Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -r54e58f64179ea382d2e2c403c8c3b9a15a612636 -rd332a26f463cc5d209be77e562952f70775cf913 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 54e58f64179ea382d2e2c403c8c3b9a15a612636) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision d332a26f463cc5d209be77e562952f70775cf913) @@ -24,6 +24,7 @@ #include "DGDefs.h" #include "Heaters.h" #include "InternalADC.h" +#include "MessageSupport.h" #include "OperationModes.h" #include "PIControllers.h" #include "ROPump.h" @@ -56,7 +57,7 @@ #define MAXIMUM_TARGET_TEMPERATURE 90.0 ///< Maximum allowed target temperature for the heaters. #define HEATERS_RAMP_STATE_CHECK_INTERVAL_COUNT 20U ///< Heaters ramp check interval count. -#define HEATERS_CONTROL_STATE_CHECK_INTERVAL_COUNT ( 10 * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Temperature sensors interval count. +#define HEATERS_CONTROL_STATE_CHECK_INTERVAL_COUNT ( 10 * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Temperature sensors interval count. #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 170.0 ///< Heaters max allowed internal temperature in C. #define HEATERS_MAX_ALLOWED_COLD_JUNCTION_TEMPERATURE_C 80.0 ///< Heaters max allowed cold junction temperature in C. @@ -71,53 +72,59 @@ #define PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_SLOPE 0.31644 ///< Primary heaters thermal power to voltage slope. #define PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_INTERCEPT 0.021 ///< Primary heaters thermal power to voltage intercept. +#define DELTA_DUTY_CYCLE_GAIN 0.1 ///< Delta duty cycle gain. +#define DELTA_TEMPERATURE_GAIN 1.27 ///< Delta temperature gain. +#define DRAIN_AND_IDLE_MODE_TARGET_TEMPERATURE_OFFSET 3.0 ///< Drain and Idle modes temperature offset from dialysate. + typedef enum Heaters_Exec_States { - HEATER_EXEC_STATE_NOT_RUNNING = 0, ///< Heater exec state not running - HEATER_EXEC_STATE_RAMP_TO_TARGET, ///< Heater exec state ramp to target - HEATER_EXEC_STATE_CONTROL_TO_TARGET, ///< Heater exec state control to target - NUM_OF_HEATERS_STATE, ///< Number of heaters state + HEATER_EXEC_STATE_NOT_RUNNING = 0, ///< Heater exec state not running. + HEATER_EXEC_STATE_RAMP_TO_TARGET, ///< Heater exec state ramp to target. + HEATER_EXEC_STATE_CONTROL_TO_TARGET, ///< Heater exec state control to target. + NUM_OF_HEATERS_STATE, ///< Number of heaters state. } HEATERS_STATE_T; /// Heaters data structure typedef struct { - F32 targetTemp; ///< Heater Target temperature - F32 previousTemps[ TEMPERATURES_MOVING_AVG_SIZE ]; ///< Heater Previous temperatures array - U32 previousTempsIndex; ///< Heater previous temperatures arrays current index - HEATERS_STATE_T state; ///< Heater state - TEMPERATURE_SENSORS_T feedbackSensor; ///< Heater feedback sensor for controlling - U32 controlTimerCounter; ///< Heater control timer counter - BOOL startHeaterSignal; ///< Heater start indication flag - BOOL isHeaterOn; ///< Heater on/off status flag + F32 targetTemp; ///< Heater target temperature. + F32 originalTargetTemp; ///< Heater original target temperature set by user. + F32 previousTemps[ TEMPERATURES_MOVING_AVG_SIZE ]; ///< Heater Previous temperatures array. + U32 previousTempsIndex; ///< Heater previous temperatures arrays current index. + HEATERS_STATE_T state; ///< Heater state. + TEMPERATURE_SENSORS_T feedbackSensor; ///< Heater feedback sensor for controlling. + U32 controlTimerCounter; ///< Heater control timer counter. + BOOL startHeaterSignal; ///< Heater start indication flag. + BOOL isHeaterOn; ///< Heater on/off status flag. + F32 dutycycle; ///< Heater duty cycle. + F32 targetROFlow; ///< Heater target flow. + U32 rampStateStartTime; ///< Heater ramp state start time. + U32 heaterOnWithNoFlowTimer; ///< Heater on with no flow timer. + BOOL isFlowBelowMin; ///< Heater flow below minimum flag indicator. + F32 initialDutyCycle; ///< Heater initial duty cycle before a hand off. + BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. + + + PI_CONTROLLER_ID_T controllerID; ///< Heater PI controller ID TODO remove this? U32 tempOutOfRangeTimer; ///< Heater temperature out of range timer TODO remove once the mechanical thermal cutoff was