Add Current based cover (#1439)

* Adding first version of current_base cover. No Interlock yet.

* simplifying code

* Implementing malfunction protection

* Adding test

* Fixing too long lines

* Fixing test sensor names

* Adding missing id's in ade7953 tests

* Adding code owners as requested

* Fixing issue setting position when stop reached

* Fixing issue setting position when stop reached

* Black formatting

* Fixing format issues

* Fix for concurrent changes

Co-authored-by: Oxan van Leeuwen <oxan@oxanvanleeuwen.nl>

CODEOWNERS

@@ -39,6 +39,7 @@ esphome/components/coolix/* @glmnet
 esphome/components/cover/* @esphome/core
 esphome/components/cs5460a/* @balrog-kun
 esphome/components/ct_clamp/* @jesserockz
+esphome/components/current_based/* @djwmarcx
 esphome/components/daly_bms/* @s1lvi0
 esphome/components/dashboard_import/* @esphome/core
 esphome/components/debug/* @OttoWinter

esphome/components/current_based/__init__.py

@@ -0,0 +1 @@
+CODEOWNERS = ["@djwmarcx"]

esphome/components/current_based/cover.py

@@ -0,0 +1,124 @@
+import esphome.codegen as cg
+import esphome.config_validation as cv
+from esphome import automation
+from esphome.components import sensor, cover
+from esphome.const import (
+    CONF_CLOSE_ACTION,
+    CONF_CLOSE_DURATION,
+    CONF_ID,
+    CONF_OPEN_ACTION,
+    CONF_OPEN_DURATION,
+    CONF_STOP_ACTION,
+    CONF_MAX_DURATION,
+)
+
+
+CONF_OPEN_SENSOR = "open_sensor"
+CONF_OPEN_MOVING_CURRENT_THRESHOLD = "open_moving_current_threshold"
+CONF_OPEN_OBSTACLE_CURRENT_THRESHOLD = "open_obstacle_current_threshold"
+
+CONF_CLOSE_SENSOR = "close_sensor"
+CONF_CLOSE_MOVING_CURRENT_THRESHOLD = "close_moving_current_threshold"
+CONF_CLOSE_OBSTACLE_CURRENT_THRESHOLD = "close_obstacle_current_threshold"
+
+CONF_OBSTACLE_ROLLBACK = "obstacle_rollback"
+CONF_MALFUNCTION_DETECTION = "malfunction_detection"
+CONF_MALFUNCTION_ACTION = "malfunction_action"
+CONF_START_SENSING_DELAY = "start_sensing_delay"
+
+current_based_ns = cg.esphome_ns.namespace("current_based")
+CurrentBasedCover = current_based_ns.class_(
+    "CurrentBasedCover", cover.Cover, cg.Component
+)
+
+CONFIG_SCHEMA = cover.COVER_SCHEMA.extend(
+    {
+        cv.GenerateID(): cv.declare_id(CurrentBasedCover),
+        cv.Required(CONF_STOP_ACTION): automation.validate_automation(single=True),
+        cv.Required(CONF_OPEN_SENSOR): cv.use_id(sensor.Sensor),
+        cv.Required(CONF_OPEN_MOVING_CURRENT_THRESHOLD): cv.float_range(
+            min=0, min_included=False
+        ),
+        cv.Optional(CONF_OPEN_OBSTACLE_CURRENT_THRESHOLD): cv.float_range(
+            min=0, min_included=False
+        ),
+        cv.Required(CONF_OPEN_ACTION): automation.validate_automation(single=True),
+        cv.Required(CONF_OPEN_DURATION): cv.positive_time_period_milliseconds,
+        cv.Required(CONF_CLOSE_SENSOR): cv.use_id(sensor.Sensor),
+        cv.Required(CONF_CLOSE_MOVING_CURRENT_THRESHOLD): cv.float_range(
