/************************************************************************** * * Copyright (c) 2024-2024 Diality Inc. - All Rights Reserved. * * THIS CODE MAY NOT BE COPIED OR REPRODUCED IN ANY FORM, IN PART OR IN * WHOLE, WITHOUT THE EXPLICIT PERMISSION OF THE COPYRIGHT OWNER. * * @file Heaters.c * * @author (last) Vinayakam Mani * @date (last) 07-Oct-2024 * * @author (original) Vinayakam Mani * @date (original) 07-Oct-2024 * ***************************************************************************/ #include // Used for mathematical operations #include "FpgaDD.h" #include "Heaters.h" #include "Level.h" #include "MessageSupport.h" #include "Messaging.h" //#include "NVDataMgmt.h" #include "OperationModes.h" #include "PersistentAlarm.h" #include "PIControllers.h" #include "SafetyShutdown.h" #include "TaskGeneral.h" #include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" #include "Utilities.h" /** * @addtogroup Heaters * @{ */ // ********** private definitions ********** #ifndef __ALPHA_AO_VER__ #define HEATERS_MAX_DUTY_CYCLE 100.00F ///< Heaters max duty cycle (100%) or ON state #define HEATERS_MIN_DUTY_CYCLE 0.00F ///< Heaters minimum duty cycle (0.00%) or OFF state #define D5_HEAT_ON 50.00F ///< Primary heater ON control #define HEATERS_DISINFECT_DUTY_CYCLE 80.0F ///< Heaters disinfect cycle. #define HEATERS_DISINFECT_TRANSFER_DUTY_CYCLE 60.0F ///< Heaters disinfect transfer duty cycle. #else #define HEATERS_MAX_DUTY_CYCLE 1.00F ///< Heaters max duty cycle (100%) or ON state #define HEATERS_MIN_DUTY_CYCLE 0.00F ///< Heaters minimum duty cycle (0.00%) or OFF state #define D5_HEAT_ON 1.00F ///< Primary heater ON control #define HEATERS_DISINFECT_DUTY_CYCLE 0.80F ///< Heaters disinfect cycle. #define HEATERS_DISINFECT_TRANSFER_DUTY_CYCLE 0.60F ///< Heaters disinfect transfer duty cycle. #endif #define HEATERS_DISINFECT_TEMPERATURE_DRIFT_C 3.0F ///< Heaters disinfect temperature drift in C. #define HEATERS_ZERO_DELTA_TEMP_C 0.0F ///< Heaters zero delta temperature in C. #define HEATERS_DUTY_CYCLE_CONVERSION_FACTOR 100.0F ///< Heaters duty cycle 0: OFF, 100: 100% duty cycle. #define D45_HEAT_GAIN 10.0F ///< Trimmer heater gain for testing. #define D5_HEAT_P_COEFFICIENT 21.0F ///< P Term for primary heater control. #define D5_HEAT_I_COEFFICIENT 6.00F ///< I Term for primary heater control. #define D45_HEAT_P_COEFFICIENT 35.0F ///< P Term for trimmer heater control. #define D45_HEAT_I_COEFFICIENT 5.00F ///< I Term for trimmer heater control. #define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. #define HEATER_TEMP_CONTROL_TOLERANCE 2.0F ///< Primary Heater temp tolerance for ON/Off control #define HEATER_TARGET_TEMPERATURE_MIN 10.0F ///< Minimum allowed target temperature for the heaters. #define HEATER_TARGET_TEMPERATURE_MAX 90.0F ///< Maximum allowed target temperature for the heaters. #define D5_HEAT_ON_NO_FLUID_TIMEOUT_MS ( 10 * MS_PER_SECOND ) ///< Primary heater on with no flow time out in milliseconds. #define D45_HEAT_ON_NO_FLUID_TIMEOUT_MS ( 12 * MS_PER_SECOND ) ///< Trimmer heater on with no flow time out in milliseconds. #define HEATERS_MAX_OPERATING_VOLTAGE_V 24.0F ///< Heaters max operating voltage in volts. #define HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ( 2 * MS_PER_SECOND ) ///< Heaters voltage out of range time out in milliseconds. #define HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL 0.2F ///< Heaters max voltage out of range tolerance. #define D45_HEAT_INITIAL_CONTROL_INTERVAL_COUNT ( ( 5 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater initial control interval count. #define D45_HEAT_CONTROL_INTERVAL_COUNT ( ( 10 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Trimmer heater control interval count. #define D5_HEAT_CONTROL_INTERVAL_COUNT ( ( 1 * MS_PER_SECOND ) / TASK_GENERAL_INTERVAL ) ///< Primary heater control interval count. #define TX_PRIMARY_HEATER_MAX_PWR_WATTS 700 ///< Estimated power to be supplied to the primary heater during treatement mode #define HEAT_PRIMARY_HEATER_MAX_PWR_WATTS 1000 ///< Estimated power to be supplied to the primary heater