implemented BOOL isHeaterTempOutOfRange; ///< Heater temperature out of range flag indicator TODO remove once the mechanical thermal cutoff was implemented - F32 dutycycle; ///< Heater duty cycle - F32 targetROFlow; ///< Heater target flow - U32 rampStateStartTime; ///< Heater ramp state start time - U32 heaterOnWithNoFlowTimer; ///< Heater on with no flow timer - BOOL isFlowBelowMin; ///< Heater flow below minimum flag indicator - PI_CONTROLLER_ID_T controllerID; ///< Heater PI controller ID TODO remove this? - F32 initialDutyCycle; ///< Heater initial duty cycle before a hand off } HEATER_STATUS_T; -static HEATER_STATUS_T heaterStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. -static U32 dataPublicationTimerCounter; ///< Data publication timer counter. -static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, - HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. -static U32 heatersOnWithNoFlowTimer; ///< Heaters are on but there is no sufficient flow. TODO remove +static HEATER_STATUS_T heatersStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. +static U32 dataPublicationTimerCounter; ///< Data publication timer counter. +static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. +static U32 voltageMonitorTimeCounter = 0; ///< Heaters voltage monitor counter. +static U32 operationMode = 0; -static BOOL isFlowBelowMin = FALSE; ///< Boolean flag to indicate if the flow is below the minimum. TODo remove -static U32 voltageMonitorTimeCounter = 0; ///< Heaters voltage monitor counter. - // ********** private function prototypes ********** static HEATERS_STATE_T handleHeaterStateNotRunning( DG_HEATERS_T heater ); static HEATERS_STATE_T handleHeaterStateRampToTarget( DG_HEATERS_T heater ); static HEATERS_STATE_T handleHeaterStateControlToTarget( DG_HEATERS_T heater ); static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ); -static F32 calculateHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 targetFlow ); +static F32 calculateHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow ); +static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ); static void setMainPrimaryHeaterPWM( F32 pwm ); static void setSmallPrimaryHeaterPWM( F32 pwm ); @@ -131,44 +138,47 @@ * @brief * The initHeaters initializes the heaters driver. * @details Inputs: none - * @details Outputs: isFlowBelowMin, voltageMonitorTimeCounter, heaterStatus + * @details Outputs: voltageMonitorTimeCounter, heaterStatus, + * hasTreatmentInternalTempBeenSet * @return none *************************************************************************/ void initHeaters( void ) { DG_HEATERS_T heater; - isFlowBelowMin = FALSE; voltageMonitorTimeCounter = 0; + operationMode = 0; for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - heaterStatus[ heater ].controlTimerCounter = 0; + heatersStatus[ heater ].controlTimerCounter = 0; // The default feedback sensor of the primary heater is TPo but it changes to THd in heat disinfect // The default feedback sensor of the trimmer heater is TDi all the time - heaterStatus[ heater ].feedbackSensor = ( DG_PRIMARY_HEATER == heater ? TEMPSENSORS_OUTLET_PRIMARY_HEATER : TEMPSENSORS_INLET_DIALYSATE ); - heaterStatus[ heater ].startHeaterSignal = FALSE; - heaterStatus[ heater ].tempOutOfRangeTimer = 0; - heaterStatus[ heater ].isHeaterTempOutOfRange = FALSE; - heaterStatus[ heater ].state = HEATER_EXEC_STATE_NOT_RUNNING; - heaterStatus[ heater ].targetTemp = 0.0; - heaterStatus[ heater ].dutycycle = 0.0; - heaterStatus[ heater ].targetROFlow = 0.0; - heaterStatus[ heater ].previousTempsIndex = 0; - heaterStatus[ heater ].controllerID = ( DG_PRIMARY_HEATER == heater ? PI_CONTROLLER_ID_PRIMARY_HEATER : PI_CONTROLLER_ID_TRIMMER_HEATER ); - heaterStatus[ heater ].initialDutyCycle = 0.0; + heatersStatus[ heater ].feedbackSensor = ( DG_PRIMARY_HEATER == heater ? TEMPSENSORS_OUTLET_PRIMARY_HEATER : TEMPSENSORS_INLET_DIALYSATE ); + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].tempOutOfRangeTimer = 0; + heatersStatus[ heater ].isHeaterTempOutOfRange = FALSE; + heatersStatus[ heater ].state = HEATER_EXEC_STATE_NOT_RUNNING; + heatersStatus[ heater ].targetTemp = 0.0; + heatersStatus[ heater ].originalTargetTemp = 