Index: firmware/App/Controllers/LoadCell.c =================================================================== diff -u -rcea079b61dbd17b2ddaec99b1124248147d14e72 -r3b70632c04247a6973960e1f37ae73eb4384a6b7 --- firmware/App/Controllers/LoadCell.c (.../LoadCell.c) (revision cea079b61dbd17b2ddaec99b1124248147d14e72) +++ firmware/App/Controllers/LoadCell.c (.../LoadCell.c) (revision 3b70632c04247a6973960e1f37ae73eb4384a6b7) @@ -1,24 +1,25 @@ /************************************************************************** * -* Copyright (c) 2019-2020 Diality Inc. - All Rights Reserved. +* Copyright (c) 2020-2022 Diality Inc. - All Rights Reserved. * * THIS CODE MAY NOT BE COPIED OR REPRODUCED IN ANY FORM, IN PART OR IN * WHOLE, WITHOUT THE EXPLICIT PERMISSION OF THE COPYRIGHT OWNER. * -* @file LoadCell.c +* @file LoadCell.c * -* @author (last) Quang Nguyen -* @date (last) 26-Aug-2020 +* @author (last) Michael Garthwaite +* @date (last) 07-Sep-2022 * -* @author (original) Saeed Nejatali -* @date (original) 25-Feb-2020 +* @author (original) Saeed Nejatali +* @date (original) 25-Feb-2020 * ***************************************************************************/ #include // For load cells calibration calculations #include "FPGA.h" #include "LoadCell.h" +#include "MessageSupport.h" #include "NVDataMgmt.h" #include "PersistentAlarm.h" #include "SystemCommMessages.h" @@ -34,51 +35,59 @@ // TODO check the maximum weight on the load cells in tare. There was 1500 grams limit // but it has been removed. Check the load cells data sheet. -#define LOAD_CELL_REPORT_PERIOD (100 / TASK_PRIORITY_INTERVAL) ///< Broadcast load cell values message every 100 ms. +#define LOAD_CELL_REPORT_PERIOD (100 / TASK_PRIORITY_INTERVAL) ///< Broadcast load cell values message every 100 ms. /// Conversion factor from ADC counts to grams. -static const F32 ADC2GRAM = (0.0894 * 1.1338); -#define LOAD_CELL_FILTER_ALPHA 0.05 ///< Alpha factor for the alpha filter used on load cell readings. +static const F32 ADC2GRAM = (0.0894F * 1.1338F); -#define SIZE_OF_SMALL_LOAD_CELL_AVG 100 ///< Small load cell moving average has 100 raw samples @ 10ms intervals (1-second). -#define SIZE_OF_LARGE_LOAD_CELL_AVG 40 ///< Large load cell moving average has 40 samples from small filter @ 100ms intervals (4-second). +#define SIZE_OF_SMALL_LOAD_CELL_AVG 100 ///< Small load cell moving average has 100 raw samples @ 10ms intervals (1-second). +#define SIZE_OF_LARGE_LOAD_CELL_AVG 40 ///< Large load cell moving average has 40 samples from small filter @ 100ms intervals (4-second). -#define LOAD_CELL_ADC_ERROR_PERSISTENCE 500 ///< Alarm persistence period (in ms) for load cell ADC errors. -#define EMPTY_RESERVOIR_WEIGHT_GRAMS 1600 ///< Reservoirs empty weight in grams. -#define MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS 300 ///< Max allowed extra weight before tare in grams. +#define LOAD_CELL_ADC_ERROR_PERSISTENCE 500 ///< Alarm persistence period (in ms) for load cell ADC errors. +#define LOAD_CELL_MIN_ALLOWED_WEIGHT_GRAMS 0.0F ///< Load cell minimum allowed weight in grams. +#define LOAD_CELL_MAX_ALLOWED_WEIGHT_GRAMS 4500.0F ///< Load cell maximum allowed weight in grams. +#define LOAD_CELL_MIN_ALLOWED_WEIGHT_BEFORE_TARE_GRAMS 1600.0F ///< Load cell minimum allowed weight before tare in grams. +#define LOAD_CELL_WEIGHT_OUT_RANGE_PERSISTENT_PERIOD_MS (5 * MS_PER_SECOND) ///< Load cell weight out of range persistent period in milliseconds. +#define LOAD_CELL_PRIMARY_BACKUP_MAX_DRIFT_PERSISTENT_PERIOD_MS (5 * MS_PER_SECOND) ///< Load cell primary and backup maximum allowed weight drift persistent period in milliseconds. +#define EMPTY_RESERVOIR_WEIGHT_GRAMS 1600.0F ///< Reservoirs empty weight in grams. +#define MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_FIRST_TARE_GRAMS 300.0F ///< Max allowed extra weight before first tare in grams. +#define MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS 60.0F ///< Max allowed extra weight before tare in grams. +#define LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS 60.0F ///< Load cell primary and backup maximum allowed weight drift in grams. +#define DATA_PUBLISH_COUNTER_START_COUNT 0 ///< Data publish counter start count. /// Load cell data structure. typedef struct { - U32 rawReading; ///< Latest raw load cell reading - OVERRIDE_F32_T weight; ///< Latest load cell weight - F32 autoCalOffset; ///< Load cell auto-calibration offset - F32 loadCellVelocity_g_min; ///< Velocity (in g/min) of load cell. + U32 rawReading; ///< Latest raw load cell reading. + F32 weight; ///< Latest load cell weight. + F32 autoCalOffset; ///< Load cell auto-calibration offset. + F32 loadCellVelocity_g_min; ///< Velocity (in g/min) of load cell. - F32 smallFilterReadings[ SIZE_OF_SMALL_LOAD_CELL_AVG ]; ///< Load cell samples for small load cell moving average. - F64 smallFilterTotal; ///< Small filter rolling total - used to calc small load cell moving average. - F32 smallFilteredWeight; ///< Load cell small filtered (100 100Hz raw sample) weight. + F32 smallFilterReadings[ SIZE_OF_SMALL_LOAD_CELL_AVG ]; ///< Load cell samples for small load cell moving average. + F64 smallFilterTotal; ///< Small filter rolling total - used to calc small load cell moving average. + OVERRIDE_F32_T smallFilteredWeight; ///< Load cell small filtered (100 100Hz raw sample) weight. - F32 largeFilterReadings[ SIZE_OF_LARGE_LOAD_CELL_AVG ]; ///< Load cell samples for large load cell moving average. - F64 largeFilterTotal; ///< Large filter rolling total - used to calc small load cell moving average. - F32 largeFilteredWeight; ///< Load cell large filtered (40 10Hz filtered sample) weight. + F32 largeFilterReadings[ SIZE_OF_LARGE_LOAD_CELL_AVG ]; ///< Load cell samples for large load cell moving average. + F64 largeFilterTotal; ///< Large filter rolling total - used to calc small load cell moving average. + F32 largeFilteredWeight; ///< Load cell large filtered (40 10Hz filtered sample) weight. } LOADCELL_T; // ********** private data ********** static OVERRIDE_U32_T loadCellDataPublishInterval = { LOAD_CELL_REPORT_PERIOD, - LOAD_CELL_REPORT_PERIOD, 0, 0 }; ///< Broadcast load cell data publish interval. -static LOADCELL_T loadcells[ NUM_OF_LOAD_CELLS ]; ///< Load cell data structures. -static U32 loadCellFilterTimerCount = 0; ///< Load cell filtering timer count. -static U32 loadCellDataPublicationTimerCounter = 0; ///< Load cell data publication timer counter to CAN bus. + LOAD_CELL_REPORT_PERIOD, 0, 0 }; ///< Broadcast load cell data publish interval. +static LOADCELL_T loadcells[ NUM_OF_LOAD_CELLS ]; ///< Load cell data structures. +static U32 loadCellFilterTimerCount = 0; ///< Load cell filtering timer count. +static U32 loadCellDataPublicationTimerCounter; ///< Load cell data publication timer counter to CAN bus. -static U32 smallReadingsIdx; ///< Index for next sample in load cell small rolling average sample array. -static U32 largeReadingsIdx; ///< Index for next sample in load cell large rolling average