Index: firmware/App/Controllers/ROPump.c =================================================================== diff -u -rf68e01a2daee6cb88bb54816aee56668d662bcd4 -r25770b4b27e75e730d89ac046f7db405b1bfe39f --- firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision f68e01a2daee6cb88bb54816aee56668d662bcd4) +++ firmware/App/Controllers/ROPump.c (.../ROPump.c) (revision 25770b4b27e75e730d89ac046f7db405b1bfe39f) @@ -48,46 +48,60 @@ #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_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_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_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. #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). +/// The time in counts to check the flow and make sure it is in range. +#define FLOW_VERIFICATION_COUNTER_TARGET ( 2 * MS_PER_SECOND / TASK_GENERAL_INTERVAL ) //TODO remove -#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 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. + + /// 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 ( 10 * 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 ( 20 * 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 ( 2 * MS_PER_SECOND ) ///< RO pump safety shutdown activation timeout in ms. +#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. +#define ROP_FLOW_STABILIZE_TIME ( 3 * MS_PER_SECOND ) ///< Time required for RO flow to stabilize. TODO remove +#define ROP_MAX_RAMP_UP_RETRY 5 ///< Maximum ramp up retires before alarm. +// ************ New defines for pump control ****************// + + /// Enumeration of RO pump states. 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 + 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 @@ -113,18 +127,18 @@ static PUMP_CONTROL_MODE_T roPumpControlModeSet = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< currently set RO pump control mode. static F32 targetROPumpFlowRate = 0.0; ///< Target RO flow rate (in L/min). -static U32 targetROPumpPressure = 0; ///< Target RO pressure (in PSI). +static F32 targetROPumpPressure = 0; ///< Target RO 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 flowVerificationCounter = 0; ///< Counter to verify the flow is in range. +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. -static F32 roPumpPressureRunningSum = 0; ///< RO pump pressure running sum. +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. @@ -133,10 +147,14 @@ 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 ); @@ -146,7 +164,7 @@ static void setROPumpControlSignalDutyCycle( F32 dutyCycle ); static void stopROPump( void ); static void publishROPumpData( void ); -static U32 getPublishROPumpDataInterval( void ); +static U32 getPublishROPumpDataInterval( void ); /*********************************************************************//** * @brief @@ -166,10 +184,6 @@ initializePIController( PI_CONTROLLER_ID_RO_PUMP, MIN_RO_PUMP_DUTY_CYCLE, ROP_P_COEFFICIENT, ROP_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, - 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_UPPER_RANGE, TRUE, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL, FLOW_OUT_OF_RANGE_PERSISTENT_INTERVAL ); @@ -197,6 +211,7 @@ flowFilterCounter = 0; flowVerificationCounter = 0; roPumpDataPublicationTimerCounter = 0; + rampUpRetryCount = 0; roPumpState = RO_PUMP_OFF_STATE; roPumpControlMode = NUM_OF_PUMP_CONTROL_MODES; roPumpControlModeSet = roPumpControlMode; @@ -232,6 +247,7 @@ 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 @@ -296,7 +312,7 @@ // 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 ) @@ -322,18 +338,15 @@ // meaning, it is controlling to a certain pressure if ( roPumpControlMode == PUMP_CONTROL_MODE_CLOSED_LOOP && roPumpState == RO_PUMP_CONTROL_TO_TARGET_STATE ) { - F32 currentFlow = getMeasuredROFlowRate(); - F32 targetFlow = getTargetROPumpFlowRate(); - F32 error = fabs( 1.0 - ( currentFlow / targetFlow ) ); - + F32 const currentFlow = getMeasuredROFlowRate(); + F32 const targetFlow = getTargetROPumpFlowRate(); + 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 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 ); - } + 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 @@ -342,7 +355,7 @@ F32 pressureInlet = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_INLET ); BOOL isPumpRunning = ( pressureInlet + MAX_PRESSURE_TARGET_TOLERANCE ) < actualPressure; - checkPersistentAlarm( PERSISTEMT_ALARM_RO_PUMP_OFF_ERROR, isPumpRunning, pressureInlet, ( pressureInlet + MAX_PRESSURE_TARGET_TOLERANCE ) ); + 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 ) ) @@ -370,6 +383,10 @@ roPumpState = handleROPumpOffState(); break; + case RO_PUMP_CONTROL_SETUP_STATE: + //roPumpState = handleROPumpControlSetupState(); + break; + case