Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -r3b6bf2cb6d15da8cb273cff109d2c4b1ee99d546 -re12eefac42a3806a34f3ddac6df30bbb5ca51f6f --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 3b6bf2cb6d15da8cb273cff109d2c4b1ee99d546) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision e12eefac42a3806a34f3ddac6df30bbb5ca51f6f) @@ -29,6 +29,7 @@ #include "SafetyShutdown.h" #include "TaskGeneral.h" #include "TaskPriority.h" +#include "TDInterface.h" #include "TemperatureSensors.h" #include "Timers.h" #include "Utilities.h" @@ -40,24 +41,26 @@ // ********** private definitions ********** -#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. +#define AC_HEATER_TX_MAX_DUTY_CYCLE 0.50F ///< AC Heater Treatement mode max duty cycle (50% of 1400W : 700W ) or ON state +#define AC_HEATER_HEAT_MAX_DUTY_CYCLE 0.70F ///< AC Heater heat disinfect mode max duty cycle (70% of 1400W : 980W ) or ON state +#define AC_HEATER_MAX_DUTY_CYCLE 1.0F ///< AC Heater max duty cycle (100.0%) or ON state +#define DC_HEATER_MAX_DUTY_CYCLE 1.0F ///< DC Heater max duty cycle (100%) or ON state +#define HEATERS_MIN_DUTY_CYCLE 0.0F ///< Heaters minimum duty cycle (0.00%) or OFF state #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 HEATERS_ZERO_EFFICIENCY 0.0F ///< Zero heater efficiency -#define D5_HEAT_P_COEFFICIENT 1.0F ///< P Term for primary heater control. -#define D5_HEAT_I_COEFFICIENT 1.0F ///< I Term for primary heater control. -#define D45_HEAT_P_COEFFICIENT 1.0F ///< P Term for trimmer heater control. -#define D45_HEAT_I_COEFFICIENT 1.0F ///< I Term for trimmer heater control. +#define D5_HEAT_TX_INIT_FEED_FORWARD 0.0F ///< Initial Feed forward term for heater control +#define D5_HEAT_TX_P_COEFFICIENT 0.015F ///< P Term for AC primary heater control during treatment mode. +#define D5_HEAT_TX_I_COEFFICIENT 0.0021F ///< I Term for AC primary heater control during treatment mode. -#define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. +#define D45_HEAT_P_COEFFICIENT 0.35F ///< P Term for trimmer heater control. +#define D45_HEAT_I_COEFFICIENT 0.05F ///< I Term for trimmer heater control. +#define D45_HEAT_TX_INIT_FEED_FORWARD 0.0F ///< Initial Feed forward term for heater control -#define HEATER_TEMP_CONTROL_TOLERANCE 2.0F ///< Primary Heater temp tolerance for ON/Off control +#define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. +#define HEATER_TEMP_CONTROL_TRANSFER 1.0F ///< Primary Heater temperature difference to switch to control function #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. @@ -66,10 +69,22 @@ #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 D5_HEAT_CONTROL_INTERVAL_MS 30000 /// Primary heater control interval in milli seconds +#define D5_HEAT_CONTROL_INTERVAL_COUNT ( D5_HEAT_CONTROL_INTERVAL_MS / TASK_GENERAL_INTERVAL ) ///< Primary heater control interval count. +#define D45_HEAT_CONTROL_INTERVAL_MS ( 1 * MS_PER_SECOND ) ///< Trimmer heater control interval in milli seconds +#define D45_HEAT_CONTROL_INTERVAL_COUNT ( D45_HEAT_CONTROL_INTERVAL_MS / TASK_GENERAL_INTERVAL ) ///< Trimmer heater control interval count. +#define PRIMARY_HEATER_MAX_PWR_WATTS 1400.0F ///< AC Primary Heater Max Power consumeption in Watts +#define TX_PRIMARY_HEATER_MAX_PWR_WATTS 700.0F ///< Estimated power to be supplied to the primary heater during treatement mode +#define HEAT_PRIMARY_HEATER_MAX_PWR_WATTS 980.0F ///< Estimated power to be