+            min=0, min_included=False
+        ),
+        cv.Optional(CONF_CLOSE_OBSTACLE_CURRENT_THRESHOLD): cv.float_range(
+            min=0, min_included=False
+        ),
+        cv.Required(CONF_CLOSE_ACTION): automation.validate_automation(single=True),
+        cv.Required(CONF_CLOSE_DURATION): cv.positive_time_period_milliseconds,
+        cv.Optional(CONF_OBSTACLE_ROLLBACK, default="10%"): cv.percentage,
+        cv.Optional(CONF_MAX_DURATION): cv.positive_time_period_milliseconds,
+        cv.Optional(CONF_MALFUNCTION_DETECTION, default=True): cv.boolean,
+        cv.Optional(CONF_MALFUNCTION_ACTION): automation.validate_automation(
+            single=True
+        ),
+        cv.Optional(
+            CONF_START_SENSING_DELAY, default="500ms"
+        ): cv.positive_time_period_milliseconds,
+    }
+).extend(cv.COMPONENT_SCHEMA)
+
+
+def to_code(config):
+    var = cg.new_Pvariable(config[CONF_ID])
+    yield cg.register_component(var, config)
+    yield cover.register_cover(var, config)
+
+    yield automation.build_automation(
+        var.get_stop_trigger(), [], config[CONF_STOP_ACTION]
+    )
+
+    # OPEN
+    bin = yield cg.get_variable(config[CONF_OPEN_SENSOR])
+    cg.add(var.set_open_sensor(bin))
+    cg.add(
+        var.set_open_moving_current_threshold(
+            config[CONF_OPEN_MOVING_CURRENT_THRESHOLD]
+        )
+    )
+    if CONF_OPEN_OBSTACLE_CURRENT_THRESHOLD in config:
+        cg.add(
+            var.set_open_obstacle_current_threshold(
+                config[CONF_OPEN_OBSTACLE_CURRENT_THRESHOLD]
+            )
+        )
+    cg.add(var.set_open_duration(config[CONF_OPEN_DURATION]))
+    yield automation.build_automation(
+        var.get_open_trigger(), [], config[CONF_OPEN_ACTION]
+    )
+
+    # CLOSE
+    bin = yield cg.get_variable(config[CONF_CLOSE_SENSOR])
+    cg.add(var.set_close_sensor(bin))
+    cg.add(
+        var.set_close_moving_current_threshold(
+            config[CONF_CLOSE_MOVING_CURRENT_THRESHOLD]
+        )
+    )
+    if CONF_CLOSE_OBSTACLE_CURRENT_THRESHOLD in config:
+        cg.add(
+            var.set_close_obstacle_current_threshold(
+                config[CONF_CLOSE_OBSTACLE_CURRENT_THRESHOLD]
+            )
+        )
+    cg.add(var.set_close_duration(config[CONF_CLOSE_DURATION]))
+    yield automation.build_automation(
+        var.get_close_trigger(), [], config[CONF_CLOSE_ACTION]
+    )
+
+    cg.add(var.set_obstacle_rollback(config[CONF_OBSTACLE_ROLLBACK]))
+    if CONF_MAX_DURATION in config:
+        cg.add(var.set_max_duration(config[CONF_MAX_DURATION]))
+    cg.add(var.set_malfunction_detection(config[CONF_MALFUNCTION_DETECTION]))
+    if CONF_MALFUNCTION_ACTION in config:
+        yield automation.build_automation(
+            var.get_malfunction_trigger(), [], config[CONF_MALFUNCTION_ACTION]
+        )
+    cg.add(var.set_start_sensing_delay(config[CONF_START_SENSING_DELAY]))