0.0; + heatersStatus[ heater ].dutycycle = 0.0; + heatersStatus[ heater ].targetROFlow = 0.0; + heatersStatus[ heater ].previousTempsIndex = 0; + heatersStatus[ heater ].controllerID = ( DG_PRIMARY_HEATER == heater ? PI_CONTROLLER_ID_PRIMARY_HEATER : PI_CONTROLLER_ID_TRIMMER_HEATER ); + heatersStatus[ heater ].initialDutyCycle = 0.0; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; // Set the array of the previous temperatures to 0.0 - memset( &heaterStatus[ heater ].previousTemps, 0.0, sizeof( TEMPERATURES_MOVING_AVG_SIZE ) ); + memset( &heatersStatus[ heater ].previousTemps, 0.0, sizeof( TEMPERATURES_MOVING_AVG_SIZE ) ); } // Initialize the PI controller for the primary heaters initializePIController( PI_CONTROLLER_ID_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATER_P_COEFFICIENT, PRIMARY_HEATER_I_COEFFICIENT, - HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); + HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); // TODO remove // 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, HEATERS_MAX_DUTY_CYCLE ); + HEATERS_MIN_DUTY_CYCLE, HEATERS_MAX_DUTY_CYCLE ); // TODO remove? } /*********************************************************************//** @@ -185,10 +195,21 @@ { if( heater < NUM_OF_DG_HEATERS ) { - if ( ( targetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + // Assume the target temperature has not changed + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + + F32 currentTargetTemperature = heatersStatus[ heater ].originalTargetTemp; + + // Check if the current target temperature in structure is different from the new requested target temperature + if ( fabs( targetTemperature - currentTargetTemperature ) > NEARLY_ZERO ) { - heaterStatus[ heater ].targetTemp = targetTemperature; - // TODO alarm if temperature if out of range or just reject? + // Check if the requested temperature is within the allowed range + if ( ( targetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + { + heatersStatus[ heater ].originalTargetTemp = targetTemperature; + heatersStatus[ heater ].hasTargetTempChanged = TRUE; + // TODO alarm if temperature if out of range or just reject? + } } } else @@ -206,7 +227,7 @@ *************************************************************************/ F32 getHeaterTargetTemperature( DG_HEATERS_T heater ) { - return heaterStatus[ heater ].targetTemp; + return heatersStatus[ heater ].targetTemp; } /*********************************************************************//** @@ -223,12 +244,10 @@ if( heater < NUM_OF_DG_HEATERS ) { - F32 targetTemp = heaterStatus[ heater ].targetTemp; - - if ( ( targetTemp >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemp <= MAXIMUM_TARGET_TEMPERATURE ) ) + if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) { status = TRUE; - heaterStatus[ heater ].startHeaterSignal = TRUE; + heatersStatus[ heater ].startHeaterSignal = TRUE; } } else @@ -249,7 +268,7 @@ *************************************************************************/ void stopHeater( DG_HEATERS_T heater ) { - heaterStatus[ heater ].isHeaterOn = FALSE; + heatersStatus[ heater ].isHeaterOn = FALSE; } /*********************************************************************//** @@ -266,26 +285,26 @@ for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - state = heaterStatus[ heater ].state; + state = heatersStatus[ heater ].state; switch( state ) { case HEATER_EXEC_STATE_NOT_RUNNING: - heaterStatus[ heater ].state = handleHeaterStateNotRunning( heater ); + heatersStatus[ heater ].state = handleHeaterStateNotRunning( heater ); break; case HEATER_EXEC_STATE_RAMP_TO_TARGET: - heaterStatus[ heater ].state = handleHeaterStateRampToTarget( heater ); + heatersStatus[ heater ].state = handleHeaterStateRampToTarget( heater ); break; case HEATER_EXEC_STATE_CONTROL_TO_TARGET: - heaterStatus[ heater ].state = handleHeaterStateControlToTarget( heater ); + heatersStatus[ heater ].state = handleHeaterStateControlToTarget( heater ); break; default: // The heater is in an unknown state. Turn it off and switch to not running state stopHeater( heater ); - heaterStatus[ heater ].state = HEATER_EXEC_STATE_NOT_RUNNING; + heatersStatus[ heater ].state = HEATER_EXEC_STATE_NOT_RUNNING; SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_EXEC_STATE, heater ); break; } @@ -315,8 +334,8 @@ { cmdResponse.rejected = FALSE; #ifndef DISABLE_HEATERS_AND_TEMPS - heaterStatus[ DG_TRIMMER_HEATER ].targetTemp = heaterCmdPtr->targetTemp; - heaterStatus[ DG_TRIMMER_HEATER ].startHeaterSignal = TRUE; + heatersStatus[ DG_TRIMMER_HEATER ].targetTemp = heaterCmdPtr->targetTemp; + heatersStatus[ DG_TRIMMER_HEATER ].startHeaterSignal = TRUE; #endif } else @@ -339,64 +358,60 @@ * The internal temperature sensors and the voltages of the heaters are * monitored. The flow is continuously checked and if there is no flow * for a period of time, the heaters are turned off. - * @details Inputs: isTrimmerHeaterOn, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle, - * heatersOnWithNoFlowTimer, isFlowBelowMin - * @details Outputs: heatersOnWithNoFlowTimer, isFlowBelowMin + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus * @return none *************************************************************************/ void execHeatersMonitor( void ) { + DG_HEATERS_T heater; + #ifndef IGNORE_HEATERS_MONITOR checkPrimaryHeaterTempSensors(); checkTrimmerHeaterTempSensors(); #endif - // Monitor the heaters voltage - //monitorHeatersVoltage(); - - /* - * 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 ) ) + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) { - F32 measuredFlow = getMeasuredROFlowRate(); - - if ( measuredFlow < MIN_RO_FLOWRATE_LPM ) + // Check if a heater is on and whether is duty cycle is not zero + if ( ( TRUE == heatersStatus[ heater ].isHeaterOn ) && ( ( heatersStatus[ heater ].dutycycle - HEATERS_MIN_DUTY_CYCLE ) > NEARLY_ZERO ) ) { - // Flow is below minimum for the first time - if ( FALSE == isFlowBelowMin ) + // TODO add the function that gets the flow of the new flow sensor for DG. For now it is assumed that trimmer heater flow sensor + // is not 0 so the heater can run if needed + F32 measFlow = ( DG_PRIMARY_HEATER == heater ? getMeasuredROFlowRate() : 50.0 ); + // TODO get the minimum new flow sensor flow sensor + F32 minFlow = ( DG_PRIMARY_HEATER == heater ? MIN_RO_FLOWRATE_LPM : MIN_RO_FLOWRATE_LPM ); + BOOL isFlowLow = ( measFlow < minFlow ? TRUE : FALSE ); + + if ( TRUE == isFlowLow ) { - isFlowBelowMin = TRUE; - heatersOnWithNoFlowTimer = getMSTimerCount(); + // Check if the flow of the heater is below minimum for the first time + if ( FALSE == heatersStatus[ heater ].isFlowBelowMin ) + { + heatersStatus[ heater ].isFlowBelowMin = TRUE; + heatersStatus[ heater ].heaterOnWithNoFlowTimer = getMSTimerCount(); + } + else if ( TRUE == didTimeout( heatersStatus[ heater ].heaterOnWithNoFlowTimer, HEATERS_ON_NO_FLOW_TIMEOUT_MS ) ) + { + // Heater has been on with no flow time out + stopHeater( heater ); + + ALARM_ID_T alarm = ( DG_PRIMARY_HEATER == heater ? ALARM_ID_DG_PRIMARY_HEATER_ON_WITH_NO_FLOW_TIMEOUT : + ALARM_ID_DG_TRIMMER_HEATER_ON_WITH_NO_FLOW_TIMEOUT ); + activateAlarmNoData( alarm ); + } } - // Flow is below minimum for a long time so raise the alarm - else if ( TRUE == didTimeout( heatersOnWithNoFlowTimer, HEATERS_ON_NO_FLOW_TIMEOUT_MS ) ) + else { - stopPrimaryHeater(); - stopTrimmerHeater(); - - activateAlarmNoData( ALARM_ID_DG_HEATERS_ON_WITH_NO_FLOW_TIMEOUT ); + heatersStatus[ heater ].isFlowBelowMin = FALSE; + heatersStatus[ heater ].heaterOnWithNoFlowTimer = getMSTimerCount(); } } - else - { - isFlowBelowMin = FALSE; - heatersOnWithNoFlowTimer = getMSTimerCount(); - } - }*/ + } + // TODO un-comment the heaters voltage + //monitorHeatersVoltage(); + // Check for data publication publishHeatersData(); } @@ -413,35 +428,30 @@ { HEATERS_STATE_T state = HEATER_EXEC_STATE_NOT_RUNNING; - if ( TRUE == heaterStatus[ heater ].startHeaterSignal ) + if ( TRUE == heatersStatus[ heater ].startHeaterSignal ) { - heaterStatus[ heater ].isHeaterOn = TRUE; - heaterStatus[ heater ].startHeaterSignal = FALSE; - heaterStatus[ heater ].targetROFlow = getTargetROPumpFlowRate(); + heatersStatus[ heater ].isHeaterOn = TRUE; + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].targetROFlow = getTargetROPumpFlowRate(); + // Heaters control work with target temperature internally. Original target temperature is set by