Index: firmware/App/Controllers/Heaters.c =================================================================== diff -u -rde2ef5ff6293f23a43414c5e2e40630468a68ddf -r01da5a9677431082a2ce6cdd69c26f9e778537b4 --- firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision de2ef5ff6293f23a43414c5e2e40630468a68ddf) +++ firmware/App/Controllers/Heaters.c (.../Heaters.c) (revision 01da5a9677431082a2ce6cdd69c26f9e778537b4) @@ -15,7 +15,7 @@ * ***************************************************************************/ -#include +#include // Used for converting slope to radians and square root // TI PWM driver #include "etpwm.h" @@ -24,11 +24,14 @@ #include "DGDefs.h" #include "Heaters.h" #include "InternalADC.h" +#include "MessageSupport.h" +#include "ModeFill.h" #include "OperationModes.h" #include "PIControllers.h" #include "ROPump.h" #include "SafetyShutdown.h" #include "SystemCommMessages.h" +#include "TaskGeneral.h" #include "TaskPriority.h" #include "TemperatureSensors.h" #include "Timers.h" @@ -40,29 +43,17 @@ // ********** private definitions ********** -#define MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE 1.00 ///< Main primary heater (heater A) max duty cycle (100%). -#define SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE 1.00 ///< Small Primary heater (heater B) max duty cycle (100%). -#define TRIMMER_HEATER_MAX_DUTY_CYCLE 1.00 ///< Trimmer heater max duty cycle (100%). -#define HEATERS_MIN_DUTY_CYCLE 0.00 ///< Primary and trimmer heaters minimum duty cycle (0.00%). -#define PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ( MAIN_PRIMARY_HEATER_MAX_DUTY_CYCLE + \ - SMALL_PRIMAY_HEATER_MAX_DUTY_CYCLE ) ///< Primary heaters cumulative duty cycle. -#define PRIMARY_HEATER_INITIAL_DUTY_CYCLE_ESTIMATE_DIVISOR 2.0 ///< Primary heaters initial duty cycle estimation divisor. -#define MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR 2.0 ///< Main and small primary heater duty cycle divisor +#define HEATERS_MAX_DUTY_CYCLE 1.00 ///< Heaters max duty cycle (100%). +#define HEATERS_MIN_DUTY_CYCLE 0.00 ///< Heaters minimum duty cycle (0.00%). +#define HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE 0.6 ///< Heaters minimum duty cycle during heat disinfect. -#define PRIMARY_HEATERS_P_COEFFICIENT 0.15 ///< Primary heaters proportional coefficient. -#define PRIMARY_HEATERS_I_COEFFICIENT 0.001 ///< Primary heaters integral coefficient. - -#define TRIMMER_HEATER_P_COEFFICIENT 0.02 ///< Trimmer heater proportional coefficient. -#define TRIMMER_HEATER_I_COEFFICIENT 0.001 ///< Trimmer heater integral coefficient. - -#define CONTROLLER_CHECK_INTERVAL_COUNT 10U ///< Time interval count to check the PI controller. -#define TEMP_SENSORS_INTERVAL_COUNT 10U ///< Temperature sensors interval count. - #define HEATERS_DATA_PUBLISH_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters data publish interval. #define MINIMUM_TARGET_TEMPERATURE 10.0 ///< Minimum allowed target temperature for the heaters. #define MAXIMUM_TARGET_TEMPERATURE 90.0 ///< Maximum allowed target temperature for the heaters. +#define MAXIMUM_IDLE_DRAIN_TARGET_TEMPERATURE 58.0 ///< Maximum allowed target temperature for the idle and drain modes. +#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. @@ -71,221 +62,245 @@ #define HEATERS_MAX_OPERATING_VOLTAGE_V 24.0 ///< Heaters max operating voltage in volts. #define HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Heaters voltage monitor timer interval. #define HEATERS_MAX_VOLTAGE_OUT_OF_RANGE_TOL 0.2 ///< Heaters max voltage out of range tolerance. +#define HEATERS_MIN_RAMP_TIME_MS ( 6 * MS_PER_SECOND ) ///< Heaters minimum time that they have to stay in the ramp state in milliseconds. +#define TEMPERATURES_MOVING_AVG_SIZE 3U ///< Heaters ramp state temperatures moving average size. -/// Primary heaters exec states -typedef enum primary_heaters_exec_states -{ - PRIMARY_HEATERS_EXEC_STATE_OFF = 0, ///< Primary heaters exec state off - PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET, ///< Primary heaters exec state control to target (PI controller state) - NUM_OF_PRIMARY_HEATERS_EXEC_STATES ///< Number of primary heaters exec states -} PRIMARY_HEATERS_EXEC_STATES_T; +#define DELTA_TEMPERATURE_TIME_COSNTANT_C 8.6 ///< Delta temperature calculated from time constant. +#define MAXIMUM_ALLOWED_TARGET_TEMPERATURE_DEVIATION_C 0.25 ///< Maximum allowed temperature deviation from target temperature in C. +#define PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C 0.03 ///< Primary heaters duty cycle per temperature in C. -/// Trimmer heater exec states -typedef enum trimmer_heater_exec_states +static const F32 WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES = 4184 / SEC_PER_MIN; ///< Water specific heat in J/KgC / 60. +static const F32 PRIMARY_HEATERS_MAXIMUM_POWER_WATTS = 475 + 237.5; ///< Primary heaters maximum power (main primary = 475W and small primary = 237.5W). + +/// Heaters exec states +typedef enum Heaters_Exec_States { - TRIMMER_HEATER_EXEC_STATE_OFF = 0, ///< Trimmer heater exec state off - TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET, ///< Trimmer heater exec state control to target (PI controller state) - NUM_OF_TRIMMER_HEATER_EXEC_STATES ///< Number of trimmer heater exec states -} TRIMMER_HEATER_EXEC_STATES_T; + HEATER_EXEC_STATE_OFF = 0, ///< Heater exec state off. + HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET, ///< Heater exec state primary ramp to target. + HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET, ///< Heater exec state primary control to target. + HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET, ///< Heater exec state control to disinfect (heat or chemical) target. + HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET, ///< Heater exec state trimmer ramp to target. + HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET, ///< Heater exec state trimmer control to target. + NUM_OF_HEATERS_STATE, ///< Number of heaters state. +} HEATERS_STATE_T; -/// Name of the heaters states -typedef enum name_of_heaters +/// Heaters data structure +typedef struct { - PRIMARY_HEATER = 0, ///< Primary heater - TRIMMER_HEATER, ///< Trimmer heater - NUM_OF_HEATERS ///< Number of heaters -} NAME_OF_HEATER_T; + F32 targetTemp; ///< Heater target temperature. + HEATERS_STATE_T state; ///< Heater state. + BOOL startHeaterSignal; ///< Heater start indication flag. + BOOL isHeaterOn; ///< Heater on/off status flag. + F32 dutycycle; ///< Heater duty cycle. + F32 targetROFlow; ///< Heater target flow. + U32 heaterOnWithNoFlowTimer; // TODO remove ///< Heater on with no flow timer. + BOOL isFlowBelowMin; ///< Heater flow below minimum flag indicator. + BOOL hasTargetTempChanged; ///< Heater target temperature change flag indicator. + F32 heaterEfficiency; ///< Heater efficiency during the run. + BOOL hasTargetBeenReached; ///< Heater flag to indicate whether the target temperature has been reached. -// ********** private data ********** + 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 +} HEATER_STATUS_T; -static PRIMARY_HEATERS_EXEC_STATES_T primaryHeatersExecState; ///< Primary heaters exec state. -static TRIMMER_HEATER_EXEC_STATES_T trimmerHeaterExecState; ///< Trimmer heater exec state. +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 F32 primaryHeaterTargetTemperature; ///< Primary heaters target temperature. -static F32 trimmerHeaterTargetTemperature; ///< Trimmer heater target temperature. - -static F32 mainPrimaryHeaterDutyCycle; ///< Main primary heater duty cycle. -static F32 smallPrimaryHeaterDutyCycle; ///< Small primary heater duty cycle. -static F32 trimmerHeaterDutyCycle; ///< Trimmer heater duty cycle. -static U32 primaryHeaterTimerCounter; ///< Primary heater timer counter. -static U32 trimmerHeaterTimerCounter; ///< Trimmer heater timer counter. -static U32 dataPublicationTimerCounter; ///< Data publication timer counter. -static BOOL isPrimaryHeaterOn; ///< Flag to show if the primary heater is on. -static BOOL isTrimmerHeaterOn; ///< Flag to show if the trimmer heater is on. - -static OVERRIDE_U32_T heatersDataPublishInterval = { HEATERS_DATA_PUBLISH_INTERVAL, - HEATERS_DATA_PUBLISH_INTERVAL, 0, 0 }; ///< Heaters data publish time interval. -static BOOL hasStartPrimaryHeaterRequested; ///< Start primary heater request flag. -static BOOL hasStartTrimmerHeaterRequested; ///< Start trimmer heater request flag. -static U32 heatersOnWithNoFlowTimer; ///< Heaters are on but there is no sufficient flow. -static TEMPERATURE_SENSORS_T primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_PRIMARY_HEATER; ///< Primary heaters feedback temperature sensors. -static TEMPERATURE_SENSORS_T trimmerHeaterFeedbackTempSensor = TEMPSENSORS_INLET_DIALYSATE; ///< Trimmer heater feedback temperature sensors. -static U32 primaryHeaterTempOutTimer = 0; ///< Primary heaters temperature out of range start timer. -static U32 trimmerHeaterTempOutTimer = 0; ///< Trimmer heater internal temperature out of range timer. -static BOOL isPrimaryHeaterTempOutOfRange = FALSE; ///< Boolean flag to indicate if the primary heaters internal temperature out of range. -static BOOL isTrimmerHeaterTempOutOfRange = FALSE; ///< Boolean flag to indicate if the trimmer heater internal temperature out of range. -static BOOL isFlowBelowMin = FALSE; ///< Boolean flag to indicate if the flow is below the minimum. -static U32 heatersVoltageMonitorTimeCounter = 0; ///< Heaters voltage monitor counter. - // ********** private function prototypes ********** -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ); -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ); +static HEATERS_STATE_T handleHeaterStateOff( DG_HEATERS_T heater ); +static HEATERS_STATE_T handleHeaterStatePrimaryRampToTarget( void ); +static HEATERS_STATE_T handleHeaterStatePrimaryControlToTarget( void ); +static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DG_HEATERS_T heater ); +static HEATERS_STATE_T handleHeaterStateTrimmerRampToTarget( void ); +static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ); -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ); -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ); +static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ); +static F32 calculatePrimaryHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ); +static BOOL haveHeaterControlConditionsChanged( DG_HEATERS_T heater ); static void setMainPrimaryHeaterPWM( F32 pwm ); static void setSmallPrimaryHeaterPWM( F32 pwm ); static void setTrimmerHeaterPWM( F32 pwm ); -static void resetHeaterState( NAME_OF_HEATER_T heater ); static void publishHeatersData( void ); static void checkPrimaryHeaterTempSensors( void ); static void checkTrimmerHeaterTempSensors( void ); static void monitorHeatersVoltage( void ); /*********************************************************************//** * @brief - * The initHeaters function initializes the variables and the PI controllers - * for the primary and trimmer heaters. + * The initHeaters initializes the heaters driver. * @details Inputs: none - * @details Outputs: Heaters module initialized + * @details Outputs: voltageMonitorTimeCounter, heaterStatus, + * hasTreatmentInternalTempBeenSet * @return none *************************************************************************/ void initHeaters( void ) { - primaryHeatersExecState = PRIMARY_HEATERS_EXEC_STATE_OFF; - trimmerHeaterExecState = TRIMMER_HEATER_EXEC_STATE_OFF; - primaryHeaterTargetTemperature = 0.0; - trimmerHeaterTargetTemperature = 0.0; - primaryHeaterTimerCounter = 0; - trimmerHeaterTimerCounter = 5; - dataPublicationTimerCounter = 0; - isPrimaryHeaterOn = FALSE; - isTrimmerHeaterOn = FALSE; - primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_PRIMARY_HEATER; - trimmerHeaterFeedbackTempSensor = TEMPSENSORS_INLET_DIALYSATE; - primaryHeaterTempOutTimer = 0; - trimmerHeaterTempOutTimer = 0; - isPrimaryHeaterTempOutOfRange = FALSE; - isTrimmerHeaterTempOutOfRange = FALSE; - isFlowBelowMin = FALSE; - heatersVoltageMonitorTimeCounter = 0; + DG_HEATERS_T heater; - // Initialize the PI controller for the primary heaters - initializePIController( PI_CONTROLLER_ID_PRIMARY_HEATER, HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATERS_P_COEFFICIENT, PRIMARY_HEATERS_I_COEFFICIENT, - HEATERS_MIN_DUTY_CYCLE, PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ); + voltageMonitorTimeCounter = 0; + operationMode = 0; - // 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, TRIMMER_HEATER_MAX_DUTY_CYCLE ); + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) + { + heatersStatus[ heater ].startHeaterSignal = FALSE; + heatersStatus[ heater ].tempOutOfRangeTimer = 0; + heatersStatus[ heater ].isHeaterTempOutOfRange = FALSE; + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + heatersStatus[ heater ].targetTemp = 0.0; + heatersStatus[ heater ].dutycycle = 0.0; + heatersStatus[ heater ].targetROFlow = 0.0; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + heatersStatus[ heater ].heaterEfficiency = 1.0; // Assuming 100% efficiency during initialization until it is updated + heatersStatus[ heater ].hasTargetBeenReached = FALSE; + } } /*********************************************************************//** * @brief - * The setPrimaryHeaterTargetTemperature function sets the primary heater - * target temperature. + * The setHeaterTargetTemperature function sets the target temperature of a heater. * @details Inputs: none - * @details Outputs: primaryHeaterTargetTemperature - * @param targetTemp target temperature for the primary heater + * @details Outputs: heaterStatus + * @param heater: heater ID that its target temperature is set + * @param targetTemperature: target temperature of that the heater has to + * heat the fluid * @return none *************************************************************************/ -void setPrimaryHeaterTargetTemperature( F32 targetTemp ) +void setHeaterTargetTemperature( DG_HEATERS_T heater, F32 targetTemperature ) { - primaryHeaterTargetTemperature = targetTemp; + if( heater < NUM_OF_DG_HEATERS ) + { + // Assume the target temperature has not changed + heatersStatus[ heater ].hasTargetTempChanged = FALSE; + + // Check if the requested temperature is within the allowed range + if ( ( targetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( targetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + { + heatersStatus[ heater ].targetTemp = targetTemperature; + heatersStatus[ heater ].hasTargetTempChanged = TRUE; + // TODO alarm if temperature if out of range or just reject? + } + } + else + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) + } } /*********************************************************************//** * @brief - * The setTrimmerHeaterTargetTemperature function sets the trimmer heater - * target temperature. + * The getHeaterTargetTemperature function returns the heater target temperature. * @details Inputs: none - * @details Outputs: trimmerHeaterTargetTemperature - * @param targetTemp target temperature for the trimmer heater - * @return none + * @details Outputs: heaterStatus + * @return heater target temperature *************************************************************************/ -void setTrimmerHeaterTargetTemperature( F32 targetTemp ) +F32 getHeaterTargetTemperature( DG_HEATERS_T heater ) { - trimmerHeaterTargetTemperature = targetTemp; + return heatersStatus[ heater ].targetTemp; } /*********************************************************************//** * @brief - * The getPrimaryHeaterTargetTemperature function return the primary heater - * target temperature. - * @details Inputs: primaryHeaterTargetTemperature - * @details Outputs: none - * @return the current primary heater target temperature - *************************************************************************/ -F32 getPrimaryHeaterTargetTemperature( void ) -{ - return primaryHeaterTargetTemperature; -} - -/*********************************************************************//** - * @brief * The startPrimaryHeater function starts the primary heaters. It resets * the primary heaters state and sets the main primary heater duty cycle. * @details Inputs: primaryHeaterTargetTemperature * @details Outputs: hasStartPrimaryHeaterRequested * @return status *************************************************************************/ -BOOL startPrimaryHeater( void ) +BOOL startHeater( DG_HEATERS_T heater ) { BOOL status = FALSE; - if ( ( primaryHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( primaryHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + if( heater < NUM_OF_DG_HEATERS ) { - hasStartPrimaryHeaterRequested = TRUE; - status = TRUE; + if ( TRUE == heatersStatus[ heater ].hasTargetTempChanged ) + { + status = TRUE; + heatersStatus[ heater ].startHeaterSignal = TRUE; + } } - - return status; -} - -/*********************************************************************//** - * @brief - * The startTrimmerHeater function starts the trimmer heater. It resets the - * trimmer heater's state and sets the duty cycle of the trimmer heater. - * @details Inputs: trimmerHeaterTargetTemperature - * @details Outputs: hasStartTrimmerHeaterRequested - * @return status - *************************************************************************/ -BOOL startTrimmerHeater( void ) -{ - BOOL status = FALSE; - - if ( ( trimmerHeaterTargetTemperature >= MINIMUM_TARGET_TEMPERATURE ) && ( trimmerHeaterTargetTemperature <= MAXIMUM_TARGET_TEMPERATURE ) ) + else { - hasStartTrimmerHeaterRequested = TRUE; - status = TRUE; + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_HEATER_ID_SELECTED, heater ) } return status; } /*********************************************************************//** * @brief - * The stopPrimaryHeater function stops the primary heater. + * The stopHeater stops the specified heater. * @details Inputs: none - * @details Outputs: Primary heater stops - * @return none + * @details Outputs: heaterStatus + * @param heater: heater ID that is requested to turn on + * @return TRUE if the start was accepted otherwise, FALSE *************************************************************************/ -void stopPrimaryHeater( void ) +void stopHeater( DG_HEATERS_T heater ) { - isPrimaryHeaterOn = FALSE; + heatersStatus[ heater ].isHeaterOn = FALSE; } /*********************************************************************//** * @brief - * The stopTrimmerHeater function stops the trimmer heater. - * @details Inputs: none - * @details Outputs: Trimmer heater stops + * The execHeaters function executes the heaters state machine. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus * @return none *************************************************************************/ -void stopTrimmerHeater( void ) +void execHeaters( void ) { - isTrimmerHeaterOn = FALSE; + DG_HEATERS_T heater; + HEATERS_STATE_T state; + + for ( heater = DG_PRIMARY_HEATER; heater < NUM_OF_DG_HEATERS; heater++ ) + { + state = heatersStatus[ heater ].state; + + switch( state ) + { + case HEATER_EXEC_STATE_OFF: + heatersStatus[ heater ].state = handleHeaterStateOff( heater ); + break; + + case HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStatePrimaryRampToTarget(); + break; + + case HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStatePrimaryControlToTarget(); + break; + + case HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET: + heatersStatus[ heater ].state = handleHeaterStateControlToDisinfectTarget( heater ); + break; + + case HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStateTrimmerRampToTarget(); + break; + + case HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET: + heatersStatus[ heater ].state = handleHeaterStateTrimmerControlToTarget(); + break; + + default: + // The heater is in an unknown state. Turn it off and switch to not running state + stopHeater( heater ); + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_INVALID_EXEC_STATE, heater ); + break; + } + + // Check if the heater is requested to be off + if ( FALSE == heatersStatus[ heater ].isHeaterOn ) + { + setHeaterDutyCycle( heater, HEATERS_MIN_DUTY_CYCLE ); + heatersStatus[ heater ].state = HEATER_EXEC_STATE_OFF; + } + } } /*********************************************************************//** @@ -301,8 +316,8 @@ { DG_CMD_RESPONSE_T cmdResponse; - cmdResponse.commandID = DG_CMD_START_TRIMMER_HEATER; - cmdResponse.rejected = TRUE; + cmdResponse.commandID = DG_CMD_START_TRIMMER_HEATER; + cmdResponse.rejected = TRUE; cmdResponse.rejectCode = DG_CMD_REQUEST_REJECT_REASON_NONE; if ( TRUE == heaterCmdPtr->startHeater ) @@ -311,8 +326,8 @@ { cmdResponse.rejected = FALSE; #ifndef DISABLE_HEATERS_AND_TEMPS - trimmerHeaterTargetTemperature = heaterCmdPtr->targetTemp; - hasStartTrimmerHeaterRequested = TRUE; + heatersStatus[ DG_TRIMMER_HEATER ].targetTemp = heaterCmdPtr->targetTemp; + heatersStatus[ DG_TRIMMER_HEATER ].startHeaterSignal = TRUE; #endif } else @@ -323,7 +338,7 @@ else { cmdResponse.rejected = FALSE; - stopTrimmerHeater(); + stopHeater( DG_TRIMMER_HEATER ); } sendCommandResponseMsg( &cmdResponse ); @@ -335,293 +350,344 @@ * 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 ) { +#ifdef 0 // This code is disabled to prevent any heaters monitoring while the driver in in development. + 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(); - } } + monitorHeatersVoltage(); +#endif + // Check for data publication publishHeatersData(); } + /*********************************************************************//** * @brief - * The execPrimaryHeaters function executes the primary heaters' state machine. - * @details Inputs: primaryHeatersExecState - * @details Outputs: primaryHeatersExecState + * The resetHeatersEfficiency function resets the heaters efficiency upon + * the start of a treatment. + * @details Inputs: none + * @details Outputs: heaterStatus * @return none *************************************************************************/ -void execPrimaryHeaters( void ) +void resetHeatersEfficiency( void ) { - switch ( primaryHeatersExecState ) - { - case PRIMARY_HEATERS_EXEC_STATE_OFF: - primaryHeatersExecState = handlePrimaryHeaterStateOff(); - break; - - case PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET: - primaryHeatersExecState = handlePrimaryHeaterStateControlToTarget(); - break; - - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_PRIMARY_HEATER_EXEC_INVALID_STATE, primaryHeatersExecState ); - primaryHeatersExecState = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; - break; - } + heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency = 1.0; + heatersStatus[ DG_TRIMMER_HEATER ].heaterEfficiency = 1.0; } /*********************************************************************//** * @brief - * The execTrimmerHeater function executes the trimmer heater's state machine. - * @details Inputs: trimmerHeaterExecState - * @details Outputs: trimmerHeaterExecState - * @return none + * The handleHeaterStateOff function handles the heater not running state. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @param heater: The heater Id that its not running state is handled + * @return next state of the state machine *************************************************************************/ -void execTrimmerHeater( void ) +static HEATERS_STATE_T handleHeaterStateOff( DG_HEATERS_T heater ) { - switch ( trimmerHeaterExecState ) + HEATERS_STATE_T state = HEATER_EXEC_STATE_OFF; + + if ( TRUE == heatersStatus[ heater ].startHeaterSignal ) { - case TRIMMER_HEATER_EXEC_STATE_OFF: - trimmerHeaterExecState = handleTrimmerHeaterStateOff(); - break; + heatersStatus[ heater ].isHeaterOn = TRUE; + heatersStatus[ heater ].startHeaterSignal = FALSE; - case TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET: - trimmerHeaterExecState = handleTrimmerHeaterControlToTarget(); - break; - - default: - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_HEATERS_TRIMMER_HEATER_EXEC_INVALID_STATE, trimmerHeaterExecState ); - trimmerHeaterExecState = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; - break; + // Depending on which heater is called, go to different states + state = ( heater == DG_PRIMARY_HEATER ? HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET : HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET ); } + + return state; } /*********************************************************************//** * @brief - * The handlePrimaryHeaterStateOff function handles the primary heaters at - * off state. - * @details Inputs: hasStartPrimaryHeaterRequested, isPrimaryHeaterOn - * @details Outputs: state (PRIMARY_HEATERS_EXEC_STATES_T), isPrimaryHeaterOn - * @return state (PRIMARY_HEATERS_EXEC_STATES_T) + * The handleHeaterStatePrimaryRampToTarget function handles the primary heaters' + * control while they are ramping to target temperature. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine *************************************************************************/ -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateOff( void ) +static HEATERS_STATE_T handleHeaterStatePrimaryRampToTarget( void ) { - PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_OFF; + HEATERS_STATE_T state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; + DG_HEATERS_T heater = DG_PRIMARY_HEATER; + F32 inletTemperature = getTemperatureValue( (U32)TEMPSENSORS_HEAT_DISINFECT ); + F32 targetFlow = 0.0; + F32 dutyCycle = 0.0; + F32 targetTemperature = heatersStatus[ heater ].targetTemp; - if ( TRUE == hasStartPrimaryHeaterRequested ) + if ( DG_MODE_FILL == getCurrentOperationMode() ) { - resetHeaterState( PRIMARY_HEATER ); - // Once the primary heaters duty cycle is set, it is divided into 2 - // so both heaters will start and both elements are heated up - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); - isPrimaryHeaterOn = TRUE; - hasStartPrimaryHeaterRequested = FALSE; - - // Check if the operation mode is heat disinfect. If the mode is - // heat disinfect, the feedback sensor will be Thd - if ( DG_MODE_HEAT == getCurrentOperationMode() ) - { -#ifdef THD_USING_TRO_CONNECTOR - // Set the feedback temperature sensor - // THd uses TRo in V3 - primaryHeatersFeedbackTempSensor = TEMPSENSORS_OUTLET_REDUNDANT; -#else - primaryHeatersFeedbackTempSensor = TEMPSENSORS_HEAT_DISINFECT; -#endif - } - - state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; + // If the previous average fill flow rate is 0, use the nominal target RO flow from the RO pump + targetFlow = ( getAvgFillFlowRate() - 0.0 > NEARLY_ZERO ? getAvgFillFlowRate() : getTargetROPumpFlowRate() ); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, TRUE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; } + else if ( ( DG_MODE_GENE == getCurrentOperationMode() ) || ( DG_MODE_DRAI == getCurrentOperationMode() ) ) + { + targetTemperature += DELTA_TEMPERATURE_TIME_COSNTANT_C; + // Use target flow rate during Idle and drain + targetFlow = getTargetROPumpFlowRate(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + } + else if ( ( DG_MODE_HEAT == getCurrentOperationMode() ) || ( DG_MODE_CHEM == getCurrentOperationMode() ) ) + { + // If the mode is any of the disinfects, especially heat, 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 + targetFlow = getTargetROPumpFlowRate(); + dutyCycle = calculatePrimaryHeaterDutyCycle( targetTemperature, inletTemperature, targetFlow, FALSE ); + state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; + } + setHeaterDutyCycle( heater, dutyCycle ); + return state; } /*********************************************************************//** * @brief - * The handlePrimaryHeaterStateControlToTarget function handles the primary - * heaters at control state when the heaters are active. - * @details Inputs: primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle, isPrimaryHeaterOn - * @details Outputs: primaryHeaterTimerCounter, mainPrimaryHeaterDutyCycle, - * smallPrimaryHeaterDutyCycle - * @return state (PRIMARY_HEATERS_EXEC_STATES_T) + * The handleHeaterStatePrimaryControlToTarget function handles the primary + * heaters' control to target while the heater is targeting to reach to temperature. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine *************************************************************************/ -static PRIMARY_HEATERS_EXEC_STATES_T handlePrimaryHeaterStateControlToTarget( void ) +static HEATERS_STATE_T handleHeaterStatePrimaryControlToTarget( void ) { - PRIMARY_HEATERS_EXEC_STATES_T state = PRIMARY_HEATERS_EXEC_STATE_CONTROL_TO_TARGET; + HEATERS_STATE_T state = HEATER_EXEC_STATE_PRIMARY_CONTROL_TO_TARGET; + DG_HEATERS_T heater = DG_PRIMARY_HEATER; - if ( ++primaryHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) + if ( TRUE == haveHeaterControlConditionsChanged( heater ) ) { - // Check if the flow is not below minimum required first - // If the flow is below minimum, send 0.00 to the PWM until the flow comes back to range - // If the flow is within range, run the PI controller to control the heaters normally - if ( FALSE == isFlowBelowMin ) - { - F32 outletTemp = getTemperatureValue( primaryHeatersFeedbackTempSensor ); - mainPrimaryHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, primaryHeaterTargetTemperature, outletTemp ); + state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; + } - // Once the primary heaters duty cycle is set, it is divided into 2 so both heaters will start and both elements are heated up - smallPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; - mainPrimaryHeaterDutyCycle = mainPrimaryHeaterDutyCycle / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; + return state; +} - setMainPrimaryHeaterPWM( mainPrimaryHeaterDutyCycle ); - setSmallPrimaryHeaterPWM( smallPrimaryHeaterDutyCycle ); - } - // Flow is below the minimum required flow to run the primary heaters - else - { - setMainPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - setSmallPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - } +/*********************************************************************//** + * @brief + * The handleHeaterStateControlToDisinfectTarget function handles the + * heaters' control to target while the operation mode is heat or chemical + * disinfects. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @param heater: The heater Id that its on state is handled + * @return next state of the state machine + *************************************************************************/ +static HEATERS_STATE_T handleHeaterStateControlToDisinfectTarget( DG_HEATERS_T heater ) +{ + HEATERS_STATE_T state = HEATER_EXEC_STATE_CONTROL_TO_DISINFECT_TARGET; - primaryHeaterTimerCounter = 0; + F32 heatDisinfectSensorTemp = getTemperatureValue( TEMPSENSORS_HEAT_DISINFECT ); + + // Check if the heaters control conditions have changed, if yes, switch back to ramp to target + if ( TRUE == haveHeaterControlConditionsChanged( heater ) ) + { + state = HEATER_EXEC_STATE_PRIMARY_RAMP_TO_TARGET; } - // If the primary heater is running and another start primary heater request - // is set, reset the primary heater again - if ( TRUE == hasStartPrimaryHeaterRequested ) + // If the heat disifect sensor indicates that the temperature is below target temperature but the target temperature had been reached + // before turn on the heaters with 100% power + if ( ( heatDisinfectSensorTemp <= heatersStatus[ heater ].targetTemp ) && ( TRUE == heatersStatus[ heater ].hasTargetBeenReached ) ) { - resetHeaterState( PRIMARY_HEATER ); - hasStartPrimaryHeaterRequested = FALSE; + heatersStatus[ heater ].hasTargetBeenReached = FALSE; + setHeaterDutyCycle( heater, HEATERS_MAX_DUTY_CYCLE ); } - if ( FALSE == isPrimaryHeaterOn ) + // If we have reached to target temperature, turn off the heaters + if ( heatDisinfectSensorTemp > heatersStatus[ heater ].targetTemp ) { - // Switch to off state. Set the duty cycles to 0 - mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setMainPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - setSmallPrimaryHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - state = PRIMARY_HEATERS_EXEC_STATE_OFF; + // Set the flag to true for the next run + heatersStatus[ heater ].hasTargetBeenReached = TRUE; + // The primary heater are not turned off but it is set to a minimum duty cycle so the temperature is kept + // above the target + setHeaterDutyCycle( heater, HEATERS_MIN_HEAT_DISINFECT_DUTY_CYCLE ); } return state; } /*********************************************************************//** * @brief - * The handleTrimmerHeaterStateOff function handles the trimmer heater at - * off state. - * @details Inputs: hasStartTrimmerHeaterRequested, isTrimmerHeaterOn - * @details Outputs: state (TRIMMER_HEATER_EXEC_STATES_T), isTrimmerHeaterOn - * @return state (TRIMMER_HEATER_EXEC_STATES_T) + * The handleHeaterStateTrimmerRampToTarget function handles the trimmer + * heater's ramp to target. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine *************************************************************************/ -static TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterStateOff( void ) +static HEATERS_STATE_T handleHeaterStateTrimmerRampToTarget( void ) { - TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_OFF; + HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_RAMP_TO_TARGET; - if ( TRUE == hasStartTrimmerHeaterRequested ) + return state; +} + +/*********************************************************************//** + * @brief + * The handleHeaterStateTrimmerControlToTarget function handles the trimmer + * heater's control to target. + * @details Inputs: heaterStatus + * @details Outputs: heaterStatus + * @return next state of the state machine + *************************************************************************/ +static HEATERS_STATE_T handleHeaterStateTrimmerControlToTarget( void ) +{ + HEATERS_STATE_T state = HEATER_EXEC_STATE_TRIMMER_CONTROL_TO_TARGET; + + + return state; +} + +/*********************************************************************//** + * @brief + * The setHeaterDutyCycle function sets the duty cycle of a heater. + * @details Inputs: none + * @details Outputs: none + * @param heater: The heater Id that its duty cycle is set + * @param pwm: The PWM that is set + * @return none + *************************************************************************/ +static void setHeaterDutyCycle( DG_HEATERS_T heater, F32 pwm ) +{ + if ( DG_PRIMARY_HEATER == heater ) { - resetHeaterState( TRIMMER_HEATER ); - isTrimmerHeaterOn = TRUE; - hasStartTrimmerHeaterRequested = FALSE; - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); - state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; + setMainPrimaryHeaterPWM( pwm ); + setSmallPrimaryHeaterPWM( pwm ); } + else if ( DG_TRIMMER_HEATER == heater ) + { + setTrimmerHeaterPWM( pwm ); + } - return state; + heatersStatus[ heater ].dutycycle = pwm; } /*********************************************************************//** * @brief - * The handleTrimmerHeaterControlToTarget function handles the trimmer - * heater at control state when the heater is active. - * @details Inputs: trimmerHeaterTimerCounter, trimmerHeaterDutyCycle - * @details Outputs: trimmerHeaterTimerCounter, trimmerHeaterDutyCycle, - * isTrimmerHeaterOn - * @return state (TRIMMER_HEATER_EXEC_STATES_T) + * The calculatePrimaryHeaterDutyCycle function calculates the primary + * heater's duty cycle. + * @details Inputs: 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 TRIMMER_HEATER_EXEC_STATES_T handleTrimmerHeaterControlToTarget( void ) +static F32 calculatePrimaryHeaterDutyCycle( F32 targetTemperature, F32 currentTemperature, F32 flow, BOOL checkEfficiency ) { - TRIMMER_HEATER_EXEC_STATES_T state = TRIMMER_HEATER_EXEC_STATE_CONTROL_TO_TARGET; + // Get the primary heater's efficiency and the last fill temperature from the ModeFill + F32 heaterEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency; - if ( ++trimmerHeaterTimerCounter >= CONTROLLER_CHECK_INTERVAL_COUNT ) + if ( TRUE == checkEfficiency ) { - // Check if the flow is not below minimum required first - // If the flow is below minimum, send 0.00 to the PWM until the flow comes back to range - // If the flow is within range, run the PI controller to control the heaters normally - if ( FALSE == isFlowBelowMin ) + F32 lastFillTemperature = getLastFillTemperature(); + + // If the last fill temperature > target temperature, it means the primary heater overshot the duty cycle + // so with its efficiency is toned down for the next fill cycle + // If the heater undershoots the duty cycle, the efficiency increases the duty cycle for the next fill cycle + if ( lastFillTemperature - targetTemperature > MAXIMUM_ALLOWED_TARGET_TEMPERATURE_DEVIATION_C ) { - F32 outletTemp = getTemperatureValue( trimmerHeaterFeedbackTempSensor ); - trimmerHeaterDutyCycle = runPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, trimmerHeaterTargetTemperature, outletTemp ); - setTrimmerHeaterPWM( trimmerHeaterDutyCycle ); + heaterEfficiency -= ( lastFillTemperature - targetTemperature ) * PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C; } - else + else if ( lastFillTemperature - targetTemperature <= MAXIMUM_ALLOWED_TARGET_TEMPERATURE_DEVIATION_C ) { - setTrimmerHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); + heaterEfficiency += ( lastFillTemperature - targetTemperature ) * PRIMARY_HEATER_DUTY_CYCLE_PER_TEMPERATURE_C; } - trimmerHeaterTimerCounter = 0; + // Update the heaters efficiency + heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency = heaterEfficiency; } - if ( TRUE == hasStartTrimmerHeaterRequested ) - { - hasStartTrimmerHeaterRequested = FALSE; - } + // Duty cycle = ( 69.73 * flow rate * deltaT / primary heater maximum power ) ^ 1/2 + // Multiply the duty cycle to the heater efficiency + F32 dutyCycle = sqrt( ( WATER_SPECIFIC_HEAT_DIVIDED_BY_MINUTES * + fabs( targetTemperature - currentTemperature ) * flow ) / PRIMARY_HEATERS_MAXIMUM_POWER_WATTS ) * heaterEfficiency; - if ( FALSE == isTrimmerHeaterOn ) + // Check the boundaries of the calculated duty cycle + dutyCycle = ( dutyCycle > HEATERS_MAX_DUTY_CYCLE ? HEATERS_MAX_DUTY_CYCLE : dutyCycle ); + dutyCycle = ( dutyCycle < HEATERS_MIN_DUTY_CYCLE ? HEATERS_MIN_DUTY_CYCLE : dutyCycle ); + + return dutyCycle; +} + +/*********************************************************************//** + * @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 ) +{ + 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 ) ) { - // Set the duty cycle to 0 and switch to off state - trimmerHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - setTrimmerHeaterPWM( HEATERS_MIN_DUTY_CYCLE ); - state = TRIMMER_HEATER_EXEC_STATE_OFF; + status = TRUE; + + // Moving back from control to target to ramp. + heatersStatus[ heater ].targetROFlow = targetFlow; + heatersStatus[ heater ].hasTargetTempChanged = FALSE; } - return state; + return status; } /*********************************************************************//** @@ -665,51 +731,6 @@ /*********************************************************************//** * @brief - * The resetHeaterState function resets the PI controller of the selected heater. - * @details Inputs: mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle - * @details Outputs: mainPrimaryHeaterDutyCycle, trimmerHeaterDutyCycle - * @param heater enumeration of the heater for which the PI controller will be reset - * @return none - *************************************************************************/ -static void resetHeaterState( NAME_OF_HEATER_T heater ) -{ - if ( PRIMARY_HEATER == heater ) - { - // Calculate the delta temperature from the inlet primary heater to target temperature - F32 inletPrimaryHeaterTemp = getTemperatureValue( TEMPSENSORS_INLET_PRIMARY_HEATER ); - F32 deltaTemp = primaryHeaterTargetTemperature - inletPrimaryHeaterTemp; - - // If the delta temperature (target temperature - inlet primary heater temperature) - // Is 0 or negative, the duty cycle is 0.0 - if ( deltaTemp <= 0.0 ) - { - mainPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - smallPrimaryHeaterDutyCycle = HEATERS_MIN_DUTY_CYCLE; - } - else - { - // The formula for the initial guess is: (delta temperature * target flow) / 2.0 - F32 targetFlow = getTargetROPumpFlowRate(); - F32 duty = ( targetFlow * deltaTemp ) / PRIMARY_HEATER_INITIAL_DUTY_CYCLE_ESTIMATE_DIVISOR; - // If the duty cycle is greater 200% on the primary and small primary heaters, set it to 200%, otherwise set it to the - // estimated duty cycles - duty = ( duty > PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE ? PRIMARY_HEATERS_CUMULATIVE_DUTY_CYCLE : duty ); - mainPrimaryHeaterDutyCycle = duty / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; - smallPrimaryHeaterDutyCycle = duty / MAIN_AND_SMALL_PRIMARY_HEATER_DUTY_CYCLE_DIVISOR; - } - - // The PI controller of the primary heater consists of main and small primary heaters duty cycles - resetPIController( PI_CONTROLLER_ID_PRIMARY_HEATER, mainPrimaryHeaterDutyCycle + smallPrimaryHeaterDutyCycle ); - } - else if ( TRIMMER_HEATER == heater ) - { - trimmerHeaterDutyCycle = TRIMMER_HEATER_MAX_DUTY_CYCLE; - resetPIController( PI_CONTROLLER_ID_TRIMMER_HEATER, TRIMMER_HEATER_MAX_DUTY_CYCLE ); - } -} - -/*********************************************************************//** - * @brief * The publishTemperatureData function publishes the heaters data into * at the defined time interval. * @details Inputs: dataPublicationTimerCounter @@ -722,13 +743,18 @@ { HEATERS_DATA_T data; - data.mainPrimayHeaterDC = mainPrimaryHeaterDutyCycle * 100.0; - data.smallPrimaryHeaterDC = smallPrimaryHeaterDutyCycle * 100.0; - data.trimmerHeaterDC = trimmerHeaterDutyCycle * 100.0; - data.primaryTargetTemp = primaryHeaterTargetTemperature; - data.trimmerTargetTemp = trimmerHeaterTargetTemperature; + 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 = 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; + data.primaryEfficiency = heatersStatus[ DG_PRIMARY_HEATER ].heaterEfficiency * 100; - broadcastHeatersData( &data ); + broadcastData( MSG_ID_DG_HEATERS_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&data, sizeof( HEATERS_DATA_T ) ); dataPublicationTimerCounter = 0; } @@ -760,8 +786,8 @@ SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_PRIMARY_HEATER_CJ_TEMP_OUT_OF_RANGE, primaryHeaterInternalTemp ); } - // If any of the temperatures are above the range - if ( ( FALSE == isPrimaryHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) + /*/ If any of the temperatures are above the range + /if ( ( FALSE == isPrimaryHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) { stopPrimaryHeater(); isPrimaryHeaterTempOutOfRange = TRUE; @@ -773,7 +799,7 @@ { isPrimaryHeaterTempOutOfRange = FALSE; activateSafetyShutdown(); - } + }*/ } /*********************************************************************//** @@ -804,7 +830,7 @@ // If it is above the range for the first time, stop the trimmer heater // and set the variables - if ( ( FALSE == isTrimmerHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) + /*if ( ( FALSE == isTrimmerHeaterTempOutOfRange ) && ( TRUE == isTempOut ) ) { stopTrimmerHeater(); isTrimmerHeaterTempOutOfRange = TRUE; @@ -815,19 +841,19 @@ ( TRUE == didTimeout( trimmerHeaterTempOutTimer, HEATERS_MAX_ALLOWED_INTERNAL_TEMPERATURE_TIMEOUT_MS ) ) ) { activateSafetyShutdown(); - } + }*/ } /*********************************************************************//** * @brief * The monitorHeatersVoltage function monitors the heaters' voltages - * @details Inputs: heatersVoltageMonitorTimeCounter - * @details Outputs: heatersVoltageMonitorTimeCounter + * @details Inputs: voltageMonitorTimeCounter + * @details Outputs: voltageMonitorTimeCounter * @return none *************************************************************************/ static void monitorHeatersVoltage( void ) { - if ( ++heatersVoltageMonitorTimeCounter >= HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ) + if ( ++voltageMonitorTimeCounter >= HEATERS_VOLTAGE_MONITOR_TIME_INTERVAL ) { F32 mainPriVoltage = getIntADCVoltageConverted( INT_ADC_PRIMARY_HEATER_24_VOLTS ); // TODO it is assumed that the main and small primary heaters have equal voltage since the PWMs are divided into 2 @@ -837,9 +863,9 @@ F32 trimmerVoltage = getIntADCVoltageConverted( INT_ADC_TRIMMER_HEATER_24_VOLTS ); // Voltage to PWM is reverse. If PWM = 0 -> V = 24V - F32 mainPri = 1.0 - mainPrimaryHeaterDutyCycle; - F32 smallPri = 1.0 - smallPrimaryHeaterDutyCycle; - F32 trimmer = 1.0 - trimmerHeaterDutyCycle; + 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 @@ -858,7 +884,7 @@ SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_TRIMMER_HEATER_VOLTAGE_OUT_OF_RANGE, trimmerVoltage ); } - heatersVoltageMonitorTimeCounter = 0; + voltageMonitorTimeCounter = 0; } }