Index: firmware/App/Controllers/ROPump.c =================================================================== diff -u -r256d5cb05f1ef09e19e2f2733a111f600c73a7ee -r2e21405574597474db0ebae86cdd7fa2d517f71c --- firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 256d5cb05f1ef09e19e2f2733a111f600c73a7ee) +++ firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 2e21405574597474db0ebae86cdd7fa2d517f71c) @@ -63,7 +63,6 @@ #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 ( 1.0F / (F32)FLOW_SAMPLES_TO_AVERAGE ) ///< Optimization - multiplying is faster than dividing. // The ADC to LPM factor is calculated using the following steps: @@ -76,7 +75,6 @@ /// 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 MAX_ALLOWED_FLOW_DEVIATION 0.1F ///< Max allowed deviation from target flow. #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. @@ -90,7 +88,6 @@ #define ROP_FEEDBACK_0_PCT_DUTY_CYCLE_VOLTAGE 2.51F ///< RO pump 0% duty cycle feedback voltage. #define ROP_DUTY_CYCLE_OUT_OF_RANGE_TOLERANCE 0.05F ///< RO pump duty cycle out of range tolerance. - #define DATA_PUBLISH_COUNTER_START_COUNT 50 ///< Data publish counter start count. /// Enumeration of RO pump states. @@ -129,14 +126,8 @@ static F32 targetROPumpMaxPressure; ///< 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). static U32 roControlTimerCounter; ///< Determines when to perform control on RO pump. static F32 roPumpOpenLoopTargetDutyCycle; ///< Target RO pump open loop PWM. -static S32 measuredFlowReadingsSum; ///< Raw flow reading sums for averaging. -static U32 flowFilterCounter; ///< Flow filtering counter. -static DG_FLOW_SENSORS_CAL_RECORD_T flowSensorsCalRecord; ///< Flow sensors calibration record. -static OVERRIDE_F32_T measuredROFlowRateWithConcPumpsLPM = { 0.0, 0.0, 0.0, 0 }; ///< Measure RO flow rate with concentrate pumps (L/min). -static DG_RO_PUMP_CAL_RECORD_T roPumpCalRecord; ///< RO pump calibration record. static F32 roVolumeL; ///< RO water generated in liters. // ********** private function prototypes ********** @@ -156,11 +147,10 @@ * @brief * The initROPump function initializes the RO Pump module. * @details Inputs: roControlTimerCounter,roPumpOpenLoopTargetDutyCycle, - * roPumpFlowRateRunningSum, roPumpPressureRunningSum, measuredFlowReadingsSum, - * flowFilterCounter, flowVerificationCounter, roPumpState, roPumpControlMode - * roPumpDataPublicationTimerCounter, rawFlowLP, targetROPumpFlowRateLPM, + * roPumpPressureRunningSum, flowFilterCounter, flowVerificationCounter, + * roPumpState, roPumpControlMode, roPumpDataPublicationTimerCounter, rawFlowLP, * roPumpPWMDutyCyclePct, roPumpDutyCyclePctSet, pendingROPumpCmdMaxPressure, - * pendingROPumpCmdTargetFlow, pendingROPumpCmdCountDown, targetROPumpMaxPressure + * pendingROPumpCmdTargetFlow, pendingROPumpCmdCountDown, targetROPumpMaxPressure, * @details Outputs: none * @return none *************************************************************************/ @@ -190,8 +180,6 @@ // Initialize the variables roControlTimerCounter = 0; roPumpOpenLoopTargetDutyCycle = 0; - measuredFlowReadingsSum = 0; - flowFilterCounter = 0; roPumpDataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; roPumpState = RO_PUMP_OFF_STATE; roPumpControlMode = NUM_OF_PUMP_CONTROL_MODES; @@ -345,53 +333,19 @@ F32 roFeedbackVoltage = getIntADCVoltageConverted( INT_ADC_RO_PUMP_FEEDBACK_DUTY_CYCLE ); // Read the pressure at the sensor. The pump cannot be more that the maximum allowed pressure // 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 ? TRUE : FALSE ); + F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); + BOOL isPressureMax = ( actualPressure >= MAX_ALLOWED_MEASURED_PRESSURE_PSI ? TRUE : FALSE ); BOOL isDutyCylceOutOfRange = FALSE; - // Update sum for flow average calculation - measuredFlowReadingsSum += (S32)roFlowReading; - checkPersistentAlarm( ALARM_ID_RO_PUMP_PRESSURE_OUT_OF_RANGE, isPressureMax, actualPressure, MAX_ALLOWED_MEASURED_PRESSURE_PSI ); - // Check if