esphome/components/current_based/current_based_cover.cpp

@@ -0,0 +1,251 @@
+#include "current_based_cover.h"
+#include "esphome/core/hal.h"
+#include "esphome/core/log.h"
+#include <cfloat>
+
+namespace esphome {
+namespace current_based {
+
+static const char *const TAG = "current_based.cover";
+
+using namespace esphome::cover;
+
+CoverTraits CurrentBasedCover::get_traits() {
+  auto traits = CoverTraits();
+  traits.set_supports_position(true);
+  traits.set_is_assumed_state(false);
+  return traits;
+}
+void CurrentBasedCover::control(const CoverCall &call) {
+  if (call.get_stop()) {
+    this->direction_idle_();
+  }
+  if (call.get_position().has_value()) {
+    auto pos = *call.get_position();
+    if (pos == this->position) {
+      // already at target
+    } else {
+      auto op = pos < this->position ? COVER_OPERATION_CLOSING : COVER_OPERATION_OPENING;
+      this->target_position_ = pos;
+      this->start_direction_(op);
+    }
+  }
+}
+void CurrentBasedCover::setup() {
+  auto restore = this->restore_state_();
+  if (restore.has_value()) {
+    restore->apply(this);
+  } else {
+    this->position = 0.5f;
+  }
+}
+
+void CurrentBasedCover::loop() {
+  if (this->current_operation == COVER_OPERATION_IDLE)
+    return;
+
+  const uint32_t now = millis();
+
+  if (this->current_operation == COVER_OPERATION_OPENING) {
+    if (this->malfunction_detection_ && this->is_closing_()) {  // Malfunction
+      this->direction_idle_();
+      this->malfunction_trigger_->trigger();
+      ESP_LOGI(TAG, "'%s' - Malfunction detected during opening. Current flow detected in close circuit",
+               this->name_.c_str());
+    } else if (this->is_opening_blocked_()) {  // Blocked
+      ESP_LOGD(TAG, "'%s' - Obstacle detected during opening.", this->name_.c_str());
+      this->direction_idle_();
+      if (this->obstacle_rollback_ != 0) {
+        this->set_timeout("rollback", 300, [this]() {
+          ESP_LOGD(TAG, "'%s' - Rollback.", this->name_.c_str());
+          this->target_position_ = clamp(this->position - this->obstacle_rollback_, 0.0F, 1.0F);
+          this->start_direction_(COVER_OPERATION_CLOSING);
+        });
+      }
+    } else if (this->is_initial_delay_finished_() && !this->is_opening_()) {  // End reached
+      auto dur = (now - this->start_dir_time_) / 1e3f;
+      ESP_LOGD(TAG, "'%s' - Open position reached. Took %.1fs.", this->name_.c_str(), dur);
+      this->direction_idle_(COVER_OPEN);
+    }
+  } else if (this->current_operation == COVER_OPERATION_CLOSING) {
+    if (this->malfunction_detection_ && this->is_opening_()) {  // Malfunction
+      this->direction_idle_();
+      this->malfunction_trigger_->trigger();
+      ESP_LOGI(TAG, "'%s' - Malfunction detected during closing. Current flow detected in open circuit",
+               this->name_.c_str());
+    } else if (this->is_closing_blocked_()) {  // Blocked
+      ESP_LOGD(TAG, "'%s' - Obstacle detected during closing.", this->name_.c_str());
+      this->direction_idle_();
+      if (this->obstacle_rollback_ != 0) {
