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Merged
nmpluta merged 1 commit into from
Sep 6, 2025
Merged

modules: sensor: add warmup delays to prevent CCS811 early read failures #17

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4 changes: 2 additions & 2 deletions app/src/modules/controller/controller_module.c
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Original file line number Diff line number Diff line change
Expand Up @@ -15,7 +15,7 @@ ZBUS_SUBSCRIBER_DEFINE(controller_sensor_subscriber,
CONFIG_CONTROLLER_MODULE_ZBUS_SUBSCRIBER_QUEUE_SIZE);

/* Controller state machine object initialization macro */
#define CONTROLLER_MODULE_STATE_OBJECT_INIT() \
#define CONTROLLER_STATE_OBJECT_INIT() \
(struct controller_state_object) \
{ \
.sample_interval_ms = CONFIG_CONTROLLER_MODULE_SAMPLE_INTERVAL_MS, \
Expand Down Expand Up @@ -91,7 +91,7 @@ int controller_module_init(void)
LOG_INF("Initializing controller module");

/* Initialize state machine object */
controller_state_obj = CONTROLLER_MODULE_STATE_OBJECT_INIT();
controller_state_obj = CONTROLLER_STATE_OBJECT_INIT();

/* Initialize state machine */
smf_set_initial(SMF_CTX(&controller_state_obj),
Expand Down
30 changes: 30 additions & 0 deletions app/src/modules/sensor/Kconfig.sensor
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Expand Up @@ -46,6 +46,36 @@ config SENSOR_MODULE_MAX_RETRIES
help
Maximum number of recovery attempts before giving up.

# Sensor-specific warmup configurations
config SENSOR_MODULE_WARMUP_ENABLE
bool "Enable sensor warmup periods"
default y
help
Enable warmup delays for sensors that need stabilization time
before providing accurate readings.

config SENSOR_MODULE_CCS811_WARMUP_MS
int "CCS811 warmup period (ms)"
default 5000
depends on SENSOR_MODULE_WARMUP_ENABLE
help
Warmup time required for CCS811 sensor before first valid reading.
CCS811 needs time to stabilize after power-on or reset.

config SENSOR_MODULE_BME280_WARMUP_MS
int "BME280 warmup period (ms)"
default 100
depends on SENSOR_MODULE_WARMUP_ENABLE
help
Warmup time required for BME280 sensor before first valid reading.

config SENSOR_MODULE_HM3301_WARMUP_MS
int "HM3301 warmup period (ms)"
default 100
depends on SENSOR_MODULE_WARMUP_ENABLE
help
Warmup time required for HM3301 sensor before first valid reading.

config CCS811_ENV_COMPENSATION
bool "Enable environmental compensation for CCS811"
default y
Expand Down
117 changes: 111 additions & 6 deletions app/src/modules/sensor/sensor_module.c
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Original file line number Diff line number Diff line change
Expand Up @@ -10,11 +10,18 @@

LOG_MODULE_REGISTER(sensor_module, CONFIG_SENSOR_MODULE_LOG_LEVEL);

/* Macro to validate sensor type enum values */
#define IS_VALID_SENSOR_TYPE(type) ((int)(type) >= 0 && (type) < SENSOR_TYPE_COUNT)

/* Macro for type-safe sensor state object initialization */
#define SENSOR_STATE_OBJECT_INIT() \
(struct sensor_state_object) \
{ \
.ctx = {0}, .current_state = SENSOR_MODULE_STATE_INIT, .current_data = {0}, \
.error_count = 0, .max_retries = 0, .last_read_time = 0, .read_timeout_ms = 0 \
.error_count = 0, .max_retries = 0, .last_read_time = 0, .read_timeout_ms = 0, \
IF_ENABLED(CONFIG_SENSOR_MODULE_WARMUP_ENABLE, \
(.sensor_init_time = 0, \
.sensor_warmup_complete = {false})) \
}

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/* ZBUS subscriber for sensor requests */
Expand Down Expand Up @@ -56,6 +63,12 @@ struct sensor_state_object {
/* Timing */
int64_t last_read_time;
int64_t read_timeout_ms;

#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
/* Sensor warmup tracking */
int64_t sensor_init_time;
bool sensor_warmup_complete[SENSOR_TYPE_COUNT];
#endif
};

/* Forward declarations for state functions */
Expand Down Expand Up @@ -115,6 +128,11 @@ static void update_sensor_health(struct sensor_health *health, bool success);
static const char *get_sensor_name(enum sensor_type type);
static void sensor_set_state(struct sensor_state_object *ctx, enum sensor_module_state new_state);

#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
static bool is_sensor_warmup_complete(enum sensor_type type);
static int64_t get_sensor_warmup_time(enum sensor_type type);
#endif

#ifdef CONFIG_CCS811_ENV_COMPENSATION
static int update_ccs811_env_data(const struct sensor_value *temp, const struct sensor_value *hum);
static void handle_ccs811_env_compensation(const struct sensor_value *temp,
Expand All @@ -127,7 +145,7 @@ int sensor_module_init(void)
int ret;

/* Initialize state machine context */
sensor_state_obj = (struct sensor_state_object)SENSOR_STATE_OBJECT_INIT();
sensor_state_obj = SENSOR_STATE_OBJECT_INIT();
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sensor_state_obj.max_retries = CONFIG_SENSOR_MODULE_MAX_RETRIES;
sensor_state_obj.read_timeout_ms = CONFIG_SENSOR_MODULE_READ_TIMEOUT_MS;
Expand Down Expand Up @@ -246,6 +264,14 @@ static void sensor_state_init_run(void *obj)
return;
}

