Auto_Seat/Auto_Seat.ino

//
// Auto_Seat
// Automatic seat controller with EEPROM settings and optional serial tools.
//
#include <EEPROM.h>

#define seatRelayD8 8   // HIGH = OFF, LOW = ON (up relay)
#define seatRelayD9 9   // HIGH = OFF, LOW = ON (down relay)

#define parkingPin A0   // PARKING raw analog value, 0~1023
#define ignitionPin 7   // HIGH = IG1 ON, LOW = IG1 OFF

// ============================================================
// !!! SAFETY LIMIT !!!
//
// Physical maximum travel time from bottom to the highest allowed point.
// User settings saved in EEPROM must stay inside 0..6000ms.
// ============================================================
const uint16_t SEAT_HARD_LIMIT_UP_MS = 6000;

// Parking raw threshold hysteresis.
// P turns ON at 950 or higher, and turns OFF at 940 or lower.
const int PARKING_ON_THRESHOLD = 950;
const int PARKING_OFF_THRESHOLD = 940;

// Down movement is estimated as 1.1x faster than up movement.
const int DOWN_SPEED_NUM = 11;
const int DOWN_SPEED_DEN = 10;

// Input and relay protection.
const unsigned long IGNITION_STABILIZE_MS = 1000UL;
const unsigned long DRIVE_CONFIRM_MS = 80UL;
const unsigned long PARK_CONFIRM_MS = 250UL;
const unsigned long RELAY_DEADTIME_MS = 120UL;
const unsigned long DOWN_EDGE_MARGIN_MS = 300UL;

// After 10 ignition OFF events, wait 5 minutes while ignition is OFF,
// then auto-calibrate: up 7 seconds -> down 6 seconds -> set position to bottom.
const byte USES_BEFORE_AUTO_CALIBRATION = 10;
const unsigned long AUTO_CALIBRATION_DELAY_MS = 300000UL;
const unsigned long AUTO_CALIBRATION_UP_MS = 7000UL;
const unsigned long AUTO_CALIBRATION_DOWN_MS = 6000UL;

// Serial debug output.
const unsigned long DEBUG_INTERVAL_MS = 1000UL;
const long MANUAL_STEP_MS = 500;

// EEPROM map.
const int EEPROM_MAGIC_ADDR = 0;
const byte EEPROM_MAGIC_VALUE = 0x64;
const int EEPROM_USE_COUNT_ADDR = 1;
const int EEPROM_SEAT_POSITION_ADDR = 2; // uint16_t, low byte first

const byte CALIBRATION_IDLE = 0;
const byte CALIBRATION_UP = 1;
const byte CALIBRATION_DOWN = 2;

boolean ignitionState = LOW;
boolean parkingState = LOW;
boolean prevIgnitionState = LOW;
boolean isStabilizing = false;
boolean confirmedDriveMode = LOW;
boolean pendingDriveMode = LOW;

byte useCount = 0;
byte autoCalibrationState = CALIBRATION_IDLE;
bool autoCalibrationPending = false;
bool forceCalibration = false;
bool manualMode = false;

int parkingRawValue = 0;
uint16_t storedSeatPositionMs = 0;
long currentPosMs = 0;
long targetPosMs = 0;
long downSpeedRemainder = 0;
unsigned long downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
bool downEdgeMarginActive = false;

unsigned long lastTime = 0;
unsigned long stabilizeStartTime = 0;
unsigned long ignitionOffStartTime = 0;
unsigned long calibrationPhaseStartTime = 0;
unsigned long pendingDriveModeStartTime = 0;
unsigned long relayDeadtimeStartTime = 0;
unsigned long lastDebugPrintTime = 0;

int currentSeatAction = 0;
int requestedSeatAction = 0;
int lastStoppedSeatAction = 0;

bool serialIntroPrinted = false;
bool debugEnabled = false;
bool manualStepStatusPending = false;