+        this->set_timeout("rollback", 300, [this]() {
+          ESP_LOGD(TAG, "'%s' - Rollback.", this->name_.c_str());
+          this->target_position_ = clamp(this->position + this->obstacle_rollback_, 0.0F, 1.0F);
+          this->start_direction_(COVER_OPERATION_OPENING);
+        });
+      }
+    } else if (this->is_initial_delay_finished_() && !this->is_closing_()) {  // End reached
+      auto dur = (now - this->start_dir_time_) / 1e3f;
+      ESP_LOGD(TAG, "'%s' - Close position reached. Took %.1fs.", this->name_.c_str(), dur);
+      this->direction_idle_(COVER_CLOSED);
+    }
+  } else if (now - this->start_dir_time_ > this->max_duration_) {
+    ESP_LOGD(TAG, "'%s' - Max duration reached. Stopping cover.", this->name_.c_str());
+    this->direction_idle_();
+  }
+
+  // Recompute position every loop cycle
+  this->recompute_position_();
+
+  if (this->current_operation != COVER_OPERATION_IDLE && this->is_at_target_()) {
+    this->direction_idle_();
+  }
+
+  // Send current position every second
+  if (this->current_operation != COVER_OPERATION_IDLE && now - this->last_publish_time_ > 1000) {
+    this->publish_state(false);
+    this->last_publish_time_ = now;
+  }
+}
+
+void CurrentBasedCover::direction_idle_(float new_position) {
+  this->start_direction_(COVER_OPERATION_IDLE);
+  if (new_position != FLT_MAX) {
+    this->position = new_position;
+  }
+  this->publish_state();
+}
+
+void CurrentBasedCover::dump_config() {
+  LOG_COVER("", "Endstop Cover", this);
+  LOG_SENSOR("  ", "Open Sensor", this->open_sensor_);
+  ESP_LOGCONFIG(TAG, "  Open moving current threshold: %.11fA", this->open_moving_current_threshold_);
+  if (this->open_obstacle_current_threshold_ != FLT_MAX) {
+    ESP_LOGCONFIG(TAG, "  Open obstacle current threshold: %.11fA", this->open_obstacle_current_threshold_);
+  }
+  ESP_LOGCONFIG(TAG, "  Open Duration: %.1fs", this->open_duration_ / 1e3f);
+  LOG_SENSOR("  ", "Close Sensor", this->close_sensor_);
+  ESP_LOGCONFIG(TAG, "  Close moving current threshold: %.11fA", this->close_moving_current_threshold_);
+  if (this->close_obstacle_current_threshold_ != FLT_MAX) {
+    ESP_LOGCONFIG(TAG, "  Close obstacle current threshold: %.11fA", this->close_obstacle_current_threshold_);
+  }
+  ESP_LOGCONFIG(TAG, "  Close Duration: %.1fs", this->close_duration_ / 1e3f);
+  ESP_LOGCONFIG(TAG, "Obstacle Rollback: %.1f%%", this->obstacle_rollback_ * 100);
+  if (this->max_duration_ != UINT32_MAX) {
+    ESP_LOGCONFIG(TAG, "Maximun duration: %.1fs", this->max_duration_ / 1e3f);
+  }
+  ESP_LOGCONFIG(TAG, "Start sensing delay: %.1fs", this->start_sensing_delay_ / 1e3f);
+  ESP_LOGCONFIG(TAG, "Malfunction detection: %s", YESNO(this->malfunction_detection_));
+}
+
+float CurrentBasedCover::get_setup_priority() const { return setup_priority::DATA; }
+void CurrentBasedCover::stop_prev_trigger_() {
+  if (this->prev_command_trigger_ != nullptr) {
+    this->prev_command_trigger_->stop_action();
+    this->prev_command_trigger_ = nullptr;
+  }
+}
+