sample array. -static DG_LOAD_CELLS_CAL_RECORD_T loadCellsCalRecord; ///< Load cells calibration record. +static U32 smallReadingsIdx; ///< Index for next sample in load cell small rolling average sample array. +static U32 largeReadingsIdx; ///< Index for next sample in load cell large rolling average sample array. +static DG_LOAD_CELLS_CAL_RECORD_T loadCellsCalRecord; ///< Load cells calibration record. +static BOOL hasLoadCellBeenTared[ NUM_OF_LOAD_CELLS ]; ///< Flags indicating whether loadcells have been tared yet. // ********** private function prototypes ********** -static U32 getLoadCellDataPublishInterval( void ); -static BOOL processCalibrationData( void ); +static void monitorLoadCellsWeightOutOfRange( LOAD_CELL_ID_T loadCell ); +static void monitorLoadCellsPrimaryBackupDriftOutOfRange( void ); /*********************************************************************//** * @brief @@ -87,32 +96,34 @@ * @details Outputs: LoadCell module initialized. * @return none *************************************************************************/ -void initLoadCell( void ) + void initLoadCell( void ) { - U32 cell; U32 i; U32 j; - smallReadingsIdx = 0; - largeReadingsIdx = 0; + smallReadingsIdx = 0; + largeReadingsIdx = 0; + loadCellDataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; + loadCellFilterTimerCount = 0; + // Initialize load cell filter data and set calibration data as benign until loaded from non-volatile memory for ( i = 0; i < NUM_OF_LOAD_CELLS; i++ ) { - loadcells[ i ].rawReading = 0; + benignPolynomialCalRecord( &loadCellsCalRecord.loadCells[ i ] ); - loadcells[ i ].weight.data = 0.0; - loadcells[ i ].weight.ovData = 0.0; - loadcells[ i ].weight.ovInitData = 0.0; - loadcells[ i ].weight.override = OVERRIDE_RESET; + hasLoadCellBeenTared[ i ] = FALSE; + loadcells[ i ].rawReading = 0; + loadcells[ i ].weight = 0.0; + loadcells[ i ].autoCalOffset = 0.0; + loadcells[ i ].largeFilterTotal = 0.0; + loadcells[ i ].largeFilteredWeight = 0.0; + loadcells[ i ].smallFilterTotal = 0.0; + loadcells[ i ].smallFilteredWeight.data = 0.0; + loadcells[ i ].smallFilteredWeight.ovData = 0.0; + loadcells[ i ].smallFilteredWeight.ovInitData = 0.0; + loadcells[ i ].smallFilteredWeight.override = OVERRIDE_RESET; - loadcells[ i ].autoCalOffset = 0.0; - loadcells[ i ].largeFilterTotal = 0.0; - loadcells[ i ].largeFilteredWeight = 0.0; - - loadcells[ i ].smallFilterTotal = 0.0; - loadcells[ i ].smallFilteredWeight = 0.0; - for ( j = 0; j < SIZE_OF_SMALL_LOAD_CELL_AVG; j++ ) { loadcells[ i ].smallFilterReadings[ j ] = 0.0; @@ -126,19 +137,14 @@ loadcells[ i ].loadCellVelocity_g_min = 0.0; } - // Set all the load cells' calibration values to benign values - for ( cell = CAL_DATA_LOAD_CELL_A1; cell < NUM_OF_CAL_DATA_LOAD_CELLS; cell++ ) - { - // Reset the calibration variables - loadCellsCalRecord.loadCells[ cell ].fourthOrderCoeff = 0.0; - loadCellsCalRecord.loadCells[ cell ].thirdOrderCoeff = 0.0; - loadCellsCalRecord.loadCells[ cell ].secondOrderCoeff = 0.0; - loadCellsCalRecord.loadCells[ cell ].gain = 1.0; - loadCellsCalRecord.loadCells[ cell ].offset = 0.0; - } - // Initialize persistent alarm(s) initPersistentAlarm( ALARM_ID_DG_LOAD_CELL_ADC_ERROR, 0, LOAD_CELL_ADC_ERROR_PERSISTENCE ); + + initPersistentAlarm( ALARM_ID_DG_LOAD_CELL_WEIGHT_OUT_OF_RANGE, LOAD_CELL_WEIGHT_OUT_RANGE_PERSISTENT_PERIOD_MS, + LOAD_CELL_WEIGHT_OUT_RANGE_PERSISTENT_PERIOD_MS ); + + initPersistentAlarm( ALARM_ID_DG_LOAD_CELL_PRIMARY_BACKUP_DRIFT_OUT_OF_RANGE, LOAD_CELL_PRIMARY_BACKUP_MAX_DRIFT_PERSISTENT_PERIOD_MS, + LOAD_CELL_PRIMARY_BACKUP_MAX_DRIFT_PERSISTENT_PERIOD_MS ); } /*********************************************************************//** @@ -152,32 +158,35 @@ void execLoadCell( void ) { U32 ii; + U32 a1 = getFPGALoadCellA1(); U32 a2 = getFPGALoadCellA2(); U32 b1 = getFPGALoadCellB1(); U32 b2 = getFPGALoadCellB2(); // update sums for load cell average calculations loadcells[ LOAD_CELL_RESERVOIR_1_PRIMARY ].rawReading = a1 & MASK_OFF_U32_MSB; - loadcells[ LOAD_CELL_RESERVOIR_1_BACKUP ].rawReading = a2 & MASK_OFF_U32_MSB; + loadcells[ LOAD_CELL_RESERVOIR_1_BACKUP ].rawReading = a2 & MASK_OFF_U32_MSB; loadcells[ LOAD_CELL_RESERVOIR_2_PRIMARY ].rawReading = b1 & MASK_OFF_U32_MSB; - loadcells[ LOAD_CELL_RESERVOIR_2_BACKUP ].rawReading = b2 & MASK_OFF_U32_MSB; + loadcells[ LOAD_CELL_RESERVOIR_2_BACKUP ].rawReading = b2 & MASK_OFF_U32_MSB; // Check error bits from new readings - a1 = ( a1 >> 31 ) << SHIFT_24_BITS; - a2 = ( a2 >> 31 ) << SHIFT_16_BITS_FOR_WORD_SHIFT; - b1 = ( b1 >> 31 ) << SHIFT_8_BITS_FOR_BYTE_SHIFT; - b2 = ( b2 >> 31 ); + a1 = ( a1 >> SHIFT_BITS_BY_31 ) << SHIFT_24_BITS; + a2 = ( a2 >> SHIFT_BITS_BY_31 ) << SHIFT_16_BITS_FOR_WORD_SHIFT; + b1 = ( b1 >> SHIFT_BITS_BY_31 ) << SHIFT_8_BITS_FOR_BYTE_SHIFT; + b2 = ( b2 >> SHIFT_BITS_BY_31 ); if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_DG_LOAD_CELL_ADC_ERROR, ( ( a1 > 0 ) || ( a2 > 0 ) || ( b1 > 0 ) || ( b2 > 0 ) ) ) ) { SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_LOAD_CELL_ADC_ERROR, ( a1 | a2 | b1 | b2 ) ) } + // TODO use ALARM_ID_DG_LOAD_CELL_FPGA_READ_ERROR for read error + // Check if a new calibration is available - if ( isNewCalibrationRecordAvailable() == TRUE ) + if ( TRUE == isNewCalibrationRecordAvailable() ) { - // Get the new calibration data and check its validity - processCalibrationData(); + getNVRecord2Driver( GET_CAL_LOAD_CELL_SENSORS, (U08*)&loadCellsCalRecord, sizeof( DG_LOAD_CELLS_CAL_RECORD_T ), + NUM_OF_CAL_DATA_LOAD_CELLS, ALARM_ID_DG_LOAD_CELLS_INVALID_CAL_RECORD ); // Zero the current tare values when new calibration data is available loadcells[ LOAD_CELL_RESERVOIR_1_PRIMARY ].autoCalOffset = 0.0; @@ -189,23 +198,32 @@ // Rolling average of last 100 raw samples in small filter for ( ii = 0; ii < NUM_OF_LOAD_CELLS; ++ii ) { - loadcells[ ii ].weight.data = (F32)loadcells[ ii ].rawReading * ADC2GRAM; + F32 loadCell = (F32)loadcells[ ii ].rawReading * ADC2GRAM; + // Apply the calibration factors to the data. // load_cell_weight = fourth_order_coeff * (load_cell^4) + third_order_coeff * (load_cell^3) + second_order_coeff * (load_cell^2) + gain * load_cell + offset - loadcells[ ii ].weight.data = pow(loadcells[ ii ].weight.data, 4) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].fourthOrderCoeff + - pow(loadcells[ ii ].weight.data, 3) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].thirdOrderCoeff + - pow(loadcells[ ii ].weight.data, 2) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].secondOrderCoeff + - loadcells[ ii ].weight.data * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].gain + - loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].offset; - loadcells[ ii ].weight.data = loadcells[ ii ].weight.data - loadcells[ ii ].autoCalOffset; + loadcells[ ii ].weight = pow(loadCell, 4) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].fourthOrderCoeff + + pow(loadCell, 3) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].thirdOrderCoeff + + pow(loadCell, 2) * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].secondOrderCoeff + + loadCell * loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].gain + + loadCellsCalRecord.loadCells[ (CAL_DATA_DG_LOAD_CELLS_T)ii ].offset; - loadcells[ ii ].loadCellVelocity_g_min = ( getLoadCellWeight( (LOAD_CELL_ID_T)ii ) - loadcells[ ii ].smallFilterReadings[ smallReadingsIdx ] ) * (F32)SEC_PER_MIN; + loadcells[ ii ].loadCellVelocity_g_min = ( getLoadCellWeight( (LOAD_CELL_ID_T)ii ) - + loadcells[ ii ].smallFilterReadings[ smallReadingsIdx ] ) * (F32)SEC_PER_MIN; // Update small filter with new weight sample loadcells[ ii ].smallFilterTotal -= loadcells[ ii ].smallFilterReadings[ smallReadingsIdx ]; loadcells[ ii ].smallFilterReadings[ smallReadingsIdx ] = getLoadCellWeight( (LOAD_CELL_ID_T)ii ); loadcells[ ii ].smallFilterTotal += getLoadCellWeight( (LOAD_CELL_ID_T)ii ); - loadcells[ ii ].smallFilteredWeight = (F32)( loadcells[ ii ].smallFilterTotal / (F64)SIZE_OF_SMALL_LOAD_CELL_AVG ); + + // Calculate the load cell value before applying calibration to it + loadcells[ ii ].smallFilteredWeight.data = (F32)( loadcells[ ii ].smallFilterTotal / (F64)SIZE_OF_SMALL_LOAD_CELL_AVG ); + + // Monitor the load cells weight + monitorLoadCellsWeightOutOfRange( (LOAD_CELL_ID_T)ii ); + + // Apply the tare offset. NOTE: tare must be applied after checking the weight out of range. + loadcells[ ii ].smallFilteredWeight.data -= loadcells[ ii ].autoCalOffset; } smallReadingsIdx = INC_WRAP( smallReadingsIdx, 0, SIZE_OF_SMALL_LOAD_CELL_AVG - 1 ); @@ -217,8 +235,8 @@ { // Update large filter with new small filter weight sample loadcells[ ii ].largeFilterTotal -= loadcells[ ii ].largeFilterReadings[ largeReadingsIdx ]; - loadcells[ ii ].largeFilterReadings[ largeReadingsIdx ] = loadcells[ ii ].smallFilteredWeight; - loadcells[ ii ].largeFilterTotal += loadcells[ ii ].smallFilteredWeight; + loadcells[ ii ].largeFilterReadings[ largeReadingsIdx ] = getLoadCellSmallFilteredWeight((LOAD_CELL_ID_T) ii); + loadcells[ ii ].largeFilterTotal += getLoadCellSmallFilteredWeight((LOAD_CELL_ID_T) ii); loadcells[ ii ].largeFilteredWeight = (F32)( loadcells[ ii ].largeFilterTotal / (F64)SIZE_OF_LARGE_LOAD_CELL_AVG ); } @@ -227,16 +245,23 @@ } // broadcast load cell data if we are at scheduled interval. - if ( ++loadCellDataPublicationTimerCounter >= getLoadCellDataPublishInterval() ) + if ( ++loadCellDataPublicationTimerCounter >= getU32OverrideValue( &loadCellDataPublishInterval ) ) { - loadCellDataPublicationTimerCounter = 0; + LOAD_CELL_DATA_T loadCellData; - // broadcast small filtered load cell data - broadcastLoadCellData( loadcells[ LOAD_CELL_RESERVOIR_1_PRIMARY ].smallFilteredWeight, - loadcells[ LOAD_CELL_RESERVOIR_1_BACKUP ].smallFilteredWeight, - loadcells[ LOAD_CELL_RESERVOIR_2_PRIMARY ].smallFilteredWeight, - loadcells[ LOAD_CELL_RESERVOIR_2_BACKUP ].smallFilteredWeight ); + loadCellData.loadCellA1inGram = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ); + loadCellData.loadCellA2inGram = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_BACKUP ); + loadCellData.loadCellB1inGram = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ); + loadCellData.loadCellB2inGram = getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_BACKUP ); + + // Broadcast small filtered load cell data + broadcastData( MSG_ID_LOAD_CELL_READINGS, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&loadCellData, sizeof( LOAD_CELL_DATA_T ) ); + + loadCellDataPublicationTimerCounter = 0; } + + // Monitor the load