// ============================================================================ // TM-ANT-SW-001 Rev A — Motorized Antenna Switch // ESP32 / CYD Firmware — 28BYJ-48 Stepper + Hall Sensor Position Feedback // 4-position or 6-position rotary switch // WiFi/Web UI + CYD touch + push buttons + serial // ============================================================================ #include #include #include #include #include #include // ── Stepper motor pins (28BYJ-48 via ULN2003A) ──────────────────────────── #define STEP_IN1 26 #define STEP_IN2 27 #define STEP_IN3 14 #define STEP_IN4 12 // ── Hall effect sensor pins (active LOW = magnet present = at this position) #define HALL_1 4 // position 1 sensor #define HALL_2 5 // position 2 sensor #define HALL_3 18 // position 3 sensor #define HALL_4 19 // position 4 sensor // ── Status LEDs ──────────────────────────────────────────────────────────── #define LED_1 25 #define LED_2 33 #define LED_3 32 #define LED_4 13 // ── Push buttons (active LOW, internal pull-up) ──────────────────────────── #define BTN_1 4 // NOTE: may conflict with HALL_1 — use different GPIO #define BTN_FWD 16 // advance one position forward #define BTN_REV 17 // advance one position backward // ── TX inhibit ───────────────────────────────────────────────────────────── #define PIN_TX_INHIBIT 34 #define TX_INHIBIT_HIGH 1 // ── CYD backlight ────────────────────────────────────────────────────────── #define PIN_BL 21 // ── Switch configuration ─────────────────────────────────────────────────── #define NUM_POSITIONS 4 // change to 6 for SP6T switch #define STEPS_PER_REV 512 // 28BYJ-48 full steps per output shaft revolution #define DEGREES_PER_POS (360 / NUM_POSITIONS) // 90° for 4-pos, 60° for 6-pos #define STEPS_PER_POS (STEPS_PER_REV * DEGREES_PER_POS / 360) // 128 or 85 // Step timing #define STEP_DELAY_US 4000 // microseconds between steps (4ms = ~250 steps/sec) #define SETTLE_MS 80 // wait after reaching position before de-energizing // ── Colors ───────────────────────────────────────────────────────────────── #define C_BG TFT_BLACK #define C_TITLE TFT_CYAN #define C_ACTIVE TFT_GREEN #define C_IDLE 0x4A69 #define C_MOVING TFT_YELLOW #define C_ERROR TFT_RED #define C_WHITE TFT_WHITE // ── Stepper half-step sequence (8 steps per electrical cycle) ────────────── static const uint8_t STEP_SEQ[8][4] = { {1, 0, 0, 0}, {1, 1, 0, 0}, {0, 1, 0, 0}, {0, 1, 1, 0}, {0, 0, 1, 0}, {0, 0, 1, 1}, {0, 0, 0, 1}, {1, 0, 0, 1}, }; // ── Global state ─────────────────────────────────────────────────────────── enum MotorState { IDLE, MOVING_FWD, MOVING_REV, HOMING, ERROR_STATE }; static uint8_t g_position = 1; // current position (1-based) static uint8_t g_target = 1; // target position static MotorState g_motor_state = IDLE; static int g_step_idx = 0; // current step in sequence static int g_steps_remaining = 0; // steps left to reach target static uint32_t g_last_step_us = 0; // timestamp of last step static bool g_tx_active = false; static bool g_wifi_ok = false; static uint8_t g_pending = 0; static bool g_homed = false; static char g_ant_names[NUM_POSITIONS][16]; const char ANT_NAME_DEFAULT[NUM_POSITIONS][16] = { "ANT 1", "ANT 2", "ANT 3", "ANT 4" }; static const int HALL_PINS[4] = {HALL_1, HALL_2, HALL_3, HALL_4}; static const int LED_PINS[4] = {LED_1, LED_2, LED_3, LED_4}; static const int STEP_PINS[4] = {STEP_IN1, STEP_IN2, STEP_IN3, STEP_IN4}; Preferences prefs; WebServer server(80); TFT_eSPI tft = TFT_eSPI(); // ── Stepper motor control ────────────────────────────────────────────────── void step_apply(int idx) { for (int i = 0; i < 4; i++) digitalWrite(STEP_PINS[i], STEP_SEQ[idx][i]); } void step_off() { for (int i = 0; i < 4; i++) digitalWrite(STEP_PINS[i], LOW); } void step_forward_one() { g_step_idx = (g_step_idx + 1) % 8; step_apply(g_step_idx); } void step_backward_one() { g_step_idx = (g_step_idx + 7) % 8; // +7 mod 8 = -1 mod 8 step_apply(g_step_idx); } // ── Hall sensor reading ──────────────────────────────────────────────────── int read_position_from_hall() { // Returns 1-based position (1–4), or 0 if between positions / error int found = -1; int count = 0; for (int i = 0; i < NUM_POSITIONS && i < 4; i++) { if (digitalRead(HALL_PINS[i]) == LOW) { // LOW = magnet present found = i + 1; count++; } } if (count == 1) return found; // exactly one sensor active = valid position return 0; // 0 = transitioning or fault } void update_leds() { for (int i = 0; i < NUM_POSITIONS && i < 4; i++) digitalWrite(LED_PINS[i], (g_position == i + 1 && g_motor_state == IDLE) ? HIGH : LOW); // Blink target LED while moving if (g_motor_state == MOVING_FWD || g_motor_state == MOVING_REV) { static uint32_t blink_t = 0; static bool blink_state = false; if (millis() - blink_t > 200) { blink_state = !blink_state; blink_t = millis(); if (g_target >= 1 && g_target <= NUM_POSITIONS) digitalWrite(LED_PINS[g_target - 1], blink_state ? HIGH : LOW); } } } // ── Homing sequence ──────────────────────────────────────────────────────── // On power-up: read Hall sensors. If at a valid position, done. // If not at a valid position: step slowly until a sensor activates. bool home_sequence() { Serial.println("[HOME] Starting homing sequence..."); tft.fillScreen(C_BG); tft.setTextColor(C_MOVING, C_BG); tft.setTextSize(2); tft.setCursor(20, 100); tft.print("HOMING..."); int hall_pos = read_position_from_hall(); if (hall_pos > 0) { g_position = hall_pos; g_homed = true; Serial.printf("[HOME] Already at position %d\n", hall_pos); return true; } // Sweep forward up to one full revolution to find a Hall position for (int s = 0; s < STEPS_PER_REV + 50; s++) { step_forward_one(); delayMicroseconds(STEP_DELAY_US); hall_pos = read_position_from_hall(); if (hall_pos > 0) { g_position = hall_pos; g_homed = true; step_off(); Serial.printf("[HOME] Found position %d after %d steps\n", hall_pos, s); return true; } } step_off(); Serial.println("[HOME] FAILED — no Hall sensor found"); g_motor_state = ERROR_STATE; return false; } // ── Motor task — called from loop() ─────────────────────────────────────── // Non-blocking: takes one step per call if step delay has elapsed. void motor_run() { if (g_motor_state == IDLE || g_motor_state == ERROR_STATE) return; if ((micros() - g_last_step_us) < STEP_DELAY_US) return; g_last_step_us = micros(); if (g_steps_remaining > 0) { if (g_motor_state == MOVING_FWD) step_forward_one(); else step_backward_one(); g_steps_remaining--; // Check Hall sensors at every step for early stopping int hall_pos = read_position_from_hall(); if (hall_pos == (int)g_target && g_steps_remaining <= STEPS_PER_POS / 4) { // Close to target and Hall confirms position — stop early g_steps_remaining = 0; } } if (g_steps_remaining == 0) { // Verify final position via Hall delay(SETTLE_MS); int hall_pos = read_position_from_hall(); if (hall_pos == (int)g_target) { g_position = g_target; g_motor_state = IDLE; step_off(); prefs.putUChar("pos", g_position); Serial.printf("[SW] Position %d confirmed by Hall sensor\n", g_position); } else if (hall_pos > 0) { // Reached a position but wrong one — unexpected; accept it g_position = hall_pos; g_motor_state = IDLE; step_off(); Serial.printf("[SW] WARN: landed at %d (expected %d)\n", hall_pos, g_target); } else { // Between positions; advance a few more steps g_steps_remaining = STEPS_PER_POS / 8; Serial.println("[SW] WARN: Hall not found after motion; continuing..."); } draw_main_screen(); } } // ── Move to position ─────────────────────────────────────────────────────── void move_to(uint8_t target) { if (target < 1 || target > NUM_POSITIONS) return; if (target == g_position && g_motor_state == IDLE) return; // Calculate shortest path (CW vs CCW) int cur = g_position - 1; int tgt = target - 1; int fwd_steps = ((tgt - cur + NUM_POSITIONS) % NUM_POSITIONS) * STEPS_PER_POS; int rev_steps = ((cur - tgt + NUM_POSITIONS) % NUM_POSITIONS) * STEPS_PER_POS; g_target = target; if (fwd_steps <= rev_steps) { g_motor_state = MOVING_FWD; g_steps_remaining = fwd_steps; } else { g_motor_state = MOVING_REV; g_steps_remaining = rev_steps; } Serial.printf("[SW] Moving %s from %d to %d (%d steps)\n", g_motor_state == MOVING_FWD ? "FWD" : "REV", g_position, target, g_steps_remaining); draw_main_screen(); } void request_move(uint8_t target) { if (g_tx_active) { g_pending = target; Serial.printf("[SW] TX active — move to %d deferred\n", target); return; } move_to(target); g_pending = 0; } // ── TX inhibit ───────────────────────────────────────────────────────────── void check_tx_inhibit() { bool tx = (digitalRead(PIN_TX_INHIBIT) == (TX_INHIBIT_HIGH ? HIGH : LOW)); if (tx != g_tx_active) { g_tx_active = tx; if (!tx && g_pending > 0) { Serial.printf("[SW] TX cleared — executing pending move to %d\n", g_pending); move_to(g_pending); g_pending = 0; } draw_main_screen(); } } // ── Display ──────────────────────────────────────────────────────────────── void draw_main_screen() { tft.fillScreen(C_BG); tft.setTextColor(C_TITLE, C_BG); tft.setTextSize(2); tft.setCursor(10, 8); tft.print("MOTOR SWITCH"); // Motor state indicator const char* state_str = "IDLE"; uint16_t state_col = C_ACTIVE; if (g_motor_state == MOVING_FWD) { state_str = "FWD >>"; state_col = C_MOVING; } if (g_motor_state == MOVING_REV) { state_str = "<< REV"; state_col = C_MOVING; } if (g_motor_state == HOMING) { state_str = "HOMING"; state_col = C_MOVING; } if (g_motor_state == ERROR_STATE) { state_str = "ERROR"; state_col = C_ERROR; } tft.setTextSize(1); tft.setTextColor(state_col, C_BG); tft.setCursor(200, 12); tft.print(state_str); for (int i = 0; i < NUM_POSITIONS; i++) { int x = 10 + (i % 2) * 155; int y = 40 + (i / 2) * 80; bool at_pos = (g_position == i + 1 && g_motor_state == IDLE); bool is_tgt = (g_target == i + 1 && g_motor_state != IDLE); uint16_t bg = at_pos ? C_ACTIVE : (is_tgt ? C_MOVING : C_IDLE); tft.fillRoundRect(x, y, 140, 65, 8, bg); tft.drawRoundRect(x, y, 140, 65, 8, C_WHITE); tft.setTextColor(at_pos ? C_BG : C_WHITE, bg); tft.setTextSize(2); tft.setCursor(x + 10, y + 12); tft.printf("POS %d", i + 1); tft.setTextSize(1); tft.setCursor(x + 10, y + 36); tft.print(g_ant_names[i]); tft.setCursor(x + 10, y + 50); if (at_pos) tft.print("HERE"); if (is_tgt) tft.print("TARGET"); } tft.setTextSize(1); tft.setTextColor(C_WHITE, C_BG); tft.setCursor(10, 220); tft.printf("Homed:%s TX:%s IP:%s", g_homed ? "Y" : "N", g_tx_active ? "TX" : "--", g_wifi_ok ? WiFi.localIP().toString().c_str() : "---"); } // ── Web server ───────────────────────────────────────────────────────────── void web_root() { String html = "" "