the user using the APIs + heatersStatus[ heater ].targetTemp = heatersStatus[ heater ].originalTargetTemp; // If the operation mode is heat disinfect and the heater is primary heater, change the feedback sensor to THd if ( ( DG_MODE_HEAT == getCurrentOperationMode() ) && ( DG_PRIMARY_HEATER == heater ) ) { - heaterStatus[ heater ].feedbackSensor = TEMPSENSORS_HEAT_DISINFECT; + heatersStatus[ heater ].feedbackSensor = TEMPSENSORS_HEAT_DISINFECT; } - TEMPERATURE_SENSORS_T sensor = heaterStatus[ heater ].feedbackSensor; + TEMPERATURE_SENSORS_T sensor = heatersStatus[ heater ].feedbackSensor; F32 feedbackTemperature = getTemperatureValue( (U32)sensor ); - F32 targetTemperature = heaterStatus[ heater ].targetTemp; + F32 targetTemperature = heatersStatus[ heater ].targetTemp; - if ( targetTemperature > feedbackTemperature ) - { - // Set the heater duty cycle to maximum - setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); - } - else - { - // Set the heater duty cycle to minimum since we are cooling - setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); - } + // If the target temperature is greater than the feedback temperature the duty cycle is 100% otherwise, 0% + F32 duty = ( targetTemperature > feedbackTemperature ? HEATERS_MAX_DUTY_CYCLE : HEATERS_MIN_DUTY_CYCLE ); + setHeaterDutyCycle( heater, duty ); // Once the heater is staring for the first time so no minimum ramp time is needed - heaterStatus[ heater ].rampStateStartTime = getMSTimerCount(); + heatersStatus[ heater ].rampStateStartTime = getMSTimerCount(); // Turn on the heater state = HEATER_EXEC_STATE_RAMP_TO_TARGET; @@ -461,21 +471,41 @@ *************************************************************************/ static HEATERS_STATE_T handleHeaterStateRampToTarget( DG_HEATERS_T heater ) { + F32 dutyCycle; + HEATERS_STATE_T state = HEATER_EXEC_STATE_RAMP_TO_TARGET; - TEMPERATURE_SENSORS_T sensor = heaterStatus[ heater ].feedbackSensor; + TEMPERATURE_SENSORS_T sensor = heatersStatus[ heater ].feedbackSensor; F32 feedbackTemperature = getTemperatureValue( (U32)sensor ); // Continuously get the target temperature in case it was changed dynamically - F32 targetTemperature = heaterStatus[ heater ].targetTemp; - U32 currentIndex = heaterStatus[ heater ].previousTempsIndex; + F32 targetTemperature = heatersStatus[ heater ].targetTemp; + U32 currentIndex = heatersStatus[ heater ].previousTempsIndex; + F32 targetFlow = getTargetROPumpFlowRate(); + BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetROFlow ) > NEARLY_ZERO ? TRUE : FALSE ); - if ( ++heaterStatus[ heater ].controlTimerCounter > HEATERS_RAMP_STATE_CHECK_INTERVAL_COUNT ) + // Check if the target flow has changed or the target temperature has changed. + /*if ( ( TRUE == hasFlowChanged ) || ( TRUE == heaterStatus[ heater ].hasTargetTempChanged ) ) { + // Moving back from control to target to ramp. + heaterStatus[ heater ].rampStateStartTime = getMSTimerCount(); + heaterStatus[ heater ].targetROFlow = targetFlow; + heaterStatus[ heater ].hasTargetTempChanged = FALSE; + + // If the new target flow is less than the measured current flow, it means the new target flow is faster so it needs more heat power + dutyCycle = ( getMeasuredROFlowRate() < heaterStatus[ heater ].targetROFlow ? HEATERS_MAX_DUTY_CYCLE : HEATERS_MIN_DUTY_CYCLE ); + + // Go back to ramp state + setHeaterDutyCycle( heater, dutyCycle ); + }*/ + + haveHeaterControlConditionsChanged( heater ); + + if ( ++heatersStatus[ heater ].controlTimerCounter > HEATERS_RAMP_STATE_CHECK_INTERVAL_COUNT ) + { U32 i; F32 slope; F32 deltaTemperature; F32 deltaDutyCycle; - F32 dutyCycle; F32 revDeltaDutyCycle; F32 inletTemperature; F32 measuredFlow; @@ -484,13 +514,20 @@ BOOL isItHandOffTime = FALSE; // Update the temperature data array as well as the next index - heaterStatus[ heater ].previousTemps[ currentIndex ] = feedbackTemperature; - heaterStatus[ heater ].previousTempsIndex = INC_WRAP( currentIndex, 0, TEMPERATURES_MOVING_AVG_SIZE - 1 ); + heatersStatus[ heater ].previousTemps[ currentIndex ] = feedbackTemperature; + heatersStatus[ heater ].previousTempsIndex = INC_WRAP( currentIndex, 0, TEMPERATURES_MOVING_AVG_SIZE - 1 ); + // If the target temperature