void setup() {
  Serial.begin(115200);
  Serial.setTimeout(25);

  pinMode(parkingPin, INPUT);
  pinMode(ignitionPin, INPUT);
  pinMode(seatRelayD8, OUTPUT);
  pinMode(seatRelayD9, OUTPUT);

  applySeatAction(0);
  seat(0);
  loadSettings();

  measurement();
  confirmedDriveMode = getRawDriveMode();
  pendingDriveMode = confirmedDriveMode;
  targetPosMs = getTargetForConfirmedMode();
  if (ignitionState == LOW) {
    ignitionOffStartTime = millis();
  }

  lastTime = millis();
}

void loop() {
  measurement();
  handleSerial();

  unsigned long currentTime = millis();
  unsigned long deltaTime = currentTime - lastTime;
  lastTime = currentTime;

  if (prevIgnitionState == LOW && ignitionState == HIGH) {
    isStabilizing = true;
    stabilizeStartTime = currentTime;
  } else if (prevIgnitionState == HIGH && ignitionState == LOW) {
    registerIgnitionOffUse(currentTime);
  }
  prevIgnitionState = ignitionState;

  if (autoCalibrationState != CALIBRATION_IDLE) {
    updateAutoCalibration(currentTime);
    updateRelayOutput(currentTime);
    updateDebugOutput(currentTime);
    return;
  }

  if (autoCalibrationPending && ignitionState == LOW &&
      currentTime - ignitionOffStartTime >= AUTO_CALIBRATION_DELAY_MS) {
    startAutoCalibration(currentTime);
    updateRelayOutput(currentTime);
    updateDebugOutput(currentTime);
    return;
  }

  if (isStabilizing) {
    if (currentTime - stabilizeStartTime < IGNITION_STABILIZE_MS) {
      seat(0);
      updateRelayOutput(currentTime);
      updateDebugOutput(currentTime);
      return;
    }
    isStabilizing = false;
  }

  updateConfirmedDriveMode(currentTime);
  if (!manualMode) {
    targetPosMs = getTargetForConfirmedMode();
  }
  normalizeMotionState();
  updateMovement(deltaTime);
  normalizeMotionState();
  updateRelayOutput(currentTime);
  updateManualStepStatus();
  updateDebugOutput(currentTime);
}

void measurement() {
  ignitionState = digitalRead(ignitionPin);

  parkingRawValue = analogRead(parkingPin);
  if (parkingState == LOW && parkingRawValue >= PARKING_ON_THRESHOLD) {
    parkingState = HIGH;
  } else if (parkingState == HIGH && parkingRawValue <= PARKING_OFF_THRESHOLD) {
    parkingState = LOW;
  }
}

boolean getRawDriveMode() {
  if (ignitionState == HIGH && parkingState == LOW) {
    return HIGH;
  }
  return LOW;
}

long getTargetForConfirmedMode() {
  if (confirmedDriveMode == HIGH) {
    return storedSeatPositionMs;
  }
  return 0;
}

void updateConfirmedDriveMode(unsigned long currentTime) {
  boolean rawDriveMode = getRawDriveMode();

  if (rawDriveMode != pendingDriveMode) {
    pendingDriveMode = rawDriveMode;
    pendingDriveModeStartTime = currentTime;
  }

  unsigned long confirmMs = pendingDriveMode == HIGH ? DRIVE_CONFIRM_MS : PARK_CONFIRM_MS;
  if (pendingDriveMode != confirmedDriveMode &&
      currentTime - pendingDriveModeStartTime >= confirmMs) {
    confirmedDriveMode = pendingDriveMode;
    manualMode = false;
    manualStepStatusPending = false;
  }
}

void updateMovement(unsigned long deltaTime) {
  if (downEdgeMarginActive) {
    if (currentPosMs == 0 && targetPosMs == 0) {
      seat(-1);
      downEdgeMarginTime += deltaTime;
      if (downEdgeMarginTime >= DOWN_EDGE_MARGIN_MS) {
        downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
        downEdgeMarginActive = false;
        seat(0);
      }
      return;
    }