a new calibration is available - if ( TRUE == isNewCalibrationRecordAvailable() ) + if ( ( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) > NEARLY_ZERO ) && ( VALVE_STATE_CLOSED == getValveStateName( VBF ) ) ) { - getNVRecord2Driver( GET_CAL_FLOW_SENSORS, (U08*)&flowSensorsCalRecord, sizeof( DG_FLOW_SENSORS_CAL_RECORD_T ), - NUM_OF_CAL_DATA_FLOW_SENSORS, ALARM_ID_DG_RO_FLOW_SENSOR_INVALID_CAL_RECORD ); + // If the RO pump's flow is greater than zero, and the VBf valve is not open (like heat disinfect) it means RO water is being generated + // Add that water to the variable + roVolumeL += ( getMeasuredFlowRateLPM( RO_FLOW_SENSOR ) / ( SEC_PER_MIN * MS_PER_SECOND ) ) * TASK_PRIORITY_INTERVAL; } - // Read flow at the control set - if ( ++flowFilterCounter >= FLOW_SAMPLES_TO_AVERAGE ) - { - F32 flow = RO_FLOW_ADC_TO_LPM_FACTOR / ( (F32)measuredFlowReadingsSum * FLOW_AVERAGE_MULTIPLIER ); - - flow = pow(flow, 4) * flowSensorsCalRecord.flowSensors[ CAL_DATA_RO_PUMP_FLOW_SENSOR ].fourthOrderCoeff + - pow(flow, 3) * flowSensorsCalRecord.flowSensors[ CAL_DATA_RO_PUMP_FLOW_SENSOR ].thirdOrderCoeff + - pow(flow, 2) * flowSensorsCalRecord.flowSensors[ CAL_DATA_RO_PUMP_FLOW_SENSOR ].secondOrderCoeff + - flow * flowSensorsCalRecord.flowSensors[ CAL_DATA_RO_PUMP_FLOW_SENSOR ].gain + - flowSensorsCalRecord.flowSensors[ CAL_DATA_RO_PUMP_FLOW_SENSOR ].offset; - - measuredROFlowRateWithConcPumpsLPM.data = flow; - measuredROFlowRateLPM.data = flow - ( getMeasuredPumpSpeed( CONCENTRATEPUMPS_CP1_ACID ) / ML_PER_LITER ) - - ( getMeasuredPumpSpeed( CONCENTRATEPUMPS_CP2_BICARB ) / ML_PER_LITER ); - - // If the flow is less than a certain value, FPGA will return 0xFFFF meaning that - // the flow is 0. - if ( FLOW_SENSOR_ZERO_READING == roFlowReading ) - { - measuredROFlowRateLPM.data = 0.0; - } - - measuredFlowReadingsSum = 0; - flowFilterCounter = 0; - } - - if ( ( measuredROFlowRateLPM.data > NEARLY_ZERO ) && ( (U32)VALVE_STATE_CLOSED == getValveState( (U32)VBF ) ) ) - { - roVolumeL += ( measuredROFlowRateLPM.data * SEC_PER_MIN ); - } - #ifndef _RELEASE_ if ( getSoftwareConfigStatus( SW_CONFIG_DISABLE_RO_PUMP_MONITOR ) != SW_CONFIG_ENABLE_VALUE ) #endif @@ -401,7 +355,7 @@ // 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 = getMeasuredROFlowRateLPM(); + F32 currentFlow = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); F32 targetFlow = getTargetROPumpFlowRateLPM(); // The flow cannot be out of range for than 10% of the target flow BOOL isFlowOutOfRange = ( fabs( 1.0F - ( currentFlow / targetFlow ) ) > MAX_ALLOWED_FLOW_DEVIATION ? TRUE : FALSE ); @@ -504,23 +458,9 @@ SELF_TEST_STATUS_T execROPumpSelfTest( void ) { SELF_TEST_STATUS_T result = SELF_TEST_STATUS_IN_PROGRESS; - BOOL calStatus = FALSE; - calStatus |= getNVRecord2Driver( GET_CAL_FLOW_SENSORS, (U08*)&flowSensorsCalRecord, sizeof( DG_FLOW_SENSORS_CAL_RECORD_T ), - NUM_OF_CAL_DATA_FLOW_SENSORS, ALARM_ID_DG_RO_FLOW_SENSOR_INVALID_CAL_RECORD ); + // TODO is there anything else needed in POST for the RO pump? - calStatus |= getNVRecord2Driver( GET_CAL_RO_PUMP_RECORD, (U08*)&roPumpCalRecord, sizeof( DG_RO_PUMP_CAL_RECORD_T ), - NUM_OF_CAL_DATA_FLOW_SENSORS, ALARM_ID_NO_ALARM ); - - if ( TRUE == calStatus ) - { - result = SELF_TEST_STATUS_PASSED; - } - else - { - result = SELF_TEST_STATUS_FAILED; - } - return result; } @@ -552,31 +492,6 @@ /*********************************************************************//** * @brief - * The getMeasuredROFlowRateLPM function gets the measured RO pump flow rate. - * @details Inputs: measuredROFlowRateLPM - * @details Outputs: measuredROFlowRateLPM - * @return the current RO pump flow rate (in L/min). - *************************************************************************/ -F32 getMeasuredROFlowRateLPM( void ) -{ - return getF32OverrideValue( &measuredROFlowRateLPM ); -} - -/*********************************************************************//** - * @brief - * The getMeasuredROFlowRateWithConcPumpsLPM