during heat disinfect mode #define MAX_INLET_FLOW_LPM ( 800 / 1000 ) ///< Maximum inlet flow to hydraulics chamber from FP ( 800 ml/min => 0.8LPM) #define TRIMMER_HEATER_MAX_PWR_WATTS 120 ///< Maximum power supplied to trimmer heater #define AC_HEATER_PWM_PERIOD 1667 ///< PWM period for 60Hz AC ( in 10us resoultion), 1/60Hz = 16666us/10us = 1667. #define DATA_PUBLISH_COUNTER_START_COUNT 70 ///< Data publish counter start count. //static const F32 HEATERS_VOLTAGE_TOLERANCE_V = HEATERS_MAX_OPERATING_VOLTAGE_V * HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL; ///< Heaters voltage tolerance in volts. /// Heaters data structure typedef struct { HEATERS_STATE_T state; ///< Heater state. BOOL startHeaterSignal; ///< Heater start indication flag. BOOL heaterOnState; ///< Heater on/off status flag. F32 targetFlowLPM; ///< Heater target flow in L/min to calculate the duty cycle. F32 nomTargetFlowLPM; ///< Heater nominal target flow in L/min. BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. U32 controlIntervalCounter; ///< Heater control interval counter. BOOL isThisFirstControl; ///< Heater is this first control interval. F32 prevDiaTargetFlowLPM; ///< Heater previous target dialysate flow in L/min. } HEATER_STATUS_T; /// Payload record structure for heaters start request typedef struct { U32 heaterID; ///< Heater ID (0: Primary, 1: Trimmer) U32 startStop; ///< Heater Start:1 and Stop: 0 F32 temperature; ///< Temperature range ( 10.0 to 90.0 deg ) } HEATER_START_CMD_PAYLOAD_T; static HEATER_STATUS_T heatersStatus[ NUM_OF_DD_HEATERS ]; ///< Heaters status. static OVERRIDE_F32_T targetTempC[ NUM_OF_DD_HEATERS ]; ///< Heater target temperature. static OVERRIDE_F32_T control[ NUM_OF_DD_HEATERS ]; ///< Heater control ( Primary : On/Off, Trimmer : Dutycycle). static OVERRIDE_F32_T pwmPeriod[ NUM_OF_DD_HEATERS ]; ///< Total PWM period ( ON state + Off State of PWM) static U32 dataPublicationTimerCounter; ///< Data publication timer counter. static const F32 WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES = 4184 / SEC_PER_MIN; ///< Water specific heat in J/KgC / 60. static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. // ********** private function prototypes ********** static HEATERS_STATE_T handleHeaterStateOff( DD_HEATERS_T heater ); static HEATERS_STATE_T handleHeaterStateRampToTarget( DD_HEATERS_T heater ); static HEATERS_STATE_T handleHeaterStateControlToTarget( DD_HEATERS_T heater ); static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DD_HEATERS_T heater ); static void setHeaterControl( DD_HEATERS_T heater ); static F32 getHeaterControl( DD_HEATERS_T heater ); static void publishHeatersData( void ); //static void monitorHeatersVoltage( void ); /*********************************************************************//** * @brief * The initHeaters initializes the heaters controller unit. * @details \b Inputs: none * @details \b Outputs: Heaters unit variables initialized. * @return none *************************************************************************/ void initHeaters( void ) { DD_HEATERS_T heater; dataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; #ifndef __ALPHA_AO_VER__ //Enable PWM based heater control setFPGAD5HeaterPWMEnableControl( TRUE ); // Define PWM period for AC heater pwmPeriod[ D5_HEAT ].data = AC_HEATER_PWM_PERIOD; pwmPeriod[ D5_HEAT ].ovData = AC_HEATER_PWM_PERIOD; pwmPeriod[ D5_HEAT ].ovInitData = AC_HEATER_PWM_PERIOD; pwmPeriod[ D5_HEAT ].override = OVERRIDE_RESET; // TODO : Trimmer heater PWM period pwmPeriod[ D45_HEAT ].data = 0.0F; pwmPeriod[ D45_HEAT ].ovData = 0.0F; pwmPeriod[ D45_HEAT ].ovInitData = 0.0F; pwmPeriod[ D45_HEAT ].override = OVERRIDE_RESET; #endif for ( heater = DD_HEATERS_FIRST; heater < NUM_OF_DD_HEATERS; heater++ ) { targetTempC[ heater ].data = 0.0F; targetTempC[ heater ].ovData = 0.0F; targetTempC[ heater ].ovInitData = 0.0F; targetTempC[ heater ].override = OVERRIDE_RESET; heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; heatersStatus[ heater ].startHeaterSignal = FALSE; heatersStatus[ heater ].heaterOnState = FALSE; control[ heater ].data = HEATERS_MIN_DUTY_CYCLE; control[ heater ].ovData = HEATERS_MIN_DUTY_CYCLE; control[ heater ].ovInitData = HEATERS_MIN_DUTY_CYCLE; control[ heater ].override = OVERRIDE_RESET; heatersStatus[ heater ].targetFlowLPM = 0.0F; heatersStatus[ heater ].nomTargetFlowLPM = 0.0F; heatersStatus[ heater ].hasTargetTempChanged = FALSE; heatersStatus[ heater ].controlIntervalCounter = 0; heatersStatus[ heater ].isThisFirstControl = TRUE; heatersStatus[ heater ].prevDiaTargetFlowLPM = 0.0F; setHeaterControl( heater ); } // Initialize the primary controller PI controller initializePIController( PI_CONTROLLER_ID_D5_HEAT, HEATERS_MIN_DUTY_CYCLE, D5_HEAT_P_COEFFICIENT, D5_HEAT_I_COEFFICIENT, HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); // Initialize the trimmer heater PI controller initializePIController( PI_CONTROLLER_ID_D45_HEAT, HEATERS_MIN_DUTY_CYCLE, D45_HEAT_P_COEFFICIENT, D45_HEAT_I_COEFFICIENT, HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); // Initialize the persistent alarms //initPersistentAlarm( ALARM_ID_DD_D5_HEAT_VOLTAGE_OUT_OF_RANGE, 0, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); //initPersistentAlarm( ALARM_ID_DD_D45_HEAT_VOLTAGE_OUT_OF_RANGE, 0, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D5_HEAT_IS_ON, 0, D5_HEAT_ON_NO_FLUID_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D45_HEAT_IS_ON, 0, D45_HEAT_ON_NO_FLUID_TIMEOUT_MS ); } /*********************************************************************//** * @brief * The setHeaterTargetTemperature function sets the target temperature of * a given heater. * @details \b Inputs: none * @details \b Outputs: heaterStatus * @details \b Alarms: ALARM_ID_DD_SOFTWARE_FAULT when invalid heater ID * passed. * @param heater: heater ID that its target temperature is set * @param targetTemperature: target temperature of that the heater has to * heat the fluid * @return TRUE if the temperature was set otherwise, FALSE *************************************************************************/ BOOL setHeaterTargetTemperature( DD_HEATERS_T heater, F32 targetTemperature ) { BOOL result = FALSE; if( heater < NUM_OF_DD_HEATERS ) { // Assume the target temperature has not changed heatersStatus[ heater ].hasTargetTempChanged = FALSE; // Check if the requested temperature is within the allowed range if ( ( targetTemperature >= HEATER_TARGET_TEMPERATURE_MIN ) && ( targetTemperature <= HEATER_TARGET_TEMPERATURE_MAX ) ) { targetTempC[ heater ].data = targetTemperature; heatersStatus[ heater ].hasTargetTempChanged = TRUE; result = TRUE; } } else { SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) } return result; } /*********************************************************************//** * @brief * The getHeaterTargetTemperature function returns the given heater target * temperature. * @details \b Inputs: none * @details \b Outputs: targetTempC * @param heater: heater ID to get heater target temperature. * @return the given heater target temperature *************************************************************************/ F32 getHeaterTargetTemperature( DD_HEATERS_T heater ) { F32 targetTemp = getF32OverrideValue( &targetTempC[ heater ] ); return targetTemp; } /*********************************************************************//** * @brief * The getHeaterPWMPeriod function returns the given heater PWM * period. * @details \b Inputs: none * @details \b Outputs: pwmPeriod * @param heater: heater ID to get heater PWM period. * @return the given heater PWM period. *************************************************************************/ F32 getHeaterPWMPeriod( DD_HEATERS_T heater ) { F32 pwmPrd = getF32OverrideValue( &pwmPeriod[ heater ] ); return pwmPrd; } /*********************************************************************//** * @brief * The isHeaterOn function returns the given heater status whether * it is on or off * @details \b Inputs: heaterStatus * @details \b Outputs: none * @param heater: heater ID to get the heater status(On/Off). * @return heater on/off status *************************************************************************/ BOOL isHeaterOn( DD_HEATERS_T heater ) { return heatersStatus[ heater ].heaterOnState; } /*********************************************************************//** * @brief * The startHeater function starts the given heater by setting the flag. * @details \b Inputs: heatersStatus * @details \b Outputs: startHeaterSignal * @details \b Alarms: ALARM_ID_DD_SOFTWARE_FAULT when invalid heater ID passed * @param heater: heater ID to set the heater start signal. * @return None *************************************************************************/ void startHeater( DD_HEATERS_T heater ) { if( heater < NUM_OF_DD_HEATERS ) { if ( HEATER_EXEC_STATE_OFF == heatersStatus[ heater ].state ) { heatersStatus[ heater ].startHeaterSignal = TRUE; } } else { SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) } } /*********************************************************************//** * @brief * The stopHeater stops the specified heater. * @details \b Inputs: none * @details \b Outputs: heaterStatus * @details \b Alarms: ALARM_ID_DD_SOFTWARE_FAULT when invalid heater ID * passed. * @param heater: heater ID that is requested to turn on * @return none *************************************************************************/ void stopHeater( DD_HEATERS_T heater ) { if( heater < NUM_OF_DD_HEATERS ) { heatersStatus[ heater ].startHeaterSignal = FALSE; heatersStatus[ heater ].heaterOnState = FALSE; control[ heater ].data = HEATERS_MIN_DUTY_CYCLE; heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; // update duty cycle setHeaterControl( heater ); } else { SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) } } /*********************************************************************//** * @brief * The execHeatersControl function executes the heaters state machine. * @details \b Inputs: heaterStatus * @details \b Outputs: heaterStatus * @details \b Alarms: ALARM_ID_DD_SOFTWARE_FAULT when invalid heater * executive state found. * @return none *************************************************************************/ void execHeatersControl( void ) { DD_HEATERS_T heater; for ( heater = DD_HEATERS_FIRST; heater < NUM_OF_DD_HEATERS; heater++ ) { switch( heatersStatus[ heater ].state ) { case HEATER_EXEC_STATE_OFF: heatersStatus[ heater ].state = handleHeaterStateOff( heater ); break; case HEATER_EXEC_STATE_RAMP_TO_TARGET: heatersStatus[ heater ].state = handleHeaterStateRampToTarget( heater ); break; case HEATER_EXEC_STATE_CONTROL_TO_TARGET: heatersStatus[ heater ].state = handleHeaterStateControlToTarget( heater ); break; case HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET: heatersStatus[ heater ].state = handleHeaterStateControlToDisinfectTarget( heater ); break; default: // The heater is in an unknown state. Turn it off and switch to not running state stopHeater( heater ); SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_EXEC_STATE, heater ); break; } // Check if the heater is requested to be off if ( FALSE == heatersStatus[ heater ].heaterOnState ) { // stop the heater stopHeater( heater ); } } } /*********************************************************************//** * @brief * The execHeatersMonitor function monitors the status of the heaters. * The internal temperature sensors and the voltages of the heaters are * monitored. The hydraulics chamber and balance air separation level is * continuously checked and if there is no fluid at defined level, * the heaters are turned off. * @details \b Inputs: heaterStatus * @details \b Outputs: heaterStatus * @return none *************************************************************************/ void execHeatersMonitor( void ) { DD_HEATERS_T heater; for ( heater = DD_HEATERS_FIRST; heater < NUM_OF_DD_HEATERS; heater++ ) { // Check if the heater is on and if it is, check the level sensor status if ( TRUE == heatersStatus[ heater ].heaterOnState ) { ALARM_ID_T alarm; BOOL isLevelLow = FALSE; if ( D5_HEAT == heater ) { alarm = ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D5_HEAT_IS_ON; isLevelLow = ( ( getLevelStatus( D6_LEVL ) != 0 )? FALSE : TRUE ); } else { alarm = ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D45_HEAT_IS_ON; isLevelLow = ( ( getLevelStatus( D46_LEVL ) != 0 )? FALSE : TRUE ); } checkPersistentAlarm( alarm, isLevelLow, 0.0F, 0.0F ); } else { if ( D5_HEAT == heater ) { checkPersistentAlarm( ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D5_HEAT_IS_ON, FALSE, 0.0F, 0.0F ); } else { checkPersistentAlarm( ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D45_HEAT_IS_ON, FALSE, 0.0F, 0.0F ); } } } // Monitor heater voltage //monitorHeatersVoltage(); // Check for data publication publishHeatersData(); } /*********************************************************************//** * @brief * The handleHeaterStateOff function handles the heater not running state * and transition to heater On condition when the heater start flag is set to true. * @details \b Inputs: heaterStatus * @details \b Outputs: heaterStatus * @param heater: The heater Id that its not running state is handled * @return next state of the state machine *************************************************************************/ static HEATERS_STATE_T handleHeaterStateOff( DD_HEATERS_T heater ) { HEATERS_STATE_T state = HEATER_EXEC_STATE_OFF; if ( TRUE == heatersStatus[ heater ].startHeaterSignal ) { heatersStatus[ heater ].heaterOnState = TRUE; heatersStatus[ heater ].startHeaterSignal = FALSE; // proceed to ramp state state = HEATER_EXEC_STATE_RAMP_TO_TARGET; } return state; } /*********************************************************************//** * @brief * The handleHeaterStateRampToTarget function handles the given heaters' * control while they are ramping to target temperature. * @details \b Inputs: heaterStatus * @details \b Outputs: heaterStatus * @param heater: The heater Id to handle the ramping up to target temp. * @return next state of the state machine *************************************************************************/ static HEATERS_STATE_T handleHeaterStateRampToTarget( DD_HEATERS_T heater ) { HEATERS_STATE_T state = HEATER_EXEC_STATE_RAMP_TO_TARGET; F32 ctrl = 0.0F; DD_OP_MODE_T opMode = getCurrentOperationMode(); F32 measuredTemperature = 0.0F; F32 targetTemperature = getHeaterTargetTemperature( heater ); if ( D5_HEAT == heater ) { measuredTemperature = getTemperatureValue( D4_TEMP ); if ( DD_MODE_HEAT != opMode ) { #ifndef __ALPHA_AO_VER__ F32 deltaTempC = targetTemperature - measuredTemperature; F32 capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); F32 dutyCycle = sqrt( ( WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * capDeltaTempC * MAX_INLET_FLOW_LPM ) / TX_PRIMARY_HEATER_MAX_PWR_WATTS ); dutyCycle *= HEATERS_DUTY_CYCLE_CONVERSION_FACTOR; dutyCycle = MIN( dutyCycle, HEATERS_MAX_DUTY_CYCLE ); dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); control[ heater ].data = dutyCycle; resetPIController( PI_CONTROLLER_ID_D5_HEAT, dutyCycle ); #else // Assign initial value control[ heater ].data = D5_HEAT_ON; #endif state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; } else { // TODO : Calculate required duty cycle state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } } else { measuredTemperature = getTemperatureValue( D50_TEMP ); if ( DD_MODE_HEAT != opMode ) { #ifndef __ALPHA_AO_VER__ F32 deltaTempC = targetTemperature - measuredTemperature; F32 capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); F32 dutyCycle = sqrt( ( WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * capDeltaTempC * MAX_INLET_FLOW_LPM ) / TRIMMER_HEATER_MAX_PWR_WATTS ); //F32 dutyCycle = ( WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * capDeltaTempC * MAX_INLET_FLOW_LPM ) / TRIMMER_HEATER_MAX_PWR_WATTS ; dutyCycle *= HEATERS_DUTY_CYCLE_CONVERSION_FACTOR; dutyCycle = MIN( dutyCycle, HEATERS_MAX_DUTY_CYCLE ); dutyCycle = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); control[ heater ].data = dutyCycle; resetPIController( PI_CONTROLLER_ID_D45_HEAT, dutyCycle ); #else // Assign initial value ctrl = ( ( targetTemperature / HEATER_TARGET_TEMPERATURE_MAX ) * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR ) + FLOAT_TO_INT_ROUNDUP_OFFSET; #endif