIRQ(EXTI7_0_IRQn);
+            uint32_t hz = pulse_count;
+            pulse_count = 0;
+            NVIC_EnableIRQ(EXTI7_0_IRQn);
+
+            // Calculate Flow: L/min = Hz / 5.5 => mL/min = (Hz * 10000) / 55
+            flow_rate_ml_min = (hz * 10000) / 55;
+
+            // --- 2. FAILSAFE LOGIC & LOGGING ---
+            if (flow_rate_ml_min >= threshold_ml_min) {
+                // Flow OK -> Drive ALARM_PIN High (MOSFET ON, CNC OK)
+                GPIOA->BSHR = (1 << ALARM_PIN);
+
+                if (alarm_active == 1) {
+                    alarm_active = 0;
+                    printf("[INFO] Flow restored: %lu mL/min. Alarm CLEARED.\r\n", flow_rate_ml_min);
+                }
+            } else {
+                // Flow Low -> Drive ALARM_PIN Low (MOSFET OFF, CNC Alarm)
+                GPIOA->BSHR = (1 << (16 + ALARM_PIN));
+
+                if (alarm_active == 0) {
+                    alarm_active = 1;
+                    printf("[WARN] Low flow detected: %lu mL/min (Thr: %lu). Alarm TRIGGERED!\r\n", flow_rate_ml_min, threshold_ml_min);
+                }
+            }
+
+            Update_Display(flow_rate_ml_min, threshold_ml_min);
+        }
+
+        // --- 3. BUTTON HANDLING (ADC Resistor Ladder) ---
+        // Thresholds match actual voltages: no-press ~1023, BTN1 ~93, BTN2 ~0.
+        uint16_t adc_val = Read_ADC();
+
+        if ((current_time - last_button_time) > (DEBOUNCE_DELAY_MS * DELAY_US_TIME * 1000)) {
+            if (adc_val >= ADC_UP_BTN_MIN && adc_val <= ADC_UP_BTN_MAX) {
+                // Button 1: voltage divider 10k+1k -> ~0.30V -> ADC ~93
+                threshold_ml_min += 100;
+                last_button_time = current_time;
+                printf("[SET] Threshold increased to: %lu mL/min\r\n", threshold_ml_min);
+                Update_Display(flow_rate_ml_min, threshold_ml_min);
+            }
+            else if (adc_val <= ADC_DOWN_BTN_MAX) {
+                // Button 2: direct to GND -> ~0V -> ADC ~0
+                if (threshold_ml_min >= 100) threshold_ml_min -= 100;
+                last_button_time = current_time;
+                printf("[SET] Threshold decreased to: %lu mL/min\r\n", threshold_ml_min);
+                Update_Display(flow_rate_ml_min, threshold_ml_min);
+            }
+        }
+    }
+}
--- a/images/Flow_Controller.svg
+++ b/images/Flow_Controller.svg
--- a/scripts/panel/Flow_Controller_Panel-Back.pdf
+++ b/scripts/panel/Flow_Controller_Panel-Back.pdf
--- a/scripts/panel/Flow_Controller_Panel-Back.svg
+++ b/scripts/panel/Flow_Controller_Panel-Back.svg
--- a/scripts/panel/Flow_Controller_Panel-Front.pdf
+++ b/scripts/panel/Flow_Controller_Panel-Front.pdf
--- a/scripts/panel/Flow_Controller_Panel-Front.svg
+++ b/scripts/panel/Flow_Controller_Panel-Front.svg
--- a/scripts/panel/Flow_Controller_Panel.kicad_prl
+++ b/scripts/panel/Flow_Controller_Panel.kicad_prl
@@ -50,7 +50,7 @@
      "conflict_shadows",
      "shapes"
    ],
-    "visible_layers": "fffffff_ffffffff",
+    "visible_layers": "00000000_00000000_0fffffff_fffffffe",
    "zone_display_mode": 0
  },
  "git": {
--- a/scripts/panel/Flow_Controller_Panel.kicad_pro
+++ b/scripts/panel/Flow_Controller_Panel.kicad_pro
@@ -319,7 +319,7 @@
      "version": 4
    },
    "net_colors": null,
-    "netclass_assignments": {},
+    "netclass_assignments": null,
    "netclass_patterns": [
      {
        "netclass": "Board_0-Default",