RO_PUMP_RAMP_UP_STATE: roPumpState = handleROPumpRampUpState(); break; @@ -427,11 +444,9 @@ * @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 ) @@ -441,15 +456,13 @@ // 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; + roPumpDutyCyclePctSet = ( getTargetROPumpFlowRate() - getMeasuredROFlowRate() ) * 0.5; //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 @@ -465,6 +478,39 @@ /*********************************************************************//** * @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, @@ -482,19 +528,19 @@ F32 targetFlowRate = getTargetROPumpFlowRate(); F32 actualFlowRate = (F32)getMeasuredROFlowRate(); - BOOL isFlowInRange = fabs( targetFlowRate - actualFlowRate ) > ROP_FLOW_TARGET_TOLERANCE; + F32 flowRateDeviation = fabs( targetFlowRate - actualFlowRate ) / targetFlowRate; + BOOL isFlowOutOfRange = flowRateDeviation > ROP_FLOW_TARGET_TOLERANCE; - // Check if the ramp up has timed out - checkPersistentAlarm( PERSISTENT_ALARM_RO_PUMP_RAMP_UP_TO_TARGET_FLOW_TIMEOUT, isFlowInRange, actualFlowRate, MAX_ALLOWED_RAMP_UP_TIME ); - // If the ramp up persistent alarm is active, turn off the pump and go to off state - if ( isAlarmActive( ALARM_ID_RO_PUMP_RAMP_UP_TO_FLOW_TIMEOUT ) ) + /*if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_RO_PUMP_RAMP_UP_TO_FLOW_TIMEOUT, isFlowOutOfRange ) ) { stopROPump(); result = RO_PUMP_OFF_STATE; - } + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_RO_PUMP_RAMP_UP_TO_FLOW_TIMEOUT, actualFlowRate, MAX_ALLOWED_RAMP_UP_TIME ); + }*/ // Control at set interval - else if ( ++roControlTimerCounter >= ROP_CONTROL_INTERVAL ) + //else if ( ++roControlTimerCounter >= ROP_RAMP_UP_CONTROL_INTERVAL ) + if ( ++roControlTimerCounter >= ROP_RAMP_UP_CONTROL_INTERVAL ) { F32 targetPressure = getTargetROPumpPressure(); @@ -504,23 +550,32 @@ // be reset to the corresponding pressure of the target flow rate. if ( ( actualPressure > targetPressure ) || ( ( targetPressure - actualPressure ) < MAX_PRESSURE_TARGET_TOLERANCE ) ) { + resetPIController( PI_CONTROLLER_ID_RO_PUMP, roPumpDutyCyclePctSet ); result = RO_PUMP_CONTROL_TO_TARGET_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 ) * 0.5; + //roPumpDutyCyclePctSet = ROP_FLOW_TO_PWM_DC( getTargetROPumpFlowRate() ); 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, roPumpDutyCyclePctSet ); + result = RO_PUMP_CONTROL_TO_TARGET_STATE; } roControlTimerCounter = 0; } + /*if ( TRUE == setupROPumpControl ) + { + //resetPersistentAlarmTimer( ALARM_ID_RO_PUMP_RAMP_UP_TO_FLOW_TIMEOUT ); + result = RO_PUMP_CONTROL_SETUP_STATE; + }*/ + return result; } @@ -545,39 +600,40 @@ // Check if the time for flow verification has elapsed if ( ++flowVerificationCounter >= FLOW_VERIFICATION_COUNTER_TARGET ) { - 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 const targetFlowRate = getTargetROPumpFlowRate(); + F32 const avgFlowRate = roPumpFlowRateRunningSum / flowVerificationCounter; + F32 const flowRateDeviation = fabs( targetFlowRate - avgFlowRate ) / targetFlowRate; + + if ( flowRateDeviation < ROP_FLOW_TARGET_TOLERANCE ) { - // Calculate the average pressure and flow rate - F32 avgPressure = roPumpPressureRunningSum / flowVerificationCounter; - F32 avgFlowRate = roPumpFlowRateRunningSum / flowVerificationCounter; + 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; + } - 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; + // 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; + } + } - // 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; + if ( TRUE == setupROPumpControl ) + { + result = RO_PUMP_CONTROL_SETUP_STATE; } return result; @@ -601,13 +657,26 @@ { // Get the pressure to use it for setting the control F32 actualPressure = getMeasuredDGPressure( PRESSURE_SENSOR_RO_PUMP_OUTLET ); + if ( actualPressure >= targetROPumpPressure ) + { + roPumpDutyCyclePctSet -= ROP_RAMP_DOWN_DUTY_CYCLE_RATIO; + //targetROPumpFlowRate = actualFlowRate; + } + else + { + roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP, getTargetROPumpFlowRate(), getMeasuredROFlowRate() ); + } - roPumpDutyCyclePctSet = runPIController( PI_CONTROLLER_ID_RO_PUMP, getTargetROPumpPressure(), actualPressure ); setROPumpControlSignalDutyCycle( roPumpDutyCyclePctSet ); roControlTimerCounter = 0; } + /*if ( TRUE == setupROPumpControl ) + { + result = RO_PUMP_CONTROL_SETUP_STATE; + }*/ + return result; } @@ -750,6 +819,7 @@ { RO_PUMP_DATA_T pumpData; + pumpData.roPumpTgtFlowRate = getTargetROPumpFlowRate(); pumpData.roPumpTgtPressure = getTargetROPumpPressure(); pumpData.measROFlowRate = getMeasuredROFlowRate(); pumpData.roPumpDutyCycle = roPumpDutyCyclePctSet * FRACTION_TO_PERCENT_FACTOR; @@ -781,8 +851,8 @@ 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; }