Index: firmware/App/Controllers/ROPump.c =================================================================== diff -u -r25770b4b27e75e730d89ac046f7db405b1bfe39f -rc20d71064bad67c2db392c6383bb410e8a7dfa2a --- firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 25770b4b27e75e730d89ac046f7db405b1bfe39f) +++ firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision c20d71064bad67c2db392c6383bb410e8a7dfa2a) @@ -53,11 +53,9 @@ #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_P_COEFFICIENT 0.0001 ///< P term for RO pump pressure control. -#define ROP_I_COEFFICIENT 0.00005 ///< I term for RO pump pressure control. +#define ROP_P_COEFFICIENT 0.25 ///< P term for RO pump pressure control. +#define ROP_I_COEFFICIENT 0.25 ///< I term for RO pump pressure control. -#define ROP_RAMP_UP_P_COEFFICIENT 0.0 ///< P term for RO pump flow control. TODO remove -#define ROP_RAMP_UP_I_COEFFICIENT 0.1 ///< I term for RO pump flow control. TODO remove #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 0.01 ///< Pump ramp down duty cycle ratio when the pressure higher than max defined. @@ -71,8 +69,8 @@ #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_SLOPE 0.5 ///< Slope of flow to PWM line equation. -#define ROP_FLOW_TO_PWM_INTERCEPT 0.28 ///< Intercept of flow to PWM line equation. +#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 ) @@ -99,9 +97,7 @@ typedef enum ROPump_States { RO_PUMP_OFF_STATE = 0, ///< RO pump off state - RO_PUMP_CONTROL_SETUP_STATE, ///< RO pump control setup state TODO remove 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 TODO remove 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 @@ -134,11 +130,8 @@ 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. TODo remove 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. TODO remove -static F32 roPumpPressureRunningSum = 0; ///< RO pump pressure running sum. TODO remove /* 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. @@ -147,16 +140,12 @@ static S32 measuredFlowReadingsSum = 0; ///< Raw flow reading sums for averaging. static U32 flowFilterCounter = 0; ///< Flow filtering counter. -static U32 roPumpOnStartTime = 0; ///< Start time when RO pump turned on. -static BOOL setupROPumpControl = 0; ///< Flag to indicate if we need to setup RO pump control. TODO remove static U32 rampUpRetryCount = 0; ///< Number of ramp up retries. // ********** private function prototypes ********** static RO_PUMP_STATE_T handleROPumpOffState( void ); -static RO_PUMP_STATE_T handleROPumpControlSetupState( 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 handleROPumpOpenLoopState( void ); @@ -205,11 +194,8 @@ // Initialize the variables roControlTimerCounter = 0; roPumpOpenLoopTargetDutyCycle = 0; - roPumpFlowRateRunningSum = 0; - roPumpPressureRunningSum = 0; measuredFlowReadingsSum = 0; flowFilterCounter = 0; - flowVerificationCounter = 0; roPumpDataPublicationTimerCounter = 0; rampUpRetryCount = 0; roPumpState = RO_PUMP_OFF_STATE; @@ -247,7 +233,6 @@ roPumpControlMode = PUMP_CONTROL_MODE_CLOSED_LOOP; // Get the initial guess of the duty cycle roPumpPWMDutyCyclePct = ROP_FLOW_TO_PWM_DC( roFlowRate ); - setupROPumpControl = TRUE; result = TRUE; } // Requested max pressure is out of range @@ -285,7 +270,6 @@ roPumpPWMDutyCyclePct = 0.0; roPumpOpenLoopTargetDutyCycle = 0.0; roControlTimerCounter = 0; - flowVerificationCounter = 0; isROPumpOn = FALSE; targetROPumpPressure = 0; resetPIController( PI_CONTROLLER_ID_RO_PUMP, MIN_RO_PUMP_DUTY_CYCLE ); @@ -383,18 +367,10 @@ roPumpState = handleROPumpOffState(); break; - case RO_PUMP_CONTROL_SETUP_STATE: - //roPumpState = handleROPumpControlSetupState(); - break; - case RO_PUMP_RAMP_UP_STATE: roPumpState = handleROPumpRampUpState(); break; - case RO_PUMP_VERIFY_FLOW_STATE: - roPumpState = handleROPumpVerifyFlowState(); - break; - case RO_PUMP_CONTROL_TO_TARGET_STATE: roPumpState = handleROPumpControlToTargetState(); break; @@ -459,10 +435,9 @@ roPumpControlModeSet = PUMP_CONTROL_MODE_CLOSED_LOOP; // Set pump to on isROPumpOn = TRUE; - roPumpDutyCyclePctSet = ( getTargetROPumpFlowRate() - getMeasuredROFlowRate() ) * 0.5; //ROP_FLOW_TO_PWM_DC( getTargetROPumpFlowRate() ); + roPumpDutyCyclePctSet = ROP_FLOW_TO_PWM_DC( getTargetROPumpFlowRate() ); setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); result = RO_PUMP_RAMP_UP_STATE; - //setupROPumpControl = TRUE; } // 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 @@ -478,39 +453,6 @@ /*********************************************************************//** * @brief - * The handleROPumpControlSetupState function handles the RO pump control - * setup state of the controller state machine. - * @details Inputs: setupROPumpControl, roPumpPWMDutyCyclePct - * @details Outputs: setup RO pump PI controller and wait for flow stabilize - * @return next state of the controller state machine - *************************************************************************/ -static RO_PUMP_STATE_T handleROPumpControlSetupState( void ) -{ - RO_PUMP_STATE_T result = RO_PUMP_CONTROL_SETUP_STATE; - - if ( TRUE == setupROPumpControl ) - { - roPumpControlModeSet = roPumpControlMode; - // Set initial PWM duty cycle - roPumpDutyCyclePctSet = roPumpPWMDutyCyclePct; - setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); - // Reset controller - resetPIController( I_CONTROLLER_ID_RO_PUMP_RAMP_UP, roPumpDutyCyclePctSet ); - setupROPumpControl = FALSE; - roPumpOnStartTime = getMSTimerCount(); - } - - if ( TRUE == didTimeout( roPumpOnStartTime, ROP_FLOW_STABILIZE_TIME ) ) - { - rampUpRetryCount = 0; - result = RO_PUMP_RAMP_UP_STATE; - } - - return result; -} - -/*********************************************************************//** - * @brief * The handleROPumpRampUpState function handles the RO pump ramp up state * of the controller state machine. * @details Inputs: roControlTimerCounter, roPumpPWMDutyCyclePctSet, @@ -581,66 +523,6 @@ /*********************************************************************//** * @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 - * @return next state of the controller state machine - *************************************************************************/ -static RO_PUMP_STATE_T handleROPumpVerifyFlowState( void ) -{ - RO_PUMP_STATE_T result = RO_PUMP_VERIFY_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 ) - { - - // Calculate the average pressure and flow rate - F32 const targetFlowRate = getTargetROPumpFlowRate(); - F32 const avgFlowRate = roPumpFlowRateRunningSum / flowVerificationCounter; - F32 const flowRateDeviation = fabs( targetFlowRate - avgFlowRate ) / targetFlowRate; - - if ( flowRateDeviation < ROP_FLOW_TARGET_TOLERANCE ) - { - F32 const avgPressure = roPumpPressureRunningSum / flowVerificationCounter; - // If the flow has been achieved without reaching the maximum pressure, set the new pressure - // otherwise, stay with the maximum allowed pressure as target pressure - if ( avgPressure < getTargetROPumpPressure() ) - { - targetROPumpPressure = avgPressure; - } - - // Set initial PWM duty cycle and reset controller - setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); - resetPIController( PI_CONTROLLER_ID_RO_PUMP, roPumpDutyCyclePctSet ); - result = RO_PUMP_CONTROL_TO_TARGET_STATE; - } - else - { - if ( ++rampUpRetryCount > ROP_MAX_RAMP_UP_RETRY ) - { - SET_ALARM_WITH_2_F32_DATA( ALARM_ID_DG_RO_PUMP_TOO_MANY_RAMP_UP_RETRY, rampUpRetryCount, ROP_MAX_RAMP_UP_RETRY ); - } - result = RO_PUMP_RAMP_UP_STATE; - } - } - - if ( TRUE == setupROPumpControl ) - { - result = RO_PUMP_CONTROL_SETUP_STATE; - } - - return result; -} - -/*********************************************************************//** - * @brief * The handleROPumpControlToTargetState function handles the control to * target state of the RO pump controller state machine. * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter, @@ -660,7 +542,7 @@ if ( actualPressure >= targetROPumpPressure ) { roPumpDutyCyclePctSet -= ROP_RAMP_DOWN_DUTY_CYCLE_RATIO; - //targetROPumpFlowRate = actualFlowRate; + resetPIController( PI_CONTROLLER_ID_RO_PUMP, roPumpDutyCyclePctSet ); } else {