Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rb04db69f541f245e543df343257bcbdb73fbbc3d -r94789b2f2324d5901685b6ff7b6224d4af3a0276 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision b04db69f541f245e543df343257bcbdb73fbbc3d) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 94789b2f2324d5901685b6ff7b6224d4af3a0276) @@ -7,8 +7,8 @@ * * @file Heaters.c * -* @author (last) Michael Garthwaite -* @date (last) 30-Mar-2026 +* @author (last) Vinayakam Mani +* @date (last) 14-Apr-2026 * * @author (original) Vinayakam Mani * @date (original) 11-Oct-2024 @@ -24,6 +24,7 @@ #include "Level.h" #include "MessageSupport.h" #include "Messaging.h" +#include "ModeGenDialysate.h" //#include "NVDataMgmt.h" #include "OperationModes.h" #include "PersistentAlarm.h" @@ -55,13 +56,12 @@ #define HEATER_CNTL_TRANSFER_DELTA_TEMP_C 0.50F ///< AC heater delta temperature to transfer control from open to close loop #define ADJ_DELTA_TEMP_STEP 2.0F ///< Adjust target temperature based on D28 feedback per cycle. #define MAX_ADJ_DELTA_TEMP_C 7.0F ///< Maximum adjusted delta temperature to add/remove from calculated target temperature - #define D5_HEAT_TX_INIT_FEED_FORWARD 0.0F ///< Initial Feed forward term for heater control -#define D5_HEAT_TX_P_COEFFICIENT 0.035F ///< P Term for AC primary heater control during treatment mode. -#define D5_HEAT_TX_I_COEFFICIENT 0.004F ///< I Term for AC primary heater control during treatment mode. +#define D5_HEAT_TX_P_COEFFICIENT 0.05F ///< P Term for AC primary heater control during treatment mode. +#define D5_HEAT_TX_I_COEFFICIENT 0.001F ///< I Term for AC primary heater control during treatment mode. -#define D45_HEAT_P_COEFFICIENT 0.20F ///< P Term for trimmer heater control. -#define D45_HEAT_I_COEFFICIENT 0.05F ///< I Term for trimmer heater control. +#define D45_HEAT_P_COEFFICIENT 0.01F ///< P Term for trimmer heater control. +#define D45_HEAT_I_COEFFICIENT 0.005F ///< I Term for trimmer heater control. #define D45_HEAT_TX_INIT_FEED_FORWARD 0.0F ///< Initial Feed forward term for heater control #define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. @@ -75,25 +75,69 @@ #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 D5_HEATER_DEADBAND_CONTROL 0.1F ///< Heater deadband range for conrtol. +#define D5_HEATER_DEADBAND_CONTROL 0.1F ///< Heater dead band range for control. +#define D5_HEATER_PWM_ADJ_SLOPE_FACTOR 0.00005F ///< AC heater close loop PWM adjustment slope factor +#define D5_HEATER_PWM_INTERCEPT_FACTOR 0.0055F ///< AC heater close loop PWM adjustment intercept factor #define D5_HEAT_CONTROL_INTERVAL_MS 3000 /// 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_MS ( 3 * 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 D5_TARGET_TEMP_ADJUST_INTERVAL_MS ( 3 * SEC_PER_MIN * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Adjust primary target temperature -#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 D5_TARGET_TEMP_ADJUST_LOW_QD_INTERVAL ( 3 * SEC_PER_MIN * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Adjust primary target temperature - outer loop control interval for low Qd. +#define D5_TARGET_TEMP_ADJUST_HIGH_QD_INTERVAL ( 1 * SEC_PER_MIN * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Adjust primary target temperature - outer loop control interval for high Qd. +#define PRIMARY_HEATER_MAX_PWR_WATTS 1400.0F ///< AC Primary Heater Max Power consumption in Watts +#define TX_PRIMARY_HEATER_MAX_PWR_WATTS 700.0F ///< Estimated power to be supplied