# ─────────────────────────────────────────────────────────────────────────────
#  Smart PLC Condition Monitor — Single Machine Version
#  K.K. Wagh Institute | Dept. E&TC | Group 19
#  Guide: Prof. Smita A. Karpe
#
#  SENSORS:
#    GP20 (1-Wire) = DS18B20 #1 → Motor Temp     (−55 to +125 °C)
#    GP21 (1-Wire) = DS18B20 #2 → Bearing Temp   (−55 to +125 °C)
#    GP26 (ADC0)   = Potentiometer → Vibration Level (0-3.3V simulated)
#    GP27 (ADC1)   = ACS712-5A → Current Sensor (0-5A, centered at 2.5V)
#    (Each DS18B20 with 4.7 kΩ pull-up to 3.3V)
#
#  STATUS OUTPUTS:
#    GP0 = Green  LED   (NORMAL)
#    GP1 = Yellow LED   (WARNING)
#    GP2 = Red    LED   (CRITICAL)
#    GP3 = Buzzer       (CRITICAL alarm)
#
#  RELAY & MOTOR CONTROL:
#    GP4 = Relay → Machine Power Control
#    GP6 = STEP (A4988 stepper driver)
#    GP7 = DIR  (A4988 stepper driver)
#    GP8 = EN   (A4988 stepper driver)
#
#  THRESHOLDS:
#    Temperature: NORMAL < 60°C, WARNING 60-79°C, CRITICAL ≥ 80°C
#    Current:     NORMAL < 3A,   WARNING 3-4A,    CRITICAL ≥ 4A
#    Vibration:   NORMAL < 1.5V, WARNING 1.5-2.5V, CRITICAL ≥ 2.5V
#
#  STAGE LOGIC:
#    NORMAL   → Relay ON  + Motor FAST
#    WARNING  → Relay ON  + Motor SLOW
#    CRITICAL → Relay OFF + Motor STOP
# ─────────────────────────────────────────────────────────────────────────────

import onewire, ds18x20
from machine import Pin, ADC
import time

# ── DS18B20 Setup (2 separate 1-Wire buses) ──────────────────────────────────
OW_PINS = [20, 21]   # GP20 → Motor Temp, GP21 → Bearing Temp
_buses   = []
_sensors = []
_roms    = []

print("Scanning DS18B20 sensors...")
for gp in OW_PINS:
    ow = onewire.OneWire(Pin(gp))
    ds = ds18x20.DS18X20(ow)
    rm = ds.scan()
    _buses.append(ow)
    _sensors.append(ds)
    _roms.append(rm)
    status = f"{len(rm)} sensor found" if rm else "NOT FOUND (using 25.0C)"
    print(f"  GP{gp}: {status}")

def read_all_temps():
    """Trigger all DS18B20 conversions at once, wait, then read all."""
    for ds in _sensors:
        try:
            ds.convert_temp()
        except:
            pass
    time.sleep_ms(750)          # DS18B20 max conversion time
    temps = []
    for ds, rm in zip(_sensors, _roms):
        if rm:
            try:
                t = ds.read_temp(rm[0])
                temps.append(round(t, 1) if -55 <= t <= 125 else 25.0)
            except:
                temps.append(25.0)
        else:
            temps.append(25.0)
    return temps

# ── ADC Setup (Potentiometer + Current Sensor) ───────────────────────────────
vib_adc  = ADC(26)   # GP26 → Potentiometer (Vibration simulation)
curr_adc = ADC(27)   # GP27 → ACS712 Current Sensor

def read_vibration():
    """Read potentiometer voltage (0-3.3V) as vibration level."""
    raw = vib_adc.read_u16()
    voltage = (raw / 65535) * 3.3
    return round(voltage, 2)

def read_current():
    """Read ACS712 sensor and convert to current (A).
    ACS712-5A: 185 mV/A, centered at 2.5V (Vcc/2)
    For Pico: Vcc = 3.3V, so center = 1.65V
    Sensitivity = 0.185 V/A
    Current = (Vsensor - 1.65) / 0.185
    """
    raw = curr_adc.read_u16()
    voltage = (raw / 65535) * 3.3
    # ACS712 offset at 1.65V for 3.3V supply
    current = abs((voltage - 1.65) / 0.185)
    return round(current, 2)

# ── Status LEDs + Buzzer ──────────────────────────────────────────────────────
LED_G  = Pin(0, Pin.OUT)
LED_Y  = Pin(1, Pin.OUT)
LED_R  = Pin(2, Pin.OUT)
BUZZER = Pin(3, Pin.OUT)

# ── Relay Coil (Machine power control) ───────────────────────────────────────
RELAY = Pin(4, Pin.OUT, value=1)   # HIGH = relay ON = Machine powered