function gets the measured RO - * pump flow rate with the concentrate pumps. - * @details Inputs: measuredROFlowRateWithConcPumpsLPM - * @details Outputs: measuredROFlowRateWithConcPumpsLPM - * @return the current RO pump flow rate with the concentrate pumps (in L/min). - *************************************************************************/ -F32 getMeasuredROFlowRateWithConcPumpsLPM( void ) -{ - return getF32OverrideValue( &measuredROFlowRateWithConcPumpsLPM ); -} - -/*********************************************************************//** - * @brief * The getTargetROPumpPressure function gets the current target RO pump * pressure. * @details Inputs: targetROPumpPressure @@ -592,7 +507,7 @@ * @brief * The getROGeneratedVolumeL function returns the RO generated volume in liters. * @details Inputs: none - * @details Outputs: none + * @details Outputs: roVolumeL * @return the RO generated volume in liters *************************************************************************/ F32 getROGeneratedVolumeL( void ) @@ -860,14 +775,13 @@ if ( ++roPumpDataPublicationTimerCounter >= getU32OverrideValue( &roPumpDataPublishInterval ) ) { RO_PUMP_DATA_T pumpData; - pumpData.roPumpTgtFlowRateLM = getTargetROPumpFlowRateLPM(); - pumpData.roPumpTgtPressure = getTargetROPumpPressure(); - pumpData.measROFlowRate = getMeasuredFlowRateLPM( RO_FLOW_SENSOR ); //getMeasuredROFlowRateLPM(); - pumpData.roPumpDutyCycle = roPumpDutyCyclePctSet * FRACTION_TO_PERCENT_FACTOR; - pumpData.roPumpState = (U32)roPumpState; - pumpData.roPumpFBDutyCycle = roPumpFeedbackDutyCyclePct * FRACTION_TO_PERCENT_FACTOR; - pumpData.roPumpMeasFlowWithConcPumps = getMeasuredROFlowRateWithConcPumpsLPM(); + pumpData.roPumpTgtFlowRateLM = getTargetROPumpFlowRateLPM(); + pumpData.roPumpTgtPressure = getTargetROPumpPressure(); + pumpData.roPumpDutyCycle = roPumpDutyCyclePctSet * FRACTION_TO_PERCENT_FACTOR; + pumpData.roPumpState = (U32)roPumpState; + pumpData.roPumpFBDutyCycle = roPumpFeedbackDutyCyclePct * FRACTION_TO_PERCENT_FACTOR; + broadcastData( MSG_ID_RO_PUMP_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&pumpData, sizeof( RO_PUMP_DATA_T ) ); roPumpDataPublicationTimerCounter = 0; } @@ -985,54 +899,6 @@ /*********************************************************************//** * @brief - * The testSetMeasuredROFlowRateOverride function overrides the measured - * RO flow rate. - * @details Inputs: measuredROFlowRateLPM - * @details Outputs: measuredROFlowRateLPM - * @param: value : override measured RO pump motor speed (in L/min) - * @return TRUE if override successful, FALSE if not - *************************************************************************/ -BOOL testSetMeasuredROFlowRateOverride( F32 value ) -{ - BOOL result = FALSE; - - if ( TRUE == isTestingActivated() ) - { - measuredROFlowRateLPM.ovInitData = measuredROFlowRateLPM.data; - measuredROFlowRateLPM.ovData = value; - measuredROFlowRateLPM.override = OVERRIDE_KEY; - result = TRUE; - } - - return result; -} - -/*********************************************************************//** - * @brief - * The testResetMeasuredROFlowRateOverride function resets the override - * of the measured RO flow rate. - * @details Inputs: measuredROFlowRateLPM - * @details Outputs: measuredROFlowRateLPM - * @return TRUE if override successful, FALSE if not - *************************************************************************/ -BOOL testResetMeasuredROFlowRateOverride( void ) -{ - BOOL result = FALSE; - - if ( TRUE == isTestingActivated() ) - { - measuredROFlowRateLPM.data = measuredROFlowRateLPM.ovInitData; - measuredROFlowRateLPM.override = OVERRIDE_RESET; - measuredROFlowRateLPM.ovInitData = 0.0; - measuredROFlowRateLPM.ovData = 0.0; - result = TRUE; - } - - return result; -} - -/*********************************************************************//** - * @brief * The testSetTargetDutyCycleOverride function overrides the target duty * cycle of the RO pump. * @details Inputs: none