to the primary heater during treatment 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_PWM_PERIOD 10000 ///< PWM period 100ms( in 10us resolution), 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 RINSE_PUMP_EST_FLOWRATE 110 ///< Estimated rinse pump flow rate #define DATA_PUBLISH_COUNTER_START_COUNT 70 ///< Data publish counter start count. +#define AC_HEAT_EFFICIENCY_LOW 0.1F ///< Lower allowable range for heater efficiency adjustment +#define AC_HEAT_EFFICIENCY_HIGH 10.0F ///< higher allowable range for heater efficiency adjustment +#define AC_HEAT_PWM_ADJUST_PERCENT 0.5F ///< AC heater PWM gain adjustment percentage for close loop control +#define AC_HEAT_PWM_ADJ_MIN -0.10F ///< Minimum PWM value that can adjust the calculated Feed forward value +#define AC_HEAT_PWM_ADJ_MAX 0.10F ///< Maximum PWM value that can adjust the calculated Feed forward value +#define AC_HEAT_PWM_MIN_MAX_FACTOR 2.0F ///< factor used to calculate range values for PWM adjustment +#define D5_HEAT_OUT_TX_P_COEFFICIENT 0.5F ///< P Term for AC primary heater outer loop control during treatment mode. +#define D5_HEAT_OUT_TX_I_COEFFICIENT 0.40F ///< I Term for AC primary heater outer loop control during treatment mode. +#define D5_HEAT_OUT_MIN_DELTA_TEMP 0.0F ///< Minimum Delta temperature that can be adjusted for D5 control +#define D5_HEAT_OUT_MAX_DELTA_TEMP 50.0 ///< Maximum Delta temperature that can be adjusted for D5 control +#define D5_HEAT_OUT_DEADBAND_CONTROL 0.1F ///< Heater outer loop dead band range for control. +#define HIGH_DIAL_FLOW_RATE 300.0F ///< Decide outer loop heater control based on the dialysate flow rate + +#define QUAD_FIRST_COEFFICIENT 0.0006F ///< First coefficient used in adjusted dialysate temperature quadratic calculation for low Qds +#define QUAD_SECOND_COEFFICIENT -0.1743F ///< Second coefficient used in adjusted dialysate temperature quadratic calculation for low Qds +#define QUAD_THIRD_COEFFICIENT 17.3F ///< Third coefficient used in adjusted dialysate temperature quadratic calculation for low Qds +#define LINEAR_SLOPE_FACTOR -0.0029F ///< Slope factor used in adjusted dialysate temperature linear calculation for high Qds +#define LINEAR_INTERCEPT_FACTOR 3.47F ///< Intercept factor used in adjusted dialysate temperature linear calculation for high Qds +#define LOW_DIAL_FLOW_RATE 150.0F ///< Dialysate flow rate lesser than 150 considered to be low Qds. + +#define B1B2_HEAT_DIS_FIRST_COEFF 0.00000000487858F ///< First coefficient for Heat loss dissipation calculation from D4 to D28(cubic equation). +#define B1B2_HEAT_DIS_SEC_COEFF 0.0000063124F ///< Second coefficient for Heat loss dissipation calculation from D4 to D28. +#define B1B2_HEAT_DIS_THIRD_COEFF 0.00258513F ///< Third coefficient for Heat loss dissipation calculation from D4 to D28. +#define B1B2_HEAT_DIS_FOURTH_COEFF 0.242013F ///< Fourth coefficient for Heat loss dissipation calculation from D4 to D28. +#define B3_HEAT_DIS_FIRST_COEFF 0.0000000067756F ///< First coefficient for Heat loss dissipation calculation from D28 to Dialyzer(cubic equation). +#define B3_HEAT_DIS_SEC_COEFF 0.0000085278F ///< Second coefficient for Heat loss dissipation calculation from D28 to Dialyzer. +#define B3_HEAT_DIS_THIRD_COEFF 0.0035126F ///< Third coefficient for Heat loss dissipation calculation from D28 to Dialyzer. +#define B3_HEAT_DIS_FOURTH_COEFF 0.63893F ///< Fourth coefficient for Heat loss dissipation calculation from D28 to Dialyzer. + +#define