/*
  Fan Tester created by JIMMY HO - WELLEGION INDUSTRIES
  REV 1.0.0
  Date: 2023/08/07

  MODEL - 3-WIRE DC FAN Tester
  Able to test up to 10 differint Fan Model

  Function Test lists-
  (1)Voltage reading
  (2)Current reading
  (3)RPM reading

  ARDUINO PIN DEFINED
  ------------------------------------
  A0 = Current Sensor
  A1 = Voltage Sensor
  A2 = PWM Control
  A3 = Buzzer
  A4 = I2C LCD SDA
  A5 = I2C LCD SCL
  D2 = FAN RPM read
  D3 = TEST RUNNING Indicator LED
  D4 = TEST FAIL Indicator LED
  D5 = TEST PASS Indicator LED
  D6 = VCC_CHECK
  D7 = GND_CHECK
  D8 = TACHO_CHECK
  D9 = Push to Start Testing
  D10 = Push to Change Fan Model
  D11 = Supply 24VDC to FAN
  D12 = Supply 12VDC to FAN
  D13 = Supply 5VDC to FAN
  ------------------------------------
*/

#include <LiquidCrystal_I2C.h> // Using this library for I2C LCD

LiquidCrystal_I2C lcd(0x27, 20, 4); // set the LCD address to 0x3F for a 20 chars and 4 line display

// integer pin for Relay and Push Button
const int FAN_24VDC = 11;
const int FAN_12VDC = 12;
const int FAN_5VDC = 13;
const int START_BUTTON = 9;
const int CHANGE_MODEL = 10;

// interger pin for BUZZER
const int BUZZER = A3;

// interger count = 1
int model_count = 1;

// integer pin for Indicator LED
const int TEST_RUN = 3;
const int TEST_FAIL = 6;
const int TEST_PASS = 5;

// integer for test pass requirement
float test_voltage = 23;
float test_current = 0.4;
float test_rpm = 5500;

// integer for Short Test before RUN
const int VCC_CHECK = 4;
const int GND_CHECK = 7;
const int TACHO_CHECK = 8;
int value2;

// integer for RPM read
int value;
int count = 0;
int rpm;
unsigned long start_time;

// integer for Voltage Sense
const int VoltageSensor = A1;
int sum = 0;
unsigned char sample_count = 0;
float voltage = 0.0;
float voltage_result = 0.0;
float vOUT = 0.0;
float vIN = 0.0;
float R1 = 30000.0;
float R2 = 7500.0;

// integer for Current Sense
const int CurrentSensor = A0;
float average;
float current;
int value1 = 0;
int i = 0;

unsigned long endTime;

// start create custom characters
byte blank[8] = {B00000, B00000, B01110, B01110,
                 B01110, B01110, B00000, B00000
                };
byte blank1[8] = {B00000, B00000, B00000, B11111,
                  B11111, B00000, B00000, B00000
                 };
byte blank2[8] = {B00100, B00100, B00100, B00100,
                  B00100, B00100, B00100, B00100
                 };
byte fan1[8] = {B00000, B00000, B00000, B00000,
                B01110, B11111, B11111, B00001
               };
byte fan2[8] = {B00000, B00000, B00000, B01100,
                B01110, B01110, B01110, B11100
               };
byte fan3[8] = {B00111, B01110, B01110, B01110,
                B00110, B00000, B00000, B00000
               };
byte fan4[8] = {B10000, B11111, B11111, B01110,
                B00000, B00000, B00000, B00000
               };
byte five[8] = {B11111, B11111, B11111, B11111,
                B11111, B11111, B11111, B11111
               };
// end create custom characters

void counter() {
  count++;
}

void setup()
{
  Serial.begin(9600); // initializes the Serial Monitor with 9600
  lcd.begin(20, 4); // initializes the interface to the LCD screen
  lcd.init(); // initialization LCD
  lcd.backlight(); // turn on back light
  lcd.clear(); // clear LCD screen

  // start createchar for custom character
  lcd.createChar(0, blank);
  lcd.createChar(1, blank1);
  lcd.createChar(2, blank2);
  lcd.createChar(3, fan1);
  lcd.createChar(4, fan2);
  lcd.createChar(5, fan3);
  lcd.createChar(6, fan4);
  lcd.createChar(7, five);
  // end createchar for custom character