supplied to the primary heater during heat disinfect mode +#define MAX_INLET_FLOW_LPM ( 600.0F / 1000.0F ) ///< Maximum inlet flow to hydraulics chamber from FP +#define LITER_IN_ML 1000.0F ///< Liter in milliliter units +#define TRIMMER_HEATER_MAX_PWR_WATTS 120.0F ///< Maximum power supplied to trimmer heater +#define AC_HEATER_PWM_PERIOD 10000 ///< PWM period 100 ms( in 10us resoultion), 1/10Hz = 1000000us/10us = 10000. +#define AC_HEATER_EFFICIENCY 0.90F ///< Approximated AC heater efficiency to be used in energy calcualtions. +#define DC_HEATER_EFFICIENCY 1.0F ///< DC heater efficiency +#define D5_HEAT_CONTROL_INTERVAL_START_COUNT ( D5_HEAT_CONTROL_INTERVAL_COUNT - 10 ) ///< AC heater control interval start count to jump feedforward control from open loop. + #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. @@ -99,15 +114,25 @@ 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 controlInterval[ NUM_OF_DD_HEATERS ]; ///< Heater control interval time. static U32 dataPublicationTimerCounter; ///< Data publication timer counter. +static const F32 WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES = 4184.0F / (F32)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. +static F32 convertDC; ///< AC Heater converted duty cycle +static BOOL startupHeaterControl; ///< First time control with the energy equation. +//For testing +#ifdef __HEATERS_DEBUG__ +static F32 pIControlSignal[ NUM_OF_CONTROLLER_SIGNAL ]; +#endif // ********** 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 F32 calculateDutyCycle( F32 flowrate, F32 deltaTemp, F32 power, F32 efficiency, F32 min, F32 max ); static void setHeaterControl( DD_HEATERS_T heater ); static F32 getHeaterControl( DD_HEATERS_T heater ); @@ -125,8 +150,38 @@ void initHeaters( void ) { DD_HEATERS_T heater; - dataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; +#ifdef __HEATERS_DEBUG__ + U32 i; +#endif + // Assign start count + dataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; + + //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; + + //Initialize Converted Duty cycle + convertDC = 0.0F; + controlInterval[ D5_HEAT ] = D5_HEAT_CONTROL_INTERVAL_COUNT; + controlInterval[ D45_HEAT ] = D45_HEAT_CONTROL_INTERVAL_COUNT; + + // Assign counter close to the target period + heatersStatus[ D5_HEAT ].controlIntervalCounter = D5_HEAT_CONTROL_INTERVAL_START_COUNT; + heatersStatus[ D45_HEAT ].controlIntervalCounter = 0; + startupHeaterControl = TRUE; + for ( heater = DD_HEATERS_FIRST; heater < NUM_OF_DD_HEATERS; heater++ ) { targetTempC[ heater ].data = 0.0F; @@ -143,20 +198,26 @@ 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 primary heater PI controller + initializePIController( PI_CONTROLLER_ID_D5_HEAT, HEATERS_MIN_DUTY_CYCLE, D5_HEAT_TX_P_COEFFICIENT, D5_HEAT_TX_I_COEFFICIENT, + HEATERS_MIN_DUTY_CYCLE, AC_HEATER_TX_MAX_DUTY_CYCLE, TRUE, D5_HEAT_TX_INIT_FEED_FORWARD ); // 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 ); + HEATERS_MIN_DUTY_CYCLE, DC_HEATER_MAX_DUTY_CYCLE, FALSE, D45_HEAT_TX_INIT_FEED_FORWARD ); +#ifdef __HEATERS_DEBUG__ + for ( i = 0; i < NUM_OF_CONTROLLER_SIGNAL; i++ ) + { + pIControlSignal[ i ] = 0.0F; + } +#endif + // 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 ); @@ -220,6 +281,22 @@ /*********************************************************************//** * @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 @@ -234,6 +311,28 @@ /*********************************************************************//** * @brief + * The signalHeaterControlOnQDUpdate function updates heater control based on + * the latest treatment paratmeter (Dialysate Flow rate) change + * @details \b Inputs: heatersStatus + * @details \b Outputs: none + * @param heater: heater ID to update the heater control. + * @return none + *************************************************************************/ +void signalHeaterControlOnQDUpdate( DD_HEATERS_T heater ) +{ + if ( D5_HEAT == heater ) + { + // check heater state + if ( HEATER_EXEC_STATE_CONTROL_TO_TARGET == heatersStatus[ heater ].state ) + { + // Set flag to recalculate the feedforward signals + startupHeaterControl = TRUE; + } + } +} + +/*********************************************************************//** + * @brief * The startHeater function starts the given heater by setting the flag. * @details \b Inputs: heatersStatus * @details \b Outputs: startHeaterSignal @@ -270,10 +369,13 @@ { 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; + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].heaterOnState = FALSE; + control[ heater ].data = HEATERS_MIN_DUTY_CYCLE; + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + heatersStatus[ D5_HEAT ].controlIntervalCounter = D5_HEAT_CONTROL_INTERVAL_START_COUNT; + heatersStatus[ D45_HEAT ].controlIntervalCounter = 0; + startupHeaterControl = TRUE; // update duty cycle setHeaterControl( heater ); @@ -355,22 +457,16 @@ ALARM_ID_T alarm; BOOL isLevelLow = FALSE; - switch ( heater ) + if ( D5_HEAT == heater ) { - case D5_HEAT: - alarm = ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D5_HEAT_IS_ON; - isLevelLow = ( ( getLevelStatus( D6_LEVL ) != 0 )? FALSE : TRUE ); - break; - - case D45_HEAT: - alarm = ALARM_ID_DD_FLUID_TOO_LOW_WHILE_D45_HEAT_IS_ON; - isLevelLow = ( ( getLevelStatus( D46_LEVL ) != 0 )? FALSE : TRUE ); - break; - - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) - break; + 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 ); } @@ -412,7 +508,7 @@ heatersStatus[ heater ].heaterOnState = TRUE; heatersStatus[ heater ].startHeaterSignal = FALSE; - // proceed to ramp state + // proceed to setup state state = HEATER_EXEC_STATE_RAMP_TO_TARGET; } @@ -425,22 +521,36 @@ * 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. + * @param heater: The heater Id to handle the initial setup control for heater. * @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 targetTemperature = getHeaterTargetTemperature( 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 ) { - control[ heater ].data = D5_HEAT_ON; - state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; + F32 deltaTempC = targetTemperature - measuredTemperature; + F32 capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); + + if ( capDeltaTempC <= HEATER_TEMP_CONTROL_TRANSFER ) + { + // Transfer Control to target when delta temp is minimal. + state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; + } + else + { + // Start Open loop control with max power + control[ heater ].data = AC_HEATER_TX_MAX_DUTY_CYCLE; + } } else { @@ -450,9 +560,19 @@ } else { + measuredTemperature = getTemperatureValue( D50_TEMP ); + if ( DD_MODE_HEAT != opMode ) { - ctrl = ( ( targetTemperature / HEATER_TARGET_TEMPERATURE_MAX ) * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR ) + FLOAT_TO_INT_ROUNDUP_OFFSET; + F32 deltaTempC = targetTemperature - measuredTemperature; + F32 capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); + F32 flowrate = getTDDialysateFlowrate() / LITER_IN_ML ; + F32 dutyCycle = calculateDutyCycle( flowrate, capDeltaTempC, TRIMMER_HEATER_MAX_PWR_WATTS, DC_HEATER_EFFICIENCY, + HEATERS_MIN_DUTY_CYCLE, DC_HEATER_MAX_DUTY_CYCLE ); + + control[ heater ].data = dutyCycle; + resetPIController( PI_CONTROLLER_ID_D45_HEAT, dutyCycle, D45_HEAT_TX_INIT_FEED_FORWARD ); + state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; } else @@ -484,47 +604,59 @@ { HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; F32 targetTemperature = getHeaterTargetTemperature( heater ); + F32 inletTemperature = 0.0F; F32 measuredTemperature = 0.0F; F32 ctrl = 0.0F; - if( ++heatersStatus[ heater ].controlIntervalCounter > D5_HEAT_CONTROL_INTERVAL_COUNT ) + if( ++heatersStatus[ heater ].controlIntervalCounter > controlInterval[ heater ] ) { - switch ( heater ) + if ( D5_HEAT == heater ) { - case D5_HEAT: - measuredTemperature = getTemperatureValue( (U32)D4_TEMP ); - if ( measuredTemperature >= targetTemperature ) - { - // Turn off heater - control[ heater ].data = HEATERS_MIN_DUTY_CYCLE; - } - else - { - // Turn On heater - control[ heater ].data = D5_HEAT_ON; - } + measuredTemperature = getTemperatureValue( D4_TEMP ); + // Inlet temperature post heat exchanger + inletTemperature = getTemperatureValue( X6_TEMP ); - //control = runPIController( PI_CONTROLLER_ID_D5_HEAT, targetTemperature, measuredTemperature ); - break; + if ( TRUE == startupHeaterControl ) + { + startupHeaterControl = FALSE; + //TODO : testing + //F32 deltaTempC = targetTemperature - inletTemperature; + F32 deltaTempC = 10.0F; // Hard code for testing, later remove it. + F32 capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); + F32 flowrate = getTDDialysateFlowrate() / LITER_IN_ML ; + F32 feedforward = calculateDutyCycle( flowrate, capDeltaTempC, PRIMARY_HEATER_MAX_PWR_WATTS, AC_HEATER_EFFICIENCY, + HEATERS_MIN_DUTY_CYCLE, AC_HEATER_TX_MAX_DUTY_CYCLE ); + control[ heater ].data = feedforward; + resetPIController( PI_CONTROLLER_ID_D5_HEAT, HEATERS_MIN_DUTY_CYCLE, feedforward ); + } + else + { + ctrl = runPIController( PI_CONTROLLER_ID_D5_HEAT, targetTemperature, measuredTemperature ); + control[ heater ].data = ctrl; + } +#ifdef __HEATERS_DEBUG__ + U32 i; - case D45_HEAT: - measuredTemperature = getTemperatureValue( (U32)D50_TEMP ); - //control = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); - 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 ); - } + for ( i = 0; i < NUM_OF_CONTROLLER_SIGNAL; i++ ) + { + pIControlSignal[ i ] = getPIControllerSignals( PI_CONTROLLER_ID_D5_HEAT, (PI_CONTROLLER_SIGNALS_ID)i ); + } +#endif + } + else + { + measuredTemperature = getTemperatureValue( D50_TEMP ); - control[ heater ].data = ( ctrl * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR ) + FLOAT_TO_INT_ROUNDUP_OFFSET; - break; + ctrl = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); + control[ heater ].data = ctrl; +#ifdef __HEATERS_DEBUG__ + U32 i; - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DD_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) - break; + for ( i = 0; i < NUM_OF_CONTROLLER_SIGNAL; i++ ) + { + pIControlSignal[ i ] = getPIControllerSignals( PI_CONTROLLER_ID_D45_HEAT, (PI_CONTROLLER_SIGNALS_ID)i ); + } +#endif } heatersStatus[ heater ].hasTargetTempChanged = FALSE; @@ -572,18 +704,22 @@ { if ( heater < NUM_OF_DD_HEATERS ) { - F32 control; + F32 control = getHeaterControl( heater ); + F32 period = getHeaterPWMPeriod ( heater ); - control = getHeaterControl( heater ); - if ( D5_HEAT == heater ) { - BOOL heaterCntrl = (BOOL)control; - setFPGACPrimaryHeaterOnOffControl( heaterCntrl ); + //Convert duty cycle into LowState and multiply by period + F32 duty = AC_HEATER_MAX_DUTY_CYCLE - control; + convertDC = duty * period; + + setFPGAD5HeaterPWMPeriod( (U16)period ); + setFPGAD5HeaterPWMLowState( (U16)convertDC ); } else { - setFPGATrimmerHeaterPWMControl( (U08)control ); + U08 ctrl = ( control * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR ) + FLOAT_TO_INT_ROUNDUP_OFFSET; + setFPGAD45HeaterPWMControl( ctrl ); } } else @@ -609,6 +745,37 @@ /*********************************************************************//** * @brief + * The calculateDutyCycle function calculates the heater's duty cycle + * based on the delta temperature, flowrate and power applied to the heater. + * @details \b Inputs: none + * @details \b Outputs: duty cycle + * @param flowrate: dialysate flowrate. + * @param deltaTemp: Temperature difference between actual and target. + * @param power: Power supplied to the heater + * @param efficiency: Heater efficeincy to compensate heatloss + * @param min: heaters minimum duty cycle + * @param max: heaters maximum duty cycle + * @return calcualted PWM duty cycle + *************************************************************************/ +static F32 calculateDutyCycle( F32 flowrate, F32 deltaTemp, F32 power, F32 efficiency, F32 min, F32 max ) +{ + F32 duty = ( WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * deltaTemp * flowrate ) / power; + + // Updated duty with efficiency + if ( HEATERS_ZERO_EFFICIENCY != efficiency ) + { + duty = duty / efficiency; + } + + // Apply min/max limits + duty = MIN( duty, max ); + duty = MAX( duty, min ); + + return duty; +} + +/*********************************************************************//** + * @brief * The monitorHeatersVoltage function monitors the heaters' voltages * @details \b Inputs: Voltage range * @details \b Outputs: none @@ -669,8 +836,24 @@ data.d45_HeaterTargetTemp = getHeaterTargetTemperature( D45_HEAT ); data.d5_HeaterState = heatersStatus[ D5_HEAT ].state; data.d45_HeaterState = heatersStatus[ D45_HEAT ].state; +#ifndef __HEATERS_DEBUG__ data.d5_HeaterControlCounter = heatersStatus[ D5_HEAT ].controlIntervalCounter; data.d45_HeaterControlCounter = heatersStatus[ D45_HEAT ].controlIntervalCounter; +#else + data.d5_HeaterControlCounter = (U32)convertDC; + data.d45_HeaterControlCounter = (U32)getHeaterPWMPeriod( D5_HEAT ); +#endif +#ifdef __HEATERS_DEBUG__ + data.dbg1 = pIControlSignal[ 0 ]; + data.dbg2 = pIControlSignal[ 1 ]; + data.dbg3 = pIControlSignal[ 2 ]; + data.dbg4 = pIControlSignal[ 3 ]; + data.dbg5 = pIControlSignal[ 4 ]; + data.dbg6 = pIControlSignal[ 5 ]; + data.dbg7 = pIControlSignal[ 6 ]; + data.dbg8 = pIControlSignal[ 7 ]; + data.dbg9 = pIControlSignal[ 8 ]; +#endif dataPublicationTimerCounter = 0; @@ -737,6 +920,23 @@ /*********************************************************************//** * @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 @@ -749,7 +949,7 @@ { BOOL result = FALSE; - // Verify tester has logged in with TD + // Verify tester has logged in with DD if ( TRUE == isTestingActivated() ) { // Verify payload length is valid