BETA2_0_B1B2_HEAT_DIS_FIRST_COEFF -0.000000000005212F ///< First coefficient for Heat loss dissipation calculation from D4 to D28(Beta2.0 quartic equation). +#define BETA2_0_B1B2_HEAT_DIS_SEC_COEFF 0.000000009754882F ///< Second coefficient for Heat loss dissipation calculation from D4 to D28. +#define BETA2_0_B1B2_HEAT_DIS_THIRD_COEFF 0.000006714979798F ///< Third coefficient for Heat loss dissipation calculation from D4 to D28. +#define BETA2_0_B1B2_HEAT_DIS_FOURTH_COEFF 0.002289024242423F ///< Fourth coefficient for Heat loss dissipation calculation from D4 to D28. +#define BETA2_0_B1B2_HEAT_DIS_FIFTH_COEFF 0.317550545454563F ///< Fifth coefficient for Heat loss dissipation calculation from D4 to D28. +#define BETA2_0_B3_HEAT_DIS_FIRST_COEFF -0.0000000000389F ///< First coefficient for Heat loss dissipation calculation from D28 to Dialyzer(Beta2.0 quartic equation). +#define BETA2_0_B3_HEAT_DIS_SEC_COEFF 0.0000000619946F ///< Second coefficient for Heat loss dissipation calculation from D28 to Dialyzer. +#define BETA2_0_B3_HEAT_DIS_THIRD_COEFF 0.0000359241717F ///< Third coefficient for Heat loss dissipation calculation from D28 to Dialyzer. +#define BETA2_0_B3_HEAT_DIS_FOURTH_COEFF 0.0092543272727F ///< Fourth coefficient for Heat loss dissipation calculation from D28 to Dialyzer. +#define BETA2_0_B3_HEAT_DIS_FIFTH_COEFF 1.079412363636F ///< Fifth coefficient for Heat loss dissipation calculation from D28 to Dialyzer. + //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 @@ -122,7 +166,7 @@ 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 control[ NUM_OF_DD_HEATERS ]; ///< Heater control ( Primary : On/Off, Trimmer : Duty cycle). 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. @@ -133,8 +177,12 @@ 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 F32 d5Efficiency; ///< AC heater efficiency factor. +static F32 adjustD5PWM; ///< AC heater close loop PWM adjustment +static F32 capAdjustD5PWM; ///< AC heater PWM adjustment after range check static F32 lastDialTargetTemperatureSet[ NUM_OF_DD_HEATERS ]; ///< last dialysate target temperature set for heater control -static BOOL startupHeaterControl; ///< First time control with the energy equation. +static F32 d5FeedForward; ///< AC heater feed forward calculated value +static U32 d5OuterLoopControlInterval; ///< AC heater outer loop control valve //For testing #ifdef __HEATERS_DEBUG__ @@ -148,6 +196,11 @@ static HEATERS_STATE_T handleHeaterStateControlToTarget( DD_HEATERS_T heater ); static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DD_HEATERS_T heater ); static void updatePrimaryHeaterTargetTemp( void ); +static F32 calculateBeta2HeatDissipationB1andB2( void ); +static F32 calculateBeta2HeatDissipationB3( void ); +static F32 calculateHeatDissipationB1andB2( void ); +static F32 calculateHeatDissipationB3( void ); +static F32 calculateInitialTemp( F32 targetTemp, F32 heatDissipation ); static F32 calculateDutyCycle( F32 flowrate, F32 deltaTemp, F32 power, F32 efficiency, F32 min, F32 max ); static void setHeaterControl( DD_HEATERS_T heater ); @@ -192,15 +245,19 @@ convertDC = 0.0F; controlInterval[ D5_HEAT ] = D5_HEAT_CONTROL_INTERVAL_COUNT; controlInterval[ D45_HEAT ] = D45_HEAT_CONTROL_INTERVAL_COUNT; + d5OuterLoopControlInterval = D5_TARGET_TEMP_ADJUST_HIGH_QD_INTERVAL; // Assign counter close to the target period heatersStatus[ D5_HEAT ].controlIntervalCounter = D5_HEAT_CONTROL_INTERVAL_START_COUNT; heatersStatus[ D45_HEAT ].controlIntervalCounter = 0; - startupHeaterControl = TRUE; lastDialTargetTemperatureSet[ D5_HEAT ] = 0.0F; lastDialTargetTemperatureSet[ D45_HEAT ] = 0.0F; primaryTargetTempAdjCounter = 0; adjustedPrimaryTargetTemp = 0.0F; + d5Efficiency = AC_HEATER_EFFICIENCY; + adjustD5PWM = 0.0F; + capAdjustD5PWM = 0.0F; + d5FeedForward = 0.0F; isTargetTempAdjusted = FALSE; isDialyzerTempFeedbackEnabled = TRUE; @@ -229,6 +286,9 @@ 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 ); + initializePIController( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, D5_HEAT_OUT_MIN_DELTA_TEMP, D5_HEAT_OUT_TX_P_COEFFICIENT, D5_HEAT_OUT_TX_I_COEFFICIENT, + D5_HEAT_OUT_MIN_DELTA_TEMP, D5_HEAT_OUT_MAX_DELTA_TEMP, 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, DC_HEATER_MAX_DUTY_CYCLE, FALSE, D45_HEAT_TX_INIT_FEED_FORWARD ); @@ -277,11 +337,6 @@ heatersStatus[ heater ].hasTargetTempChanged = TRUE; result = TRUE; lastDialTargetTemperatureSet[ heater ] = targetTemperature; - - if ( D5_HEAT == heater ) - { - startupHeaterControl = TRUE; - } } } else @@ -367,9 +422,11 @@ // check heater state if ( HEATER_EXEC_STATE_CONTROL_TO_TARGET == heatersStatus[ heater ].state ) { - // Set flag to recalculate the feedforward signals - startupHeaterControl = TRUE; + // Reset the adjusted temperature target isTargetTempAdjusted = FALSE; + + // Reset the AC heater PWM adjustment + adjustD5PWM = HEATERS_MIN_DUTY_CYCLE; } } } @@ -390,6 +447,67 @@ /*********************************************************************//** * @brief + * The calculateTargetDialysateTemp function calculate the delta temperature + * required for dialysate temperature to meet the set temperature at dialyzer. + * @details \b Inputs: Qd and target temperature. + * @details \b Outputs: Adjusted Target temperature + * @return none. + *************************************************************************/ +void calculateTargetDialysateTemp( void ) +{ + // Get the dialysate flow rate from TD + F32 dialFlowrate = getTDDialysateFlowrate(); + F32 deltaTemp = 0.0F; + F32 heatDissipation_b1b2 = 0.0F; + F32 heatDissipation_b3 = 0.0F; + F32 targetTemp = getTDTargetDialysateTemperature(); + F32 targetTempAtD28 = 0.0F; + F32 targetTempAtD4 = 0.0F; + +#ifndef __REVISED_HEATER_MODEL__ + if ( dialFlowrate >= LOW_DIAL_FLOW_RATE ) + { + // linear relationship seen against high dialysate flowrate Vs DeltaTemp + // deltaTemp = (-0.0029 * Qd) + 3.47 + deltaTemp = ( LINEAR_SLOPE_FACTOR * dialFlowrate ) + LINEAR_INTERCEPT_FACTOR; + } + else + { + // deltaTemp = (0.0006 * Qd * Qd)-(0.1743*Qd) + 17.3 + deltaTemp = ( QUAD_FIRST_COEFFICIENT * dialFlowrate * dialFlowrate ) + + ( QUAD_SECOND_COEFFICIENT * dialFlowrate ) + QUAD_THIRD_COEFFICIENT; + } + // Adjust the D4 target temperature + targetTempAtD4 = getTDTargetDialysateTemperature() + deltaTemp; + setTargetHydChamberTemp( targetTempAtD4 ); +#else + // Heat loss model predicts the heat loss ( B1,B2 and B3) in the DD flow path and + // finds the delta temperature to be added with the target temperature + // to maintain the target temperature at dialyzer. + // Lets calculate the B1,B2 and B3 heat dissipation factors + if ( TRUE == getTestConfigStatus( TEST_CONFIG_DD_FP_ENABLE_BETA_2_0_HW ) ) + { + // based on Beta2.0 heat loss model + heatDissipation_b3 = calculateBeta2HeatDissipationB3(); + heatDissipation_b1b2 = calculateBeta2HeatDissipationB1andB2(); + } + else + { + heatDissipation_b3 = calculateHeatDissipationB3(); + heatDissipation_b1b2 = calculateHeatDissipationB1andB2(); + } + + // Reverse calculation of target temp at D28 to get the target dialyzer temperature + targetTempAtD28 = calculateInitialTemp( targetTemp, heatDissipation_b3 ); + // calculation of target temp at D4 to get the target temp at D28 level + targetTempAtD4 = calculateInitialTemp( targetTempAtD28, heatDissipation_b1b2 ); + //Update target temperature + setTargetHydChamberTemp( targetTempAtD4 ); +#endif +} + +/*********************************************************************//** + * @brief * The updatePrimaryHeaterTargetTemp function adjusts the previosuly calcualted * target dialysate temperature * @details \b Inputs: Set Target Temperature, D28 Temp @@ -398,7 +516,7 @@ *************************************************************************/ static void updatePrimaryHeaterTargetTemp( void ) { - if ( ++primaryTargetTempAdjCounter >= D5_TARGET_TEMP_ADJUST_INTERVAL_MS ) + if ( ++primaryTargetTempAdjCounter >= d5OuterLoopControlInterval ) { F32 targetTempfromTD = getTDTargetDialysateTemperature(); F32 measuredTempAtDialyzer = 0.0F; @@ -416,7 +534,8 @@ F32 dialysateFlowrate = getTDDialysateFlowrate(); F32 deltaTempC = targetTempfromTD - measuredTempAtDialyzer; F32 capDeltaTempC = MIN( fabs(deltaTempC), ADJ_DELTA_TEMP_STEP ); - + F32 ctrl = 0.0F; +#if 0 //Assign the initial calcualted temp for adjsutment if ( FALSE == isTargetTempAdjusted ) { @@ -449,6 +568,21 @@ isTargetTempAdjusted = TRUE; primaryTargetTempAdjCounter = 0; +#else + if ( FALSE == isTargetTempAdjusted ) + { + isTargetTempAdjusted = TRUE; + adjustedPrimaryTargetTemp = calcTargetTemp; + resetPIController( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, calcTargetTemp, HEATERS_MIN_DUTY_CYCLE ); + } + else if ( fabs(deltaTempC) >= D5_HEAT_OUT_DEADBAND_CONTROL ) + { + ctrl = runPIController( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, getTDTargetDialysateTemperature(), measuredTempAtDialyzer ); + adjustedPrimaryTargetTemp = ctrl; + } + + primaryTargetTempAdjCounter = 0; +#endif } } @@ -499,7 +633,6 @@ if ( D5_HEAT == heater ) { heatersStatus[ D5_HEAT ].controlIntervalCounter = D5_HEAT_CONTROL_INTERVAL_START_COUNT; - startupHeaterControl = TRUE; } else { @@ -659,11 +792,12 @@ F32 ctrl = 0.0F; DD_OP_MODE_T opMode = getCurrentOperationMode(); F32 measuredTemperature = 0.0F; + F32 feedforward = 0.0F; F32 targetTemperature = getHeaterTargetTemperature( heater ); if ( D5_HEAT == heater ) { - measuredTemperature = getD4AverageTemperature(); + measuredTemperature = getFilteredTemperatureValue( D4_TEMP ); if ( DD_MODE_HEAT != opMode ) { @@ -672,6 +806,10 @@ if ( capDeltaTempC >= HEATER_CNTL_TRANSFER_DELTA_TEMP_C ) { + // Reset PI Controllers with + resetPIController( PI_CONTROLLER_ID_D5_HEAT, HEATERS_MIN_DUTY_CYCLE, feedforward ); + resetPIController( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, targetTemperature, HEATERS_MIN_DUTY_CYCLE ); + // Transfer Control to target when delta temp is minimal. state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; } @@ -689,7 +827,7 @@ } else { - measuredTemperature = getD50AverageTemperature(); + measuredTemperature = getFilteredTemperatureValue( D50_TEMP ); if ( DD_MODE_HEAT != opMode ) { @@ -733,10 +871,14 @@ { 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 0 + F32 d5_eff = 0.0F; + F32 d5_p_gain = 0.0F; + F32 d5_final_FF = 0.0F; + F32 d5_cap_final_FF = 0.0F; +#endif // Update primary heater target temperature at defined interval if ( D5_HEAT == heater ) { @@ -747,64 +889,92 @@ { if ( D5_HEAT == heater ) { - measuredTemperature = getD4AverageTemperature(); // Inlet temperature post heat exchanger - inletTemperature = getTemperatureValue( D78_TEMP ); + F32 inletTemperature = getFilteredTemperatureValue( D78_TEMP ); + F32 deltaTempC = targetTemperature - inletTemperature; + F32 capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); + F32 flowrate = ( getTDDialysateFlowrate() + RINSE_PUMP_EST_FLOWRATE ) / LITER_IN_ML ; + d5FeedForward = calculateDutyCycle( flowrate, capDeltaTempC, PRIMARY_HEATER_MAX_PWR_WATTS, d5Efficiency, + HEATERS_MIN_DUTY_CYCLE, AC_HEATER_TX_MAX_DUTY_CYCLE ); - if ( TRUE == startupHeaterControl ) + //Update the calculated feed forward value + setPIControllerFeedForward( PI_CONTROLLER_ID_D5_HEAT, d5FeedForward ); + + // decide outer loop control interval based on the Qd + flowrate = getTDDialysateFlowrate(); + d5OuterLoopControlInterval = ( flowrate >= HIGH_DIAL_FLOW_RATE ? D5_TARGET_TEMP_ADJUST_HIGH_QD_INTERVAL : D5_TARGET_TEMP_ADJUST_LOW_QD_INTERVAL ); + + // If D28 feedback control is enabled and adjusted temp calculation is done + // then update the target temperature. + if ( ( TRUE == isTargetTempAdjusted ) && ( TRUE == isDialyzerTempFeedbackEnabled ) ) { - F32 deltaTempC = targetTemperature - inletTemperature; - 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 ); - startupHeaterControl = FALSE; - control[ heater ].data = feedforward; - resetPIController( PI_CONTROLLER_ID_D5_HEAT, HEATERS_MIN_DUTY_CYCLE, feedforward ); + targetTemperature = adjustedPrimaryTargetTemp; } - else +#if 1 + measuredTemperature = getFilteredTemperatureValue( D4_TEMP ); + deltaTempC = fabs( targetTemperature - measuredTemperature ); + + if ( deltaTempC >= D5_HEATER_DEADBAND_CONTROL ) { - F32 deltaTempC = 0.0F; + ctrl = runPIController( PI_CONTROLLER_ID_D5_HEAT, targetTemperature, measuredTemperature ); + control[ heater ].data = ctrl; + } +#else + measuredTemperature = getFilteredTemperatureValue( D4_TEMP ); + deltaTempC = targetTemperature - measuredTemperature; + capDeltaTempC = fabs(deltaTempC); + d5_p_gain = ( D5_HEATER_PWM_ADJ_SLOPE_FACTOR * getTDDialysateFlowrate() ) + D5_HEATER_PWM_INTERCEPT_FACTOR; - // If D28 feedback control is enabled and adjusted temp calculation is done - // then update the target temperature. - if ( ( TRUE == isTargetTempAdjusted ) && ( TRUE == isDialyzerTempFeedbackEnabled ) ) + if ( d5FeedForward > NEARLY_ZERO ) + { + if ( capDeltaTempC >= D5_HEATER_DEADBAND_CONTROL ) { - targetTemperature = adjustedPrimaryTargetTemp; - } - deltaTempC = fabs( targetTemperature - measuredTemperature ); + F32 minAdjPWM = -(d5_p_gain * AC_HEAT_PWM_MIN_MAX_FACTOR); + F32 maxAdjPWM = d5_p_gain * AC_HEAT_PWM_MIN_MAX_FACTOR; - if ( deltaTempC >= D5_HEATER_DEADBAND_CONTROL ) - { - ctrl = runPIController( PI_CONTROLLER_ID_D5_HEAT, targetTemperature, measuredTemperature ); - control[ heater ].data = ctrl; + // Compute the PWM adjustment with 50% gain adjustment + adjustD5PWM += ( d5_p_gain * AC_HEAT_PWM_ADJUST_PERCENT * deltaTempC ); + adjustD5PWM = RANGE(adjustD5PWM, minAdjPWM, maxAdjPWM ); } } -//#ifdef __HEATERS_DEBUG__ -// U32 i; -// -// 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 = getD50AverageTemperature(); + else + { + //When feed forward produces zero PWM, no adjustment is needed + adjustD5PWM = HEATERS_MIN_DUTY_CYCLE; + } - ctrl = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); - control[ heater ].data = ctrl; + // Update the feed forward PWM