🎭 Motor Switch

"; String state = "IDLE"; if (g_motor_state == MOVING_FWD) state = "MOVING FWD"; if (g_motor_state == MOVING_REV) state = "MOVING REV"; if (g_motor_state == ERROR_STATE) state = "ERROR"; html += "

State: " + state + " | Pos: " + String(g_position) + " | Homed: " + (g_homed ? "Yes" : "No") + "

"; if (g_tx_active) html += "

TX ACTIVE — switch deferred

"; for (int i = 0; i < NUM_POSITIONS; i++) { html += "" + String(g_ant_names[i]) + ""; } html += "

Re-Home | " "JSON

"; server.send(200, "text/html", html); } void web_move() { if (server.hasArg("pos")) { uint8_t p = server.arg("pos").toInt(); if (p >= 1 && p <= NUM_POSITIONS) { request_move(p); server.sendHeader("Location", "/"); server.send(302); return; } } server.send(400, "text/plain", "Bad request"); } void web_home() { Serial.println("[WEB] Re-home requested"); if (g_motor_state == IDLE) { g_homed = false; home_sequence(); } server.sendHeader("Location", "/"); server.send(302); } void web_status() { String j = "{\"position\":" + String(g_position) + ",\"target\":" + String(g_target) + ",\"state\":\"" + String(g_motor_state == IDLE ? "idle" : g_motor_state == MOVING_FWD ? "fwd" : "rev") + "\"" + ",\"homed\":" + (g_homed ? "true" : "false") + ",\"tx\":" + (g_tx_active ? "true" : "false") + "}"; server.send(200, "application/json", j); } void setup_webserver() { server.on("/", HTTP_GET, web_root); server.on("/move", HTTP_GET, web_move); server.on("/home", HTTP_GET, web_home); server.on("/api/status", HTTP_GET, web_status); server.begin(); } // ── Serial commands ──────────────────────────────────────────────────────── void handle_serial() { if (!Serial.available()) return; String cmd = Serial.readStringUntil('\n'); cmd.trim(); cmd.toUpperCase(); if (cmd.startsWith("MOVE ") || cmd.startsWith("POS ")) { int p = cmd.substring(5).toInt(); if (p >= 1 && p <= NUM_POSITIONS) { request_move(p); Serial.printf("OK moving to %d\n", p); } else { Serial.println("ERR: position out of range"); } } else if (cmd == "HOME") { g_homed = false; home_sequence(); set_antenna_leds(); draw_main_screen(); } else if (cmd == "STATUS") { Serial.printf("Pos:%d Target:%d State:%s Homed:%s TX:%s\n", g_position, g_target, g_motor_state==IDLE?"IDLE":g_motor_state==MOVING_FWD?"FWD":"REV", g_homed?"Y":"N", g_tx_active?"TX":"idle"); } else if (cmd == "HELP") { Serial.println("Commands: MOVE <1-4> POS <1-4> HOME STATUS HELP"); } } void set_antenna_leds() { for (int i = 0; i < NUM_POSITIONS && i < 4; i++) digitalWrite(LED_PINS[i], (g_position == i+1) ? HIGH : LOW); } // ── Setup ────────────────────────────────────────────────────────────────── void setup() { Serial.begin(115200); Serial.println("\n[BOOT] TM-ANT-SW-001 Motor Switch v1.0"); // Stepper pins for (int i = 0; i < 4; i++) { pinMode(STEP_PINS[i], OUTPUT); digitalWrite(STEP_PINS[i], LOW); } // Hall sensors for (int i = 0; i < 4; i++) pinMode(HALL_PINS[i], INPUT_PULLUP); // LEDs for (int i = 0; i < 4; i++) { pinMode(LED_PINS[i], OUTPUT); digitalWrite(LED_PINS[i], LOW); } pinMode(BTN_FWD, INPUT_PULLUP); pinMode(BTN_REV, INPUT_PULLUP); pinMode(PIN_TX_INHIBIT, INPUT); pinMode(PIN_BL, OUTPUT); digitalWrite(PIN_BL, HIGH); // TFT tft.init(); tft.setRotation(1); tft.fillScreen(C_BG); // NVS prefs.begin("mot-sw", false); for (int i = 0; i < NUM_POSITIONS; i++) { String def = ANT_NAME_DEFAULT[i]; String saved = prefs.getString(("ant" + String(i)).c_str(), def); saved.toCharArray(g_ant_names[i], 16); } g_target = prefs.getUChar("pos", 1); // WiFi String ssid = prefs.getString("ssid", ""); String pass = prefs.getString("pass", ""); if (ssid.length() > 0) { WiFi.begin(ssid.c_str(), pass.c_str()); uint32_t t = millis(); while (WiFi.status() != WL_CONNECTED && millis() - t < 8000) delay(250); if (WiFi.status() == WL_CONNECTED) { g_wifi_ok = true; Serial.printf("[WiFi] %s\n", WiFi.localIP().toString().c_str()); setup_webserver(); } } // Home and move to last position if (home_sequence()) { if (g_target != g_position) move_to(g_target); } draw_main_screen(); Serial.println("[BOOT] Ready."); } // ── Loop ─────────────────────────────────────────────────────────────────── void loop() { motor_run(); check_tx_inhibit(); update_leds(); handle_serial(); if (g_wifi_ok) server.handleClient(); // Forward button static bool btn_fwd_last = true; bool btn_fwd = digitalRead(BTN_FWD); if (!btn_fwd && btn_fwd_last) { uint8_t nxt = (g_position % NUM_POSITIONS) + 1; request_move(nxt); } btn_fwd_last = btn_fwd; // Reverse button static bool btn_rev_last = true; bool btn_rev = digitalRead(BTN_REV); if (!btn_rev && btn_rev_last) { uint8_t prv = (g_position - 2 + NUM_POSITIONS) % NUM_POSITIONS + 1; request_move(prv); } btn_rev_last = btn_rev; delay(5); }