#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
/* Initialize warmup timing */
ctx->sensor_init_time = k_uptime_get();
for (int i = 0; i < SENSOR_TYPE_COUNT; i++) {
ctx->sensor_warmup_complete[i] = false;
}
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#endif

/* Initialize context with configured values */
ctx->error_count = 0;
ctx->max_retries = sensor_state_obj.max_retries;
Expand Down Expand Up @@ -292,6 +318,15 @@ static void sensor_state_reading_run(void *obj)
continue;
}

#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
/* Check if sensor warmup is complete */
if (!is_sensor_warmup_complete(i)) {
LOG_DBG("Sensor SM: %s warmup not complete, skipping read",
get_sensor_name(i));
continue;
}
#endif

int ret = read_sensor_data(i, &ctx->current_data);
if (ret == 0) {
successful_reads++;
Expand Down Expand Up @@ -319,18 +354,43 @@ static void sensor_state_reading_run(void *obj)
}
}

/* Count enabled sensors */
/* Count enabled sensors that have completed warmup */
int enabled_sensor_count = 0;
for (int i = 0; i < SENSOR_TYPE_COUNT; i++) {
if (sensors[i].enabled) {
#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
if (is_sensor_warmup_complete(i)) {
enabled_sensor_count++;
}
#else
enabled_sensor_count++;
#endif
}
}

/* Only publish data if at least one sensor read successfully */
if (successful_reads == 0) {
#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
/* Check if any sensors are still warming up */
bool any_warming = false;
for (int i = 0; i < SENSOR_TYPE_COUNT; i++) {
if (sensors[i].enabled && !is_sensor_warmup_complete(i)) {
any_warming = true;
break;
}
}

if (any_warming) {
LOG_DBG("Sensor SM: No readings yet - sensors still warming up");
sensor_set_state(ctx, SENSOR_MODULE_STATE_IDLE);
} else {
LOG_ERR("Sensor SM: All sensors failed, entering error state");
sensor_set_state(ctx, SENSOR_MODULE_STATE_ERROR);
}
#else
LOG_ERR("Sensor SM: All sensors failed, entering error state");
sensor_set_state(ctx, SENSOR_MODULE_STATE_ERROR);
#endif
} else if (successful_reads < enabled_sensor_count) {
LOG_WRN("Sensor SM: Partial sensor failure (%d/%d successful), but publishing "
"available data",
Expand Down Expand Up @@ -441,8 +501,8 @@ static int read_sensor_data(enum sensor_type type, struct sensor_msg *data)
return -EINVAL;
}

if (type >= SENSOR_TYPE_COUNT || !sensors[type].enabled) {
LOG_ERR("Invalid or disabled sensor type: %d", type);
if (!IS_VALID_SENSOR_TYPE(type) || !sensors[type].enabled) {
LOG_ERR("Invalid or disabled sensor type: %d", (int)type);
return -EINVAL;
}

Expand Down Expand Up @@ -610,7 +670,7 @@ static void handle_ccs811_fallback_compensation(void)

int sensor_module_get_sensor_info(enum sensor_type sensor_type, struct sensor_info *sensor_info)
{
if (sensor_type >= SENSOR_TYPE_COUNT || !sensor_info) {
if (!IS_VALID_SENSOR_TYPE(sensor_type) || !sensor_info) {
LOG_ERR("Invalid parameters for sensor info request");
return -EINVAL;
}
Expand Down Expand Up @@ -703,3 +763,48 @@ static void sensor_set_state(struct sensor_state_object *ctx, enum sensor_module
ctx->current_state = new_state;
smf_set_state(SMF_CTX(ctx), &sensor_states[new_state]);
}

#ifdef CONFIG_SENSOR_MODULE_WARMUP_ENABLE
/* Helper function to get warmup time for a sensor type */
static int64_t get_sensor_warmup_time(enum sensor_type type)
{
switch (type) {
case SENSOR_TYPE_BME280:
return CONFIG_SENSOR_MODULE_BME280_WARMUP_MS;
case SENSOR_TYPE_CCS811:
return CONFIG_SENSOR_MODULE_CCS811_WARMUP_MS;
case SENSOR_TYPE_HM3301:
return CONFIG_SENSOR_MODULE_HM3301_WARMUP_MS;
default:
return 0;
}
}

/* Helper function to check if sensor warmup is complete */
static bool is_sensor_warmup_complete(enum sensor_type type)
{
if (!IS_VALID_SENSOR_TYPE(type)) {
LOG_ERR("Invalid sensor type: %d", (int)type);
return false;
}

/* Check if already marked as complete */
if (sensor_state_obj.sensor_warmup_complete[type]) {
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return true;
}

/* Check if warmup time has elapsed */
int64_t elapsed_time = k_uptime_get() - sensor_state_obj.sensor_init_time;
int64_t warmup_time = get_sensor_warmup_time(type);

if (elapsed_time >= warmup_time) {
/* Mark as complete and log */
sensor_state_obj.sensor_warmup_complete[type] = true;
LOG_INF("Sensor SM: %s warmup complete after %lld ms", get_sensor_name(type),
elapsed_time);
return true;
}

return false;
}
#endif /* CONFIG_SENSOR_MODULE_WARMUP_ENABLE */