Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rd748813399d38ef5b71d760e327e368cc82d7a38 -r3ebcff44116a7853d2011c7b2f1eb38c1f37ba2a --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision d748813399d38ef5b71d760e327e368cc82d7a38) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 3ebcff44116a7853d2011c7b2f1eb38c1f37ba2a) @@ -54,7 +54,7 @@ #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 AC_HEATER_EFFICIENCY_ADJ 0.01F ///< AC heater efficiency adjustment factor ( 1%) #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. @@ -74,25 +74,41 @@ #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_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 D5_TARGET_TEMP_ADJUST_INTERVAL_MS ( 1 * 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 consumption 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_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. + + //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 @@ -121,7 +137,7 @@ 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. @@ -132,8 +148,11 @@ 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 //For testing #ifdef __HEATERS_DEBUG__ @@ -195,11 +214,14 @@ // 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; @@ -228,6 +250,9 @@ 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 ); @@ -276,11 +301,6 @@ heatersStatus[ heater ].hasTargetTempChanged = TRUE; result = TRUE; lastDialTargetTemperatureSet[ heater ] = targetTemperature; - - if ( D5_HEAT == heater ) - { - startupHeaterControl = TRUE; - } } } else @@ -366,9 +386,11 @@ // 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; } } } @@ -409,7 +431,9 @@ 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 ) { @@ -442,6 +466,16 @@ isTargetTempAdjusted = TRUE; primaryTargetTempAdjCounter = 0; +#else + if ( fabs(deltaTempC) >= D5_HEAT_OUT_DEADBAND_CONTROL ) + { + ctrl = runPIController( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, targetTempfromTD, measuredTempAtDialyzer ); + adjustedPrimaryTargetTemp = ctrl; + } + + isTargetTempAdjusted = TRUE; + primaryTargetTempAdjCounter = 0; +#endif } } @@ -492,7 +526,6 @@ if ( D5_HEAT == heater ) { heatersStatus[ D5_HEAT ].controlIntervalCounter = D5_HEAT_CONTROL_INTERVAL_START_COUNT; - startupHeaterControl = TRUE; } else { @@ -652,6 +685,7 @@ 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 ) @@ -665,6 +699,10 @@ 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; } @@ -726,10 +764,14 @@ { 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 ) { @@ -740,64 +782,103 @@ { if ( D5_HEAT == heater ) { - measuredTemperature = getD4AverageTemperature(); // Inlet temperature post heat exchanger - inletTemperature = getTemperatureValue( D78_TEMP ); - - if ( TRUE == startupHeaterControl ) + F32 inletTemperature = getD78AverageTemperature(); + 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 1 + //Update the calculated feed forward value + setPIControllerFeedForward( PI_CONTROLLER_ID_D5_HEAT, d5FeedForward ); +#else + d5_p_gain = ( D5_HEATER_PWM_ADJ_SLOPE_FACTOR * getTDDialysateFlowrate() ) + D5_HEATER_PWM_INTERCEPT_FACTOR; +#endif + // 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 = getD4AverageTemperature(); + 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 = getD4AverageTemperature(); + deltaTempC = targetTemperature - measuredTemperature; + capDeltaTempC = fabs(deltaTempC); - // If D28 feedback control is enabled and adjusted temp calculation is done - // then update the target temperature. - if ( ( TRUE == isTargetTempAdjusted ) && ( TRUE == isDialyzerTempFeedbackEnabled ) ) +// // Adjusted efficiency used for next feed forward control +// if ( capDeltaTempC >= D5_HEATER_DEADBAND_CONTROL ) +// { +// if ( deltaTempC > NEARLY_ZERO ) +// { +// d5_eff = d5Efficiency - ( capDeltaTempC * AC_HEATER_EFFICIENCY_ADJ ); +// } +// else +// { +// d5_eff = d5Efficiency + ( capDeltaTempC * AC_HEATER_EFFICIENCY_ADJ ); +// } +// //Range check +// d5Efficiency = RANGE( d5_eff, AC_HEAT_EFFICIENCY_LOW, AC_HEAT_EFFICIENCY_HIGH ); +// } + 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 = getD50AverageTemperature(); + 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; @@ -975,10 +1056,13 @@ 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_dutyCycleCnt = convertDC; data.d5_PWMPeriod = getHeaterPWMPeriod( D5_HEAT ); + data.d5_dutyCycleCnt = d5FeedForward * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR; + //data.d5_PWMPeriod = capAdjustD5PWM * HEATERS_DUTY_CYCLE_CONVERSION_FACTOR; data.d5_adjsutedTargetTemp = adjustedPrimaryTargetTemp; data.d5_targetTempFromTD = getTDTargetDialysateTemperature(); + data.d5_efficiency = d5Efficiency; #ifdef __HEATERS_DEBUG__ data.dbg1 = pIControlSignal[ 0 ]; data.dbg2 = pIControlSignal[ 1 ]; @@ -990,7 +1074,6 @@ 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 ) );