Index: firmware/App/Controllers/BloodFlow.c =================================================================== diff -u -rc05775820109b5e83596c58a3b4248ac6cdb1d65 -r8466e63f95f65a3ffb18c3af85ac99328e41167b --- firmware/App/Controllers/BloodFlow.c (.../BloodFlow.c) (revision c05775820109b5e83596c58a3b4248ac6cdb1d65) +++ firmware/App/Controllers/BloodFlow.c (.../BloodFlow.c) (revision 8466e63f95f65a3ffb18c3af85ac99328e41167b) @@ -49,10 +49,11 @@ #define MAX_BLOOD_PUMP_PWM_DUTY_CYCLE 0.89 ///< Controller will error if PWM duty cycle > 90%, so set max to 89% #define MIN_BLOOD_PUMP_PWM_DUTY_CYCLE 0.10 ///< Controller will error if PWM duty cycle < 10%, so set min to 10% +#define BP_CONTROL_INTERVAL_SEC 10 ///< Blood pump control interval (in seconds). /// Interval (ms/task time) at which the blood pump is controlled. -static const U32 BP_CONTROL_INTERVAL = ( 10000 / TASK_GENERAL_INTERVAL ); -#define BP_P_COEFFICIENT 0.00035 ///< P term for blood pump control -#define BP_I_COEFFICIENT 0.00035 ///< I term for blood pump control +static const U32 BP_CONTROL_INTERVAL = ( BP_CONTROL_INTERVAL_SEC * MS_PER_SECOND / TASK_GENERAL_INTERVAL ); +#define BP_P_COEFFICIENT 0.0001 ///< P term for blood pump control +#define BP_I_COEFFICIENT 0.00075 ///< I term for blood pump control #define BP_HOME_RATE 100 ///< Target pump speed (in estimate mL/min) for homing. #define BP_HOME_TIMEOUT_MS 10000 ///< Maximum time allowed for homing to complete (in ms). @@ -61,43 +62,44 @@ /// Number of hall sensor counts kept in buffer to hold last 1 second of count data. #define BP_SPEED_CALC_BUFFER_LEN ( MS_PER_SECOND / BP_SPEED_CALC_INTERVAL / TASK_PRIORITY_INTERVAL ) #define BP_MAX_ROTOR_SPEED_RPM 100.0 ///< Maximum rotor speed allowed for blood pump. - + +#define BP_MAX_FLOW_RATE 1320.0 ///< Maximum measured BP flow rate allowed. +#define BP_MIN_FLOW_RATE -1320.0 ///< Minimum measured BP flow rate allowed. #define BP_MAX_FLOW_VS_SPEED_DIFF_RPM 200.0 ///< Maximum difference between measured speed and speed implied by measured flow. #define BP_MAX_MOTOR_SPEED_WHILE_OFF_RPM 100.0 ///< Maximum motor speed (RPM) while motor is commanded off. #define BP_MAX_ROTOR_VS_MOTOR_DIFF_RPM 5.0 ///< Maximum difference in speed between motor and rotor (in rotor RPM). #define BP_MAX_MOTOR_SPEED_ERROR_RPM 300.0 ///< Maximum difference in speed between measured and commanded RPM. /// Persist time (task intervals) for flow vs. motor speed error condition. -static const U32 BP_FLOW_VS_SPEED_PERSIST = ((5 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL); +static const U32 BP_FLOW_VS_SPEED_PERSIST = ( 5 * MS_PER_SECOND ); /// Persist time (task intervals) for motor off error condition. -static const U32 BP_OFF_ERROR_PERSIST = ((5 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL); +static const U32 BP_OFF_ERROR_PERSIST = ( 5 * MS_PER_SECOND ); /// Persist time (task intervals) motor speed error condition. -static const U32 BP_MOTOR_SPEED_ERROR_PERSIST = ((5 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL); +static const U32 BP_MOTOR_SPEED_ERROR_PERSIST = ( 5 * MS_PER_SECOND ); /// Persist time (task intervals) rotor speed error condition. -static const U32 BP_ROTOR_SPEED_ERROR_PERSIST = ((12 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL); +static const U32 BP_ROTOR_SPEED_ERROR_PERSIST = ( 12 * MS_PER_SECOND ); /// Persist time (task intervals) pump direction error condition. -static const U32 BP_DIRECTION_ERROR_PERSIST = (250 / TASK_PRIORITY_INTERVAL); -/// Persist time (task intervals) blood pump rotor speed too fast error condition. -static const U32 BP_MAX_ROTOR_SPEED_ERROR_PERSIST = ((1 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL); +static const U32 BP_DIRECTION_ERROR_PERSIST = ( 250 ); +/// Persist time period blood pump rotor speed too fast error condition. +static const U32 BP_MAX_ROTOR_SPEED_ERROR_PERSIST = ( 1 * MS_PER_SECOND ); +/// Persist time (task intervals) blood flow rate out of range error condition. +static const U32 BP_MAX_FLOW_RATE_OUT_OF_RANGE_PERSIST = ((1 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL); #define BP_MAX_CURR_WHEN_STOPPED_MA 150.0 ///< Motor controller current should not exceed this when pump should be stopped #define BP_MAX_CURR_WHEN_RUNNING_MA 2000.0 ///< Motor controller current should not exceed this when pump should be running #define BP_MAX_CURR_ERROR_DURATION_MS 2000 ///< Motor controller current errors persisting beyond this duration will trigger an alarm -#ifndef V2_0_SYSTEM - #define BP_SPEED_ADC_TO_RPM_FACTOR 1.751752 ///< Conversion factor from ADC counts to RPM for blood pump motor - #define BP_MOTOR_RPM_TO_PWM_DC_FACTOR 0.00025 ///< ~40 BP motor RPM = 1% PWM duty cycle -#else - #define BP_SPEED_ADC_TO_RPM_FACTOR 1.280938 ///< Conversion factor from ADC counts to RPM for blood pump motor - #define BP_MOTOR_RPM_TO_PWM_DC_FACTOR 0.0003125 ///< ~32 BP motor RPM = 1% PWM duty cycle -#endif +#define BP_SPEED_ADC_TO_RPM_FACTOR 1.751752 ///< Conversion factor from ADC counts to RPM for blood pump motor +#define BP_MOTOR_RPM_TO_PWM_DC_FACTOR 0.000238 ///< ~42 BP motor RPM = 1% PWM duty cycle #define BP_CURRENT_ADC_TO_MA_FACTOR 3.002 ///< Conversion factor from ADC counts to mA for blood pump motor #define BP_REV_PER_LITER 150.0 ///< Rotor revolutions per liter #define BP_ML_PER_MIN_TO_PUMP_RPM_FACTOR ( BP_REV_PER_LITER / ML_PER_LITER ) ///< Conversion factor from mL/min to motor RPM. #define BP_GEAR_RATIO 32.0 ///< Blood pump motor to blood pump gear ratio #define BP_PWM_ZERO_OFFSET 0.1 ///< 10% PWM duty cycle = zero speed -/// Conversion factor from mL/min to estimated PWM duty cycle %. -#define BP_PWM_FROM_ML_PER_MIN(rate) ( (rate) * BP_ML_PER_MIN_TO_PUMP_RPM_FACTOR * BP_GEAR_RATIO * BP_MOTOR_RPM_TO_PWM_DC_FACTOR + BP_PWM_ZERO_OFFSET ) +/// Conversion macro from mL/min to estimated PWM duty cycle %. +#define BP_PWM_FROM_ML_PER_MIN(rate) ( (rate) * BP_ML_PER_MIN_TO_PUMP_RPM_FACTOR * BP_GEAR_RATIO * BP_MOTOR_RPM_TO_PWM_DC_FACTOR + BP_PWM_ZERO_OFFSET ) +/// Conversion from PWM duty cycle % to commanded pump motor speed. +#define BP_PWM_TO_MOTOR_SPEED_RPM(pwm) ( ((pwm) - BP_PWM_ZERO_OFFSET) * 4000.0 ) #define BLOODPUMP_ADC_FULL_SCALE_V 3.0 ///< BP analog signals are 0-3V (while int. ADC ref may be different) #define BLOODPUMP_ADC_ZERO 1998 ///< Blood pump ADC channel zero offset. @@ -107,7 +109,7 @@ #define SIZE_OF_ROLLING_AVG ( ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) * 10 ) /// Blood flow sensor signal strength low alarm persistence. -#define FLOW_SIG_STRGTH_ALARM_PERSIST ( 5 * MS_PER_SECOND ) +#define FLOW_SIG_STRGTH_ALARM_PERSIST ( BP_CONTROL_INTERVAL_SEC * MS_PER_SECOND ) #define MIN_FLOW_SIG_STRENGTH 0.9 ///< Minimum flow sensor signal strength (90%). /// Blood flow fast read timeout alarm persistence. @@ -161,8 +163,6 @@ static MOTOR_DIR_T bloodPumpDirectionSet = MOTOR_DIR_FORWARD; ///< Currently set blood flow direction static PUMP_CONTROL_MODE_T bloodPumpControlMode = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< Requested blood pump control mode. static PUMP_CONTROL_MODE_T bloodPumpControlModeSet = PUMP_CONTROL_MODE_CLOSED_LOOP; ///< Currently set blood pump control mode. -static F32 bloodFlowCalGain = 1.0; ///< Blood flow calibration gain. -static F32 bloodFlowCalOffset = 0.0; ///< Blood flow calibration offset. /// Interval (in task intervals) at which to publish blood flow data to CAN bus. static OVERRIDE_U32_T bloodFlowDataPublishInterval = { BLOOD_FLOW_DATA_PUB_INTERVAL, BLOOD_FLOW_DATA_PUB_INTERVAL, BLOOD_FLOW_DATA_PUB_INTERVAL, 0 }; @@ -186,24 +186,16 @@ static U32 bpMotorSpeedCalcIdx = 0; ///< Index into 1 second buffer of motor speed hall sensor counts static U32 bpMotorSpeedCalcTimerCtr = 0; ///< Counter determines interval for calculating blood pump motor speed from hall sensor count. -static U32 errorBloodFlowVsMotorSpeedPersistTimerCtr = 0; ///< Persistence timer counter for flow vs. motor speed error condition. -static U32 errorBloodMotorOffPersistTimerCtr = 0; ///< Persistence timer counter for motor off check error condition. -static U32 errorBloodMotorSpeedPersistTimerCtr = 0; ///< Persistence timer counter for motor speed error condition. -static U32 errorBloodRotorSpeedPersistTimerCtr = 0; ///< Persistence timer counter for rotor speed error condition. -static U32 errorBloodPumpDirectionPersistTimerCtr = 0; ///< Persistence timer counter for pump direction error condition. -static U32 errorBloodPumpRotorTooFastPersistTimerCtr = 0; ///< Persistence timer counter for pump rotor too fast error condition. - static F32 flowReadings[ SIZE_OF_ROLLING_AVG ]; ///< Holds flow samples for a rolling average. static U32 flowReadingsIdx = 0; ///< Index for next sample in rolling average array. static F32 flowReadingsTotal = 0.0; ///< Rolling total - used to calc average. static U32 flowReadingsCount = 0; ///< Number of samples in flow rolling average buffer. -static U32 bpCurrErrorDurationCtr = 0; ///< Used for tracking persistence of bp current errors. - static U08 lastBloodFlowFastPacketReadCtr = 0; ///< Previous read counter for the blood flow fast packets. static U08 lastBloodFlowSlowPacketReadCtr = 0; ///< Previous read counter for the blood flow slow packets. static U08 lastBloodPumpDirectionCount = 0; ///< Previous pump direction error count reported by FPGA. static U08 lastBloodFlowCommErrorCount = 0; ///< Previous BP flow sensor comm error count. +static HD_FLOW_SENSORS_CAL_RECORD_T bloodFlowCalRecord; ///< Blood flow sensor calibration record. // ********** private function prototypes ********** @@ -224,8 +216,8 @@ static void checkBloodPumpSpeeds( void ); static void checkBloodPumpFlowAgainstSpeed( void ); static void checkBloodPumpMCCurrent( void ); -static void checkBloodFlowSensorSignalStrength( void ); -static U32 getPublishBloodFlowDataInterval( void ); +static void checkBloodFlowSensorSignalStrength( void ); +static BOOL processCalibrationData( void ); /*********************************************************************//** * @brief @@ -256,11 +248,19 @@ BP_P_COEFFICIENT, BP_I_COEFFICIENT, MIN_BLOOD_PUMP_PWM_DUTY_CYCLE, MAX_BLOOD_PUMP_PWM_DUTY_CYCLE ); - // Initialize persistent alarm for flow sensor signal strength too low + // Initialize persistent alarm for flow sensor + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_FLOW_VS_MOTOR_SPEED_CHECK, 0, BP_FLOW_VS_SPEED_PERSIST ); + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_OFF_CHECK, 