  // set pinMode
  pinMode(FAN_24VDC, OUTPUT);
  pinMode(FAN_12VDC, OUTPUT);
  pinMode(FAN_5VDC, OUTPUT);
  pinMode(START_BUTTON, INPUT);
  pinMode(CHANGE_MODEL, INPUT_PULLUP);
  pinMode(TEST_RUN, OUTPUT);
  pinMode(TEST_FAIL, OUTPUT);
  pinMode(TEST_PASS, OUTPUT);
  attachInterrupt(digitalPinToInterrupt(2), counter, RISING); // Blue Wire with 5V pullup

  lcd.setCursor(0, 1); // set Cursor to 0,1
  lcd.print("W");
  delay(50);
  lcd.print("E");
  delay(50);
  lcd.print("L");
  delay(50);
  lcd.print("L");
  delay(50);
  lcd.print("E");
  delay(50);
  lcd.print("G");
  delay(50);
  lcd.print("I");
  delay(50);
  lcd.print("O");
  delay(50);
  lcd.print("N");
  delay(50);
  lcd.print(" ");
  delay(50);
  lcd.print("I");
  delay(50);
  lcd.print("N");
  delay(50);
  lcd.print("D");
  delay(50);
  lcd.print("U");
  delay(50);
  lcd.print("S");
  delay(50);
  lcd.print("T");
  delay(50);
  lcd.print("R");
  delay(50);
  lcd.print("I");
  delay(50);
  lcd.print("E");
  delay(50);
  lcd.print("S");
  delay(50);
  lcd.setCursor(4, 2); // set Cursor to 4,2
  lcd.print("(");
  delay(50);
  lcd.print("M");
  delay(50);
  lcd.print(")");
  delay(50);
  lcd.print(" ");
  delay(50);
  lcd.print("S");
  delay(50);
  lcd.print("D");
  delay(50);
  lcd.print("N");
  delay(50);
  lcd.print(" ");
  delay(50);
  lcd.print("B");
  delay(50);
  lcd.print("H");
  delay(50);
  lcd.print("D");
  delay(500);
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.write(0);
  delay(50);
  lcd.write(1);
  delay(50);
  lcd.write(1);
  delay(50);
  lcd.write(0);
  delay(50);
  lcd.setCursor(0, 1); // set Cursor to 0,1
  lcd.write(2);
  delay(50);
  lcd.write(3);
  delay(50);
  lcd.write(4);
  delay(50);
  lcd.write(2);
  delay(50);
  lcd.setCursor(0, 2); // set cursor to 0,2
  lcd.write(2);
  delay(50);
  lcd.write(5);
  delay(50);
  lcd.write(6);
  delay(50);
  lcd.write(2);
  delay(50);
  lcd.setCursor(0, 3); // set cursor to 0,3
  lcd.write(0);
  delay(50);
  lcd.write(1);
  delay(50);
  lcd.write(1);
  delay(50);
  lcd.write(0);
  delay(50);
  lcd.setCursor(9, 0); // set cursor to 10,1
  lcd.print("3");
  delay(50);
  lcd.print("-");
  delay(50);
  lcd.print("W");
  delay(50);
  lcd.print("I");
  delay(50);
  lcd.print("R");
  delay(50);
  lcd.print("E");
  delay(50);
  lcd.setCursor(6, 1); // set cursor to 10,1
  lcd.print("D");
  delay(50);
  lcd.print("C");
  delay(50);
  lcd.print(" ");
  delay(50);
  lcd.print("F");
  delay(50);
  lcd.print("A");
  delay(50);
  lcd.print("N");
  delay(50);
  lcd.print(" ");
  delay(50);
  lcd.print("T");
  delay(50);
  lcd.print("E");
  delay(50);
  lcd.print("S");
  delay(50);
  lcd.print("T");
  delay(50);
  lcd.print("E");
  delay(50);
  lcd.print("R");
  delay(50);
  lcd.setCursor(16, 3); // set Cursor to 8,2
  lcd.print("V");
  delay(50);
  lcd.print("1");
  delay(50);
  lcd.print(".");
  delay(50);
  lcd.print("0");
  delay(1000);
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("FUNCTION TEST LISTS:-");
  lcd.setCursor(0, 1); // set Cursor to 0,1
  lcd.print("(1) VOLTAGE   (V)");
  lcd.setCursor(0, 2); // set Cursor to 0,2
  lcd.print("(2) CURRENT   (A)");
  lcd.setCursor(0, 3); // set Cursor to 0,3
  lcd.print("(3) SPEED    (RPM)");
  delay(3000);
  lcd.clear();
  lcd.setCursor(1, 0); // set Cursor to 0,0
  lcd.print("------------------");
  lcd.setCursor(0, 1); // set Cursor to 0,1
  lcd.print("|FAN MODEL SELECT: |");
  lcd.setCursor(0, 2); // set Cursor to 0,2
  lcd.print("| (1) 414J/2HH     |");
  lcd.setCursor(1, 3); // set Cursor to 0,3
  lcd.print("------------------");
}

