/************************************************************************** * * Copyright (c) 2019-2020 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) Quang Nguyen * @date (last) 14-Sep-2020 * * @author (original) Dara Navaei * @date (original) 23-Apr-2020 * ***************************************************************************/ #include // TI PWM driver #include "etpwm.h" #include "AlarmMgmt.h" #include "DGDefs.h" #include "Heaters.h" #include "OperationModes.h" #include "PIControllers.h" #include "ROPump.h" #include "SafetyShutdown.h" #include "SystemCommMessages.h" #include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" /** * @addtogroup Heaters * @{ */ // ********** private definitions ********** #ifndef V_2_SYSTEM #define MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE 1.00 ///< Main primary heater (heater A) max duty cycle (100%). #define SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE 1.00 ///< Small Primary heater (heater B) max duty cycle (100%). #define TRIMMER_HEATER_MAX_DUTY_CYCLE 1.00 ///< Trimmer heater max duty cycle (100%). #else #define MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE 0.89 ///< Main primary heater (heater A) max duty cycle (89%). #define SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE 0.50 ///< Small Primary heater (heater B) max duty cycle (50%). #define TRIMMER_HEATER_MAX_DUTY_CYCLE 0.50 ///< Trimmer heater max duty cycle (50%). #endif #define HEATERS_MIN_DUTY_CYCLE 0.00 ///< Primary and trimmer heaters minimum duty cycle (0.00%). #define PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ( MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE + \ SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE ) ///< Primary heaters cumulative duty cycle. #define PRIMARY_HEATER_INITIAL_DUTY_CYCLE_ESTIMATE_DIVISOR 2.0 ///< Primary heaters initial duty cycle estimation divisor. #define MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR 2.0 ///< Main and small primary heater duty cycle divisor #define PRIMARY_HEATERS_P_COEFFICIENT 0.15 ///< Primary heaters proportional coefficient. #define PRIMARY_HEATERS_I_COEFFICIENT 0.001 ///< Primary heaters integral coefficient. #define TRIMMER_HEATER_P_COEFFICIENT 0.02 ///< Trimmer heater proportional coefficient. #define TRIMMER_HEATER_I_COEFFICIENT 0.001 ///< Trimmer heater integral coefficient. #define CONTROLLER_CHECK_INTERVAL_COUNT 10U ///< Time interval count to check the PI controller. #define TEMP_SENSORS_INTERVAL_COUNT 10U ///< Temperature sensors interval count. #define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. #define MINIMUM_TARGET_TEMPERATURE 10.0 ///< Minimum allowed target temperature for the heaters. #define MAXIMUM_TARGET_TEMPERATURE 90.0 ///< Maximum allowed target temperature for the heaters. #define HEATERS_ON_WITH_NO_FLOW_TIMEOUT_COUNT ( ( 3 * MS_PER_SECOND ) / TASK_PRIORITY_INTERVAL ) ///< Heaters are on but there is no sufficient flow timeout in counts. #define HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_C 190.0 ///< Heaters max allowed internal temperature in degrees C. TODO figure out the max temperature value #define HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Heaters max allowed internal temperature timeout in milliseconds. #define HEATERS_ON_NO_FLOW_TIMEOUT_MS ( 2 * SEC_PER_MIN * MS_PER_SECOND ) ///< Heaters on with no flow time out in milliseconds. /// Primary heaters exec states typedef enum primary_heaters_exec_states { PRIMARY_HEATERS_EXEC_STATE_OFF = 0, ///< Primary heaters exec state off PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET, ///< Primary heaters exec state control to target (PI controller state) NUM_OF_PRIMARY_HEATERS_EXEC_STATES ///< Number of primary heaters exec states } PRIMARY_HEATERS_EXEC_STATES_T; /// Trimmer heater exec states typedef enum trimmer_heater_exec_states { TRIMMER_HEATER_EXEC_STATE_OFF = 0, ///< Trimmer heater exec state off TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET, ///< Trimmer heater exec state control to target (PI controller state) NUM_OF_TRIMMER_HEATER_EXEC_STATES ///< Number of trimmer heater exec states } TRIMMER_HEATER_EXEC_STATES_T; /// Name of the heaters states typedef enum name_of_heaters { PRIMARY_HEATER = 0, ///< Primary heater TRIMMER_HEATER, ///< Trimmer heater NUM_OF_HEATERS ///< Number of heaters } NAME_OF_HEATER_T; // ********** private data ********** static PRIMARY_HEATERS_EXEC_STATES_T primaryHeatersExecState; ///< Primary heaters exec state. static TRIMMER_HEATER_EXEC_STATES_T