    downEdgeMarginActive = false;
    downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
  }

  if (currentPosMs < targetPosMs) {
    seat(1);
    currentPosMs += deltaTime;
    if (currentPosMs >= targetPosMs) {
      currentPosMs = targetPosMs;
      seat(0);
    }
  } else if (currentPosMs > targetPosMs) {
    seat(-1);
    long downMoveScaled = deltaTime * DOWN_SPEED_NUM + downSpeedRemainder;
    currentPosMs -= downMoveScaled / DOWN_SPEED_DEN;
    downSpeedRemainder = downMoveScaled % DOWN_SPEED_DEN;
    if (currentPosMs <= targetPosMs) {
      currentPosMs = targetPosMs;
      downSpeedRemainder = 0;
      if (targetPosMs == 0) {
        startDownEdgeMargin();
      } else {
        seat(0);
      }
    }
  } else {
    seat(0);
  }
}

void startDownEdgeMargin() {
  downEdgeMarginActive = true;
  downEdgeMarginTime = 0;
  seat(-1);
}

void registerIgnitionOffUse(unsigned long currentTime) {
  ignitionOffStartTime = currentTime;

  if (useCount < USES_BEFORE_AUTO_CALIBRATION) {
    useCount++;
    EEPROM.update(EEPROM_USE_COUNT_ADDR, useCount);
  }

  if (useCount >= USES_BEFORE_AUTO_CALIBRATION) {
    autoCalibrationPending = true;
  }
}

void startAutoCalibration(unsigned long currentTime) {
  manualMode = false;
  manualStepStatusPending = false;
  downSpeedRemainder = 0;
  downEdgeMarginActive = false;
  downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
  autoCalibrationState = CALIBRATION_UP;
  calibrationPhaseStartTime = currentTime;
  seat(1);
}

void updateAutoCalibration(unsigned long currentTime) {
  if (ignitionState == HIGH && !forceCalibration) {
    seat(0);
    autoCalibrationState = CALIBRATION_IDLE;
    manualStepStatusPending = false;
    downSpeedRemainder = 0;
    downEdgeMarginActive = false;
    downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
    ignitionOffStartTime = currentTime;
    return;
  }

  if (autoCalibrationState == CALIBRATION_UP) {
    if (currentTime - calibrationPhaseStartTime >= AUTO_CALIBRATION_UP_MS) {
      autoCalibrationState = CALIBRATION_DOWN;
      calibrationPhaseStartTime = currentTime;
      seat(-1);
    } else {
      seat(1);
    }
  } else if (autoCalibrationState == CALIBRATION_DOWN) {
    if (currentTime - calibrationPhaseStartTime >= AUTO_CALIBRATION_DOWN_MS) {
      seat(0);
      autoCalibrationState = CALIBRATION_IDLE;
      autoCalibrationPending = false;
      forceCalibration = false;
      useCount = 0;
      EEPROM.update(EEPROM_USE_COUNT_ADDR, useCount);
      currentPosMs = 0;
      targetPosMs = 0;
      downSpeedRemainder = 0;
      downEdgeMarginActive = false;
      downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
    } else {
      seat(-1);
    }
  }
}

void handleSerial() {
  if (!Serial.available()) {
    return;
  }

  String command = Serial.readStringUntil('\n');
  command.trim();

  if (debugEnabled) {
    command.toLowerCase();
    if (command == "x") {
      debugEnabled = false;
      Serial.println(F("DEBUG_STOPPED"));
      printStatus(F("STATUS"));
    }
    return;
  }

  if (!serialIntroPrinted) {
    if (command.length() == 0) {
      printIntro();
      serialIntroPrinted = true;
    }
    return;
  }

