Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rdb7a07277014e802f582716c4215044ff905266b -rf3746f881341ba8bc8302cbba7d0e22e7b930d90 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision db7a07277014e802f582716c4215044ff905266b) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision f3746f881341ba8bc8302cbba7d0e22e7b930d90) @@ -54,8 +54,6 @@ #define HEATERS_DUTY_CYCLE_CONVERSION_FACTOR 100.0F ///< Heaters duty cycle 0: OFF, 100: 100% duty cycle. #define HEATERS_ZERO_EFFICIENCY 0.0F ///< Zero heater efficiency #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 0.034F ///< 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. @@ -76,13 +74,12 @@ #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 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 ( 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 D45_HEATER_DEADBAND_CONTROL 0.1F ///< Trimmer heater dead band range for control. #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 @@ -97,12 +94,6 @@ #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. @@ -178,8 +169,6 @@ 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 F32 d5FeedForward; ///< AC heater feed forward calculated value static U32 d5OuterLoopControlInterval; ///< AC heater outer loop control valve @@ -255,8 +244,6 @@ primaryTargetTempAdjCounter = 0; adjustedPrimaryTargetTemp = 0.0F; d5Efficiency = AC_HEATER_EFFICIENCY; - adjustD5PWM = 0.0F; - capAdjustD5PWM = 0.0F; d5FeedForward = 0.0F; isTargetTempAdjusted = FALSE; isDialyzerTempFeedbackEnabled = TRUE; @@ -287,11 +274,11 @@ 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 ); + D5_HEAT_OUT_MIN_DELTA_TEMP, D5_HEAT_OUT_MAX_DELTA_TEMP, FALSE, 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 ); + HEATERS_MIN_DUTY_CYCLE, DC_HEATER_MAX_DUTY_CYCLE, TRUE, D45_HEAT_TX_INIT_FEED_FORWARD ); #ifdef __HEATERS_DEBUG__ for ( i = 0; i < NUM_OF_CONTROLLER_SIGNAL; i++ ) @@ -422,9 +409,6 @@ { // Reset the adjusted temperature target isTargetTempAdjusted = FALSE; - - // Reset the AC heater PWM adjustment - adjustD5PWM = HEATERS_MIN_DUTY_CYCLE; } if ( HEATER_EXEC_STATE_CONTROL_TO_TARGET == heatersStatus[ D45_HEAT ].state ) @@ -446,30 +430,12 @@ { // 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. @@ -492,7 +458,6 @@ targetTempAtD4 = calculateInitialTemp( targetTempAtD28, heatDissipation_b1b2 ); //Update target temperature setTargetHydChamberTemp( targetTempAtD4 ); -#endif } /*********************************************************************//** @@ -505,59 +470,26 @@ *************************************************************************/ static void updatePrimaryHeaterTargetTemp( void ) { + F32 calcTargetTemp = 0.0F; + F32 deltaTempC = 0.0F; + F32 ctrl = 0.0F; + F32 measuredTempAtDialyzer = 0.0F; + F32 targetTempfromTD = 0.0F; + if ( ++primaryTargetTempAdjCounter >= d5OuterLoopControlInterval ) { - F32 targetTempfromTD = getTDTargetDialysateTemperature(); - F32 measuredTempAtDialyzer = 0.0F; - if ( getTestConfigStatus( TEST_CONFIG_DD_FP_ENABLE_BETA_2_0_HW ) != TRUE ) { - measuredTempAtDialyzer = getTeensyConductivityTemperatureValue( D27_COND ); + measuredTempAtDialyzer = getTeensyConductivityTemperatureValue( D27_COND ); } else { - measuredTempAtDialyzer = getFilteredConductivitySensorTemperature( D27_COND ); + measuredTempAtDialyzer = getFilteredConductivitySensorTemperature( D27_COND ); } - F32 calcTargetTemp = getHeaterTargetTemperature( D5_HEAT ); - 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 ) - { - adjustedPrimaryTargetTemp = calcTargetTemp; - } + calcTargetTemp = getHeaterTargetTemperature( D5_HEAT ); + deltaTempC = targetTempfromTD - measuredTempAtDialyzer; - //Keep adjusting the temperature based on D28 feedback - if ( deltaTempC > HEATERS_ZERO_DELTA_TEMP_C ) - { - adjustedPrimaryTargetTemp = adjustedPrimaryTargetTemp + capDeltaTempC; - } - else - { - adjustedPrimaryTargetTemp = adjustedPrimaryTargetTemp - capDeltaTempC; - } - - //Make sure the adjusted temp not crossing the max and min limits. - adjustedPrimaryTargetTemp = MIN( adjustedPrimaryTargetTemp, ( calcTargetTemp + MAX_ADJ_DELTA_TEMP_C ) ); - - // For Qd <= 150, The bottom range of second level temperature correction not to go below the initial - // Delta temperature adjustment. - if ( dialysateFlowrate > DELTA_TEMP_ADJ_FLOW_RATE ) - { - adjustedPrimaryTargetTemp = MAX( adjustedPrimaryTargetTemp, ( calcTargetTemp - MAX_ADJ_DELTA_TEMP_C ) ); - } - else - { - adjustedPrimaryTargetTemp = MAX( adjustedPrimaryTargetTemp, calcTargetTemp ); - } - - isTargetTempAdjusted = TRUE; - primaryTargetTempAdjCounter = 0; -#else if ( FALSE == isTargetTempAdjusted ) { isTargetTempAdjusted = TRUE; @@ -571,7 +503,6 @@ } primaryTargetTempAdjCounter = 0; -#endif } } @@ -795,7 +726,7 @@ if ( capDeltaTempC >= HEATER_CNTL_TRANSFER_DELTA_TEMP_C ) { - // Reset PI Controllers with + // Reset PI Controllers resetPIController( PI_CONTROLLER_ID_D5_HEAT, HEATERS_MIN_DUTY_CYCLE, feedforward ); resetPIController( PI_CONTROLLER_ID_D5_HEAT_OUTER_LOOP, targetTemperature, HEATERS_MIN_DUTY_CYCLE ); @@ -860,14 +791,15 @@ { 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 + F32 deltaTempC = 0.0F; + F32 absDeltaTempC = 0.0F; + F32 capDeltaTempC = 0.0F; + F32 flowrate = 0.0F; + F32 dutyCycle = 0.0F; + // Update primary heater target temperature at defined interval if ( D5_HEAT == heater ) { @@ -879,11 +811,11 @@ if ( D5_HEAT == heater ) { // Inlet temperature post heat exchanger - 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, + inletTemperature = getFilteredTemperatureValue( D78_TEMP ); + deltaTempC = targetTemperature - inletTemperature; + capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); + 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 ); //Update the calculated feed forward value @@ -899,7 +831,7 @@ { targetTemperature = adjustedPrimaryTargetTemp; } -#if 1 + measuredTemperature = getFilteredTemperatureValue( D4_TEMP ); deltaTempC = fabs( targetTemperature - measuredTemperature ); @@ -908,37 +840,7 @@ 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 ( d5FeedForward > NEARLY_ZERO ) - { - if ( capDeltaTempC >= D5_HEATER_DEADBAND_CONTROL ) - { - F32 minAdjPWM = -(d5_p_gain * AC_HEAT_PWM_MIN_MAX_FACTOR); - F32 maxAdjPWM = d5_p_gain * AC_HEAT_PWM_MIN_MAX_FACTOR; - - // Compute the PWM adjustment with 50% gain adjustment - adjustD5PWM += ( d5_p_gain * AC_HEAT_PWM_ADJUST_PERCENT * deltaTempC ); - adjustD5PWM = RANGE(adjustD5PWM, minAdjPWM, maxAdjPWM ); - } - } - else - { - //When feed forward produces zero PWM, no adjustment is needed - adjustD5PWM = HEATERS_MIN_DUTY_CYCLE; - } - - // 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; @@ -951,9 +853,20 @@ else { measuredTemperature = getFilteredTemperatureValue( D50_TEMP ); + deltaTempC = targetTemperature - measuredTemperature; + absDeltaTempC = fabs( deltaTempC ); + capDeltaTempC = MAX( deltaTempC, HEATERS_ZERO_DELTA_TEMP_C ); + flowrate = getTDDialysateFlowrate() / LITER_IN_ML ; + dutyCycle = calculateDutyCycle( flowrate, capDeltaTempC, TRIMMER_HEATER_MAX_PWR_WATTS, DC_HEATER_EFFICIENCY, + HEATERS_MIN_DUTY_CYCLE, DC_HEATER_MAX_DUTY_CYCLE ); + //Update the calculated feed forward value + setPIControllerFeedForward( PI_CONTROLLER_ID_D45_HEAT, dutyCycle ); - ctrl = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); - control[ heater ].data = ctrl; + if ( absDeltaTempC > D45_HEATER_DEADBAND_CONTROL ) + { + ctrl = runPIController( PI_CONTROLLER_ID_D45_HEAT, targetTemperature, measuredTemperature ); + control[ heater ].data = ctrl; + } //#ifdef __HEATERS_DEBUG__ // U32 i; //