trimmerHeaterExecState; ///< Trimmer heater exec state. static F32 primaryHeaterTargetTemperature; ///< Primary heaters target temperature. static F32 trimmerHeaterTargetTemperature; ///< Trimmer heater target temperature. static F32 mainPrimaryHeaterDutyCycle; ///< Main primary heater duty cycle. static F32 smallPrimaryHeaterDutyCycle; ///< Small primary heater duty cycle. static F32 trimmerHeaterDutyCycle; ///< Trimmer heater duty cycle. static U32 primaryHeaterTimerCounter; ///< Primary heater timer counter. static U32 trimmerHeaterTimerCounter; ///< Trimmer heater timer counter. static U32 dataPublicationTimerCounter; ///< Data publication timer counter. static BOOL isPrimaryHeaterOn; ///< Flag to show if the primary heater is on. static BOOL isTrimmerHeaterOn; ///< Flag to show if the trimmer heater is on. static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. static BOOL hasStartPrimaryHeaterRequested; ///< Start primary heater request flag. static BOOL hasStartTrimmerHeaterRequested; ///< Start trimmer heater request flag. static U32 heatersOnWithNoFlowTimer; ///< Heaters are on but there is no sufficient flow. static TEMPERATURE_SENSORS_T primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_PRIMARY_HEATER; ///< Primary heaters feedback temperature sensors. static TEMPERATURE_SENSORS_T trimmerHeaterFeedbackTempSensor = TEMPSENSORS_INLET_DIALYSATE; ///< Trimmer heater feedback temperature sensors. static U32 primaryHeatersInternalTempOutTimer = 0; ///< Primary heaters internal temperature out of range timer. static U32 trimmerHeaterInternalTempOutTimer = 0; ///< Trimmer heater internal temperature out of range timer. static BOOL isPrimaryHeatersTempOutOfRange = FALSE; ///< Boolean flag to indicate if the primary heaters internal temperature out of range. static BOOL isTrimmerHeaterTempOutOfRange = FALSE; ///< Boolean flag to indicate if the trimmer heater internal temperature out of range. static BOOL isFlowBelowMin = FALSE; ///< Boolean flag to indicate if the flow is below the minimum. // ********** private function prototypes ********** static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ); static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ); static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ); static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ); static void setMainPrimaryHeaterPWM( F32 pwm ); static void setSmallPrimaryHeaterPWM( F32 pwm ); static void setTrimmerHeaterPWM( F32 pwm ); static void resetHeaterState( NAME_OF_HEATER_T heater ); static void publishHeatersData( void ); static U32 getPublishHeatersDataInterval( void ); /*********************************************************************//** * @brief * The initHeaters function initializes the variables and the PI controllers * for the primary and trimmer heaters. * @details Inputs: none * @details Outputs: Heaters module initialized * @return none *************************************************************************/ void initHeaters( void ) { primaryHeatersExecState = PRIMARY_HEATERS_EXEC_STATE_OFF; trimmerHeaterExecState = TRIMMER_HEATER_EXEC_STATE_OFF; primaryHeaterTargetTemperature = 0.0; trimmerHeaterTargetTemperature = 0.0; primaryHeaterTimerCounter = 0; trimmerHeaterTimerCounter = 5; dataPublicationTimerCounter = 0; isPrimaryHeaterOn = FALSE; isTrimmerHeaterOn = FALSE; primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_PRIMARY_HEATER; trimmerHeaterFeedbackTempSensor = TEMPSENSORS_INLET_DIALYSATE; primaryHeatersInternalTempOutTimer = 0; trimmerHeaterInternalTempOutTimer = 0; isPrimaryHeatersTempOutOfRange = FALSE; isTrimmerHeaterTempOutOfRange = FALSE; isFlowBelowMin = FALSE; // Initialize the PI controller for the primary heaters initializePIController( PI_CONTROLLER_ID_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATERS_P_COEFFICIENT, PRIMARY_HEATERS_I_COEFFICIENT, HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ); // Initialize the PI controller for the trimmer heater initializePIController( PI_CONTROLLER_ID_TRIMMER_HEATER, HEATERS_MIN_DUTY_CYCLE, TRIMMER_HEATER_P_COEFFICIENT, TRIMMER_HEATER_I_COEFFICIENT, HEATERS_MIN_DUTY_CYCLE, TRIMMER_HEATER_MAX_DUTY_CYCLE ); } /*********************************************************************//** * @brief * The setPrimaryHeaterTargetTemperature function sets the primary heater * target temperature. * @details Inputs: none * @details Outputs: primaryHeaterTargetTemperature * @param targetTemp target temperature for the primary heater * @return none *************************************************************************/ void setPrimaryHeaterTargetTemperature( F32 targetTemp ) { primaryHeaterTargetTemperature = targetTemp; } /*********************************************************************//** * @brief * The setTrimmerHeaterTargetTemperature function sets the trimmer heater * target temperature. * @details Inputs: none * @details Outputs: trimmerHeaterTargetTemperature * @param targetTemp target temperature for the trimmer heater * @return none *************************************************************************/ void setTrimmerHeaterTargetTemperature( F32 targetTemp ) { trimmerHeaterTargetTemperature = targetTemp; } /*********************************************************************//** * @brief * The startPrimaryHeater function starts the primary heaters. It resets * the primary heaters state and sets the main primary heater duty cycle. * @details Inputs: primaryHeaterTargetTemperature * @details Outputs: hasStartPrimaryHeaterRequested * @return status *************************************************************************/ BOOL startPrimaryHeater( void ) { BOOL status = FALSE; if ( ( primaryHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( primaryHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) { hasStartPrimaryHeaterRequested = TRUE; status = TRUE; } return status; } /*********************************************************************//** * @brief * The startTrimmerHeater function starts the trimmer heater. It resets the * trimmer heater's state and sets the duty cycle of the trimmer heater. * @details Inputs: trimmerHeaterTargetTemperature * @details Outputs: hasStartTrimmerHeaterRequested * @return status *************************************************************************/ BOOL startTrimmerHeater( void ) { BOOL status = FALSE; if ( ( trimmerHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( trimmerHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) { hasStartTrimmerHeaterRequested = TRUE; status = TRUE; } return status; } /*********************************************************************//** * @brief * The stopPrimaryHeater function stops the primary heater. * @details Inputs: none * @details Outputs: Primary heater stops * @return none *************************************************************************/ void stopPrimaryHeater( void ) { setMainPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); setSmallPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); isPrimaryHeaterOn = FALSE; } /*********************************************************************//** * @brief * The stopTrimmerHeater function stops the trimmer heater. * @details Inputs: none * @details Outputs: Trimmer heater stops * @return none *************************************************************************/ void stopTrimmerHeater( void ) { setTrimmerHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); isTrimmerHeaterOn = FALSE; } /*********************************************************************//** * @brief * The handleTrimmerHeaterCmd handles a start trimmer heater command from the HD. * It resets the trimmer heater's state and sets the duty cycle of the trimmer heater. * @details Inputs: none * @details Outputs: process command and send back response * @param heaterCmdPtr pointer to heater command data record * @return status *************************************************************************/ void handleTrimmerHeaterCmd( TRIMMER_HEATER_CMD_T *heaterCmdPtr ) { DG_CMD_RESPONSE_T cmdResponse; cmdResponse.commandID = DG_CMD_START_TRIMMER_HEATER; cmdResponse.rejected = TRUE; cmdResponse.rejectCode = DG_CMD_REQUEST_REJECT_REASON_NONE; if ( TRUE == heaterCmdPtr->startHeater ) { if ( ( MINIMUM_TARGET_TEMPERATURE <= heaterCmdPtr->targetTemp ) && ( heaterCmdPtr->targetTemp <= MAXIMUM_TARGET_TEMPERATURE ) ) { cmdResponse.rejected = FALSE; #ifndef DISABLE_HEATERS_AND_TEMPS trimmerHeaterTargetTemperature = heaterCmdPtr->targetTemp; hasStartTrimmerHeaterRequested = TRUE; #endif } else { cmdResponse.rejectCode = DG_CMD_REQUEST_REJECT_REASON_INVALID_PARAMETER; } } else { cmdResponse.rejected = FALSE; stopTrimmerHeater(); } sendCommandResponseMsg( &cmdResponse ); } /*********************************************************************//** * @brief * The execHeatersMonitor function turns off the heaters when RO pump is * not on. * @details Inputs: none * @details Outputs: Turns off the heaters when RO pump is not on * @return none *************************************************************************/ void execHeatersMonitor( void ) { // TODO check for the heaters' fault flags and fault if any of them are at fault it should alarm #ifndef IGNORE_HEATERS_MONITOR F32 primaryHeatersInternalTemp = getTemperatureValue( TEMPSENSORS_PRIMARY_HEATER_INTERNAL ); F32 trimmerHeaterInternalTemp = getTemperatureValue( TEMPSENSORS_TRIMMER_HEATER_INTERNAL ); // Check if the primary heaters' internal temperature is above the limit if ( primaryHeatersInternalTemp > HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_C ) { SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_PRIMARY_HEATERS_INTERNAL_TEMP_OUT_OF_RANGE, primaryHeatersInternalTemp ); // If it is above the range for the first time, stop the primary heaters // and set the variables if ( FALSE == isPrimaryHeatersTempOutOfRange ) { stopPrimaryHeater(); isPrimaryHeatersTempOutOfRange = TRUE; primaryHeatersInternalTempOutTimer = getMSTimerCount(); } // If the primary heaters internal temperature was out for more than the define period, activate the safety shutdown else if ( TRUE == didTimeout( primaryHeatersInternalTempOutTimer, HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ) ) { activateSafetyShutdown(); } } // Check if the trimmer heater internal temperature is above the limit if ( trimmerHeaterInternalTemp > HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_C ) { SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_TRIMMER_HEATER_INTERNAL_TEMP_OUT_OF_RANGE, trimmerHeaterInternalTemp ); // If it is above the range for the first time, stop the trimmer heater // and set the variables if ( FALSE == isTrimmerHeaterTempOutOfRange ) { stopTrimmerHeater(); isTrimmerHeaterTempOutOfRange = TRUE; trimmerHeaterInternalTempOutTimer = getMSTimerCount(); } // If the trimmer heater internal temperature was out for more than the define period, activate the safety shutdown else if ( TRUE == didTimeout( trimmerHeaterInternalTempOutTimer, HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ) ) { activateSafetyShutdown(); } } #endif /* * If any of the heaters are on or any of the heaters' PWMs are not zero, check if the flow is below than the minimum value * If the flow is below minimum for the first time, set the variables * If the flow is below minimum for more than the defined time, stop the heaters and raise the alarm * If the flow is in range, reset the variables * This is to make sure that any of the heaters do not stay on while there is no flow * In the monitor, trimmer heater is only monitored if heat disinfect mode is active. Trimmer heater is usually * controlled by HD so checking the DG flow rate to decide whether it should be on or off is not appropriate */ BOOL isModeHeat = ( DG_MODE_HEAT == getCurrentOperationMode() ) && ( TRUE == isTrimmerHeaterOn ); BOOL isHeaterOn = ( TRUE == isPrimaryHeaterOn ) || ( TRUE == isModeHeat ); BOOL isPWMNonZero = ( mainPrimaryHeaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ) || ( smallPrimaryHeaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ) || ( trimmerHeaterDutyCycle > HEATERS_MIN_DUTY_CYCLE ); if ( ( TRUE == isHeaterOn ) || ( TRUE == isPWMNonZero ) ) { F32 measuredFlow = getMeasuredROFlowRate(); if ( measuredFlow < MIN_RO_FLOWRATE_LPM ) { // Flow is below minimum for the first time if ( FALSE == isFlowBelowMin ) { isFlowBelowMin = TRUE; heatersOnWithNoFlowTimer = getMSTimerCount(); } // Flow is below minimum for a long time so raise the alarm else if ( TRUE == didTimeout( heatersOnWithNoFlowTimer, HEATERS_ON_NO_FLOW_TIMEOUT_MS ) ) { stopPrimaryHeater(); stopTrimmerHeater(); SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_HEATERS_ON_WITH_NO_FLOW_TIMEOUT, measuredFlow ); } } else { isFlowBelowMin = FALSE; heatersOnWithNoFlowTimer = getMSTimerCount(); } } // Check for data publication publishHeatersData(); } /*********************************************************************//** * @brief * The execPrimaryHeaters function executes the primary heaters' state machine. * @details Inputs: primaryHeatersExecState * @details Outputs: primaryHeatersExecState * @return none *************************************************************************/ void execPrimaryHeaters( void ) { switch ( primaryHeatersExecState ) { case PRIMARY_HEATERS_EXEC_STATE_OFF: primaryHeatersExecState = handlePrimaryHeaterStateOff(); break; case PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET: primaryHeatersExecState = handlePrimaryHeaterStateControlToTarget(); break; default: SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_PRIMARY_HEATER_EXEC_INVALID_STATE, primaryHeatersExecState ); primaryHeatersExecState = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; break; } } /*********************************************************************//** * @brief * The execTrimmerHeater function executes the trimmer heater's state machine. * @details Inputs: trimmerHeaterExecState * @details Outputs: trimmerHeaterExecState * @return none *************************************************************************/ void execTrimmerHeater( void ) { switch ( trimmerHeaterExecState ) { case TRIMMER_HEATER_EXEC_STATE_OFF: trimmerHeaterExecState = handleTrimmerHeaterStateOff(); break; case TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET: trimmerHeaterExecState = handleTrimmerHeaterControlToTarget(); break; default: SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_TRIMMER_HEATER_EXEC_INVALID_STATE, trimmerHeaterExecState ); trimmerHeaterExecState = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; break; } } /*********************************************************************//** * @brief * The handlePrimaryHeaterStateOff function handles the primary heaters at * off state. * @details Inputs: hasStartPrimaryHeaterRequested, isPrimaryHeaterOn * @details Outputs: state (PRIMARY_HEATERS_EXEC_STATES_T), isPrimaryHeaterOn * @return state (PRIMARY_HEATERS_EXEC_STATES_T) *************************************************************************/ static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ) { PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_OFF; if ( TRUE == hasStartPrimaryHeaterRequested ) { resetHeaterState( PRIMARY_HEATER ); // Once the primary heaters duty cycle is set, it is divided into 2 // so both heaters will start and both elements are heated up setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); isPrimaryHeaterOn = TRUE; hasStartPrimaryHeaterRequested = FALSE; // Check if the operation mode is heat disinfect. If the mode is // heat disinfect, the feedback sensor will be Thd if ( DG_MODE_HEAT == getCurrentOperationMode() ) { #ifdef THD_USING_TRO_CONNECTOR // Set the feedback temperature sensor // THd uses TRo in V3 primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_REDUNDANT; #else primaryHeatersFeedbackTempSensor = TEMPSENSORS_HEAT_DISINFECT; #endif } state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; } return state; } /*********************************************************************//** * @brief * The handlePrimaryHeaterStateControlToTarget function handles the primary * heaters at control state when the heaters are active. * @details Inputs: primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, * smallPrimaryHeaterDutyCycle, isPrimaryHeaterOn * @details Outputs: primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, * smallPrimaryHeaterDutyCycle * @return state (PRIMARY_HEATERS_EXEC_STATES_T) *************************************************************************/ static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ) { PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; if ( ++primaryHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) { // Check if the flow is not below minimum required first // If the flow is below minimum, send 0.00 to the PWM until the flow comes back to range // If the flow is within range, run the PI controller to control the heaters normally if ( FALSE == isFlowBelowMin ) { // If the primary heater is running and another start primary heater request // is set, reset the primary heater again if ( TRUE == hasStartPrimaryHeaterRequested ) { resetHeaterState( PRIMARY_HEATER ); hasStartPrimaryHeaterRequested = FALSE; } else { F32 outletTemp = getTemperatureValue( primaryHeatersFeedbackTempSensor ); mainPrimaryHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, primaryHeaterTargetTemperature, outletTemp ); // Once the primary heaters duty cycle is set, it is divided into 2 so both heaters will start and both elements are heated up smallPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; mainPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; } setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); } // Flow is below the minimum required flow to run the primary heaters else { setMainPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); setSmallPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); } primaryHeaterTimerCounter = 0; } if ( FALSE == isPrimaryHeaterOn ) { // Switch to off state. Set the duty cycles to 0 mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; state = PRIMARY_HEATERS_EXEC_STATE_OFF; } return state; } /*********************************************************************//** * @brief * The handleTrimmerHeaterStateOff function handles the trimmer heater at * off state. * @details Inputs: hasStartTrimmerHeaterRequested, isTrimmerHeaterOn * @details Outputs: state (TRIMMER_HEATER_EXEC_STATES_T), isTrimmerHeaterOn * @return state (TRIMMER_HEATER_EXEC_STATES_T) *************************************************************************/ static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ) { TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_OFF; if ( TRUE == hasStartTrimmerHeaterRequested ) { resetHeaterState( TRIMMER_HEATER ); isTrimmerHeaterOn = TRUE; hasStartTrimmerHeaterRequested = FALSE; setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; } return state; } /*********************************************************************//** * @brief * The handleTrimmerHeaterControlToTarget function handles the trimmer * heater at control state when the heater is active. * @details Inputs: trimmerHeaterTimerCounter, trimmerHeaterDutyCycle * @details Outputs: trimmerHeaterTimerCounter, trimmerHeaterDutyCycle, * isTrimmerHeaterOn * @return state (TRIMMER_HEATER_EXEC_STATES_T) *************************************************************************/ static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ) { TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; if ( ++trimmerHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) { // Check if the flow is not below minimum required first // If the flow is below minimum, send 0.00 to the PWM until the flow comes back to range // If the flow is within range, run the PI controller to control the heaters normally if ( FALSE == isFlowBelowMin ) { F32 outletTemp = getTemperatureValue( trimmerHeaterFeedbackTempSensor ); trimmerHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, trimmerHeaterTargetTemperature, outletTemp ); setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); } else { setTrimmerHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); } trimmerHeaterTimerCounter = 0; } if ( FALSE == isTrimmerHeaterOn ) { // Set the duty cycle to 0 and switch to off state trimmerHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; state = TRIMMER_HEATER_EXEC_STATE_OFF; } return state; } /*********************************************************************//** * @brief * The setMainPrimaryHeaterPWM function sets the PWM of the main primary heater. * @details Inputs: none * @details Outputs: Sets the PWM duty cycle for the main primary heater * @param pwm PWM duty cycle to set for 1st primary heater element * @return none *************************************************************************/ static void setMainPrimaryHeaterPWM( F32 pwm ) { etpwmSetCmpA( etpwmREG1, (U32)( (S32)( ( pwm * (F32)(etpwmREG1->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); } /*********************************************************************//** * @brief * The setSmallPrimaryHeaterPWM function sets the PWM of the small primary heater. * @details Inputs: none * @details Outputs: Sets the PWM duty cycle for the small primary heater * @param pwm PWM duty cycle to set for 2nd primary heater element * @return none *************************************************************************/ static void setSmallPrimaryHeaterPWM( F32 pwm ) { etpwmSetCmpB( etpwmREG1, (U32)( (S32)( ( pwm * (F32)(etpwmREG1->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); } /*********************************************************************//** * @brief * The setTrimmerHeaterPWM function sets the PWM of the trimmer heater. * @details Inputs: none * @details Outputs: Sets the PWM duty cycle for the trimmer heater * @param pwm PWM duty cycle to set for trimmer heater * @return none *************************************************************************/ static void setTrimmerHeaterPWM( F32 pwm ) { etpwmSetCmpA( etpwmREG3, (U32)( (S32)( ( pwm * (F32)(etpwmREG3->TBPRD) ) + FLOAT_TO_INT_ROUNDUP_OFFSET ) ) ); } /*********************************************************************//** * @brief * The resetHeaterState function resets the PI controller of the selected heater. * @details Inputs: mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle * @details Outputs: mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle * @param heater enumeration of the heater for which the PI controller will be reset * @return