  if (command.length() == 0) {
    return;
  }

  processSerialCommand(command);
}

bool isSeatCommandBusy() {
  return manualStepStatusPending ||
         autoCalibrationState != CALIBRATION_IDLE ||
         downEdgeMarginActive ||
         currentPosMs != targetPosMs ||
         requestedSeatAction != 0 ||
         currentSeatAction != 0;
}

void processSerialCommand(String command) {
  command.trim();
  command.toLowerCase();
  if (command.length() == 0) {
    printStatus(F("EMPTY_INPUT_STATUS"));
    return;
  }

  if (command.length() != 1) {
    Serial.println(F("ERR: one-character command only. Send h for help."));
    printStatus(F("ACK"));
    return;
  }

  char name = command.charAt(0);

  if (requiresParkingForCommand(name) && parkingState != HIGH) {
    Serial.println(F("ERR: check gear state. Command requires P."));
    printStatus(F("GEAR_CHECK_FAILED"));
    return;
  }

  if (isSeatCommandBusy()) {
    Serial.println(F("ERR: busy. Wait until seat movement is done."));
    printStatus(F("BUSY"));
    return;
  }

  if (name == 'h') {
    printIntro();
  } else if (name == 's') {
    printStatus(F("STATUS"));
  } else if (name == 'p') {
    saveCurrentPositionCommand();
  } else if (name == 'u') {
    handleRelativeStep(1);
  } else if (name == 'd') {
    handleRelativeStep(-1);
  } else if (name == 'g') {
    debugEnabled = true;
    lastDebugPrintTime = 0;
    printStatus(F("DEBUG_STARTED_X_TO_STOP"));
  } else if (name == 'a') {
    manualStepStatusPending = false;
    manualMode = false;
    targetPosMs = getTargetForConfirmedMode();
    printStatus(F("AUTO_MODE_RESTORED"));
  } else if (name == 'c') {
    manualStepStatusPending = false;
    forceCalibration = true;
    autoCalibrationPending = false;
    startAutoCalibration(millis());
    printStatus(F("CALIBRATION_STARTED_UP7_DOWN6"));
  } else if (name == 'r') {
    useCount = 0;
    autoCalibrationPending = false;
    EEPROM.update(EEPROM_USE_COUNT_ADDR, useCount);
    printStatus(F("USE_COUNT_RESET"));
  } else {
    Serial.println(F("Unknown command. Send h for help."));
    printStatus(F("ACK"));
  }
}

bool requiresParkingForCommand(char name) {
  return name == 'p' ||
         name == 'u' ||
         name == 'd' ||
         name == 'a' ||
         name == 'c' ||
         name == 'r';
}

void saveCurrentPositionCommand() {
  currentPosMs = clampPosition(currentPosMs);
  targetPosMs = currentPosMs;

  storedSeatPositionMs = (uint16_t)currentPosMs;
  writeUint16(EEPROM_SEAT_POSITION_ADDR, storedSeatPositionMs);
  manualMode = true;
  targetPosMs = currentPosMs;
  printStatus(F("CURRENT_POSITION_SAVED"));
}

void handleRelativeStep(int direction) {
  long nextTarget = currentPosMs + (direction * MANUAL_STEP_MS);
  if (nextTarget < 0 || nextTarget > SEAT_HARD_LIMIT_UP_MS) {
    Serial.print(F("WARN: ignored. Requested target "));
    Serial.print(nextTarget);
    Serial.print(F("ms is outside 0.."));
    Serial.print(SEAT_HARD_LIMIT_UP_MS);
    Serial.println(F("ms."));
    printStatus(F("ACK"));
    return;
  }

  manualMode = true;
  targetPosMs = nextTarget;
  manualStepStatusPending = true;
}

void updateManualStepStatus() {
  if (!manualStepStatusPending) {
    return;
  }

  if (currentPosMs == targetPosMs && requestedSeatAction == 0 && currentSeatAction == 0) {
    manualStepStatusPending = false;
    printStatus(F("MANUAL_STEP_DONE"));
  }
}

