Index: firmware/App/Controllers/ROPump.c =================================================================== diff -u -r28b5f2e7f757647145a82a39aca0a5f3652c68a1 -r604d8aaceeb8e0b650ac2054644333fc7717bb51 --- firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 28b5f2e7f757647145a82a39aca0a5f3652c68a1) +++ firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 604d8aaceeb8e0b650ac2054644333fc7717bb51) @@ -1,17 +1,17 @@ /************************************************************************** * -* 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 ROPump.c +* @file ROPump.c * -* @author (last) Quang Nguyen -* @date (last) 14-Sep-2020 +* @author (last) Dara Navaei +* @date (last) 31-Mar-2022 * -* @author (original) Sean -* @date (original) 04-Apr-2020 +* @author (original) Sean +* @date (original) 04-Apr-2020 * ***************************************************************************/ @@ -20,10 +20,14 @@ #include "etpwm.h" #include "mibspi.h" +#include "ConcentratePumps.h" #include "FPGA.h" +#include "InternalADC.h" +#include "NVDataMgmt.h" +#include "MessageSupport.h" #include "OperationModes.h" -#include "PIControllers.h" #include "PersistentAlarm.h" +#include "PIControllers.h" #include "Pressures.h" #include "ROPump.h" #include "SafetyShutdown.h" @@ -63,16 +67,14 @@ #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 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 RO_FLOW_ADC_TO_LPM_FACTOR 300.0 ///< 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 0.1 ///< 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 ( 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. @@ -84,6 +86,11 @@ #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. +#define ROP_FEEDBACK_0_PCT_DUTY_CYCLE_VOLTAGE 2.51 ///< RO pump 0% duty cycle feedback voltage. +#define ROP_DUTY_CYCLE_OUT_OF_RANGE_TOLERANCE 0.05 ///< 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. typedef enum ROPump_States { @@ -111,27 +118,29 @@ 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 F32 roPumpFeedbackDutyCyclePct = 0.0; ///< RO pump feedback duty cycle in percent. 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 pendingROPumpCmdMaxPressure = 0.0; ///< Delayed (pending) RO pump max pressure (in PSI) setting. +static F32 pendingROPumpCmdTargetFlow = 0.0; ///< Delayed (pending) RO pump target flow rate (in mL/min) setting. +static U32 pendingROPumpCmdCountDown = 0; ///< Delayed (pending) RO pump command count down timer (in task intervals). + 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. + 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 = 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 S32 measuredFlowReadingsSum = 0; ///< Raw flow reading sums for averaging. static U32 flowFilterCounter = 0; ///< 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. // ********** private function prototypes ********** @@ -145,15 +154,14 @@ static void setROPumpControlSignalDutyCycle( F32 dutyCycle ); static void stopROPump( void ); static void publishROPumpData( void ); -static U32 getPublishROPumpDataInterval( void ); /*********************************************************************//** * @brief * The initROPump function initializes the RO Pump module. * @details Inputs: roControlTimerCounter,roPumpOpenLoopTargetDutyCycle, * roPumpFlowRateRunningSum, roPumpPressureRunningSum, measuredFlowReadingsSum, * flowFilterCounter, flowVerificationCounter, roPumpState, roPumpControlMode - * roPumpDataPublicationTimerCounter, roPumpControlModeSet + * roPumpDataPublicationTimerCounter, rawFlowLP * @details Outputs: none * @return none *************************************************************************/ @@ -171,29 +179,25 @@ // Initialize the persistent alarm for flow out of upper and lower range initPersistentAlarm( ALARM_ID_FLOW_RATE_OUT_OF_UPPER_RANGE, 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( 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 ); + initPersistentAlarm( ALARM_ID_RO_PUMP_DUTY_CYCLE_OUT_OF_RANGE, SAFETY_SHUTDOWN_TIMEOUT, SAFETY_SHUTDOWN_TIMEOUT ); // Initialize the variables roControlTimerCounter = 0; roPumpOpenLoopTargetDutyCycle = 0; measuredFlowReadingsSum = 0; flowFilterCounter = 0; - roPumpDataPublicationTimerCounter = 0; + roPumpDataPublicationTimerCounter = DATA_PUBLISH_COUNTER_START_COUNT; roPumpState = RO_PUMP_OFF_STATE; roPumpControlMode = NUM_OF_PUMP_CONTROL_MODES; - roPumpControlModeSet = roPumpControlMode; isROPumpOn = FALSE; + roPumpFeedbackDutyCyclePct = 0.0; } /*********************************************************************//** @@ -209,7 +213,7 @@ * can reach * @return TRUE if new target flow rate is set successfully, FALSE if not *************************************************************************/ -BOOL setROPumpTargetFlowRate( F32 roFlowRate, U32 maxPressure ) +BOOL setROPumpTargetFlowRateLPM( F32 roFlowRate, U32 maxPressure ) { BOOL result = FALSE; @@ -248,6 +252,49 @@ /*********************************************************************//** * @brief + * The setROPumpTargetFlowRateDelayed function sets a new target flow rate for the + * RO pump to be set after given delay. + * @details Inputs: none + * @details Outputs: pendingROPumpCmdMaxPressure, pendingROPumpCmdTargetFlow, + * pendingROPumpCmdCountDown + * @param roFlowRate which is target RO flow rate + * @param maxPressure which is the maximum allowed pressure that the RO pump + * can reach + * @param delayMs delay duration (in ms) before RO pump started + * @return TRUE if new target flow rate is set successfully, FALSE if not + *************************************************************************/ +BOOL setROPumpTargetFlowRateDelayed( F32 roFlowRate, U32 maxPressure, U32 delayMs ) +{ + BOOL result = FALSE; + + // First of all, the flow rate must be in range + if ( ( roFlowRate <= MAX_RO_FLOWRATE_LPM ) && ( roFlowRate >= MIN_RO_FLOWRATE_LPM ) ) + { + // Then the max pressure that we are allowed to reach must be in range + if ( ( maxPressure >= MIN_ALLOWED_PRESSURE_PSI ) && ( maxPressure <= MAX_ALLOWED_PRESSURE_PSI ) ) + { + pendingROPumpCmdMaxPressure = (F32)maxPressure; + pendingROPumpCmdTargetFlow = roFlowRate; + pendingROPumpCmdCountDown = delayMs / TASK_GENERAL_INTERVAL; + result = TRUE; + } + // Requested max pressure is out of range + else + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_RO_PUMP_INVALID_FLOW_RATE_SET, maxPressure ) + } + } + // Requested flow rate is out of range + else + { + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_DG_SOFTWARE_FAULT, SW_FAULT_ID_RO_PUMP_INVALID_PRESSURE_SELECTED, roFlowRate ) + } + + return result; +} + +/*********************************************************************//** + * @brief * The signalROPumpHardStop function stops the RO pump immediately and * resets all the variables associated with the RO pump run. * @details Inputs: targetROPumpFlowRate, roPumpState, roPumpPWMDutyCyclePct, @@ -268,12 +315,16 @@ roControlTimerCounter = 0; isROPumpOn = FALSE; targetROPumpMaxPressure = 0; + pendingROPumpCmdMaxPressure = 0.0; + pendingROPumpCmdTargetFlow = 0.0; + pendingROPumpCmdCountDown = 0; resetPIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, MIN_RO_PUMP_DUTY_CYCLE ); } /*********************************************************************//** * @brief - * The execROPumpMonitor function executes the RO pump monitor. + * The execROPumpMonitor function executes the RO pump monitor. The RO flow + * sensor is read, filtered, converted to L/min and calibrated. * @details Inputs: measuredFlowReadingsSum, flowFilterCounter, * measuredROFlowRateLPM, measuredROFlowRateLPM, roPumpState, * flowOutOfRangeCounter, roPumpControlMode @@ -283,70 +334,85 @@ *************************************************************************/ void execROPumpMonitor( void ) { - U16 roFlowReading = getFPGAROPumpFlowRate(); + U32 roFlowReading = (U32)getFPGAROPumpFlowRate(); + F32 roFeedbackVoltage = getIntADCVoltageConverted( INT_ADC_RO_PUMP_FEEDBACK_DUTY_CYCLE ); // Update sum for flow average calculation measuredFlowReadingsSum += (S32)roFlowReading; // 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; + BOOL isPressureMax = ( actualPressure >= MAX_ALLOWED_MEASURED_PRESSURE_PSI ? TRUE : FALSE ); 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() ) + { + getNVRecord2Driver( GET_CAL_FLOW_SENSORS, (U08*)&flowSensorsCalRecord, sizeof( DG_FLOW_SENSORS_CAL_RECORD_T ), + NUM_OF_CAL_DATA_FLOW_SENSORS, ALARM_ID_DG_FLOW_SENSORS_INVALID_CAL_RECORD ); + } + // Read flow at the control set if ( ++flowFilterCounter >= FLOW_SAMPLES_TO_AVERAGE ) { - F32 avgROFlow = (F32)measuredFlowReadingsSum * FLOW_AVERAGE_MULTIPLIER; + F32 flow = RO_FLOW_ADC_TO_LPM_FACTOR / ( (F32)measuredFlowReadingsSum * FLOW_AVERAGE_MULTIPLIER ); - // If the flow is less than a certain value, FPGA will return 0xFFFF meaning that - // the flow is 0. Otherwise, convert the count to flow rate in mL/min - if ( ( roFlowReading == FLOW_SENSOR_ZERO_READING ) || ( roFlowReading == 0 ) ) - { - measuredROFlowRateLPM.data = 0.0; - } - else - { - measuredROFlowRateLPM.data = RO_FLOW_ADC_TO_LPM_FACTOR / avgROFlow; - } + 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; + flowFilterCounter = 0; } #ifndef IGNORE_RO_PUMP_MONITOR + // The feedback voltage is on the 0V line so when the duty cycle is 0, the feedback is 2.5V + // The duty cycle is calculated by getting the 1 - (ratio of feedback / to the voltage at 0 percent duty cycle). + roPumpFeedbackDutyCyclePct = 1.0 - ( roFeedbackVoltage / ROP_FEEDBACK_0_PCT_DUTY_CYCLE_VOLTAGE ); + // 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 const currentFlow = getMeasuredROFlowRate(); - F32 const targetFlow = getTargetROPumpFlowRate(); + F32 currentFlow = getMeasuredROFlowRateLPM(); + F32 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; + BOOL isFlowOutOfRange = ( fabs( 1.0 - ( currentFlow / targetFlow ) ) > MAX_ALLOWED_FLOW_DEVIATION ? TRUE : FALSE ); // Figure out whether flow is out of range from which side - BOOL const isFlowOutOfUpperRange = isFlowOutOfRange && ( currentFlow > targetFlow ); - BOOL const isFlowOutOfLowerRange = isFlowOutOfRange && ( currentFlow < targetFlow ); + BOOL isFlowOutOfUpperRange = ( isFlowOutOfRange && ( currentFlow > targetFlow ) ? TRUE : FALSE ); + BOOL isFlowOutOfLowerRange = ( isFlowOutOfRange && ( currentFlow < targetFlow ) ? TRUE : FALSE ); 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; + // Check whether the Duty cycle is out of range + BOOL isDCOutOfRange = ( fabs( roPumpFeedbackDutyCyclePct - roPumpDutyCyclePctSet ) > ROP_DUTY_CYCLE_OUT_OF_RANGE_TOLERANCE ? TRUE : FALSE ); - checkPersistentAlarm( ALARM_ID_RO_PUMP_OFF_FAULT, isPumpRunning, pressureInlet, ( pressureInlet + MAX_PRESSURE_TARGET_TOLERANCE ) ); + checkPersistentAlarm( ALARM_ID_RO_PUMP_DUTY_CYCLE_OUT_OF_RANGE, isDCOutOfRange, roPumpFeedbackDutyCyclePct, roPumpDutyCyclePctSet ); - // Check if it has timed out - if ( isAlarmActive( ALARM_ID_RO_PUMP_OFF_FAULT ) ) - { - activateSafetyShutdown(); - } + // Check if it the alarm has timed out and if the pump is supposed to be off but it is still on, activate the safety shutdown + if ( ( TRUE == isAlarmActive( ALARM_ID_RO_PUMP_DUTY_CYCLE_OUT_OF_RANGE ) ) && ( FALSE == isROPumpOn ) ) + { + activateSafetyShutdown(); } #endif + // Publish RO pump data on interval publishROPumpData(); } @@ -360,6 +426,26 @@ *************************************************************************/ void execROPumpController( void ) { + // Handle pending delayed RO pump command + if ( pendingROPumpCmdCountDown > 0 ) + { + pendingROPumpCmdCountDown--; + if ( 0 == pendingROPumpCmdCountDown ) + { + targetROPumpMaxPressure = pendingROPumpCmdMaxPressure; + targetROPumpFlowRate = pendingROPumpCmdTargetFlow; + pendingROPumpCmdMaxPressure = 0.0; + pendingROPumpCmdTargetFlow = 0.0; + 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( targetROPumpFlowRate ); + roControlTimerCounter = 0; + isROPumpOn = TRUE; + } + } + + // Execute RO pump control state machine switch ( roPumpState ) { case RO_PUMP_OFF_STATE: @@ -391,36 +477,100 @@ /*********************************************************************//** * @brief - * The isReverseOsmosisPumpOn function returns the on/off status of RO pump. + * The execROPumpSelfTest function executes the RO pump's self-test. + * @details Inputs: none + * @details Outputs: none + * @return PressuresSelfTestResult (SELF_TEST_STATUS_T) + *************************************************************************/ +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_FLOW_SENSORS_INVALID_CAL_RECORD ); + + 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; +} + +/*********************************************************************//** + * @brief + * The isROPumpRunning function returns the on/off status of RO pump. * @details Inputs: isROPumpOn * @details Outputs: none * @return isROPumpOn the boolean flag that is TRUE if the pump is on and * FALSE if it is off *************************************************************************/ -BOOL isReverseOsmosisPumpOn( void ) +BOOL isROPumpRunning( void ) { return isROPumpOn; } /*********************************************************************//** * @brief - * The execROPumpTest function executes the state machine for the RO pump - * self-test. - * @details Inputs: TODO FILL UP - * @details Outputs: TODO FILL UP - * @return the current state of the ROPump self test. + * The getTargetROPumpFlowRate function gets the current target RO pump + * flow rate. + * @details Inputs: targetROPumpFlowRate + * @details Outputs: targetROPumpFlowRate + * @return the current target RO flow rate (in L/min). *************************************************************************/ -SELF_TEST_STATUS_T execROPumpTest( void ) +F32 getTargetROPumpFlowRate( void ) { - SELF_TEST_STATUS_T result = SELF_TEST_STATUS_FAILED; + return targetROPumpFlowRate; +} - // TODO - implement self-test(s) +/*********************************************************************//** + * @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 ); +} - return result; +/*********************************************************************//** + * @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 + * @details Outputs: targetROPumpPressure + * @return the current target RO targetROPumpPressure in psi. + *************************************************************************/ +F32 getTargetROPumpPressure( void ) +{ + return targetROPumpMaxPressure; +} + +/*********************************************************************//** + * @brief * The handleROPumpOffState function handles the RO pump off state of the * controller state machine. * @details Inputs: roPumpControlMode, roPumpPWMDutyCyclePctSet, @@ -435,7 +585,6 @@ // 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 = PUMP_CONTROL_MODE_CLOSED_LOOP; // Set pump to on isROPumpOn = TRUE; roPumpDutyCyclePctSet = ROP_FLOW_TO_PWM_DC( getTargetROPumpFlowRate() ); @@ -471,7 +620,7 @@ // Get the current pressure from the sensor F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); F32 targetFlowRate = getTargetROPumpFlowRate(); - F32 actualFlowRate = (F32)getMeasuredROFlowRate(); + F32 actualFlowRate = (F32)getMeasuredROFlowRateLPM(); F32 flowRateDeviation = fabs( targetFlowRate - actualFlowRate ) / targetFlowRate; BOOL isFlowOutOfRange = flowRateDeviation > ROP_FLOW_TARGET_TOLERANCE; @@ -489,7 +638,7 @@ 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 ( TRUE == isFlowOutOfRange ) { roPumpDutyCyclePctSet += ( targetFlowRate - actualFlowRate ) * ROP_RAMP_UP_P_COEFFICIENT; @@ -516,8 +665,7 @@ * @brief * The handleROPumpControlToTargetFlowState function handles the control to * target flow state of the RO pump controller state machine. - * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter, - * roPumpControlModeSet + * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter * @details Outputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter * @return next state of the controller state machine *************************************************************************/ @@ -531,15 +679,14 @@ // Get the pressure to use it for setting the control F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); - 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() ); + roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP_FLOW, getTargetROPumpFlowRate(), getMeasuredROFlowRateLPM() ); } setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); @@ -554,8 +701,7 @@ * @brief * The handleROPumpControlToMaxPressureState function handles the control * to max pressure state of the RO pump controller state machine. - * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter, - * roPumpControlModeSet + * @details Inputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter * @details Outputs: roPumpPWMDutyCyclePctSet, roControlTimerCounter * @return next state of the controller state machine *************************************************************************/ @@ -576,7 +722,7 @@ } else { - roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, getTargetROPumpFlowRate(), getMeasuredROFlowRate() ); + roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP_MAX_PRES, getTargetROPumpFlowRate(), getMeasuredROFlowRateLPM() ); } setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); @@ -627,6 +773,9 @@ roPumpPWMDutyCyclePct = roPumpOpenLoopTargetDutyCycle; roPumpDutyCyclePctSet = roPumpPWMDutyCyclePct; roPumpControlMode = PUMP_CONTROL_MODE_OPEN_LOOP; + + // Set the new duty cycle of the pump + setROPumpControlSignalDutyCycle( roPumpOpenLoopTargetDutyCycle ); } /*********************************************************************//** @@ -659,71 +808,6 @@ /*********************************************************************//** * @brief - * The getPublishROPumpDataInterval function gets the RO pump data publish - * interval. - * @details Inputs: roPumpDataPublishInterval - * @details Outputs: roPumpDataPublishInterval - * @return the current RO pump data publication interval (in ms). - *************************************************************************/ -static U32 getPublishROPumpDataInterval( void ) -{ - U32 result = roPumpDataPublishInterval.data; - - if ( OVERRIDE_KEY == roPumpDataPublishInterval.override ) - { - result = roPumpDataPublishInterval.ovData; - } - - return result; -} - -/*********************************************************************//** - * @brief - * The getTargetROPumpFlowRate function gets the current target RO pump - * flow rate. - * @details Inputs: targetROPumpFlowRate - * @details Outputs: targetROPumpFlowRate - * @return the current target RO flow rate (in L/min). - *************************************************************************/ -F32 getTargetROPumpFlowRate( void ) -{ - return targetROPumpFlowRate; -} - -/*********************************************************************//** - * @brief - * The getMeasuredROFlowRate 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 getMeasuredROFlowRate( void ) -{ - F32 result = measuredROFlowRateLPM.data; - - if ( OVERRIDE_KEY == measuredROFlowRateLPM.override ) - { - result = measuredROFlowRateLPM.ovData; - } - - return result; -} - -/*********************************************************************//** - * @brief - * The getTargetROPumpPressure function gets the current target RO pump - * pressure. - * @details Inputs: targetROPumpPressure - * @details Outputs: targetROPumpPressure - * @return the current target RO targetROPumpPressure in psi. - *************************************************************************/ -F32 getTargetROPumpPressure( void ) -{ - return targetROPumpMaxPressure; -} - -/*********************************************************************//** - * @brief * The publishROPumpData function publishes RO pump data at the set interval. * @details Inputs: roPumpDataPublicationTimerCounter * @details Outputs: roPumpDataPublicationTimerCounter @@ -732,21 +816,24 @@ static void publishROPumpData( void ) { // publish RO pump data on interval - if ( ++roPumpDataPublicationTimerCounter >= getPublishROPumpDataInterval() ) + if ( ++roPumpDataPublicationTimerCounter >= getU32OverrideValue( &roPumpDataPublishInterval ) ) { RO_PUMP_DATA_T pumpData; - pumpData.roPumpTgtFlowRate = getTargetROPumpFlowRate(); - pumpData.roPumpTgtPressure = getTargetROPumpPressure(); - pumpData.measROFlowRate = getMeasuredROFlowRate(); - pumpData.roPumpDutyCycle = roPumpDutyCyclePctSet * FRACTION_TO_PERCENT_FACTOR; - pumpData.roPumpState = (U32)roPumpState; + pumpData.roPumpTgtFlowRateLM = getTargetROPumpFlowRate(); + pumpData.roPumpTgtPressure = getTargetROPumpPressure(); + pumpData.measROFlowRate = getMeasuredROFlowRateLPM(); + pumpData.roPumpDutyCycle = roPumpDutyCyclePctSet * FRACTION_TO_PERCENT_FACTOR; + pumpData.roPumpState = (U32)roPumpState; + pumpData.roPumpFBDutyCycle = roPumpFeedbackDutyCyclePct * FRACTION_TO_PERCENT_FACTOR; + pumpData.roPumpMeasFlowWithConcPumps = getMeasuredROFlowRateWithConcPumpsLPM(); - broadcastROPumpData( &pumpData ); + broadcastData( MSG_ID_RO_PUMP_DATA, COMM_BUFFER_OUT_CAN_DG_BROADCAST, (U08*)&pumpData, sizeof( RO_PUMP_DATA_T ) ); roPumpDataPublicationTimerCounter = 0; } } + /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/ @@ -813,9 +900,9 @@ if ( TRUE == isTestingActivated() ) { // The flow rate and pressure must be in range - if ( flow <= MAX_RO_FLOWRATE_LPM && flow >= MIN_RO_FLOWRATE_LPM ) + if ( ( flow <= MAX_RO_FLOWRATE_LPM ) && ( flow >= MIN_RO_FLOWRATE_LPM ) ) { - result = setROPumpTargetFlowRate( flow, MAX_ALLOWED_PRESSURE_PSI ); + result = setROPumpTargetFlowRateLPM( flow, MAX_ALLOWED_PRESSURE_PSI ); } }