state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; } else { // TODO : Calculate required duty cycle state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } // Update the duty cycle control[ heater ].data = ctrl; } setHeaterControl( heater ); return state; } /*********************************************************************//** * @brief * The handleHeaterStateControlToTarget function handles the given * heaters' control to target while the heater is targeting to reach to temperature. * @details \b Inputs: heaterStatus * @details \b Outputs: heaterStatus * @details \b Alarms: ALARM_ID_DD_SOFTWARE_FAULT when invalid heater ID passed * @param heater: The heater Id to handle the control to target state * @return next state of the state machine *************************************************************************/ static HEATERS_STATE_T handleHeaterStateControlToTarget( DD_HEATERS_T heater ) { HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; F32 targetTemperature = getHeaterTargetTemperature( heater ); F32 measuredTemperature = 0.0F; F32 ctrl = 0.0F; if( ++heatersStatus[ heater ].controlIntervalCounter > D5_HEAT_CONTROL_INTERVAL_COUNT ) { if ( D5_HEAT == heater ) { measuredTemperature = getTemperatureValue( D4_TEMP ); #ifndef __ALPHA_AO_VER__ ctrl = runPIController( PI_CONTROLLER_ID_D5_HEAT, targetTemperature, measuredTemperature ); control[ heater ].data = ctrl; #else if ( measuredTemperature >= targetTemperature ) { // Turn off heater control[ heater ].data = HEATERS_MIN_DUTY_CYCLE; } else { // Turn On heater control[ heater ].data = D5_HEAT_ON; } #endif } else { measuredTemperature = getTemperatureValue( D50_TEMP ); #ifndef __ALPHA_AO_VER__ ctrl = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); control[ heater ].data = ctrl; #else if ( targetTemperature > 0.0F ) { ctrl = HEATERS_MAX_DUTY_CYCLE - ( measuredTemperature / targetTemperature ); ctrl = ( ctrl < 0.0F ? HEATERS_MIN_DUTY_CYCLE: ctrl * D45_HEAT_GAIN ); //Apply dutycycle limit ctrl = MIN( ctrl, HEATERS_MAX_DUTY_CYCLE ); ctrl = MAX( ctrl, HEATERS_MIN_DUTY_CYCLE ); } control[ heater ].data = ( ctrl * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR ) + FLOAT_TO_INT_ROUNDUP_OFFSET; #endif } heatersStatus[ heater ].hasTargetTempChanged = FALSE; heatersStatus[ heater ].controlIntervalCounter = 0; setHeaterControl( heater ); } return state; } /*********************************************************************//** * @brief * The handleHeaterStateControlToDisinfectTarget function handles the * heaters' control to target while the operation mode is heat or chemical * disinfects. * @details \b Inputs: heaterStatus * @details \b Outputs: heaterStatus * @param heater: The heater Id that its on state is handled * @return next state of the state machine *************************************************************************/ static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DD_HEATERS_T heater ) { HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; //TODO : update dutycycle for the heat disinfect state setHeaterControl( D45_HEAT ); setHeaterControl( D5_HEAT ); return state; } /*********************************************************************//** * @brief * The setHeaterControl function sets the duty cycle of a heater. * @details \b Inputs: control * @details \b Outputs: FPGA heater control * @details \b Alarms: ALARM_ID_DD_SOFTWARE_FAULT when invalid heater ID * is selected. * @param heater: The heater Id that its duty cycle is set * @return none *************************************************************************/ static void setHeaterControl( DD_HEATERS_T heater ) { if ( heater < NUM_OF_DD_HEATERS ) { F32 control = getHeaterControl( heater ); F32 period = getHeaterPWMPeriod ( heater ); if ( D5_HEAT == heater ) { #ifndef __ALPHA_AO_VER__ //Convert duty cycle into LowState and multiply by period for now F32 convertDC = ( HEATERS_DUTY_CYCLE_CONVERSION_FACTOR - control ) * period; setFPGAD5HeaterPWMPeriod( (U16)period ); setFPGAD5HeaterPWMLowState( (U16)convertDC ); #else BOOL heaterCntrl = (BOOL)control; setFPGAD5HeaterOnOffControl( heaterCntrl ); #endif } else { setFPGAD45HeaterPWMControl( (U08)control ); } } else { SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ); } } /*********************************************************************//** * @brief * The getHeaterControl function returns the heater's duty cycle. * @details \b Inputs: heaterStatus * @details \b Outputs: none * @param heater: The heater Id to get the duty cycle. * @return PWM duty cycle for the given heater *************************************************************************/ static F32 getHeaterControl( DD_HEATERS_T heater ) { F32 duty = getF32OverrideValue( &control[ heater ] ); return duty; } /*********************************************************************//** * @brief * The monitorHeatersVoltage function monitors the heaters' voltages * @details \b Inputs: Voltage range * @details \b Outputs: none * @details \b Alarms: ALARM_ID_DD_MAIN_D5_HEAT_VOLTAGE_OUT_OF_RANGE when * primary heater voltage found out of range. * @details \b Alarms: ALARM_ID_D45_HEAT_VOLTAGE_OUT_OF_RANGE when * trimmer heater voltage found out of range. * @return none *************************************************************************/ //static void monitorHeatersVoltage( void ) //{ // F32 mainPriVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_MAIN_PRIM_HTR_V ); // F32 trimmerVoltage = getMonitoredLineLevel( MONITORED_LINE_24V_GND_TRIM_HTR_V ); // // // Voltage to PWM is reverse. If PWM = 0 -> V = 24V // F32 mainPriDC = getHeaterControl( D5_HEAT ); // F32 trimmerDC = getHeaterControl( D45_HEAT ); // // // The expected voltage is the inverse of the duty cycle // F32 mainPriExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - mainPriDC ); // F32 trimmerExpectedVoltage = HEATERS_MAX_OPERATING_VOLTAGE_V * ( 1.0F - trimmerDC ); // // BOOL isMainPriOut = FALSE; // BOOL isTrimmerOut = FALSE; // // // If the system is DVT, check the FPGA persistent alarm of the main primary heater's voltage ADC // checkFPGAPersistentAlarms( FPGA_PERS_ERROR_MAIN_D5_HEAT_VOLTAGE_ADC, getFPGAHeaterGateADCReadCount() ); // // isMainPriOut = ( fabs( mainPriExpectedVoltage - mainPriVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); // isTrimmerOut = ( fabs( trimmerExpectedVoltage - trimmerVoltage ) > HEATERS_VOLTAGE_TOLERANCE_V ? TRUE : FALSE ); // // if ( getCurrentOperationMode() != DD_MODE_INIT ) // { // checkPersistentAlarm( ALARM_ID_DD_MAIN_D5_HEAT_VOLTAGE_OUT_OF_RANGE, isMainPriOut, mainPriDC, HEATERS_VOLTAGE_TOLERANCE_V ); // checkPersistentAlarm( ALARM_ID_D45_HEAT_VOLTAGE_OUT_OF_RANGE, isTrimmerOut, trimmerDC, HEATERS_VOLTAGE_TOLERANCE_V ); // } //} /*********************************************************************//** * @brief * The publishHeatersData function publishes the heaters data info * at the defined time interval. * @details \b Inputs: dataPublicationTimerCounter * @details \b Outputs: dataPublicationTimerCounter * @details \b Message \b Sent: MSG_ID_DD_HEATERS_DATA to publish * heaters data. * @return none *************************************************************************/ static void publishHeatersData( void ) { if ( ++dataPublicationTimerCounter >= getU32OverrideValue( &heatersDataPublishInterval ) ) { HEATERS_DATA_T data; data.d5_HeaterDC = getHeaterControl( D5_HEAT ); data.d45_HeaterDC = getHeaterControl( D45_HEAT ); data.d5_HeaterTargetTemp = getHeaterTargetTemperature( D5_HEAT ); data.d45_HeaterTargetTemp = getHeaterTargetTemperature( D45_HEAT ); data.d5_HeaterState = heatersStatus[ D5_HEAT ].state; data.d45_HeaterState = heatersStatus[ D45_HEAT ].state; data.d5_HeaterControlCounter = heatersStatus[ D5_HEAT ].controlIntervalCounter; data.d45_HeaterControlCounter = heatersStatus[ D45_HEAT ].controlIntervalCounter; dataPublicationTimerCounter = 0; broadcastData( MSG_ID_DD_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DD_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); } } /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/ /*********************************************************************//** * @brief * The