long clampPosition(long value) {
  if (value < 0) {
    return 0;
  }
  if (value > SEAT_HARD_LIMIT_UP_MS) {
    return SEAT_HARD_LIMIT_UP_MS;
  }
  return value;
}

void normalizeMotionState() {
  currentPosMs = clampPosition(currentPosMs);
  targetPosMs = clampPosition(targetPosMs);

  if (storedSeatPositionMs > SEAT_HARD_LIMIT_UP_MS) {
    storedSeatPositionMs = SEAT_HARD_LIMIT_UP_MS;
  }

  if (targetPosMs != 0 && downEdgeMarginActive) {
    downEdgeMarginActive = false;
    downEdgeMarginTime = DOWN_EDGE_MARGIN_MS;
  }

  if (currentPosMs <= targetPosMs) {
    downSpeedRemainder = 0;
  }
}

void updateDebugOutput(unsigned long currentTime) {
  if (!debugEnabled) {
    return;
  }

  if (lastDebugPrintTime == 0 || currentTime - lastDebugPrintTime >= DEBUG_INTERVAL_MS) {
    lastDebugPrintTime = currentTime;
    printStatus(F("DEBUG"));
  }
}

void loadSettings() {
  if (EEPROM.read(EEPROM_MAGIC_ADDR) != EEPROM_MAGIC_VALUE) {
    EEPROM.update(EEPROM_MAGIC_ADDR, EEPROM_MAGIC_VALUE);
    EEPROM.update(EEPROM_USE_COUNT_ADDR, 0);
    writeUint16(EEPROM_SEAT_POSITION_ADDR, SEAT_HARD_LIMIT_UP_MS);
  }

  useCount = EEPROM.read(EEPROM_USE_COUNT_ADDR);
  if (useCount > USES_BEFORE_AUTO_CALIBRATION) {
    useCount = 0;
    EEPROM.update(EEPROM_USE_COUNT_ADDR, useCount);
  }
  autoCalibrationPending = (useCount >= USES_BEFORE_AUTO_CALIBRATION);

  storedSeatPositionMs = readUint16(EEPROM_SEAT_POSITION_ADDR);
  if (storedSeatPositionMs > SEAT_HARD_LIMIT_UP_MS) {
    storedSeatPositionMs = SEAT_HARD_LIMIT_UP_MS;
    writeUint16(EEPROM_SEAT_POSITION_ADDR, storedSeatPositionMs);
  }
}

uint16_t readUint16(int addr) {
  byte lowByte = EEPROM.read(addr);
  byte highByte = EEPROM.read(addr + 1);
  return (uint16_t)lowByte | ((uint16_t)highByte << 8);
}

void writeUint16(int addr, uint16_t value) {
  EEPROM.update(addr, value & 0xFF);
  EEPROM.update(addr + 1, (value >> 8) & 0xFF);
}

void printIntro() {
  Serial.println();
  Serial.println(F("+--------------------------------------------------+"));
  Serial.println(F("| Auto Seat Serial Console                         |"));
  Serial.println(F("+--------------------------------------------------+"));
  Serial.println(F("| Units: milliseconds. 0 = bottom. 6000 = top cap. |"));
  Serial.println(F("| Normal auto move target is saved in EEPROM.      |"));
  Serial.println(F("| Action commands require gear P for safety.       |"));
  Serial.println(F("| Serial output is quiet unless a command is used. |"));
  Serial.println(F("+--------------------------------------------------+"));
  Serial.println(F("Commands:"));
  Serial.println(F("  s                   Print current state once"));
  Serial.println(F("  p                   Save current position to EEPROM"));
  Serial.println(F("  u                   Manual up +500ms if inside 0..6000"));
  Serial.println(F("  d                   Manual down -500ms if inside 0..6000"));
  Serial.println(F("  g                   Debug every 1s; only x works in debug"));
  Serial.println(F("  x                   Stop debug mode only"));
  Serial.println(F("                      d=down, g=debug to avoid command overlap"));
  Serial.println(F("  a                   Return to gear-based automatic target"));
  Serial.println(F("  c                   Run calibration now: up 7s, down 6s, set 0"));
  Serial.println(F("  r                   Clear 10-use auto calibration counter"));
  Serial.println(F("  h                   Print this help"));
  Serial.println(F("+--------------------------------------------------+"));
  printStatus(F("CURRENT_SETTINGS"));
}