changed, set it the flag to FALSE. In the ramp state, the target temperature + // change is addressed automatically + if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) + { + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + } + // Calculate the running sum of the temperatures for ( i = 0; i < TEMPERATURES_MOVING_AVG_SIZE; i++ ) { - slope += heaterStatus[ heater ].previousTemps[ i ]; + slope += heatersStatus[ heater ].previousTemps[ i ]; } // If the heater is the primary heater, @@ -503,19 +540,21 @@ // TODO figure out the trimmer strategy } + // TODO add comments slope = slope / (F32)TEMPERATURES_MOVING_AVG_SIZE; - measuredFlow = getMeasuredROFlowRate(); + //measuredFlow = getMeasuredROFlowRate(); TODO uncomment + measuredFlow = getTargetROPumpFlowRate(); dutyCycle = calculateHeaterDutyCycle( targetTemperature, inletTemperature, measuredFlow ); deltaDutyCycle = ( feedbackTemperature <= targetTemperature ? HEATERS_MAX_DUTY_CYCLE - dutyCycle : dutyCycle ); - // TODO add #defines for all these constants revDeltaDutyCycle = ( deltaDutyCycle - 0.0 < NEARLY_ZERO ? 0 : 1.0 / deltaDutyCycle ); - revDeltaDutyCycle = ( revDeltaDutyCycle * 0.1 < 1.0 ? revDeltaDutyCycle * 0.1 : 1.0 ); - deltaTemperature = ( ( atanf( slope ) * 1.27 ) / measuredFlow ) + revDeltaDutyCycle; + revDeltaDutyCycle = ( revDeltaDutyCycle * DELTA_DUTY_CYCLE_GAIN < HEATERS_MAX_DUTY_CYCLE ? + revDeltaDutyCycle * DELTA_DUTY_CYCLE_GAIN : HEATERS_MAX_DUTY_CYCLE ); + deltaTemperature = ( ( atanf( slope ) * DELTA_TEMPERATURE_GAIN ) / measuredFlow ) + revDeltaDutyCycle; if ( fabs( targetTemperature - feedbackTemperature ) < deltaTemperature ) { - if ( TRUE == didTimeout( heaterStatus[ heater ].rampStateStartTime, HEATERS_MIN_RAMP_TIME_MS ) ) + if ( TRUE == didTimeout( heatersStatus[ heater ].rampStateStartTime, HEATERS_MIN_RAMP_TIME_MS ) ) { isItHandOffTime = TRUE; } @@ -528,18 +567,18 @@ if ( TRUE == isItHandOffTime ) { setHeaterDutyCycle( heater, dutyCycle ); - resetPIController( heaterStatus[ heater ].controllerID, dutyCycle ); // TODO remove? + resetPIController( heatersStatus[ heater ].controllerID, dutyCycle ); // TODO remove? - heaterStatus[ heater ].initialDutyCycle = dutyCycle; + heatersStatus[ heater ].initialDutyCycle = dutyCycle; state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; } - heaterStatus[ heater ].controlTimerCounter = 0; + heatersStatus[ heater ].controlTimerCounter = 0; } // Check if the heater is requested to be off - if ( FALSE == heaterStatus[ heater ].isHeaterOn ) + if ( FALSE == heatersStatus[ heater ].isHeaterOn ) { setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); state = HEATER_EXEC_STATE_NOT_RUNNING; @@ -559,50 +598,71 @@ *************************************************************************/ static HEATERS_STATE_T handleHeaterStateControlToTarget( DG_HEATERS_T heater ) { + F32 dutyCycle; + HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_TARGET; - F32 targetFlow = getTargetROPumpFlowRate(); - BOOL hasFlowChanged = ( fabs( targetFlow - heaterStatus[ heater ].targetROFlow ) > NEARLY_ZERO ? TRUE : FALSE ); + F32 targetFlow = getTargetROPumpFlowRate(); + BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetROFlow ) > NEARLY_ZERO ? TRUE : FALSE ); + F32 feedbackTemperature = getTemperatureValue( (U32)heatersStatus[ heater ].feedbackSensor ); + F32 targetTemperature = heatersStatus[ heater ].targetTemp; - if ( TRUE == hasFlowChanged ) + // Check if the target flow has changed or the target temperature has changed. + /*if ( ( TRUE == hasFlowChanged ) || ( TRUE == heaterStatus[ heater ].hasTargetTempChanged ) ) { + // TODO for testing, remove + if ( DG_MODE_DRAI == getCurrentOperationMode() ) + { + BOOL Test = FALSE; + } + // TODO for testing, remove + // Moving back from control to target to ramp. - heaterStatus[ heater ].rampStateStartTime = getMSTimerCount(); - heaterStatus[ heater ].targetROFlow = targetFlow; + heaterStatus[ heater ].rampStateStartTime = getMSTimerCount(); + heaterStatus[ heater ].targetROFlow = targetFlow; + heaterStatus[ heater ].hasTargetTempChanged = FALSE; - // Go back to ramp state with 100% duty cycle - setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); + // If the new target