+bool CurrentBasedCover::is_opening_() const {
+  return this->open_sensor_->get_state() > this->open_moving_current_threshold_;
+}
+
+bool CurrentBasedCover::is_opening_blocked_() const {
+  if (this->open_obstacle_current_threshold_ == FLT_MAX) {
+    return false;
+  }
+  return this->open_sensor_->get_state() > this->open_obstacle_current_threshold_;
+}
+
+bool CurrentBasedCover::is_closing_() const {
+  return this->close_sensor_->get_state() > this->close_moving_current_threshold_;
+}
+
+bool CurrentBasedCover::is_closing_blocked_() const {
+  if (this->close_obstacle_current_threshold_ == FLT_MAX) {
+    return false;
+  }
+  return this->open_sensor_->get_state() > this->open_obstacle_current_threshold_;
+}
+bool CurrentBasedCover::is_initial_delay_finished_() const {
+  return millis() - this->start_dir_time_ > this->start_sensing_delay_;
+}
+
+bool CurrentBasedCover::is_at_target_() const {
+  switch (this->current_operation) {
+    case COVER_OPERATION_OPENING:
+      if (this->target_position_ == COVER_OPEN) {
+        if (!this->is_initial_delay_finished_())  // During initial delay, state is assumed
+          return false;
+        return !this->is_opening_();
+      }
+      return this->position >= this->target_position_;
+    case COVER_OPERATION_CLOSING:
+      if (this->target_position_ == COVER_CLOSED) {
+        if (!this->is_initial_delay_finished_())  // During initial delay, state is assumed
+          return false;
+        return !this->is_closing_();
+      }
+      return this->position <= this->target_position_;
+    case COVER_OPERATION_IDLE:
+    default:
+      return true;
+  }
+}
+void CurrentBasedCover::start_direction_(CoverOperation dir) {
+  if (dir == this->current_operation)
+    return;
+
+  this->recompute_position_();
+  Trigger<> *trig;
+  switch (dir) {
+    case COVER_OPERATION_IDLE:
+      trig = this->stop_trigger_;
+      break;
+    case COVER_OPERATION_OPENING:
+      trig = this->open_trigger_;
+      break;
+    case COVER_OPERATION_CLOSING:
+      trig = this->close_trigger_;
+      break;
+    default:
+      return;
+  }
+
+  this->current_operation = dir;
+
+  this->stop_prev_trigger_();
+  trig->trigger();
+  this->prev_command_trigger_ = trig;
+
+  const auto now = millis();
+  this->start_dir_time_ = now;
+  this->last_recompute_time_ = now;
+}
+void CurrentBasedCover::recompute_position_() {
+  if (this->current_operation == COVER_OPERATION_IDLE)
+    return;
+
+  float dir;
+  float action_dur;
+  switch (this->current_operation) {
+    case COVER_OPERATION_OPENING:
+      dir = 1.0F;
+      action_dur = this->open_duration_;
+      break;
+    case COVER_OPERATION_CLOSING:
+      dir = -1.0F;
+      action_dur = this->close_duration_;
+      break;
+    default:
+      return;
+  }
+
+  const auto now = millis();
+  this->position += dir * (now - this->last_recompute_time_) / action_dur;
+  this->position = clamp(this->position, 0.0F, 1.0F);
+
+  this->last_recompute_time_ = now;
+}
+
+}  // namespace current_based
+}  // namespace esphome