void printStatus(const __FlashStringHelper *tag) {
  Serial.println();
  Serial.print(F("["));
  Serial.print(tag);
  Serial.println(F("]"));
  Serial.print(F("raw="));
  Serial.print(parkingRawValue);
  Serial.print(F(" ig="));
  Serial.print(ignitionState == HIGH ? 1 : 0);
  Serial.print(F(" p="));
  Serial.print(parkingState == HIGH ? 1 : 0);
  Serial.print(F(" rawDrive="));
  Serial.print(getRawDriveMode() == HIGH ? 1 : 0);
  Serial.print(F(" confirmedDrive="));
  Serial.println(confirmedDriveMode == HIGH ? 1 : 0);

  Serial.print(F("currentMs="));
  Serial.print(currentPosMs);
  Serial.print(F(" targetMs="));
  Serial.print(targetPosMs);
  Serial.print(F(" savedPositionMs="));
  Serial.print(storedSeatPositionMs);
  Serial.print(F(" hardLimitMs="));
  Serial.println(SEAT_HARD_LIMIT_UP_MS);

  Serial.print(F("requestedRelay="));
  Serial.print(requestedSeatAction);
  Serial.print(F(" actualRelay="));
  Serial.print(currentSeatAction);
  Serial.print(F(" manualMode="));
  Serial.print(manualMode ? 1 : 0);
  Serial.print(F(" stabilizing="));
  Serial.println(isStabilizing ? 1 : 0);

  Serial.print(F("useCount="));
  Serial.print(useCount);
  Serial.print(F("/"));
  Serial.print(USES_BEFORE_AUTO_CALIBRATION);
  Serial.print(F(" autoPending="));
  Serial.print(autoCalibrationPending ? 1 : 0);
  Serial.print(F(" forceCal="));
  Serial.print(forceCalibration ? 1 : 0);
  Serial.print(F(" autoCalState="));
  Serial.println(autoCalibrationState);
}

void setRelay(int relayPin, boolean state) {
  digitalWrite(relayPin, state ? LOW : HIGH);
}

void seat(int action) {
  requestedSeatAction = action;
}

void updateRelayOutput(unsigned long currentTime) {
  if (requestedSeatAction == currentSeatAction) {
    applySeatAction(currentSeatAction);
    return;
  }

  if (currentSeatAction != 0) {
    lastStoppedSeatAction = currentSeatAction;
    currentSeatAction = 0;
    relayDeadtimeStartTime = currentTime;
    applySeatAction(0);
    return;
  }

  bool sameDirectionResume = requestedSeatAction != 0 && requestedSeatAction == lastStoppedSeatAction;
  bool deadtimeDone = currentTime - relayDeadtimeStartTime >= RELAY_DEADTIME_MS;
  if (sameDirectionResume || deadtimeDone) {
    currentSeatAction = requestedSeatAction;
  }

  applySeatAction(currentSeatAction);
}

void applySeatAction(int action) {
  if (action == 1) {
    setRelay(seatRelayD8, 1);
    setRelay(seatRelayD9, 0);
  } else if (action == -1) {
    setRelay(seatRelayD8, 0);
    setRelay(seatRelayD9, 1);
  } else {
    setRelay(seatRelayD8, 0);
    setRelay(seatRelayD9, 0);
  }
}