Try to improve backlash handling

blinds.ino

@@ -24,6 +24,16 @@ const bool CLEAR_EEPROM = false;
 
 unsigned long lastMillis = 0;
 
+// Backlash compensation and hold configuration
+const int BACKLASH_STEPS = 400;              // Tune as needed for your linkage
+const unsigned long HOLD_OUTPUTS_MS = 300;   // Hold time after moves to prevent settling
+
+// Runtime variables for compensation and holding
+int approachDir = 0;           // Desired final approach direction for current command (-1 or 1)
+long prepTarget = 0;           // First phase target used to preload backlash
+long finalMoveTarget = 0;      // Second phase target: the actual requested position
+unsigned long holdUntil = 0;   // Timestamp when we should release outputs
+
 struct Config {
   long openPosition;
   long closedPosition;
@@ -39,6 +49,9 @@ const int OPENING_BLINDS = 2;
 const int CLOSING_BLINDS = 3;
 const int IDLE = 4;
 const int ADJUSTING = 5;
+const int HOLDING = 6;
+const int OPENING_PREP = 7;
+const int CLOSING_PREP = 8;
 
 int state = SETUP;
 int previousState = SETUP;
@@ -109,18 +122,37 @@ void updateState(int newState) {
 void openBlinds() {
   if (!config.blindsOpen && state == IDLE) {
     Serial.println("Opening Blinds");
-    updateState(OPENING_BLINDS);
+    long baseTarget = config.openPosition;
+    long delta = config.openPosition - config.closedPosition;
+    int openDir = (delta > 0) ? 1 : ((delta < 0) ? -1 : -1); // default to -1 if equal (unlikely)
+    approachDir = openDir;
+
+    // Phase 1: move to preload point on the "closing" side of the final target
+    prepTarget = baseTarget - (approachDir * BACKLASH_STEPS);
+    finalMoveTarget = baseTarget;
+
+    updateState(OPENING_PREP);
     stepper.enableOutputs();
-    stepper.moveTo(config.openPosition);
+    stepper.moveTo(prepTarget);
   }
 }
 
 void closeBlinds() {
   if (config.blindsOpen && state == IDLE) {
     Serial.println("Closing Blinds");
-    updateState(CLOSING_BLINDS);
+    long baseTarget = config.closedPosition;
+    long delta = config.openPosition - config.closedPosition;
+    int openDir = (delta > 0) ? 1 : ((delta < 0) ? -1 : -1);
+    int closeDir = -openDir;
+    approachDir = closeDir;
+
+    // Phase 1: move to preload point on the "opening" side of the final target (opposite of close direction)
+    prepTarget = baseTarget - (approachDir * BACKLASH_STEPS);
+    finalMoveTarget = baseTarget;
+
+    updateState(CLOSING_PREP);
     stepper.enableOutputs();
-    stepper.moveTo(config.closedPosition);
+    stepper.moveTo(prepTarget);
   }
 }
 
@@ -213,20 +245,28 @@ void loop() {
       delay(10);  // <- fixes some issues with WiFi stability
       break;
     case SLACK:
-      if (previousState == OPENING_BLINDS) {
-        stepper.move(3000);
-      } else if (previousState == CLOSING_BLINDS) {
-        stepper.move(-3000);
-      } else if (stepper.distanceToGo() == 0) {
-        updateState(IDLE);
+      // Deprecated slack handling; transition to idle once any pending motion completes
+      if (stepper.distanceToGo() == 0) {
         stepper.disableOutputs();
-        return;
-      }
-
+        updateState(IDLE);
+      } else {
         stepper.run();
-
-      // Update previous to SLACK until we take up the slack to prevent the stepper from moving forever
-      previousState = state;
+      }
+      break;
+    case OPENING_PREP:
+    case CLOSING_PREP:
+      if (stepper.distanceToGo() != 0) {
+        stepper.run();
+      } else {
+         Serial.println("Open/Close Preparation complete");
+        // Phase 2: approach target from a consistent direction to remove backlash
+        if (state == OPENING_PREP) {
+          updateState(OPENING_BLINDS);
+        } else {
+          updateState(CLOSING_BLINDS);
+        }
+        stepper.moveTo(finalMoveTarget);
+      }
       break;
     case OPENING_BLINDS:
     case CLOSING_BLINDS:
@@ -234,17 +274,25 @@ void loop() {
         if (millis() - lastMillis > 2000) {
           Serial.print("Speed: ");
           Serial.print(stepper.speed());
-          Serial.print(" Dist: ");
+          Serial.print(" Remaining Dist: ");
           Serial.println(stepper.distanceToGo());
           lastMillis = millis();
         }
         stepper.run();
       } else {
-        stepper.disableOutputs();
         bool open = state == OPENING_BLINDS;
         config.blindsOpen = open;
         sendBlindsUpdate(open);
-        updateState(SLACK);
+        // Hold outputs briefly to prevent settling drift, then transition to IDLE
+        holdUntil = millis() + HOLD_OUTPUTS_MS;
+        updateState(HOLDING);
+      }
+      break;
+    case HOLDING:
+      if (millis() >= holdUntil) {
+        Serial.println("Hold complete, transitioning to idle");
+        stepper.disableOutputs();
+        updateState(IDLE);
       }
       break;
     case ADJUSTING:
@@ -259,8 +307,8 @@ void loop() {
         Serial.print("Finished adjusting to: ");
         Serial.println(stepper.currentPosition());
 
-        updateState(IDLE);
-        stepper.disableOutputs();
+        holdUntil = millis() + HOLD_OUTPUTS_MS;
+        updateState(HOLDING);
       }
 
       break;