void loop()
{
  int value2 = 0;

  if (digitalRead(CHANGE_MODEL) == LOW)
    {
      model_count++;
      delay(100);
      if (model_count > 5)
       {
        model_count = 1;
       }
      switch(model_count)
      {
        case 1:
          tone(BUZZER,6000);
          delay(100);
          noTone(BUZZER);
          lcd.clear();
          lcd.setCursor(1, 0); // set Cursor to 0,0
          lcd.print("------------------");
          lcd.setCursor(0, 1); // set Cursor to 0,1
          lcd.print("|FAN MODEL SELECT: |");
          lcd.setCursor(0, 2); // set Cursor to 0,2
          lcd.print("| (1) 414J/2HH     |");
          lcd.setCursor(1, 3); // set Cursor to 0,3
          lcd.print("------------------");
          break;

        case 2:
          tone(BUZZER,6000);
          delay(100);
          noTone(BUZZER);
          lcd.clear();
          lcd.setCursor(1, 0); // set Cursor to 0,0
          lcd.print("------------------");
          lcd.setCursor(0, 1); // set Cursor to 0,1
          lcd.print("|FAN MODEL SELECT: |");
          lcd.setCursor(0, 2); // set Cursor to 0,2
          lcd.print("| (2) 624/2HH      |");
          lcd.setCursor(1, 3); // set Cursor to 0,3
          lcd.print("------------------");
          break;

        case 3:
          tone(BUZZER,6000);
          delay(100);
          noTone(BUZZER);
          lcd.clear();
          lcd.setCursor(1, 0); // set Cursor to 0,0
          lcd.print("------------------");
          lcd.setCursor(0, 1); // set Cursor to 0,1
          lcd.print("|FAN MODEL SELECT: |");
          lcd.setCursor(0, 2); // set Cursor to 0,2
          lcd.print("| (3) FAN 3        |");
          lcd.setCursor(1, 3); // set Cursor to 0,3
          lcd.print("------------------");
          break;

        case 4:
          tone(BUZZER,6000);
          delay(100);
          noTone(BUZZER);
          lcd.clear();
          lcd.setCursor(1, 0); // set Cursor to 0,0
          lcd.print("------------------");
          lcd.setCursor(0, 1); // set Cursor to 0,1
          lcd.print("|FAN MODEL SELECT: |");
          lcd.setCursor(0, 2); // set Cursor to 0,2
          lcd.print("| (4) FAN 4        |");
          lcd.setCursor(1, 3); // set Cursor to 0,3
          lcd.print("------------------");
          break;

        case 5:
          tone(BUZZER,6000);
          delay(100);
          noTone(BUZZER);
          lcd.clear();
          lcd.setCursor(1, 0); // set Cursor to 0,0
          lcd.print("------------------");
          lcd.setCursor(0, 1); // set Cursor to 0,1
          lcd.print("|FAN MODEL SELECT: |");
          lcd.setCursor(0, 2); // set Cursor to 0,2
          lcd.print("| (5) FAN 5        |");
          lcd.setCursor(1, 3); // set Cursor to 0,3
          lcd.print("------------------");
          break;
      }
     }
  else {
    if (digitalRead(START_BUTTON) == LOW)
    {
    switch(model_count){
      case 1:
        tone(BUZZER,6000);
        delay(100);
        noTone(BUZZER);
        FAN1();
        break;

