Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rcc9b6f5543a7523b2173eeb5c12e81916b3e1027 -r76fc4506fd38ea6bd317abbaaf85db5aa589a7cc --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision cc9b6f5543a7523b2173eeb5c12e81916b3e1027) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 76fc4506fd38ea6bd317abbaaf85db5aa589a7cc) @@ -8,7 +8,7 @@ * @file Heaters.c * * @author (last) Dara Navaei -* @date (last) 07-Apr-2023 +* @date (last) 24-Aug-2023 * * @author (original) Dara Navaei * @date (original) 23-Apr-2020 @@ -62,7 +62,8 @@ #define MINIMUM_TARGET_TEMPERATURE 10.0F ///< Minimum allowed target temperature for the heaters. #define MAXIMUM_TARGET_TEMPERATURE 90.0F ///< Maximum allowed target temperature for the heaters. -#define HEATERS_ON_NO_FLOW_TIMEOUT_MS ( 10 * MS_PER_SECOND ) ///< Heaters on with no flow time out in milliseconds. +#define PRIMARY_HEATER_ON_NO_FLOW_TIMEOUT_MS ( 10 * MS_PER_SECOND ) ///< Primary heater on with no flow time out in milliseconds. +#define TRIMMER_HEATER_ON_NO_FLOW_TIMEOUT_MS ( 12 * MS_PER_SECOND ) ///< Trimmer heater on with no flow time out in milliseconds. #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. @@ -99,6 +100,7 @@ U32 controlIntervalCounter; ///< Heater control interval counter. BOOL isThisFirstControl; ///< Heater is this first control interval. BOOL useLastDutyCycle; ///< Heater has use previous duty cycle been requested flag. + F32 prevDiaTargetFlowLPM; ///< Heater previous target dialysate flow in L/min. } HEATER_STATUS_T; static HEATER_STATUS_T heatersStatus[ NUM_OF_DG_HEATERS ]; ///< Heaters status. @@ -156,14 +158,15 @@ heatersStatus[ heater ].controlIntervalCounter = 0; heatersStatus[ heater ].isThisFirstControl = TRUE; heatersStatus[ heater ].useLastDutyCycle = FALSE; + heatersStatus[ heater ].prevDiaTargetFlowLPM = 0.0F; } // Initialize the persistent alarms initPersistentAlarm( ALARM_ID_DG_MAIN_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_SMALL_PRIMARY_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); initPersistentAlarm( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS, HEATERS_VOLTAGE_OUT_OF_RANGE_TIMEOUT_MS ); - initPersistentAlarm( ALARM_ID_DG_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); - initPersistentAlarm( ALARM_ID_DG_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, HEATERS_ON_NO_FLOW_TIMEOUT_MS, HEATERS_ON_NO_FLOW_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_RO_FLOW_TOO_LOW_WHILE_PRIMARY_HEATER_IS_ON, 0, PRIMARY_HEATER_ON_NO_FLOW_TIMEOUT_MS ); + initPersistentAlarm( ALARM_ID_DG_DIALYSATE_FLOW_TOO_LOW_WHILE_TRIMMER_HEATER_IS_ON, 0, TRIMMER_HEATER_ON_NO_FLOW_TIMEOUT_MS ); // Initialize the FPGA persistent alarm initFPGAPersistentAlarm( FPGA_PERS_ERROR_MAIN_PRIMARY_HEATER_VOLTAGE_ADC, ALARM_ID_DG_MAIN_PRIMARY_HEATER_FPGA_FAULT, @@ -587,15 +590,15 @@ } else if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) { - F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + F32 inletTemperature = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); F32 targetTemperature = heatersStatus[ heater ].targetTempC; F32 targetFlow = getTargetROPumpFlowRateLPM(); F32 dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); heatersStatus[ heater ].calculatedTemperatureC = targetTemperature; heatersStatus[ heater ].targetFlowLPM = targetFlow; heatersStatus[ heater ].hasTargetTempChanged = FALSE; - heatersStatus[ heater ].dutyCycle.data = dutyCycle; + heatersStatus[ heater ].dutyCycle.data = dutyCycle; setHeaterDutyCycle( heater ); } @@ -680,28 +683,27 @@ // If the mode is heat disinfect, use the target flow rate instead of the avg. flow // Most of the times the heater should be running at 100% duty cycle since the target temperature is 81 C and // it is far from the inlet temperature. - currentTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + currentTemperature = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); targetFlowLPM = getTargetROPumpFlowRateLPM(); dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, FALSE ); state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; } else { // If not any of the above modes, just calculate the energy equation based on TRo - currentTemperature = getTemperatureValue( (U32)TEMPSENSORS_OUTLET_REDUNDANT ); + currentTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, currentTemperature, targetFlowLPM, TRUE ); state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; } // Update the calculated target temperature // Reset the duty cycle since the reservoir has been switched + // Cap the minimum duty cycle. So if it is calculated to negative, set it to 0 heatersStatus[ heater ].calculatedTemperatureC = currentTemperature; heatersStatus[ heater ].inactiveRsrvr = getInactiveReservoir(); heatersStatus[ heater ].targetFlowLPM = targetFlowLPM; heatersStatus[ heater ].isThisFirstControl = TRUE; - - // Cap the minimum duty cycle. So if it is calculated to negative, set it to 0 - heatersStatus[ heater ].dutyCycle.data = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); + heatersStatus[ heater ].dutyCycle.data = MAX( dutyCycle, HEATERS_MIN_DUTY_CYCLE ); setHeaterDutyCycle( heater ); return state; @@ -720,35 +722,50 @@ HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; F32 tempDutyCycle = 0.0F; DG_HEATERS_T heater = DG_TRIMMER_HEATER; + F32 targetFlowLPM = getTargetDialysateFlowLPM(); U32 controlInterval = ( TRUE == heatersStatus[ heater ].isThisFirstControl ? TRIMMER_HEATER_INITIAL_CONTROL_INTERVAL_COUNT : TRIMMER_HEATER_CONTROL_INTERVAL_COUNT ); - // If the inactive reservoir has changed from the last run transition to ramp state to recalculate the + // If the inactive reservoir has changed from the last run, transition to ramp state to recalculate the // duty cycle for the next delivery if ( heatersStatus[ heater ].inactiveRsrvr != getInactiveReservoir() ) { state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; } - else if ( ++heatersStatus[ heater ].controlIntervalCounter > controlInterval ) + else if ( ( ++heatersStatus[ heater ].controlIntervalCounter > controlInterval ) || + ( fabs( heatersStatus[ heater ].prevDiaTargetFlowLPM - targetFlowLPM ) > NEARLY_ZERO ) ) { - // Reset the control counter + // Check if it is time for another control interval or the current target flow is different from the previous flow and + // we need to reset the control counter heatersStatus[ heater ].controlIntervalCounter = 0; heatersStatus[ heater ].isThisFirstControl = FALSE; // When the trimmer heater is on, its duty cycle is adjusted at the control interval. For this control check, // dialysate inlet temperature sensor is used rather than the theoretical calculations. - F32 outletRedundantTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); - F32 targetTemperature = heatersStatus[ heater ].targetTempC; - F32 targetFlowLPM = heatersStatus[ heater ].targetFlowLPM; - F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, outletRedundantTemperature, targetFlowLPM, TRUE ); + F32 dialysateInletTemperature = getTemperatureValue( TEMPSENSORS_OUTLET_REDUNDANT ); + F32 targetTemperature = heatersStatus[ heater ].targetTempC; + F32 dutyCycle = calculateTrimmerHeaterDutyCycle( targetTemperature, dialysateInletTemperature, targetFlowLPM, TRUE ); - tempDutyCycle = heatersStatus[ heater ].dutyCycle.data + dutyCycle; + if ( fabs( heatersStatus[ heater ].prevDiaTargetFlowLPM - targetFlowLPM ) > NEARLY_ZERO ) + { + // If the current flow is different from the previous flow, restart the duty cycle as the controller is restarting itself + // Set it as it is the first control so the control interval is shorter since it is the first guess with the new dialysate flow + tempDutyCycle = dutyCycle; + heatersStatus[ heater ].isThisFirstControl = TRUE; + } + else + { + tempDutyCycle = heatersStatus[ heater ].dutyCycle.data + dutyCycle; + } + tempDutyCycle = MIN( tempDutyCycle, HEATERS_MAX_DUTY_CYCLE ); tempDutyCycle = MAX( tempDutyCycle, HEATERS_MIN_DUTY_CYCLE ); heatersStatus[ heater ].dutyCycle.data = tempDutyCycle; setHeaterDutyCycle( heater ); } + heatersStatus[ heater ].prevDiaTargetFlowLPM = targetFlowLPM; + return state; } @@ -977,6 +994,8 @@ data.primaryCalcTargetTemp = heatersStatus[ DG_PRIMARY_HEATER ].calculatedTemperatureC; data.trimmerCalcCurrentTemp = heatersStatus[ DG_TRIMMER_HEATER ].calculatedTemperatureC; data.trimmerUseLastDC = (U32)heatersStatus[ DG_TRIMMER_HEATER ].useLastDutyCycle; + data.previsouFlow = heatersStatus[ DG_TRIMMER_HEATER ].prevDiaTargetFlowLPM; + data.controlCounter = heatersStatus[ DG_TRIMMER_HEATER ].controlIntervalCounter; dataPublicationTimerCounter = 0; broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) );