esphome/components/current_based/current_based_cover.h

@@ -0,0 +1,95 @@
+#pragma once
+
+#include "esphome/components/cover/cover.h"
+#include "esphome/components/sensor/sensor.h"
+#include "esphome/core/automation.h"
+#include "esphome/core/component.h"
+#include <cfloat>
+
+namespace esphome {
+namespace current_based {
+
+class CurrentBasedCover : public cover::Cover, public Component {
+ public:
+  void setup() override;
+  void loop() override;
+  void dump_config() override;
+  float get_setup_priority() const override;
+
+  Trigger<> *get_stop_trigger() const { return this->stop_trigger_; }
+
+  Trigger<> *get_open_trigger() const { return this->open_trigger_; }
+  void set_open_sensor(sensor::Sensor *open_sensor) { this->open_sensor_ = open_sensor; }
+  void set_open_moving_current_threshold(float open_moving_current_threshold) {
+    this->open_moving_current_threshold_ = open_moving_current_threshold;
+  }
+  void set_open_obstacle_current_threshold(float open_obstacle_current_threshold) {
+    this->open_obstacle_current_threshold_ = open_obstacle_current_threshold;
+  }
+  void set_open_duration(uint32_t open_duration) { this->open_duration_ = open_duration; }
+
+  Trigger<> *get_close_trigger() const { return this->close_trigger_; }
+  void set_close_sensor(sensor::Sensor *close_sensor) { this->close_sensor_ = close_sensor; }
+  void set_close_moving_current_threshold(float close_moving_current_threshold) {
+    this->close_moving_current_threshold_ = close_moving_current_threshold;
+  }
+  void set_close_obstacle_current_threshold(float close_obstacle_current_threshold) {
+    this->close_obstacle_current_threshold_ = close_obstacle_current_threshold;
+  }
+  void set_close_duration(uint32_t close_duration) { this->close_duration_ = close_duration; }
+
+  void set_max_duration(uint32_t max_duration) { this->max_duration_ = max_duration; }
+  void set_obstacle_rollback(float obstacle_rollback) { this->obstacle_rollback_ = obstacle_rollback; }
+
+  void set_malfunction_detection(bool malfunction_detection) { this->malfunction_detection_ = malfunction_detection; }
+  void set_start_sensing_delay(uint32_t start_sensing_delay) { this->start_sensing_delay_ = start_sensing_delay; }
+
+  Trigger<> *get_malfunction_trigger() const { return this->malfunction_trigger_; }
+
+  cover::CoverTraits get_traits() override;
+
+ protected:
+  void control(const cover::CoverCall &call) override;
+  void stop_prev_trigger_();
+
+  bool is_at_target_() const;
+  bool is_opening_() const;
+  bool is_opening_blocked_() const;
+  bool is_closing_() const;
+  bool is_closing_blocked_() const;
+  bool is_initial_delay_finished_() const;
+
+  void direction_idle_(float new_position = FLT_MAX);
+  void start_direction_(cover::CoverOperation dir);
+
+  void recompute_position_();
+
+  Trigger<> *stop_trigger_{new Trigger<>()};
+
+  sensor::Sensor *open_sensor_{nullptr};
+  Trigger<> *open_trigger_{new Trigger<>()};
+  float open_moving_current_threshold_;
+  float open_obstacle_current_threshold_{FLT_MAX};
+  uint32_t open_duration_;
+
+  sensor::Sensor *close_sensor_{nullptr};
+  Trigger<> *close_trigger_{new Trigger<>()};
+  float close_moving_current_threshold_;
+  float close_obstacle_current_threshold_{FLT_MAX};
+  uint32_t close_duration_;
+
+  uint32_t max_duration_{UINT32_MAX};
+  bool malfunction_detection_{true};
+  Trigger<> *malfunction_trigger_{new Trigger<>()};
+  uint32_t start_sensing_delay_;
+  float obstacle_rollback_;
+
+  Trigger<> *prev_command_trigger_{nullptr};
+  uint32_t last_recompute_time_{0};
+  uint32_t start_dir_time_{0};
+  uint32_t last_publish_time_{0};
+  float target_position_{0};
+};
+
+}  // namespace current_based
+}  // namespace esphome

tests/test3.yaml

@@ -426,14 +426,19 @@ sensor:
     irq_pin: GPIO16
     voltage:
       name: ADE7953 Voltage
+      id: ade7953_voltage
     current_a:
       name: ADE7953 Current A
+      id: ade7953_current_a
     current_b:
       name: ADE7953 Current B
+      id: ade7953_current_b
     active_power_a:
       name: ADE7953 Active Power A
+      id: ade7953_active_power_a
     active_power_b:
       name: ADE7953 Active Power B
+      id: ade7953_active_power_b
   - platform: pzem004t
     uart_id: uart3
     voltage:
@@ -1021,6 +1026,29 @@ cover:
     close_action:
       - switch.turn_on: gpio_switch2
     close_duration: 4.5min
+  - platform: current_based
+    name: "Current Based Cover"
+    open_sensor: ade7953_current_a
+    open_moving_current_threshold: 0.5
+    open_obstacle_current_threshold: 0.8
+    open_duration: 12s
+    open_action:
+      - switch.turn_on: gpio_switch1
+    close_sensor: ade7953_current_b
+    close_moving_current_threshold: 0.5
+    close_obstacle_current_threshold: 0.8
+    close_duration: 10s
+    close_action:
+      - switch.turn_on: gpio_switch2
+    stop_action:
+      - switch.turn_off: gpio_switch1
+      - switch.turn_off: gpio_switch2
+    obstacle_rollback: 30%
+    start_sensing_delay: 0.8s
+    malfunction_detection: true
+    malfunction_action:
+      then:
+        - logger.log: "Malfunction Detected"
   - platform: template
     name: Template Cover with Tilt
     tilt_lambda: 'return 0.5;'