      case 2:
        tone(BUZZER,6000);
        delay(100);
        noTone(BUZZER);
        FAN2();
        break;

      case 3:
        tone(BUZZER,6000);
        delay(100);
        noTone(BUZZER);
        FAN3();
        break;

      case 4:
        tone(BUZZER,6000);
        delay(100);
        noTone(BUZZER);
        FAN4();
        break;

      case 5:
        tone(BUZZER,6000);
        delay(100);
        noTone(BUZZER);
        FAN5();
        break;
      }
    }
  }
}

void FAN1()
  {
  int value2 = 0;
  digitalWrite(TEST_FAIL, LOW);
  digitalWrite(TEST_PASS, LOW);
  digitalWrite(TEST_RUN, HIGH);
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("MODEL: 414J/2HH");
  lcd.setCursor(0,1); // set Cursor to 0,1
  lcd.print("Fan Connection Check");
  delay(1500);
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("MODEL: 414J/2HH");

  lcd.setCursor(0,1); // set Cursor to 0,1
  lcd.print("VCC   = ");
  pinMode(VCC_CHECK, OUTPUT);
  pinMode(GND_CHECK, INPUT);
  pinMode(TACHO_CHECK, INPUT);
  digitalWrite(VCC_CHECK, HIGH);
  delay(100);
  if (digitalRead(GND_CHECK) == HIGH)
    {lcd.print("FAIL");
    value2++;}
  else
    {
    if (digitalRead(TACHO_CHECK) == HIGH)
      {lcd.print("FAIL");
    value2++;}
    else
      {lcd.print("PASS");}
    }
  digitalWrite(VCC_CHECK, LOW);
  delay(100);

  lcd.setCursor(0,2); // set Cursor to 0,1
  lcd.print("GND   = ");
  pinMode(VCC_CHECK, INPUT);
  pinMode(GND_CHECK, OUTPUT);
  pinMode(TACHO_CHECK, INPUT);
  digitalWrite(GND_CHECK, HIGH);
  delay(100);
  if (digitalRead(VCC_CHECK) == HIGH)
    {lcd.print("FAIL");
    value2++;}
  else
    {
    if (digitalRead(TACHO_CHECK) == HIGH)
      {lcd.print("FAIL");
    value2++;}
    else
      {lcd.print("PASS");}
    }
  digitalWrite(GND_CHECK, LOW);
  delay(100);

  lcd.setCursor(0,3); // set Cursor to 0,1
  lcd.print("TACHO = ");
  pinMode(VCC_CHECK, INPUT);
  pinMode(GND_CHECK, INPUT);
  pinMode(TACHO_CHECK, OUTPUT);
  digitalWrite(TACHO_CHECK, HIGH);
  delay(100);
  if (digitalRead(VCC_CHECK) == HIGH)
    {lcd.print("FAIL");
    value2++;}
  else
    {
    if (digitalRead(GND_CHECK) == HIGH)
      {lcd.print("FAIL");
    value2++;}
    else
      {lcd.print("PASS");}
    }
  digitalWrite(TACHO_CHECK, LOW);
  delay(100);
  
  lcd.setCursor(8,2);
  if (value2 > 0)
    { digitalWrite(TEST_RUN, LOW);
      digitalWrite(TEST_FAIL, HIGH);
    tone(BUZZER,6000);
    delay(100);
    noTone(BUZZER);
    delay(100);
    tone(BUZZER,6000);
    delay(100);
    noTone(BUZZER);
    delay(100);
    tone(BUZZER,6000);
    delay(100);
    noTone(BUZZER);
    delay(100);
    tone(BUZZER,6000);
    delay(100);
    noTone(BUZZER);
    }