cells drift + monitorLoadCellsPrimaryBackupDriftOutOfRange(); } /*********************************************************************//** @@ -245,14 +270,15 @@ * It gets the calibration record from NVDataMgmt and checks whether the * values have a calibration date. * @details Inputs: none - * @details Outputs: + * @details Outputs: loadCellsCalRecord * @return result of the load cell self test *************************************************************************/ SELF_TEST_STATUS_T execLoadCellsSelfTest ( void ) { SELF_TEST_STATUS_T result = SELF_TEST_STATUS_IN_PROGRESS; - BOOL calStatus = processCalibrationData(); + BOOL calStatus = getNVRecord2Driver( GET_CAL_LOAD_CELL_SENSORS, (U08*)&loadCellsCalRecord, sizeof( DG_LOAD_CELLS_CAL_RECORD_T ), + NUM_OF_CAL_DATA_LOAD_CELLS, ALARM_ID_DG_LOAD_CELLS_INVALID_CAL_RECORD ); if ( TRUE == calStatus ) { @@ -268,6 +294,29 @@ /*********************************************************************//** * @brief + * The isLoadCellTared function returns load cell tare status + * for a given load cell ID. + * @details Inputs: none + * @details Outputs: load cell tare status + * @param loadCellID ID of load cell tare status + *************************************************************************/ +BOOL isLoadCellTared( LOAD_CELL_ID_T loadCellID ) +{ + BOOL tared = FALSE; + + if ( fabs( loadcells[ loadCellID ].autoCalOffset ) < NEARLY_ZERO ) + { + tared = FALSE; + } + else + { + tared = TRUE; + } + return tared; +} + +/*********************************************************************//** + * @brief * The tareLoadCell function sets the load cell auto calibration offset * for a given load cell ID. * @details Inputs: none @@ -277,29 +326,30 @@ void tareLoadCell( LOAD_CELL_ID_T loadCellID ) { BOOL isWeightOutOfRange = FALSE; + F32 weight = getLoadCellSmallFilteredWeight( loadCellID ); - F32 weight = getLoadCellSmallFilteredWeight( loadCellID ); - // Check if the load cell is being tared for the first time - if ( fabs(loadcells[ loadCellID ].autoCalOffset) < NEARLY_ZERO ) + if ( hasLoadCellBeenTared[ loadCellID ] != TRUE ) { // For the first tare, the weight of the reservoir should be considered // The current weight of the load cell should not be greater than the weight of the reservoir + the extra weight - F32 deltaWeight = fabs( weight - EMPTY_RESERVOIR_WEIGHT_GRAMS ); - isWeightOutOfRange = ( deltaWeight > MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS ? TRUE : FALSE ); + F32 deltaWeight = fabs( weight - EMPTY_RESERVOIR_WEIGHT_GRAMS ); + isWeightOutOfRange = ( deltaWeight > MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_FIRST_TARE_GRAMS ? TRUE : FALSE ); } else { - isWeightOutOfRange = ( fabs(weight) > MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS ? TRUE : FALSE ); + isWeightOutOfRange = ( fabs( weight ) > MAX_ALLOWED_EXTRA_WEIGHT_BEFORE_TARE_GRAMS ? TRUE : FALSE ); } if ( FALSE == isWeightOutOfRange ) { // Add old auto calibration offset to get back to actual weight value - loadcells[ loadCellID ].autoCalOffset = ( loadcells[ loadCellID ].smallFilteredWeight + loadcells[ loadCellID ].autoCalOffset ); + loadcells[ loadCellID ].autoCalOffset = ( loadcells[ loadCellID ].smallFilteredWeight.data + loadcells[ loadCellID ].autoCalOffset ); + hasLoadCellBeenTared[ loadCellID ] = TRUE; } else { + // Raise the alarm SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DG_LOAD_CELLS_TARE_WEIGHT_OUT_OF_RANGE, weight ) } } @@ -328,18 +378,11 @@ *************************************************************************/ F32 getLoadCellWeight( LOAD_CELL_ID_T loadCellID ) { - F32 result = 0; + F32 result = 0.0; if ( loadCellID < NUM_OF_LOAD_CELLS ) { - if ( OVERRIDE_KEY == loadcells[ loadCellID ].weight.override ) - { - result = loadcells[ loadCellID ].weight.ovData; - } - else - { - result = loadcells[ loadCellID ].weight.data; - } + result = loadcells[ loadCellID ].weight; } else { @@ -351,20 +394,25 @@ /*********************************************************************//** * @brief - * The getLoadCellSmallFilteredWeight function gets the small filtered load cell - * weight for a given load cell ID. + * The getLoadCellSmallFilteredWeight function gets the small filtered + * load cell weight for a given load cell ID. * @details Inputs: load cell filtered weight * @details Outputs: none * @param loadCellID ID of load cell to get large filtered weight * @return the small filtered load cell weight for the given load cell ID. *************************************************************************/ F32 getLoadCellSmallFilteredWeight( LOAD_CELL_ID_T loadCellID ) { - F32 result = 0; + F32 result = 0.0; if ( loadCellID < NUM_OF_LOAD_CELLS ) { - result = loadcells[ loadCellID ].smallFilteredWeight; + result = loadcells[ loadCellID ].smallFilteredWeight.data; + + if ( OVERRIDE_KEY == loadcells[ loadCellID ].smallFilteredWeight.override ) + { + result = loadcells[ loadCellID ].smallFilteredWeight.ovData; + } } else { @@ -426,64 +474,63 @@ /*********************************************************************//** * @brief - * The getLoadCellDataPublishInterval function gets the load cell data publish interval. - * @details Inputs: loadCellDataPublishInterval + * The monitorLoadCellsWeightOutOfRange function monitors the weight of the + * load cells and if they are not in range, it raises an alarm. + * @details Inputs: none * @details Outputs: none - * @return the current load cell data publication interval (in ms/task interval). + * @param loadCell which is the load cell ID that its range is checked + * @return none *************************************************************************/ -static U32 getLoadCellDataPublishInterval( void ) +static void monitorLoadCellsWeightOutOfRange( LOAD_CELL_ID_T loadCell ) { - U32 result = loadCellDataPublishInterval.data; + F32 weight = getLoadCellSmallFilteredWeight( loadCell ); + BOOL isWeightOutOfRange = ( weight < LOAD_CELL_MIN_ALLOWED_WEIGHT_GRAMS ) || ( weight > LOAD_CELL_MAX_ALLOWED_WEIGHT_GRAMS ); - if ( OVERRIDE_KEY == loadCellDataPublishInterval.override ) - { - result = loadCellDataPublishInterval.ovData; - } - - return result; + checkPersistentAlarm( ALARM_ID_DG_LOAD_CELL_WEIGHT_OUT_OF_RANGE, isWeightOutOfRange, weight, LOAD_CELL_MAX_ALLOWED_WEIGHT_GRAMS ); } /*********************************************************************//** * @brief - * The processCalibrationData function gets the calibration data and makes - * sure it is valid by checking the calibration date. The calibration date - * should not be 0. - * @details Inputs: loadCellsCalRecord - * @details Outputs: loadCellsCalRecord - * @return TRUE if the calibration record is valid, otherwise FALSE + * The monitorLoadCellsPrimaryBackupDriftOutOfRange function monitors the + * load cells' primary and backup drift. + * @details Inputs: none + * @details Outputs: none + * @return none *************************************************************************/ -static BOOL processCalibrationData( void ) +static void