none *************************************************************************/ static void resetHeaterState( NAME_OF_HEATER_T heater ) { if ( PRIMARY_HEATER == heater ) { // Calculate the delta temperature from the inlet primary heater to target temperature F32 inletPrimaryHeaterTemp = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); F32 deltaTemp = primaryHeaterTargetTemperature - inletPrimaryHeaterTemp; // If the delta temperature (target temperature - inlet primary heater temperature) // Is 0 or negative, the duty cycle is 0.0 if ( deltaTemp <= 0.0 ) { mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; } else { // The formula for the initial guess is: (delta temperature * target flow) / 2.0 F32 targetFlow = getTargetROPumpFlowRate(); F32 duty = ( targetFlow * deltaTemp ) / PRIMARY_HEATER_INITIAL_DUTY_CYCLE_ESTIMATE_DIVISOR; // If the duty cycle is greater 200% on the primary and small primary heaters, set it to 200%, otherwise set it to the // estimated duty cycles duty = ( duty > PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ? PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE : duty ); mainPrimaryHeaterDutyCycle = duty / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; smallPrimaryHeaterDutyCycle = duty / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; } // The PI controller of the primary heater consists of main and small primary heaters duty cycles resetPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, mainPrimaryHeaterDutyCycle + smallPrimaryHeaterDutyCycle ); } else if ( TRIMMER_HEATER == heater ) { trimmerHeaterDutyCycle = TRIMMER_HEATER_MAX_DUTY_CYCLE; resetPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, TRIMMER_HEATER_MAX_DUTY_CYCLE ); } } /*********************************************************************//** * @brief * The getPublishHeatersDataInterval function gets the publish interval. * @details Inputs: heatersDataPublishInterval * @details Outputs: none * @return result *************************************************************************/ U32 getPublishHeatersDataInterval( void ) { U32 result = heatersDataPublishInterval.data; if ( OVERRIDE_KEY == heatersDataPublishInterval.override ) { result = heatersDataPublishInterval.ovData; } return result; } /*********************************************************************//** * @brief * The publishTemperatureData function publishes the heaters data into * at the defined time interval. * @details Inputs: dataPublicationTimerCounter * @details Outputs: dataPublicationTimerCounter * @return none *************************************************************************/ static void publishHeatersData( void ) { if ( ++dataPublicationTimerCounter >= getPublishHeatersDataInterval() ) { HEATERS_DATA_T data; data.mainPrimayHeaterDC = mainPrimaryHeaterDutyCycle * 100.0; data.smallPrimaryHeaterDC = smallPrimaryHeaterDutyCycle * 100.0; data.trimmerHeaterDC = trimmerHeaterDutyCycle * 100.0; data.primaryTargetTemp = primaryHeaterTargetTemperature; data.trimmerTargetTemp = trimmerHeaterTargetTemperature; broadcastHeatersData( &data ); dataPublicationTimerCounter = 0; } } /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/ /*********************************************************************//** * @brief * The testSetHeatersPublishIntervalOverride function overrides the heaters * publish data time interval. * @details Inputs: heatersDataPublishInterval * @details Outputs: heatersDataPublishInterval * @return result *************************************************************************/ BOOL testSetHeatersPublishIntervalOverride( U32 value ) { BOOL result = FALSE; if ( isTestingActivated() ) { U32 interval = value / TASK_PRIORITY_INTERVAL; result = TRUE; heatersDataPublishInterval.ovData = interval; heatersDataPublishInterval.override = OVERRIDE_KEY; } return result; } /*********************************************************************//** * @brief * The testResetHeatersPublishIntervalOverride function resets the heaters * publish time interval to its previous time interval. * @details Inputs: heatersDataPublishInterval * @details Outputs: heatersDataPublishInterval * @return result *************************************************************************/ BOOL testResetHeatersPublishIntervalOverride( void ) { BOOL result = FALSE; if ( isTestingActivated() ) { result = TRUE; heatersDataPublishInterval.override = OVERRIDE_RESET; heatersDataPublishInterval.ovData = heatersDataPublishInterval.ovInitData; } return result; } /**@}*/