# ── A4988 Stepper Driver ──────────────────────────────────────────────────────
STEP = Pin(6, Pin.OUT, value=0)
DIR  = Pin(7, Pin.OUT, value=1)
EN   = Pin(8, Pin.OUT, value=0)   # LOW = enabled

def pulse(pin):
    pin.value(1)
    time.sleep_us(5)
    pin.value(0)

def get_stage(val, warn_thresh, crit_thresh):
    if val >= crit_thresh: return "CRITICAL"
    if val >= warn_thresh: return "WARNING"
    return "NORMAL"

def clamp(v, lo, hi):
    return max(lo, min(hi, v))

# ── Startup Banner ────────────────────────────────────────────────────────────
print()
print("=" * 70)
print("  Smart PLC Monitor — Single Machine Version")
print("  K.K. Wagh Institute | Dept. E&TC | Group 19")
print("")
print("  SENSOR          PIN    TYPE")
print("  Motor Temp      GP20   DS18B20 #1  (click sensor → set temp)")
print("  Bearing Temp    GP21   DS18B20 #2  (click sensor → set temp)")
print("  Vibration       GP26   Potentiometer (slide to adjust 0-3.3V)")
print("  Current         GP27   ACS712-5A (simulated)")
print("")
print("  THRESHOLDS:")
print("  Temperature:  NORMAL < 60°C   WARNING 60-79°C   CRITICAL ≥ 80°C")
print("  Current:      NORMAL < 3A     WARNING 3-4A      CRITICAL ≥ 4A")
print("  Vibration:    NORMAL < 1.5V   WARNING 1.5-2.5V  CRITICAL ≥ 2.5V")
print("")
print("  STAGE ACTIONS:")
print("  NORMAL   → Relay ON  + Motor RUNNING (fast)")
print("  WARNING  → Relay ON  + Motor RUNNING (slow)")
print("  CRITICAL → Relay OFF + Motor STOPPED")
print("=" * 70)
print()

# ── Main Loop ─────────────────────────────────────────────────────────────────
prev_stage = ""
tick       = 0
STEP_US    = {"NORMAL": 1200, "WARNING": 5000, "CRITICAL": 0}

while True:
    # ── Read all sensors ──────────────────────────────────────────────────────
    motor_temp, bearing_temp = read_all_temps()
    vibration_v = read_vibration()
    current_a   = read_current()

    # ── Stage classification ──────────────────────────────────────────────────
    rows = [
        ("Motor Temp",    motor_temp,   "C",  get_stage(motor_temp,   60, 80)),
        ("Bearing Temp",  bearing_temp, "C",  get_stage(bearing_temp, 60, 80)),
        ("Current",       current_a,    "A",  get_stage(current_a,     3,  4)),
        ("Vibration",     vibration_v,  "V",  get_stage(vibration_v, 1.5, 2.5)),
    ]

    # Overall system stage (worst case)
    if   any(r[3] == "CRITICAL" for r in rows): system = "CRITICAL"
    elif any(r[3] == "WARNING"  for r in rows): system = "WARNING"
    else:                                        system = "NORMAL"

    # ── Drive all outputs ─────────────────────────────────────────────────────
    is_crit = (system == "CRITICAL")
    LED_G.value(system == "NORMAL")
    LED_Y.value(system == "WARNING")
    LED_R.value(is_crit)
    BUZZER.value(is_crit)
    RELAY.value(0 if is_crit else 1)
    EN.value(1 if is_crit else 0)

    spd = STEP_US[system]

    # ── Print sensor table ────────────────────────────────────────────────────
    print()
    print("  +─────── MACHINE CONDITION MONITOR ──────+")
    for r in rows:
        print("  | {:16s} {:6.2f} {:2s} [{:8s}]  |".format(r[0], r[1], r[2], r[3]))
    print("  +─────────────────────────────────────────+")
    
    relay_status = "ON-RUNNING" if not is_crit else "TRIPPED-STOP"
    motor_status = {"NORMAL": "FAST", "WARNING": "SLOW", "CRITICAL": "STOPPED"}[system]
    
    print("  | Relay Status:     {:>21s}  |".format(relay_status))
    print("  | Motor Speed:      {:>21s}  |".format(motor_status))
    print("  | SYSTEM STATUS:    {:>21s}  |".format(system))
    print("  +─────────────────────────────────────────+")

    if system != prev_stage:
        print()
        if system == "CRITICAL":
            print("  *** CRITICAL — Relay TRIPPED, Machine STOPPED!")
        elif system == "WARNING":
            print("  *** WARNING  — Parameters rising, motor slowing!")
        elif prev_stage:
            print("  *** NORMAL   — Relay ON, Machine RUNNING at full speed!")
        prev_stage = system

    # ── Step motor for one cycle ──────────────────────────────────────────────
    if spd == 0:
        time.sleep_ms(100)  # Just wait if stopped
    else:
        steps = max(1, min(300, 1_000_000 // spd))
        for _ in range(steps):
            pulse(STEP)
            time.sleep_us(spd)

    tick += 1