monitorLoadCellsPrimaryBackupDriftOutOfRange( void ) { - BOOL status = TRUE; - U32 cell; + F32 drift = 0.0; + F32 loadCellADrift = 0.0; + F32 loadCellBDrift = 0.0; + BOOL isDriftOutOfRange = FALSE; - // Get the calibration record from NVDataMgmt - DG_LOAD_CELLS_CAL_RECORD_T calData = getDGLoadCellsCalibrationRecord(); + // Test is valid after load cells are tared + if ( isLoadCellTared( LOAD_CELL_RESERVOIR_1_PRIMARY ) && isLoadCellTared( LOAD_CELL_RESERVOIR_1_BACKUP ) ) + { + loadCellADrift = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_PRIMARY ) - + getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_1_BACKUP ) ); + } + if ( isLoadCellTared( LOAD_CELL_RESERVOIR_2_PRIMARY ) && isLoadCellTared( LOAD_CELL_RESERVOIR_2_BACKUP ) ) + { + loadCellBDrift = fabs( getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_PRIMARY ) - + getLoadCellSmallFilteredWeight( LOAD_CELL_RESERVOIR_2_BACKUP ) ); + } - for ( cell = 0; cell < NUM_OF_CAL_DATA_LOAD_CELLS; cell++ ) + if ( ( loadCellADrift > LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ) || + ( loadCellBDrift > LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ) ) { - // Check if the calibration data that was received from NVDataMgmt is legitimate - // The calibration date item should not be zero. If the calibration date is 0, - // then the load cells data is not stored in the NV memory or it was corrupted. - if ( calData.loadCells[ cell ].calibrationTime == 0 ) - { -#ifndef DISABLE_CAL_CHECK - SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_LOAD_CELLS_INVALID_CALIBRATION, (U32)cell ); -#endif - status = FALSE; - } - else - { - // The calibration data was valid, update the local copy - loadCellsCalRecord.loadCells[ cell ].fourthOrderCoeff = calData.loadCells[ cell ].fourthOrderCoeff; - loadCellsCalRecord.loadCells[ cell ].thirdOrderCoeff = calData.loadCells[ cell ].thirdOrderCoeff; - loadCellsCalRecord.loadCells[ cell ].secondOrderCoeff = calData.loadCells[ cell ].secondOrderCoeff; - loadCellsCalRecord.loadCells[ cell ].gain = calData.loadCells[ cell ].gain; - loadCellsCalRecord.loadCells[ cell ].offset = calData.loadCells[ cell ].offset; - } + isDriftOutOfRange = TRUE; + drift = ( loadCellADrift > LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ? loadCellADrift : loadCellBDrift ); } + else + { + isDriftOutOfRange = FALSE; + // Pick the biggest drift in between the two load cells when none of the is above range + drift = ( loadCellADrift > loadCellBDrift ? loadCellADrift : loadCellBDrift ); + } - return status; + checkPersistentAlarm( ALARM_ID_DG_LOAD_CELL_PRIMARY_BACKUP_DRIFT_OUT_OF_RANGE, isDriftOutOfRange, drift, + LOAD_CELL_PRIMARY_BACKUP_MAX_ALLOWED_DRIFT_GRAMS ); } @@ -510,8 +557,9 @@ if ( TRUE == isTestingActivated() ) { result = TRUE; - loadcells[ loadCellID ].weight.ovData = value; - loadcells[ loadCellID ].weight.override = OVERRIDE_KEY; + // Add tare to given value so reported load will be what is requested when tare is subtracted later + loadcells[ loadCellID ].smallFilteredWeight.ovData = value; + loadcells[ loadCellID ].smallFilteredWeight.override = OVERRIDE_KEY; } } @@ -535,8 +583,8 @@ if ( TRUE == isTestingActivated() ) { result = TRUE; - loadcells[ loadCellID ].weight.override = OVERRIDE_RESET; - loadcells[ loadCellID ].weight.ovData = loadcells[ loadCellID ].weight.ovInitData; + loadcells[ loadCellID ].smallFilteredWeight.override = OVERRIDE_RESET; + loadcells[ loadCellID ].smallFilteredWeight.ovData = loadcells[ loadCellID ].smallFilteredWeight.ovInitData; } }