Index: firmware/App/Controllers/ROPump.c =================================================================== diff -u -r28b5f2e7f757647145a82a39aca0a5f3652c68a1 -rd3819286869611f9c02add72a0f8e321598fdf42 --- firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 28b5f2e7f757647145a82a39aca0a5f3652c68a1) +++ firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision d3819286869611f9c02add72a0f8e321598fdf42) @@ -21,9 +21,10 @@ #include "mibspi.h" #include "FPGA.h" +#include "NVDataMgmt.h" #include "OperationModes.h" -#include "PIControllers.h" #include "PersistentAlarm.h" +#include "PIControllers.h" #include "Pressures.h" #include "ROPump.h" #include "SafetyShutdown.h" @@ -112,8 +113,11 @@ 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 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). @@ -123,15 +127,12 @@ 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. // ********** private function prototypes ********** @@ -145,15 +146,15 @@ static void setROPumpControlSignalDutyCycle( F32 dutyCycle ); static void stopROPump( void ); static void publishROPumpData( void ); -static U32 getPublishROPumpDataInterval( void ); +static BOOL processCalibrationData( void ); /*********************************************************************//** * @brief * The initROPump function initializes the RO Pump module. * @details Inputs: roControlTimerCounter,roPumpOpenLoopTargetDutyCycle, * roPumpFlowRateRunningSum, roPumpPressureRunningSum, measuredFlowReadingsSum, * flowFilterCounter, flowVerificationCounter, roPumpState, roPumpControlMode - * roPumpDataPublicationTimerCounter, roPumpControlModeSet + * roPumpDataPublicationTimerCounter * @details Outputs: none * @return none *************************************************************************/ @@ -171,16 +172,12 @@ // 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 ); @@ -192,7 +189,6 @@ roPumpDataPublicationTimerCounter = 0; roPumpState = RO_PUMP_OFF_STATE; roPumpControlMode = NUM_OF_PUMP_CONTROL_MODES; - roPumpControlModeSet = roPumpControlMode; isROPumpOn = FALSE; } @@ -248,6 +244,49 @@ /*********************************************************************//** * @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, @@ -294,20 +333,38 @@ BOOL isPressureMax = actualPressure >= MAX_ALLOWED_MEASURED_PRESSURE_PSI; 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() ) + { + // Get the new calibration data and check its validity + processCalibrationData(); + } + // Read flow at the control set if ( ++flowFilterCounter >= FLOW_SAMPLES_TO_AVERAGE ) { - F32 avgROFlow = (F32)measuredFlowReadingsSum * FLOW_AVERAGE_MULTIPLIER; + U32 sensor; + 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 ) ) + if ( ( FLOW_SENSOR_ZERO_READING == roFlowReading ) || ( 0 == roFlowReading ) ) { measuredROFlowRateLPM.data = 0.0; } else { - measuredROFlowRateLPM.data = RO_FLOW_ADC_TO_LPM_FACTOR / avgROFlow; + // Right now there is only one flow sensor but a for loop is used here to be able to automatically accommodate + // the future flow sensors + for( sensor = 0; sensor < NUM_OF_CAL_DATA_FLOW_SENSORS; sensor++ ) + { + measuredROFlowRateLPM.data = pow(flow, 4) * flowSensorsCalRecord.flowSensors[ sensor ].fourthOrderCoeff + + pow(flow, 3) * flowSensorsCalRecord.flowSensors[ sensor ].thirdOrderCoeff + + pow(flow, 2) * flowSensorsCalRecord.flowSensors[ sensor ].secondOrderCoeff + + flow * flowSensorsCalRecord.flowSensors[ sensor ].gain + + flowSensorsCalRecord.flowSensors[ sensor ].offset; + } } measuredFlowReadingsSum = 0; @@ -341,12 +398,13 @@ 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 ) ) + if ( TRUE == isAlarmActive( ALARM_ID_RO_PUMP_OFF_FAULT ) ) { activateSafetyShutdown(); } } #endif + // Publish RO pump data on interval publishROPumpData(); } @@ -360,6 +418,26 @@ *************************************************************************/ 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: @@ -391,32 +469,78 @@ /*********************************************************************//** * @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 = processCalibrationData(); + + 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 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 ) +{ + return getF32OverrideValue( &measuredROFlowRateLPM ); +} - 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; } /*********************************************************************//** @@ -435,7 +559,6 @@ // 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() ); @@ -489,7 +612,7 @@ 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 +639,7 @@ * @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 *************************************************************************/ @@ -554,8 +676,7 @@ * @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 *************************************************************************/ @@ -659,71 +780,48 @@ /*********************************************************************//** * @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). + * 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: none + * @details Outputs: flowSensorsCalRecord + * @return TRUE if the calibration record is valid, otherwise FALSE *************************************************************************/ -static U32 getPublishROPumpDataInterval( void ) +static BOOL processCalibrationData( void ) { - U32 result = roPumpDataPublishInterval.data; + BOOL status = TRUE; + U32 sensor; - if ( OVERRIDE_KEY == roPumpDataPublishInterval.override ) + // Get the calibration record from NVDataMgmt + DG_FLOW_SENSORS_CAL_RECORD_T calData = getDGFlowSensorsCalibrationRecord(); + + for ( sensor = 0; sensor < NUM_OF_CAL_DATA_FLOW_SENSORS; sensor++ ) { - result = roPumpDataPublishInterval.ovData; - } +#ifndef SKIP_CAL_CHECK + // 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 flow sensors data is not stored in the NV memory or it was corrupted. + if ( 0 == calData.flowSensors[ sensor ].calibrationTime ) + { - return result; -} + SET_ALARM_WITH_1_U32_DATA( ALARM_ID_DG_FLOW_SENSORS_INVALID_CAL_RECORD, (U32)sensor ); + status = FALSE; + } +#endif -/*********************************************************************//** - * @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; + // The calibration data was valid, update the local copy + flowSensorsCalRecord.flowSensors[ sensor ].fourthOrderCoeff = calData.flowSensors[ sensor ].fourthOrderCoeff; + flowSensorsCalRecord.flowSensors[ sensor ].thirdOrderCoeff = calData.flowSensors[ sensor ].thirdOrderCoeff; + flowSensorsCalRecord.flowSensors[ sensor ].secondOrderCoeff = calData.flowSensors[ sensor ].secondOrderCoeff; + flowSensorsCalRecord.flowSensors[ sensor ].gain = calData.flowSensors[ sensor ].gain; + flowSensorsCalRecord.flowSensors[ sensor ].offset = calData.flowSensors[ sensor ].offset; } - return result; + return status; } /*********************************************************************//** * @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 @@ -732,7 +830,7 @@ static void publishROPumpData( void ) { // publish RO pump data on interval - if ( ++roPumpDataPublicationTimerCounter >= getPublishROPumpDataInterval() ) + if ( ++roPumpDataPublicationTimerCounter >= getU32OverrideValue( &roPumpDataPublishInterval ) ) { RO_PUMP_DATA_T pumpData; @@ -747,6 +845,7 @@ } } + /************************************************************************* * TEST SUPPORT FUNCTIONS *************************************************************************/