with the close loop adjustment + d5_final_FF = d5FeedForward + adjustD5PWM; + d5_cap_final_FF = RANGE(d5_final_FF,HEATERS_MIN_DUTY_CYCLE,AC_HEATER_TX_MAX_DUTY_CYCLE ); + + // assign the feed forward control + control[ heater ].data = d5_cap_final_FF; +#endif #ifdef __HEATERS_DEBUG__ U32 i; for ( i = 0; i < NUM_OF_CONTROLLER_SIGNAL; i++ ) { - pIControlSignal[ i ] = getPIControllerSignals( PI_CONTROLLER_ID_D45_HEAT, (PI_CONTROLLER_SIGNALS_ID)i ); + pIControlSignal[ i ] = getPIControllerSignals( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, (PI_CONTROLLER_SIGNALS_ID)i ); } #endif } + else + { + measuredTemperature = getFilteredTemperatureValue( D50_TEMP ); + ctrl = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); + control[ heater ].data = ctrl; +//#ifdef __HEATERS_DEBUG__ +// U32 i; +// +// 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; heatersStatus[ heater ].controlIntervalCounter = 0; @@ -894,6 +1064,130 @@ /*********************************************************************//** * @brief + * The calculateBeta2HeatDissipationB1andB2 function calculates the heat dissipation + * constants called B1 and B2 that describes the heat loss between D4 to D28 in + * the PID flow path for Beta2.0 hardware. + * @details \b Inputs: Qd. + * @details \b Outputs: none + * @return the calculated heat dissipation constants. + *************************************************************************/ +static F32 calculateBeta2HeatDissipationB1andB2( void ) +{ + // Get the dialysate flow rate from TD + F32 b1b2 = 0.0F; + F32 qd = getTDDialysateFlowrate(); + F32 firstPart = BETA2_0_B1B2_HEAT_DIS_FIRST_COEFF * qd * qd * qd * qd; + F32 secondPart = BETA2_0_B1B2_HEAT_DIS_SEC_COEFF * qd * qd * qd; + F32 thirdPart = BETA2_0_B1B2_HEAT_DIS_THIRD_COEFF * qd * qd; + F32 fourthPart = BETA2_0_B1B2_HEAT_DIS_FOURTH_COEFF * qd; + + // B1B2 = (-0.000000000005212*x4)+(0.000000009754882*x3)-(0.000006714979798*x2)+(0.002289024242423*x)-0.317550545454563 + b1b2 = firstPart + secondPart - thirdPart + fourthPart - BETA2_0_B1B2_HEAT_DIS_FIFTH_COEFF; + + return b1b2; +} + +/*********************************************************************//** + * @brief + * The calculateBeta2HeatDissipationB3 function calculates the heat dissipation + * constants called B3 that describes the heat loss between D28 to dialyzer in + * the PID flow path for Beta2.0 hardware. + * @details \b Inputs: Qd. + * @details \b Outputs: none + * @return the calculated heat dissipation constant. + *************************************************************************/ +static F32 calculateBeta2HeatDissipationB3( void ) +{ + // Get the dialysate flow rate from TD + F32 b3 = 0.0F; + F32 qd = getTDDialysateFlowrate(); + F32 firstPart = BETA2_0_B3_HEAT_DIS_FIRST_COEFF * qd * qd * qd * qd; + F32 secondPart = BETA2_0_B3_HEAT_DIS_SEC_COEFF * qd * qd * qd; + F32 thirdPart = BETA2_0_B3_HEAT_DIS_THIRD_COEFF * qd * qd; + F32 fourthPart = BETA2_0_B3_HEAT_DIS_FOURTH_COEFF * qd; + + // B3 = (-0.0000000000389*x4)+(0.0000000619946*x3)-(0.0000359241717*x2)+(0.0092543272727*x)-1.079412363636 + b3 = firstPart + secondPart - thirdPart + fourthPart - BETA2_0_B3_HEAT_DIS_FIFTH_COEFF; + + return b3; +} + +/*********************************************************************//** + * @brief + * The calculateHeatDissipationB1andB2 function calculates the heat dissipation + * constants called B1 and B2 that describes the heat loss between D4 to D28 in + * the PID flow path. + * @details \b