testHeatersDataPublishIntervalOverride function overrides the * heaters data publish interval. * @details \b Inputs: heatersDataPublishInterval * @details \b Outputs: heatersDataPublishInterval * @param Override message from Dialin which includes the interval * (in ms) to override the heaters data broadcast interval to. * @return TRUE if override successful, FALSE if not *************************************************************************/ BOOL testHeatersDataPublishIntervalOverride( MESSAGE_T *message ) { BOOL result = u32BroadcastIntervalOverride( message, &heatersDataPublishInterval, TASK_PRIORITY_INTERVAL ); return result; } /*********************************************************************//** * @brief * The testHeaterDutyCycleOverride function overrides the specified heater's * duty cycle. * @details \b Inputs: heatersStatus * @details \b Outputs: heatersStatus * @param message Override message from Dialin which includes an ID of * the heater to override and the duty cyle of the heater. * @return TRUE if the override was successful otherwise FALSE *************************************************************************/ BOOL testHeaterDutyCycleOverride( MESSAGE_T *message ) { BOOL result = f32ArrayOverride( message, &control[ 0 ], NUM_OF_DD_HEATERS - 1 ); return result; } /*********************************************************************//** * @brief * The testHeaterTargetTemperatureOverride function overrides the specified heater's * target temperature. * @details \b Inputs: targetTempC * @details \b Outputs: targetTempC * @param message Override message from Dialin which includes an ID of * the heater to override and the target temperature of the heater. * @return TRUE if the override was successful otherwise FALSE *************************************************************************/ BOOL testHeaterTargetTemperatureOverride( MESSAGE_T *message ) { BOOL result = f32ArrayOverride( message, &targetTempC[ 0 ], NUM_OF_DD_HEATERS - 1 ); return result; } /*********************************************************************//** * @brief * The testHeaterPWMPeriodOverride function overrides the specified heater's * PWM period. * @details \b Inputs: pwmPeriod * @details \b Outputs: pwmPeriod * @param message Override message from Dialin which includes an ID of * the heater to override and the PWM period of the heater. * @return TRUE if the override was successful otherwise FALSE *************************************************************************/ BOOL testHeaterPWMPeriodOverride( MESSAGE_T *message ) { BOOL result = f32ArrayOverride( message, &pwmPeriod[ 0 ], NUM_OF_DD_HEATERS - 1 ); return result; } /*********************************************************************//** * @brief * The testHeaterStartStopOverride function starts/stops a given heater * at mentioned temperature. * @details \b Inputs: tester logged in * @details \b Outputs: heatersStatus[] * @param message set message from Dialin which includes the heater to set * and the state to set the heater to. * @return TRUE if set request is successful, FALSE if not *************************************************************************/ BOOL testHeaterStartStopOverride( MESSAGE_T *message ) { BOOL result = FALSE; // Verify tester has logged in with DD if ( TRUE == isTestingActivated() ) { // Verify payload length is valid if ( sizeof( HEATER_START_CMD_PAYLOAD_T ) == message->hdr.payloadLen ) { HEATER_START_CMD_PAYLOAD_T payload; memcpy( &payload, message->payload, sizeof(HEATER_START_CMD_PAYLOAD_T) ); if ( (DD_HEATERS_T)payload.heaterID < NUM_OF_DD_HEATERS ) { // Handle start command if ( ( TRUE == payload.startStop ) && ( ( payload.temperature >= HEATER_TARGET_TEMPERATURE_MIN ) && ( payload.temperature <= HEATER_TARGET_TEMPERATURE_MAX ) ) ) { setHeaterTargetTemperature( (DD_HEATERS_T)payload.heaterID, payload.temperature ); startHeater( (DD_HEATERS_T)payload.heaterID ); result = TRUE; } //Handle stop command if ( FALSE == payload.startStop ) { stopHeater( (DD_HEATERS_T)payload.heaterID ); result = TRUE; } } } } return result; } /**@}*/