flow is less than the measured current flow, it means the new target flow is faster so it needs more heat power + dutyCycle = ( getMeasuredROFlowRate() < heaterStatus[ heater ].targetROFlow ? HEATERS_MAX_DUTY_CYCLE : HEATERS_MIN_DUTY_CYCLE ); + + // Go back to ramp state + setHeaterDutyCycle( heater, dutyCycle ); state = HEATER_EXEC_STATE_RAMP_TO_TARGET; + }*/ + + if ( TRUE == haveHeaterControlConditionsChanged( heater ) ) + { + state = HEATER_EXEC_STATE_RAMP_TO_TARGET; } - else if ( ++heaterStatus[ heater ].controlTimerCounter > HEATERS_CONTROL_STATE_CHECK_INTERVAL_COUNT ) + // Check if it is the control time + else if ( ++heatersStatus[ heater ].controlTimerCounter > HEATERS_CONTROL_STATE_CHECK_INTERVAL_COUNT ) { - F32 feedbackTemperature = getTemperatureValue( (U32)heaterStatus[ heater ].feedbackSensor ); - F32 targetTemperature = heaterStatus[ heater ].targetTemp; - F32 dutyCycle = heaterStatus[ heater ].dutycycle; + dutyCycle = heatersStatus[ heater ].dutycycle; dutyCycle += ( targetTemperature - feedbackTemperature ) * PRIMARY_HEATER_P_COEFFICIENT * getMeasuredROFlowRate(); - F32 deltaDutyCycle = dutyCycle - heaterStatus[ heater ].initialDutyCycle; + F32 deltaDutyCycle = dutyCycle - heatersStatus[ heater ].initialDutyCycle; if ( ( fabs( deltaDutyCycle ) > 0.09 ) && ( deltaDutyCycle < 0.0 ) ) { - dutyCycle = heaterStatus[ heater ].initialDutyCycle - 0.09; + dutyCycle = heatersStatus[ heater ].initialDutyCycle - 0.09; // TODO add a #define } else if ( deltaDutyCycle > 0.09 ) { - dutyCycle = heaterStatus[ heater ].initialDutyCycle + 0.09; + dutyCycle = heatersStatus[ heater ].initialDutyCycle + 0.09; } + // Cap the duty cycle ranges in case they exceeded the limit dutyCycle = ( dutyCycle > HEATERS_MAX_DUTY_CYCLE ? HEATERS_MAX_DUTY_CYCLE : dutyCycle ); dutyCycle = ( dutyCycle < HEATERS_MIN_DUTY_CYCLE ? HEATERS_MIN_DUTY_CYCLE : dutyCycle ); setHeaterDutyCycle( heater, dutyCycle ); - heaterStatus[ heater ].controlTimerCounter = 0; + heatersStatus[ heater ].controlTimerCounter = 0; } // Check if the heater is requested to be off - if ( FALSE == heaterStatus[ heater ].isHeaterOn ) + if ( FALSE == heatersStatus[ heater ].isHeaterOn ) { setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); state = HEATER_EXEC_STATE_NOT_RUNNING; @@ -632,22 +692,24 @@ setTrimmerHeaterPWM( pwm ); } - heaterStatus[ heater ].dutycycle = pwm; + heatersStatus[ heater ].dutycycle = pwm; } /*********************************************************************//** * @brief * The calculateHeaterDutyCycle function calculates a heater's duty cycle * by providing the * @details Inputs: none - * @details Outputs: primaryHeaterTargetTemperature - * @param targetTemp target temperature for the primary heater - * @return none + * @details Outputs: none + * @param targetTemperature target temperature of the heater + * @oaram currentTemperature current inlet temperature of the heater + * @param flow current flow + * @return calculated duty cycle *************************************************************************/ -static F32 calculateHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 targetFlow ) +static F32 calculateHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow ) { // The power is proportional to square root of deltaT x flow - F32 power = sqrt( fabs( targetTemperature - currentTemperature ) * targetFlow ); + F32 power = sqrt( fabs( targetTemperature - currentTemperature ) * flow ); // PWM = ( power * A - B ) F32 dutyCycle = ( ( power * PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_SLOPE ) - PRIMARY_HEATERS_THERMAL_POWER_TO_VOLTAGE_INTERCEPT ); @@ -661,6 +723,71 @@ /*********************************************************************//** * @brief + * The haveHeaterControlConditionsChanged function checks whether the heater + * control conditions have changed or not. If the control conditions have + * changed it sets the changes the control parameters accordingly. + * @details Inputs: heaterStatus, operationMode + * @details Outputs: heaterStatus, operationMode + * @param heater: The heater Id that its on state is handled + * @return TRUE if the control conditions have changed otherwise, FALSE + *************************************************************************/ +static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ) +{ + F32 dutyCycle; + + BOOL status = FALSE; + F32 targetFlow = getTargetROPumpFlowRate(); + BOOL hasFlowChanged = ( fabs( targetFlow - heatersStatus[ heater ].targetROFlow ) > NEARLY_ZERO ? TRUE : FALSE ); + + // Check if the target flow has changed or the target temperature has changed. + if ( ( TRUE == hasFlowChanged ) || ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) ) + { + status = TRUE; + + // Moving back from control to target to ramp. + heatersStatus[ heater ].rampStateStartTime = getMSTimerCount(); + heatersStatus[ heater ].targetROFlow = targetFlow; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + + // If the new target flow is less than the measured current flow, it means the new target flow is faster so it needs more heat power + dutyCycle = ( getMeasuredROFlowRate() < heatersStatus[ heater ].targetROFlow ? HEATERS_MAX_DUTY_CYCLE : HEATERS_MIN_DUTY_CYCLE ); + + // Go back to ramp state + setHeaterDutyCycle( heater, dutyCycle ); + } + + if ( DG_PRIMARY_HEATER == heater ) + { + if ( ( DG_MODE_DRAI == getCurrentOperationMode() ) || ( DG_MODE_GENE == getCurrentOperationMode() ) ) + { + if ( operationMode != getCurrentOperationMode() ) + { + operationMode = getCurrentOperationMode(); + heatersStatus[ heater ].targetTemp = heatersStatus[ heater ].originalTargetTemp + DRAIN_AND_IDLE_MODE_TARGET_TEMPERATURE_OFFSET; + } + } + else if ( ( DG_MODE_FILL == getCurrentOperationMode() ) && ( operationMode != getCurrentOperationMode() ) ) + { + operationMode = getCurrentOperationMode(); + heatersStatus[ heater ].targetTemp = heatersStatus[ heater ].originalTargetTemp; + } + + /*if ( ( getCurrentOperationMode() != DG_MODE_DRAI ) || ( getCurrentOperationMode() != DG_MODE_GENE ) ) + { + if ( TRUE == ( fabs( heatersStatus[ heater ].targetTemp - heatersStatus[ heater ].originalTargetTemp ) > NEARLY_ZERO ) + { + + } + }*/ + } + + + + return status; +} + +/*********************************************************************//** + * @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 @@ -712,18 +839,16 @@ { HEATERS_DATA_T data; - data.mainPrimayHeaterDC = heaterStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; + data.mainPrimayHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; // The duty cycle of the primary heater is divided into 2 parts and is applied to main // and small primary heaters. So they are always the same. - data.smallPrimaryHeaterDC = heaterStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; - data.trimmerHeaterDC = heaterStatus[ DG_TRIMMER_HEATER ].dutycycle * 100.0; - data.primaryTargetTemp = heaterStatus[ DG_PRIMARY_HEATER ].targetTemp; - data.trimmerTargetTemp = heaterStatus[ DG_TRIMMER_HEATER ].targetTemp; - data.primaryHeaterState = heaterStatus[ DG_PRIMARY_HEATER ].state; - data.trimmerHeaterState = heaterStatus[ DG_TRIMMER_HEATER ].state; + data.smallPrimaryHeaterDC = heatersStatus[ DG_PRIMARY_HEATER ].dutycycle * 100.0; + data.trimmerHeaterDC = heatersStatus[ DG_TRIMMER_HEATER ].dutycycle * 100.0; + data.primaryTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].targetTemp; + data.trimmerTargetTemp = heatersStatus[ DG_TRIMMER_HEATER ].targetTemp; + data.primaryHeaterState = heatersStatus[ DG_PRIMARY_HEATER ].state; + data.trimmerHeaterState = heatersStatus[ DG_TRIMMER_HEATER ].state; - //broadcastHeatersData( &data ); - broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); dataPublicationTimerCounter = 0; @@ -833,9 +958,9 @@ F32 trimmerVoltage = getIntADCVoltageConverted( INT_ADC_TRIMMER_HEATER_24_VOLTS ); // Voltage to PWM is reverse. If PWM = 0 -> V = 24V - F32 mainPri = 1.0 - heaterStatus[ DG_PRIMARY_HEATER ].dutycycle; - F32 smallPri = 1.0 - heaterStatus[ DG_PRIMARY_HEATER ].dutycycle; - F32 trimmer = 1.0 - heaterStatus[ DG_TRIMMER_HEATER ].dutycycle; + F32 mainPri = 1.0 - heatersStatus[ DG_PRIMARY_HEATER ].dutycycle; + F32 smallPri = 1.0 - heatersStatus[ DG_PRIMARY_HEATER ].dutycycle; + F32 trimmer = 1.0 - heatersStatus[ DG_TRIMMER_HEATER ].dutycycle; // Check main primary heater's voltage // The corresponding voltage of the current PWM must be close to the sensed voltage