Automatic Motor Break-In System

#include <Arduino.h>
#include <WiFi.h>
#include <WebServer.h>
#include <Preferences.h>
#include <esp_arduino_version.h>
WebServer web(80);
Preferences prefs;
constexpr int PWM=25, ENABLE=26, SENSE=33, FAULT=32, TACH=27;
volatile uint32_t pulses=0,lastEdge=0;
portMUX_TYPE mux=portMUX_INITIALIZER_UNLOCKED;
void IRAM_ATTR tick(){uint32_t t=micros(); if(t-lastEdge<100)return; lastEdge=t; portENTER_CRITICAL_ISR(&mux); pulses++; portEXIT_CRITICAL_ISR(&mux);}
struct Step{uint16_t seconds; uint8_t power;};
Step steps[12]; int count=0,idx=0,duty=0;
struct Sample{uint32_t ms; float rpm; uint8_t step,power;};
Sample samples[1801]; int used=0;
bool running=false; uint32_t began=0,stepAt=0,sampleAt=0; float rpmValue=0;
String reason="Idle",program="60,25\n60,40\n60,55";
void drive(int percent){duty=percent;
#if ESP_ARDUINO_VERSION_MAJOR >= 3
ledcWrite(PWM,percent*255/100);
#else
ledcWrite(0,percent*255/100);
#endif
}
void halt(String why){drive(0);digitalWrite(ENABLE,LOW);running=false;reason=why;}
bool parse(String s){int n=0,total=0,pos=0; Step temp[12]; while(pos<(int)s.length()){int e=s.indexOf('\n',pos);if(e<0)e=s.length();String l=s.substring(pos,e);l.trim();pos=e+1;if(!l.length())continue;int sec,power;char extra;if(sscanf(l.c_str(),"%d,%d %c",&sec,&power,&extra)!=2||sec<1||sec>1800||power<0||power>100||n>=12)return false;total+=sec;if(total>1800)return false;temp[n++]={(uint16_t)sec,(uint8_t)power};}if(!n)return false;memcpy(steps,temp,n*sizeof(Step));count=n;return true;}
const char page[] PROGMEM=R"HTML(<!doctype html><meta name="viewport" content="width=device-width"><title>Motor break-in</title><h1>Motor break-in</h1><p>Secure motor and guard shaft. Never leave running unattended.</p><p id="state"></p><p>Program: seconds,power percent, one step per line. Up to 12 steps / 30 minutes. Power is PWM duty, NOT regulated RPM or voltage.</p><textarea id="p" rows="12" cols="28"></textarea><p><button onclick="send('/save')">Save program</button> <button onclick="send('/start')">Start new log</button> <button onclick="fetch('/stop',{method:'POST'})">STOP</button></p><a href="/log.csv">Download CSV</a><p>Logs are held in memory. Download before starting again or removing power. Physical stop switch works without Wi-Fi.</p><script>fetch('/program').then(r=>r.text()).then(t=>p.value=t);function send(url){fetch(url,{method:'POST',body:new URLSearchParams({p:p.value})}).then(r=>r.text()).then(alert)}setInterval(()=>fetch('/status').then(r=>r.text()).then(t=>document.getElementById('state').textContent=t),1000)</script>)HTML";
void setup(){
 pinMode(ENABLE,OUTPUT);digitalWrite(ENABLE,LOW);pinMode(SENSE,INPUT);pinMode(FAULT,INPUT_PULLUP);pinMode(TACH,INPUT_PULLUP);
#if ESP_ARDUINO_VERSION_MAJOR >= 3
 ledcAttach(PWM,20000,8);
#else
 ledcSetup(0,20000,8);ledcAttachPin(PWM,0);
#endif
 drive(0);attachInterrupt(digitalPinToInterrupt(TACH),tick,FALLING);Serial.begin(115200);
 prefs.begin("breakin",false);program=prefs.getString("program",program);if(!parse(program)){program="60,25\n60,40\n60,55";parse(program);}
 WiFi.mode(WIFI_AP);WiFi.softAP("Motor-Break-In","MotorRun123");
 web.on("/",[]{web.send_P(200,"text/html",page);});web.on("/program",[]{web.send(200,"text/plain",program);});
 web.on("/status",[]{web.send(200,"text/plain",reason+" | RPM: "+String(rpmValue,0)+" | Power: "+String(duty)+"% | Samples: "+String(used));});
 web.on("/save",HTTP_POST,[]{if(running){web.send(409,"text/plain","Stop first");return;}if(!parse(web.arg("p"))){web.send(400,"text/plain","Invalid program: seconds 1-1800, power 0-100; max 12 steps and 1800 seconds total");return;}program=web.arg("p");prefs.putString("program",program);web.send(200,"text/plain","Saved");});
 web.on("/start",HTTP_POST,[]{if(running){web.send(409,"text/plain","Already running");return;}if(!parse(web.arg("p"))){web.send(400,"text/plain","Invalid program");return;}drive(0);digitalWrite(ENABLE,HIGH);delay(2);if(!digitalRead(SENSE)||!digitalRead(FAULT)){halt("Stop switch or driver fault");web.send(409,"text/plain",reason);return;}used=0;idx=0;rpmValue=0;portENTER_CRITICAL(&mux);pulses=0;portEXIT_CRITICAL(&mux);began=stepAt=sampleAt=millis();running=true;reason="Running";drive(steps[0].power);web.send(200,"text/plain","Started; previous log cleared");});
 web.on("/stop",HTTP_POST,[]{halt("Stopped");web.send(200,"text/plain",reason);});
 web.on("/log.csv",[]{if(running){web.send(409,"text/plain","Stop before downloading");return;}web.sendHeader("Content-Disposition","attachment; filename=breakin.csv");web.setContentLength(CONTENT_LENGTH_UNKNOWN);web.send(200,"text/csv","");web.sendContent("elapsed_ms,step,pwm_percent,rpm\n");String b;for(int i=0;i<used;i++){auto &s=samples[i];b+=String(s.ms)+","+String(s.step)+","+String(s.power)+","+String(s.rpm,1)+"\n";if(b.length()>1000){web.sendContent(b);b="";}}web.sendContent(b);web.sendContent("");});
 web.begin();Serial.println("Connect to Motor-Break-In, password MotorRun123; open http://192.168.4.1");
}
void loop(){
 uint32_t now=millis();
 if(running){
 if(!digitalRead(SENSE)||!digitalRead(FAULT))halt("Stop switch or driver fault - manual restart required");
 if(running&&now-sampleAt>=1000){uint32_t n;portENTER_CRITICAL(&mux);n=pulses;pulses=0;portEXIT_CRITICAL(&mux);rpmValue=n*60000.0f/(now-sampleAt);sampleAt=now;if(used<1801)samples[used++]={now-began,rpmValue,(uint8_t)(idx+1),(uint8_t)duty};if(duty>0&&now-stepAt>=5000&&rpmValue<60)halt("No RPM detected - check motor and optical sensor");}
 if(running&&now-stepAt>=steps[idx].seconds*1000UL){idx++;if(idx>=count)halt("Complete");else{stepAt=now;drive(steps[idx].power);}}
 }
 web.handleClient();delay(1);
}

// Verified wiring: PWM25, enable26, enable sense33, fault32, tach27.