Index: firmware/App/Controllers/ROPump.c =================================================================== diff -u -r00b32a5dad2e136d31cfaf0de16f7767b9920fec -r28b5f2e7f757647145a82a39aca0a5f3652c68a1 --- firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 00b32a5dad2e136d31cfaf0de16f7767b9920fec) +++ firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 28b5f2e7f757647145a82a39aca0a5f3652c68a1) @@ -26,16 +26,14 @@ #include "PersistentAlarm.h" #include "Pressures.h" #include "ROPump.h" +#include "SafetyShutdown.h" #include "SystemCommMessages.h" #include "TaskGeneral.h" #include "TaskPriority.h" #include "Timers.h" #ifdef EMC_TEST_BUILD #include "Heaters.h" #endif -#ifdef ENABLE_DIP_SWITCHES -#include "Valves.h" -#endif /** * @addtogroup ROPump @@ -46,152 +44,156 @@ #define RO_PUMP_DATA_PUB_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< Interval (ms/task time) at which the RO Pump data is published on the CAN bus. -#define MAX_RO_PUMP_DUTY_CYCLE 0.99 ///< max duty cycle. -#define MIN_RO_PUMP_DUTY_CYCLE 0.0 ///< min duty cycle. +#define MAX_RO_PUMP_DUTY_CYCLE 0.99 ///< Max duty cycle. +#define MIN_RO_PUMP_DUTY_CYCLE 0.0 ///< Min duty cycle. -#define ROP_CONTROL_INTERVAL ( MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< interval (ms/task time) at which the RO pump is controlled. -#define ROP_P_COEFFICIENT 0.0020 ///< P term for RO pump pressure control. -#define ROP_I_COEFFICIENT 0.0015 ///< I term for RO pump pressure control. +#define ROP_CONTROL_INTERVAL ( MS_PER_SECOND / TASK_GENERAL_INTERVAL ) ///< Interval (ms/task time) at which the RO pump is controlled. +#define ROP_RAMP_UP_CONTROL_INTERVAL ( 500 / TASK_GENERAL_INTERVAL ) ///< Interval (ms/task time) at which the RO pump is controlled. +#define ROP_RAMP_UP_P_COEFFICIENT 0.22 ///< P term for RO pump ramp up to flow control. +#define ROP_FLOW_CONTROL_P_COEFFICIENT 0.25 ///< P term for RO pump flow control. +#define ROP_FLOW_CONTROL_I_COEFFICIENT 0.25 ///< I term for RO pump flow control. +#define ROP_MAX_PRESSURE_P_COEFFICIENT 0.01 ///< P term for RO pump max pressure control. +#define ROP_MAX_PRESSURE_I_COEFFICIENT 0.01 ///< I term for RO pump max pressure control. -#define ROP_RAMP_UP_P_COEFFICIENT 0.0 ///< P term for RO pump flow control. -#define ROP_RAMP_UP_I_COEFFICIENT 0.1 ///< I term for RO pump flow control. -#define ROP_FLOW_TARGET_TOLERANCE 0.05 ///< Tolerance in between the target flow rate and the actual flow rate in liter. +#define ROP_FLOW_TARGET_TOLERANCE 0.03 ///< Tolerance in between the target flow rate and the actual flow rate in percentage. +#define ROP_RAMP_DOWN_DUTY_CYCLE_RATIO 0.03 ///< Pump ramp down duty cycle ratio when the pressure higher than max defined. #define FLOW_SENSOR_ZERO_READING 0xFFFF ///< Flow sensor reading indicates zero flow (or flow lower than can be detected by sensor). #define FLOW_SAMPLES_TO_AVERAGE ( 250 / TASK_PRIORITY_INTERVAL ) ///< Averaging flow data over 250 ms intervals. #define FLOW_AVERAGE_MULTIPLIER ( 1.0 / (F32)FLOW_SAMPLES_TO_AVERAGE ) ///< Optimization - multiplying is faster than dividing. -#define FLOW_VERIFICATION_COUNTER_TARGET 40U ///< The time in counts to check the flow and make sure it is in range. -#define RO_FLOW_ADC_TO_LPM_FACTOR 10909.0909 ///< conversion factor from ADC counts to LPM (liters/min) for RO flow rate (multiply this by inverse of FPGA reading). +#define RO_FLOW_ADC_TO_LPM_FACTOR 5555 ///< Conversion factor from ADC counts to LPM (liters/min) for RO flow rate (multiply this by inverse of FPGA reading). -#define ROP_FLOW_TO_PWM_DC(flow) ( (F32)( flow / MAX_RO_FLOWRATE_LPM ) ) ///< Initial conversion factor from target flow rate to PWM duty cycle estimate. +#define ROP_FLOW_TO_PWM_SLOPE 0.1 ///< Slope of flow to PWM line equation. +#define ROP_FLOW_TO_PWM_INTERCEPT 0.0 ///< Intercept of flow to PWM line equation. + /// Initial conversion factor from target flow rate to PWM duty cycle estimate. +#define ROP_FLOW_TO_PWM_DC(flow) ( ROP_FLOW_TO_PWM_SLOPE * flow + ROP_FLOW_TO_PWM_INTERCEPT ) + #define FLOW_SENSOR_ZERO_READING 0xFFFF ///< Flow sensor reading indicates zero flow (or flow lower than can be detected by sensor). #define MAX_ALLOWED_FLOW_DEVIATION 0.1 ///< Max allowed deviation from target flow. -#define FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL 5 * MS_PER_SECOND ///< Flow out of range time out in counts. +#define FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL ( 12 * MS_PER_SECOND ) ///< Flow out of range time out in counts. #define MAX_PRESSURE_TARGET_TOLERANCE 5 ///< Pressure tolerance from maximum set pressure by user in psi. #define MAX_ALLOWED_PRESSURE_PSI 130 ///< Maximum allowed pressure that the RO pump can go to. #define MIN_ALLOWED_PRESSURE_PSI 10 ///< Minimum allowed pressure that the RO pump can go to. #define MAX_ALLOWED_MEASURED_PRESSURE_PSI 135 ///< Maximum allowed pressure that the sensor measures. RO pump shut off pressure is 140psi. #define MAX_PRESSURE_OUT_OF_RANGE_PERSISTENT_INTERVAL MS_PER_SECOND ///< Maximum allowed time that the pressure can be very high. -#define MAX_ALLOWED_RAMP_UP_TIME ( 30 * MS_PER_SECOND ) ///< Maximum allowed ramp up time to a flow rate in ms. -#define RAMP_UP_TIME_OUT_COUNT ( MAX_ALLOWED_RAMP_UP_TIME / \ - TASK_GENERAL_INTERVAL ) ///< Ramp up time out in counts. -#define ROP_PSI_TO_PWM_DC(p) ( 0.2 + ( (F32)((p) - 100) * 0.01 ) ) ///< conversion factor from target PSI to PWM duty cycle estimate. TODO remove? +#define MAX_ALLOWED_RAMP_UP_TIME ( 10 * MS_PER_SECOND ) ///< Maximum allowed ramp up time to a flow rate in ms. +#define ROP_PSI_TO_PWM_DC(p) ( 0.2 + ( (F32)((p) - 100) * 0.01 ) ) ///< Conversion factor from target PSI to PWM duty cycle estimate. +#define SAFETY_SHUTDOWN_TIMEOUT ( 3 * MS_PER_SECOND ) ///< RO pump safety shutdown activation timeout in ms. /// Enumeration of RO pump states. typedef enum ROPump_States { - RO_PUMP_OFF_STATE = 0, ///< RO pump off state - RO_PUMP_RAMP_UP_STATE, ///< RO pump ramp up to target flow rate state - RO_PUMP_VERIFY_FLOW_STATE, ///< RO pump maintain the flow rate for a set period of time - RO_PUMP_CONTROL_TO_TARGET_STATE, ///< RO pump control to target pressure state - RO_PUMP_OPEN_LOOP_STATE, ///< RO pump open loop state - NUM_OF_RO_PUMP_STATES ///< Number of RO pump states + RO_PUMP_OFF_STATE = 0, ///< RO pump off state. + RO_PUMP_RAMP_UP_TO_TARGET_FLOW_STATE, ///< RO pump ramp up to target flow rate state. + RO_PUMP_CONTROL_TO_TARGET_FLOW_STATE, ///< RO pump control to target flow state. + RO_PUMP_CONTROL_TO_MAX_PRESSURE_STATE, ///< RO pump control to max pressure state. + RO_PUMP_OPEN_LOOP_STATE, ///< RO pump open loop state. + NUM_OF_RO_PUMP_STATES ///< Number of RO pump states. } RO_PUMP_STATE_T; /// Enumeration of RO pump self-test states. typedef enum ROPump_Self_Test_States { - RO_PUMP_SELF_TEST_STATE_START = 0, ///< RO pump self-test start state - RO_PUMP_TEST_STATE_IN_PROGRESS, ///< RO pump self-tests in progress state - RO_PUMP_TEST_STATE_COMPLETE, ///< RO pump self-tests completed state - NUM_OF_RO_PUMP_SELF_TEST_STATES ///< Number of RO pump self-test states + RO_PUMP_SELF_TEST_STATE_START = 0, ///< RO pump self-test start state. + RO_PUMP_TEST_STATE_IN_PROGRESS, ///< RO pump self-tests in progress state. + RO_PUMP_TEST_STATE_COMPLETE, ///< RO pump self-tests completed state. + NUM_OF_RO_PUMP_SELF_TEST_STATES ///< Number of RO pump self-test states. } RO_PUMP_SELF_TEST_STATE_T; // ********** private data ********** -static RO_PUMP_STATE_T roPumpState = RO_PUMP_OFF_STATE; ///< current state of RO pump controller state machine -static U32 roPumpDataPublicationTimerCounter = 0; ///< used to schedule RO pump data publication to CAN bus -static BOOL isROPumpOn = FALSE; ///< RO pump is currently running -static F32 roPumpPWMDutyCyclePct = 0.0; ///< initial RO pump PWM duty cycle -static F32 roPumpDutyCyclePctSet = 0.0; ///< currently set RO pump PWM duty cycle -static PUMP_CONTROL_MODE_T roPumpControlMode = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< requested RO pump control mode -static PUMP_CONTROL_MODE_T roPumpControlModeSet = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< currently set RO pump control mode +static RO_PUMP_STATE_T roPumpState = RO_PUMP_OFF_STATE; ///< Current state of RO pump controller state machine. +static U32 roPumpDataPublicationTimerCounter = 0; ///< Used to schedule RO pump data publication to CAN bus. +static BOOL isROPumpOn = FALSE; ///< RO pump is currently running. +static F32 roPumpPWMDutyCyclePct = 0.0; ///< Initial RO pump PWM duty cycle. +static F32 roPumpDutyCyclePctSet = 0.0; ///< Currently set RO