Inputs: Qd. + * @details \b Outputs: none + * @return the calculated heat dissipation constants. + *************************************************************************/ +static F32 calculateHeatDissipationB1andB2( void ) +{ + // Get the dialysate flow rate from TD + F32 b1b2 = 0.0F; + F32 qd = getTDDialysateFlowrate(); + F32 firstPart = B1B2_HEAT_DIS_FIRST_COEFF * qd * qd * qd; + F32 secondPart = B1B2_HEAT_DIS_SEC_COEFF * qd * qd; + F32 thirdPart = B1B2_HEAT_DIS_THIRD_COEFF * qd; + + // B1B2 = 4.87858E-09x3 - 6.31264E-06x2 + 2.58513E-03x - 2.42013E-01 + b1b2 = firstPart - secondPart + thirdPart - B1B2_HEAT_DIS_FOURTH_COEFF; + + return b1b2; +} + +/*********************************************************************//** + * @brief + * The calculateHeatDissipationB3 function calculates the heat dissipation + * constants called B3 that describes the heat loss between D28 to dialyzer in + * the PID flow path. + * @details \b Inputs: Qd. + * @details \b Outputs: none + * @return the calculated heat dissipation constant. + *************************************************************************/ +static F32 calculateHeatDissipationB3( void ) +{ + // Get the dialysate flow rate from TD + F32 b3 = 0.0F; + F32 qd = getTDDialysateFlowrate(); + F32 firstPart = B3_HEAT_DIS_FIRST_COEFF * qd * qd * qd; + F32 secondPart = B3_HEAT_DIS_SEC_COEFF * qd * qd; + F32 thirdPart = B3_HEAT_DIS_THIRD_COEFF * qd; + + // B3 = 6.7756E-09x3 - 8.5278E-06x2 + 3.5126E-03x - 6.3893E-01 + b3 = firstPart - secondPart + thirdPart - B3_HEAT_DIS_FOURTH_COEFF; + + return b3; +} + +/*********************************************************************//** + * @brief + * The calculateInitialTemp function calculates the initial temperature + * required to get the target temperature considering heat loss. + * @details \b Inputs: ambient temperature + * @details \b Outputs: none + * @param targetTemp the target/final temperature + * @param heatDissipation the heat dissipation constant + * @return the calculated initial temperature. + *************************************************************************/ +static F32 calculateInitialTemp( F32 targetTemp, F32 heatDissipation ) +{ + // Get the ambient temperature from TD + //TODO : replace once amb temp is in place. using board temperature + // to make use of feeding the value via dialin + F32 ambTemp = getTemperatureValue( BRD_TEMP ); + F32 expB = exp(-heatDissipation); + F32 tempDiff = targetTemp - ambTemp; + F32 T0 = 0.0F; + + // T0 = Tamb + (Tf -Tamb)e^-B + T0 = ambTemp + ( tempDiff * expB ); + + return T0; +} + +/*********************************************************************//** + * @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 @@ -985,7 +1279,7 @@ data.d45_HeaterTargetTemp = getHeaterTargetTemperature( D45_HEAT ); data.d5_HeaterState = heatersStatus[ D5_HEAT ].state; data.d45_HeaterState = heatersStatus[ D45_HEAT ].state; - data.d5_dutyCycleCnt = convertDC; + data.d5_feedforward = d5FeedForward * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR; data.d5_PWMPeriod = getHeaterPWMPeriod( D5_HEAT ); data.d5_adjsutedTargetTemp = adjustedPrimaryTargetTemp; data.d5_targetTempFromTD = getTDTargetDialysateTemperature(); @@ -1000,7 +1294,6 @@ data.dbg8 = pIControlSignal[ 7 ]; data.dbg9 = pIControlSignal[ 8 ]; #endif - dataPublicationTimerCounter = 0; broadcastData( MSG_ID_DD_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DD_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) );