  else
    {delay(100);
    lcd.clear();
    lcd.setCursor(0, 0); // set Cursor to 0,0
    lcd.print("MODEL: 414J/2HH");
    lcd.setCursor(0,1); // set Cursor to 0,1
    lcd.print("Continuity Passed");
    lcd.setCursor(0,2); // set Cursor to 0,2
    delay(2000);
    lcd.clear(); // clear LCD screen
  digitalWrite(FAN_24VDC, HIGH); // turn on DUT fan
  digitalWrite(TEST_PASS, LOW); // turn off test pass indicator led
  digitalWrite(TEST_FAIL, LOW); // turn off test fail indicator led
  // set cursor to 0,0
  lcd.write(3);
  lcd.write(4);
  lcd.print("   WARMING UP   ");
  lcd.write(3);
  lcd.write(4);
  lcd.setCursor(0, 1); // set cursor to 0,1
  lcd.write(5);
  lcd.write(6);
  lcd.print("     DC FAN     ");
  lcd.write(5);
  lcd.write(6);
  lcd.setCursor(0, 2); // set cursor to 0,2
  delay(1000);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  delay(1000);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  delay(1000);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  delay(1000);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  delay(1000);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  lcd.write(7);
  endTime = millis() + 11000;

Testing1:
  if (millis() <= endTime)
  {
    digitalWrite(FAN_24VDC, HIGH); // turn on DUT fan
    digitalWrite(TEST_PASS, LOW); // turn off test pass indicator led

    // Calculation for RPM read and PWM control
    start_time = millis();
    count = 0;
    while ((millis() - start_time) < 1000) {}
    rpm = count * 30;
    Serial.print("Speed = ");
    Serial.print(rpm);
    Serial.println(" rpm");

    // Calculation for Voltage Sense
    while (sample_count < 20)
    {
      sum += analogRead(VoltageSensor);
      sample_count++;
      delay(10);
    }
    voltage = ((float) sum / 20 * 5.0) / 1024;
    voltage_result = voltage * 5 ;
    Serial.print("Voltage = ");
    Serial.print(voltage_result, 3);
    Serial.println(" V");

    // Calculation for Current Sense
    for (i = 0; i < 20; i++)
    {
      average = average + (.0264 * analogRead(CurrentSensor) - 13.51) / 20;
      current = average / 1.35 ;
      delay(10); // delay for 0.01 sec
    }
    Serial.print("Current = ");
    Serial.print(current, 3);
    Serial.println(" A");

    if ( voltage_result < 18 )
    {
      voltage_result = 0;
    }
    if ( current < 0)
    {
      current = 0;
    }
    // DATA CAPTURED show in LCD
    lcd.clear(); // clear LCD screen
    lcd.setCursor(0, 0); // set cursor to 0,0
    lcd.print("Voltage = ");
    lcd.print(voltage_result, 3);
    lcd.print(" V");
    lcd.setCursor(0, 1); // set cursor to 0,1
    lcd.print("Current = ");
    lcd.print(current, 3);
    lcd.print(" A");
    lcd.setCursor(0, 2); // set cursor to 0,2
    lcd.print("SPEED   = ");
    lcd.print(rpm);
    lcd.print(" rpm");
    average = 0;
    sample_count = 0;
    sum = 0;
    if ( voltage_result > test_voltage && current > test_current && rpm > test_rpm )
    {
      digitalWrite(FAN_24VDC, LOW); // turn off DUT fan
      digitalWrite(TEST_RUN, LOW); // turn off test run indicator led
      digitalWrite(TEST_PASS, HIGH); // turn on test pass indicator led
    }
    else
    {goto Testing1;}
  }
  else
  {
    digitalWrite(FAN_24VDC, LOW); // turn off DUT fan
    digitalWrite(TEST_RUN, LOW); // turn off test run indicator led
    digitalWrite(TEST_FAIL, HIGH); // turn on test fail on first loop led
  }
    }
  }

void FAN2()
  {
  int value2 = 0;
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("FAN2 TEST");
  }

void FAN3()
  {
  int value2 = 0;
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("FAN3 TEST");
  }

void FAN4()
  {
  int value2 = 0;
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("FAN4 TEST");
  }

void FAN5()
  {
  int value2 = 0;
  lcd.clear();
  lcd.setCursor(0, 0); // set Cursor to 0,0
  lcd.print("FAN5 TEST");
  }