pump PWM duty cycle. +static PUMP_CONTROL_MODE_T roPumpControlMode = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< Requested RO pump control mode. +static PUMP_CONTROL_MODE_T roPumpControlModeSet = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< Currently set RO pump control mode. TODO do we need this? -static F32 targetROPumpFlowRate = 0.0; ///< Target RO flow rate (in L/min) -static U32 targetROPumpPressure = 0; ///< Target RO pressure (in PSI) +static F32 targetROPumpFlowRate = 0.0; ///< Target RO flow rate (in L/min). +static F32 targetROPumpMaxPressure = 0.0; ///< Target RO max allowed pressure (in PSI). static OVERRIDE_U32_T roPumpDataPublishInterval = { RO_PUMP_DATA_PUB_INTERVAL, RO_PUMP_DATA_PUB_INTERVAL, - 0, 0 }; ///< Interval (in ms) at which to publish RO flow data to CAN bus -static OVERRIDE_F32_T measuredROFlowRateLPM = { 0.0, 0.0, 0.0, 0 }; ///< measured RO flow rate (in L/min) + 0, 0 }; ///< Interval (in ms) at which to publish RO flow data to CAN bus. +static OVERRIDE_F32_T measuredROFlowRateLPM = { 0.0, 0.0, 0.0, 0 }; ///< Measured RO flow rate (in L/min). -static U32 flowVerificationCounter = 0; ///< Counter to verify the flow is in range -static U32 roControlTimerCounter = 0; ///< determines when to perform control on RO pump -static F32 roPumpOpenLoopTargetDutyCycle = 0; ///< Target RO pump open loop PWM -static F32 roPumpFlowRateRunningSum = 0; ///< RO pump flow rate running sum -static F32 roPumpPressureRunningSum = 0; ///< RO pump pressure running sum +static U32 roControlTimerCounter = 0; ///< Determines when to perform control on RO pump. +static F32 roPumpOpenLoopTargetDutyCycle = 0; ///< Target RO pump open loop PWM. /* TODO These variables are used for POST. POST has not been implemented yet -static RO_PUMP_SELF_TEST_STATE_T roPumpSelfTestState = RO_PUMP_SELF_TEST_STATE_START; ///< Current ro pump self test state -static U32 roPumpSelfTestTimerCount = 0; ///< Timer counter for ro pump self test +static RO_PUMP_SELF_TEST_STATE_T roPumpSelfTestState = RO_PUMP_SELF_TEST_STATE_START; ///< Current RO pump self test state. +static U32 roPumpSelfTestTimerCount = 0; ///< Timer counter for RO pump self test. */ -static S32 measuredFlowReadingsSum = 0; ///< Raw flow reading sums for averaging -static U32 flowFilterCounter = 0; ///< Flow filtering counter -static U32 rampUp2FlowTimeoutCounter = 0; ///< Counter for ramping up to flow time +static S32 measuredFlowReadingsSum = 0; ///< Raw flow reading sums for averaging. +static U32 flowFilterCounter = 0; ///< Flow filtering counter. // ********** private function prototypes ********** static RO_PUMP_STATE_T handleROPumpOffState( void ); -static RO_PUMP_STATE_T handleROPumpRampUpState( void ); -static RO_PUMP_STATE_T handleROPumpVerifyFlowState( void ); -static RO_PUMP_STATE_T handleROPumpControlToTargetState( void ); +static RO_PUMP_STATE_T handleROPumpRampUpToTargetFlowState( void ); +static RO_PUMP_STATE_T handleROPumpControlToTargetFlowState( void ); +static RO_PUMP_STATE_T handleROPumpControlToMaxPressureState( void ); static RO_PUMP_STATE_T handleROPumpOpenLoopState( void ); static void setROPumpTargetDutyCycle( F32 duty ); static void setROPumpControlSignalDutyCycle( F32 dutyCycle ); static void stopROPump( void ); static void publishROPumpData( void ); -static U32 getPublishROPumpDataInterval( void ); +static U32 getPublishROPumpDataInterval( void ); /*********************************************************************//** * @brief * The initROPump function initializes the RO Pump module. - * @details Inputs: rampUp2FlowTimeoutCounter - * @details Outputs: rampUp2FlowTimeoutCounter + * @details Inputs: roControlTimerCounter,roPumpOpenLoopTargetDutyCycle, + * roPumpFlowRateRunningSum, roPumpPressureRunningSum, measuredFlowReadingsSum, + * flowFilterCounter, flowVerificationCounter, roPumpState, roPumpControlMode + * roPumpDataPublicationTimerCounter, roPumpControlModeSet + * @details Outputs: none * @return none *************************************************************************/ void initROPump( void ) { stopROPump(); - // Initialize RO pump PI controller - initializePIController( PI_CONTROLLER_ID_RO_PUMP, MIN_RO_PUMP_DUTY_CYCLE, ROP_P_COEFFICIENT, ROP_I_COEFFICIENT, + // Initialize RO pump PI controller to flow + initializePIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, MIN_RO_PUMP_DUTY_CYCLE, ROP_FLOW_CONTROL_P_COEFFICIENT, ROP_FLOW_CONTROL_I_COEFFICIENT, MIN_RO_PUMP_DUTY_CYCLE, MAX_RO_PUMP_DUTY_CYCLE ); - // Initialize the I controller during ramp up - initializePIController( I_CONTROLLER_ID_RO_PUMP_RAMP_UP, MIN_RO_PUMP_DUTY_CYCLE, ROP_RAMP_UP_P_COEFFICIENT, ROP_RAMP_UP_I_COEFFICIENT, + // Initialize RO pump PI controller t maximum pressure + initializePIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, MIN_RO_PUMP_DUTY_CYCLE, ROP_MAX_PRESSURE_P_COEFFICIENT, ROP_MAX_PRESSURE_I_COEFFICIENT, MIN_RO_PUMP_DUTY_CYCLE, MAX_RO_PUMP_DUTY_CYCLE ); // Initialize the persistent alarm for flow out of upper and lower range - initPersistentAlarm( PERSISTENT_ALARM_RO_FLOW_RATE_OUT_OF_UPPER_RANGE, ALARM_ID_FLOW_RATE_OUT_OF_RANGE, TRUE, - FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL ); + initPersistentAlarm( ALARM_ID_FLOW_RATE_OUT_OF_UPPER_RANGE, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL ); - initPersistentAlarm( PERSISTENT_ALARM_RO_FLOW_RATE_OUT_OF_LOWER_RANGE, ALARM_ID_FLOW_RATE_OUT_OF_RANGE, TRUE, - FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL ); + initPersistentAlarm( ALARM_ID_FLOW_RATE_OUT_OF_LOWER_RANGE, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL ); // Initialize the persistent alarm for max allowed pressure out of range - initPersistentAlarm( PERSISTENT_ALARM_RO_PUMP_PRESSURE_OUT_OF_RANGE, ALARM_ID_RO_PUMP_PRESSURE_OUT_OF_RANGE, TRUE, - MAX_PRESSURE_OUT_OF_RANGE_PERSISTENT_INTERVAL, MAX_PRESSURE_OUT_OF_RANGE_PERSISTENT_INTERVAL ); + initPersistentAlarm( ALARM_ID_RO_PUMP_PRESSURE_OUT_OF_RANGE, MAX_PRESSURE_OUT_OF_RANGE_PERSISTENT_INTERVAL, + MAX_PRESSURE_OUT_OF_RANGE_PERSISTENT_INTERVAL ); + // Initialize the persistent alarm for ramp up to target flow timeout + initPersistentAlarm( ALARM_ID_RO_PUMP_RAMP_UP_TO_FLOW_TIMEOUT, MAX_ALLOWED_RAMP_UP_TIME, MAX_ALLOWED_RAMP_UP_TIME ); + + // Initialize the persistent alarm for not turning off the pump + initPersistentAlarm( ALARM_ID_RO_PUMP_OFF_FAULT, SAFETY_SHUTDOWN_TIMEOUT, SAFETY_SHUTDOWN_TIMEOUT ); + // Initialize the variables - rampUp2FlowTimeoutCounter = 0; roControlTimerCounter = 0; roPumpOpenLoopTargetDutyCycle = 0; - roPumpFlowRateRunningSum = 0; - roPumpPressureRunningSum = 0; measuredFlowReadingsSum = 0; flowFilterCounter = 0; - rampUp2FlowTimeoutCounter = 0; - flowVerificationCounter = 0; roPumpDataPublicationTimerCounter = 0; roPumpState = RO_PUMP_OFF_STATE; roPumpControlMode = NUM_OF_PUMP_CONTROL_MODES; roPumpControlModeSet = roPumpControlMode; + isROPumpOn = FALSE; } /*********************************************************************//** @@ -219,12 +221,14 @@ { // For now maximum allowed pressure is inserted into the target pressure override // if the target flow rate exceeded the max pressure, it will set the maximum pressure - targetROPumpPressure = maxPressure; - targetROPumpFlowRate = roFlowRate; - roPumpControlMode = PUMP_CONTROL_MODE_CLOSED_LOOP; + targetROPumpMaxPressure = maxPressure; + targetROPumpFlowRate = roFlowRate; + roPumpControlMode = PUMP_CONTROL_MODE_CLOSED_LOOP; + roPumpState = RO_PUMP_RAMP_UP_TO_TARGET_FLOW_STATE; // Get the initial guess of the duty cycle - roPumpPWMDutyCyclePct = ROP_FLOW_TO_PWM_DC( roFlowRate ); - rampUp2FlowTimeoutCounter = 0; + roPumpPWMDutyCyclePct = ROP_FLOW_TO_PWM_DC( roFlowRate ); + roControlTimerCounter = 0; + isROPumpOn = TRUE; result = TRUE; } // Requested max pressure is out of range @@ -262,11 +266,9 @@ roPumpPWMDutyCyclePct = 0.0; roPumpOpenLoopTargetDutyCycle = 0.0; roControlTimerCounter = 0; - flowVerificationCounter = 0; isROPumpOn = FALSE; - rampUp2FlowTimeoutCounter = 0; - targetROPumpPressure = 0; - resetPIController( PI_CONTROLLER_ID_RO_PUMP, MIN_RO_PUMP_DUTY_CYCLE ); + targetROPumpMaxPressure = 0; + resetPIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, MIN_RO_PUMP_DUTY_CYCLE ); } /*********************************************************************//** @@ -290,7 +292,7 @@ // to make sure the hardware (especially the ROF) is not damaged. If it is the case, we need to stop immediately F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); BOOL isPressureMax = actualPressure >= MAX_ALLOWED_MEASURED_PRESSURE_PSI; - checkPersistentAlarm( PERSISTENT_ALARM_RO_PUMP_PRESSURE_OUT_OF_RANGE, isPressureMax, actualPressure, MAX_ALLOWED_MEASURED_PRESSURE_PSI ); + checkPersistentAlarm( ALARM_ID_RO_PUMP_PRESSURE_OUT_OF_RANGE, isPressureMax, actualPressure, MAX_ALLOWED_MEASURED_PRESSURE_PSI ); // Read flow at the control set if ( ++flowFilterCounter >= FLOW_SAMPLES_TO_AVERAGE ) @@ -312,24 +314,39 @@ flowFilterCounter = 0; } - // To monitor the flow, the control mode must be in closed loop and the pump should be control to target state, - // meaning, it is controlling to a certain pressure - if ( roPumpControlMode == PUMP_CONTROL_MODE_CLOSED_LOOP && roPumpState == RO_PUMP_CONTROL_TO_TARGET_STATE ) +#ifndef IGNORE_RO_PUMP_MONITOR + // To monitor the flow, the control mode must be in closed loop mode and the pump should be control to flow state + // If the pump is controlled to the maximum pressure, the flow might be different from the target flow for more than 10% + // but the pump is not able to achieve the flow. + if ( ( PUMP_CONTROL_MODE_CLOSED_LOOP == roPumpControlMode ) && ( RO_PUMP_CONTROL_TO_TARGET_FLOW_STATE == roPumpState ) ) { - F32 currentFlow = getMeasuredROFlowRate(); - F32 targetFlow = getTargetROPumpFlowRate(); - F32 error = fabs( 1.0 - ( currentFlow / targetFlow ) ); - + F32 const currentFlow = getMeasuredROFlowRate(); + F32 const targetFlow = getTargetROPumpFlowRate(); + // The flow cannot be out of range for than 10% of the target flow + BOOL const isFlowOutOfRange = fabs( 1.0 - ( currentFlow / targetFlow ) ) > MAX_ALLOWED_FLOW_DEVIATION; // Figure out whether flow is out of range from which side - if ( error > MAX_ALLOWED_FLOW_DEVIATION ) + BOOL const isFlowOutOfUpperRange = isFlowOutOfRange && ( currentFlow > targetFlow ); + BOOL const isFlowOutOfLowerRange = isFlowOutOfRange && ( currentFlow < targetFlow ); + + checkPersistentAlarm( ALARM_ID_FLOW_RATE_OUT_OF_UPPER_RANGE, isFlowOutOfUpperRange, currentFlow, targetFlow ); + checkPersistentAlarm( ALARM_ID_FLOW_RATE_OUT_OF_LOWER_RANGE, isFlowOutOfLowerRange, currentFlow, targetFlow ); + } + + // If the pump is off and PPi + 5psi < PPo for a certain period of time, activate safety shutdown + if ( FALSE == isROPumpOn ) + { + F32 pressureInlet = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_INLET ); + BOOL isPumpRunning = ( pressureInlet + MAX_PRESSURE_TARGET_TOLERANCE ) < actualPressure; + + checkPersistentAlarm( ALARM_ID_RO_PUMP_OFF_FAULT, isPumpRunning, pressureInlet, ( pressureInlet + MAX_PRESSURE_TARGET_TOLERANCE ) ); + + // Check if it has timed out + if ( isAlarmActive( ALARM_ID_RO_PUMP_OFF_FAULT ) ) { - BOOL isFlowOutOfUpperRange = currentFlow > targetFlow; - BOOL isFlowOutOfLowerRange = currentFlow < targetFlow; - checkPersistentAlarm( PERSISTENT_ALARM_RO_FLOW_RATE_OUT_OF_UPPER_RANGE, isFlowOutOfUpperRange, currentFlow, targetFlow ); - checkPersistentAlarm( PERSISTENT_ALARM_RO_FLOW_RATE_OUT_OF_LOWER_RANGE, isFlowOutOfLowerRange, currentFlow, targetFlow ); + activateSafetyShutdown(); } } - +#endif // Publish RO pump data on interval publishROPumpData(); } @@ -349,16 +366,16 @@ roPumpState = handleROPumpOffState(); break; - case RO_PUMP_RAMP_UP_STATE: - roPumpState = handleROPumpRampUpState(); + case RO_PUMP_RAMP_UP_TO_TARGET_FLOW_STATE: + roPumpState = handleROPumpRampUpToTargetFlowState(); break; - case RO_PUMP_VERIFY_FLOW_STATE: - roPumpState = handleROPumpVerifyFlowState(); + case RO_PUMP_CONTROL_TO_TARGET_FLOW_STATE: + roPumpState = handleROPumpControlToTargetFlowState(); break; - case RO_PUMP_CONTROL_TO_TARGET_STATE: - roPumpState = handleROPumpControlToTargetState(); + case RO_PUMP_CONTROL_TO_MAX_PRESSURE_STATE: + roPumpState = handleROPumpControlToMaxPressureState(); break; case RO_PUMP_OPEN_LOOP_STATE: @@ -389,9 +406,8 @@ * @brief * The execROPumpTest function executes the state machine for the RO pump * self-test. - * @details - * Inputs: TODO FILL UP - * Outputs: TODO FILL UP + * @details Inputs: TODO FILL UP + * @details Outputs: TODO FILL UP * @return the current state of the ROPump self test. *************************************************************************/ SELF_TEST_STATUS_T execROPumpTest( void ) @@ -407,184 +423,178 @@ * @brief * The handleROPumpOffState function handles the RO pump off state of the * controller state machine. - * @details Inputs: roPumpControlMode, roPumpControlModeSet, roPumpControlMode, - * roPumpPWMDutyCyclePctSet, roPumpPWMDutyCyclePct, isROPumpOn, + * @details Inputs: roPumpControlMode, roPumpPWMDutyCyclePctSet, * roPumpOpenLoopTargetDutyCycle - * @details Outputs: roPumpControlModeSet, roPumpPWMDutyCyclePctSet, - * roPumpPWMDutyCyclePct, isROPumpOn + * @details Outputs: roPumpPWMDutyCyclePct, setupROPumpControl, isROPumpOn * @return next state of the controller state machine *************************************************************************/ static RO_PUMP_STATE_T handleROPumpOffState( void ) { - RO_PUMP_STATE_T result = RO_PUMP_OFF_STATE; + RO_PUMP_STATE_T state = RO_PUMP_OFF_STATE; // If there is a flow, transition to the PI controller to get the corresponding pressure of that flow if ( getTargetROPumpFlowRate() > 0 && roPumpControlMode == PUMP_CONTROL_MODE_CLOSED_LOOP ) { - roPumpControlModeSet = roPumpControlMode; - // Set initial PWM duty cycle - roPumpDutyCyclePctSet = roPumpPWMDutyCyclePct; - setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); - // Reset controller - resetPIController( I_CONTROLLER_ID_RO_PUMP_RAMP_UP, roPumpDutyCyclePctSet ); + roPumpControlModeSet = PUMP_CONTROL_MODE_CLOSED_LOOP; // Set pump to on isROPumpOn = TRUE; - result = RO_PUMP_RAMP_UP_STATE; + roPumpDutyCyclePctSet = ROP_FLOW_TO_PWM_DC( getTargetROPumpFlowRate() ); + setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); + state = RO_PUMP_RAMP_UP_TO_TARGET_FLOW_STATE; } // If the target duty cycle is greater than zero (minimum is 10%) and the mode has been set to open // loop, set the duty cycle if ( roPumpOpenLoopTargetDutyCycle > 0 && roPumpControlMode == PUMP_CONTROL_MODE_OPEN_LOOP ) { setROPumpControlSignalDutyCycle( roPumpOpenLoopTargetDutyCycle ); isROPumpOn = TRUE; - result = RO_PUMP_OPEN_LOOP_STATE; + state = RO_PUMP_OPEN_LOOP_STATE; } - return result; + return state; } /*********************************************************************//** * @brief - * The handleROPumpRampUpState function handles the RO pump ramp up state - * of the controller state machine. + * The handleROPumpRampUpToTargetFlowState function handles the RO pump + * ramp up to flow state of the controller state machine. * @details Inputs: roControlTimerCounter, roPumpPWMDutyCyclePctSet, * rampUp2FlowTimeoutCounter * @details Outputs: roControlTimerCounter, roPumpPWMDutyCyclePctSet, * rampUp2FlowTimeoutCounter * @return next state of the controller state machine *************************************************************************/ -static RO_PUMP_STATE_T handleROPumpRampUpState( void ) +static RO_PUMP_STATE_T handleROPumpRampUpToTargetFlowState( void ) { - RO_PUMP_STATE_T result = RO_PUMP_RAMP_UP_STATE; + RO_PUMP_STATE_T state = RO_PUMP_RAMP_UP_TO_TARGET_FLOW_STATE; // Get the current pressure from the sensor F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); + F32 targetFlowRate = getTargetROPumpFlowRate(); + F32 actualFlowRate = (F32)getMeasuredROFlowRate(); - // If we are still in the ramp up mode after the specified time, get the current pressure - // and control from this - if ( ++rampUp2FlowTimeoutCounter > RAMP_UP_TIME_OUT_COUNT ) + F32 flowRateDeviation = fabs( targetFlowRate - actualFlowRate ) / targetFlowRate; + BOOL isFlowOutOfRange = flowRateDeviation > ROP_FLOW_TARGET_TOLERANCE; + + if ( ++roControlTimerCounter >= ROP_RAMP_UP_CONTROL_INTERVAL ) { - targetROPumpPressure = actualPressure; - rampUp2FlowTimeoutCounter = 0; - result = RO_PUMP_CONTROL_TO_TARGET_STATE; - } - // Control at set interval - else if ( ++roControlTimerCounter >= ROP_CONTROL_INTERVAL ) - { - F32 targetFlowRate = getTargetROPumpFlowRate(); - F32 actualFlowRate = (F32)getMeasuredROFlowRate(); + F32 targetPressure = getTargetROPumpPressure(); // If the actual pressure is greater than the target pressure or it is within the tolerance of the maximum pressure, move to set // to target pressure straight. At the beginning the maximum pressure is set in the targetROPumpPressure override variable. // If the flow rate was reached without reaching to maximum pressure, the pressure that was set to targetROPumpPressure override will // be reset to the corresponding pressure of the target flow rate. - if ( actualPressure > getTargetROPumpPressure() || ( getTargetROPumpPressure() - actualPressure ) > MAX_PRESSURE_TARGET_TOLERANCE ) + if ( ( actualPressure > targetPressure ) || ( ( targetPressure - actualPressure ) < MAX_PRESSURE_TARGET_TOLERANCE ) ) { - result = RO_PUMP_CONTROL_TO_TARGET_STATE; + resetPIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, roPumpDutyCyclePctSet ); + state = RO_PUMP_CONTROL_TO_MAX_PRESSURE_STATE; } - // If the actual flow is still far from target flow, update the duty cycle using the I controller and stay in this state - else if ( fabs( actualFlowRate - targetFlowRate ) > ROP_FLOW_TARGET_TOLERANCE ) + // + else if ( TRUE == isFlowOutOfRange ) { - roPumpDutyCyclePctSet = runPIController( I_CONTROLLER_ID_RO_PUMP_RAMP_UP, targetFlowRate, actualFlowRate ); + roPumpDutyCyclePctSet += ( targetFlowRate - actualFlowRate ) * ROP_RAMP_UP_P_COEFFICIENT; + // If the duty cycle is out of the define range for the RO pump, set the boundaries + roPumpDutyCyclePctSet = roPumpDutyCyclePctSet < MIN_RO_PUMP_DUTY_CYCLE ? MIN_RO_PUMP_DUTY_CYCLE : roPumpDutyCyclePctSet; + roPumpDutyCyclePctSet = roPumpDutyCyclePctSet > MAX_RO_PUMP_DUTY_CYCLE ? MAX_RO_PUMP_DUTY_CYCLE : roPumpDutyCyclePctSet; + setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); } // Reached to the target flow go to the next state else { - result = RO_PUMP_VERIFY_FLOW_STATE; + resetPIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, roPumpDutyCyclePctSet ); + state = RO_PUMP_CONTROL_TO_TARGET_FLOW_STATE; } roControlTimerCounter = 0; } - return result; + return state; } /*********************************************************************//** * @brief - * The handleROPumpVerifyFlowState function handles the RO pump verify - * flow state of the RO pump controller state machine. - * @details Inputs: flowVerificationCounter, targetROPumpPressure, - * roPumpFlowRateRunningSum, roPumpFlowRateRunningSum - * @details Outputs: flowVerificationCounter, targetROPumpPressure, - * roPumpFlowRateRunningSum, roPumpFlowRateRunningSum + * The handleROPumpControlToTargetFlowState function handles the control to + * target flow state of the RO pump controller state machine. + * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter, + * roPumpControlModeSet + * @details Outputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter * @return next state of the controller state machine *************************************************************************/ -static RO_PUMP_STATE_T handleROPumpVerifyFlowState( void ) +static RO_PUMP_STATE_T handleROPumpControlToTargetFlowState( void ) { - RO_PUMP_STATE_T result = RO_PUMP_VERIFY_FLOW_STATE; + RO_PUMP_STATE_T state = RO_PUMP_CONTROL_TO_TARGET_FLOW_STATE; - // Calculate the running sum of the flow rate and RO pump outlet pressure - roPumpFlowRateRunningSum = roPumpFlowRateRunningSum + (F32)getMeasuredROFlowRate(); - roPumpPressureRunningSum = roPumpPressureRunningSum + getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); - - // Check if the time for flow verification has elapsed - if ( ++flowVerificationCounter >= FLOW_VERIFICATION_COUNTER_TARGET ) + // Control at set interval + if ( ++roControlTimerCounter >= ROP_CONTROL_INTERVAL && roPumpControlMode == PUMP_CONTROL_MODE_CLOSED_LOOP ) { + // Get the pressure to use it for setting the control F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); - // If the flow has been achieved without reaching to the maximum pressure, set the new pressure - // otherwise, stay with the maximum allowed pressure as target pressure - if ( actualPressure < getTargetROPumpPressure() ) - { - // Calculate the average pressure and flow rate - F32 avgPressure = roPumpPressureRunningSum / flowVerificationCounter; - F32 avgFlowRate = roPumpFlowRateRunningSum / flowVerificationCounter; - F32 targetFlowRate = getTargetROPumpFlowRate(); - - // Calculate the flow rate deviation from the target flow rate - F32 flowRateDeviation = ( targetFlowRate - avgFlowRate ) / targetFlowRate; - // Use the flow rate deviation to adjust the average calculated pressure. This - // pressure is used as the target pressure - avgPressure = avgPressure + ( avgPressure * flowRateDeviation ); - // Save the target pressure - targetROPumpPressure = avgPressure; + if ( actualPressure >= targetROPumpMaxPressure ) + { + resetPIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, roPumpDutyCyclePctSet ); + state = RO_PUMP_CONTROL_TO_MAX_PRESSURE_STATE; } + else + { + roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, getTargetROPumpFlowRate(), getMeasuredROFlowRate() ); + } - // Reset the I controller for the flow rate as it is no longer needed - resetPIController( I_CONTROLLER_ID_RO_PUMP_RAMP_UP, MIN_RO_PUMP_DUTY_CYCLE ); - - // Set initial PWM duty cycle setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); - // Reset controller - resetPIController( PI_CONTROLLER_ID_RO_PUMP, roPumpDutyCyclePctSet ); - // Reset all the variables before leaving - flowVerificationCounter = 0; - roPumpFlowRateRunningSum = 0; - roPumpPressureRunningSum = 0; - result = RO_PUMP_CONTROL_TO_TARGET_STATE; + + roControlTimerCounter = 0; } - return result; + return state; } /*********************************************************************//** * @brief - * The handleROPumpControlToTargetState function handles the control to - * target state of the RO pump controller state machine. + * The handleROPumpControlToMaxPressureState function handles the control + * to max pressure state of the RO pump controller state machine. * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter, * roPumpControlModeSet * @details Outputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter * @return next state of the controller state machine *************************************************************************/ -static RO_PUMP_STATE_T handleROPumpControlToTargetState( void ) +static RO_PUMP_STATE_T handleROPumpControlToMaxPressureState( void ) { - RO_PUMP_STATE_T result = RO_PUMP_CONTROL_TO_TARGET_STATE; + RO_PUMP_STATE_T state = RO_PUMP_CONTROL_TO_MAX_PRESSURE_STATE; + // Get the pressure to use it for setting the control + F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); + // Control at set interval - if ( ++roControlTimerCounter >= ROP_CONTROL_INTERVAL && roPumpControlModeSet == PUMP_CONTROL_MODE_CLOSED_LOOP ) + if ( ++roControlTimerCounter >= ROP_CONTROL_INTERVAL && roPumpControlMode == PUMP_CONTROL_MODE_CLOSED_LOOP ) { - // Get the pressure to use it for setting the control - F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); + if ( actualPressure > targetROPumpMaxPressure ) + { + roPumpDutyCyclePctSet -= ROP_RAMP_DOWN_DUTY_CYCLE_RATIO; + resetPIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, roPumpDutyCyclePctSet ); + } + else + { + roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, getTargetROPumpFlowRate(), getMeasuredROFlowRate() ); + } - roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP, getTargetROPumpPressure(), actualPressure ); setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); roControlTimerCounter = 0; } - return result; + // Check if the actual pressure is out of tolerance from max pressure. + // If it is out, go back to ramp up state and to try to reach to target flow again + if ( ( targetROPumpMaxPressure - actualPressure ) > MAX_PRESSURE_TARGET_TOLERANCE ) + { + resetPIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, roPumpDutyCyclePctSet ); + state = RO_PUMP_CONTROL_TO_TARGET_FLOW_STATE; + + roControlTimerCounter = 0; + } + + return state; } /*********************************************************************//** @@ -709,7 +719,7 @@ *************************************************************************/ F32 getTargetROPumpPressure( void ) { - return targetROPumpPressure; + return targetROPumpMaxPressure; } /*********************************************************************//** @@ -726,6 +736,7 @@ { RO_PUMP_DATA_T pumpData; + pumpData.roPumpTgtFlowRate = getTargetROPumpFlowRate(); pumpData.roPumpTgtPressure = getTargetROPumpPressure(); pumpData.measROFlowRate = getMeasuredROFlowRate(); pumpData.roPumpDutyCycle = roPumpDutyCyclePctSet * FRACTION_TO_PERCENT_FACTOR; @@ -757,8 +768,8 @@ if ( TRUE == isTestingActivated() ) { U32 intvl = value / TASK_PRIORITY_INTERVAL; - roPumpDataPublishInterval.ovData = intvl; - roPumpDataPublishInterval.override = OVERRIDE_KEY; + roPumpDataPublishInterval.ovData = intvl; + roPumpDataPublishInterval.override = OVERRIDE_KEY; result = TRUE; } @@ -829,7 +840,7 @@ // Make sure the requested pressure is in range if ( value >= MIN_ALLOWED_PRESSURE_PSI && value <= MAX_ALLOWED_PRESSURE_PSI ) { - targetROPumpPressure = value; + targetROPumpMaxPressure = value; result = TRUE; } }