0, BP_OFF_ERROR_PERSIST ); + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_MOTOR_SPEED_CHECK, 0, BP_MOTOR_SPEED_ERROR_PERSIST ); + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_CHECK, 0, BP_ROTOR_SPEED_ERROR_PERSIST ); + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_MC_DIRECTION_CHECK, 0, BP_DIRECTION_ERROR_PERSIST ); + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_TOO_HIGH, 0, BP_MAX_ROTOR_SPEED_ERROR_PERSIST ); + initPersistentAlarm( ALARM_ID_BLOOD_PUMP_MC_CURRENT_CHECK, 0, BP_MAX_CURR_ERROR_DURATION_MS ); initPersistentAlarm( ALARM_ID_BLOOD_FLOW_SIGNAL_STRENGTH_TOO_LOW, FLOW_SIG_STRGTH_ALARM_PERSIST, FLOW_SIG_STRGTH_ALARM_PERSIST ); initPersistentAlarm( ALARM_ID_HD_BP_FLOW_READ_TIMEOUT_ERROR, 0, BLOOD_FLOW_FAST_READ_TO_PERSIST ); initPersistentAlarm( ALARM_ID_HD_BP_FLOW_SLOW_READ_TIMEOUT_ERROR, 0, BLOOD_FLOW_SLOW_READ_TO_PERSIST ); initPersistentAlarm( ALARM_ID_HD_BP_FLOW_SENSOR_ERROR, 0, BLOOD_FLOW_COMM_ERROR_PERSIST ); + initPersistentAlarm( ALARM_ID_HD_BLOOD_FLOW_OUT_OF_RANGE, 0, BP_MAX_FLOW_RATE_OUT_OF_RANGE_PERSIST ); } /*********************************************************************//** @@ -281,8 +281,10 @@ // Direction change while pump is running is not allowed if ( ( FALSE == isBloodPumpOn ) || ( 0 == flowRate ) || ( dir == bloodPumpDirectionSet ) ) { +#ifndef NO_PUMP_FLOW_LIMITS // Verify flow rate - if ( flowRate <= MAX_BLOOD_FLOW_RATE ) + if ( flowRate <= MAX_SET_BLOOD_FLOW_RATE ) +#endif { resetBloodFlowMovingAverage(); targetBloodFlowRate = ( dir == MOTOR_DIR_FORWARD ? (S32)flowRate : (S32)flowRate * -1 ); @@ -321,10 +323,12 @@ } result = TRUE; } +#ifndef NO_PUMP_FLOW_LIMITS else // Requested flow rate too high { SET_ALARM_WITH_2_U32_DATA( ALARM_ID_HD_SOFTWARE_FAULT, SW_FAULT_ID_BLOOD_FLOW_SET_TOO_HIGH, flowRate ) - } + } +#endif } return result; @@ -440,20 +444,34 @@ * @brief * The execBloodFlowMonitor function executes the blood flow monitor. * @details Inputs: none - * @details Outputs: measuredBloodFlowRate, adcBloodPumpMCSpeedRPM, adcBloodPumpMCCurrentmA + * @details Outputs: measuredBloodFlowRate, adcBloodPumpMCSpeedRPM, + * adcBloodPumpMCCurrentmA * @return none *************************************************************************/ void execBloodFlowMonitor( void ) { + // Check if a new calibration is available + if ( TRUE == isNewCalibrationRecordAvailable() ) + { + // Get the new calibration data and check its validity + processCalibrationData(); + } + HD_OP_MODE_T opMode = getCurrentOperationMode(); U16 bpRPM = getIntADCReading( INT_ADC_BLOOD_PUMP_SPEED ); U16 bpmA = getIntADCReading( INT_ADC_BLOOD_PUMP_MOTOR_CURRENT ); - F32 bpFlow = ( getFPGABloodFlow() * bloodFlowCalGain ) + bloodFlowCalOffset; U08 fpReadCtr = getFPGABloodFlowFastPacketReadCounter(); U08 spReadCtr = getFPGABloodFlowSlowPacketReadCounter(); U08 flowErrorCtr = getFPGABloodFlowErrorCounter(); U08 flowStatus = getFPGABloodFlowMeterStatus(); + F32 fpgaBloodFlow = getFPGABloodFlow(); + F32 bpFlow = pow(fpgaBloodFlow, 4) * bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].fourthOrderCoeff + + pow(fpgaBloodFlow, 3) * bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].thirdOrderCoeff + + pow(fpgaBloodFlow, 2) * bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].secondOrderCoeff + + fpgaBloodFlow * bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].gain + + bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].offset; + #ifndef DISABLE_PUMP_FLOW_CHECKS if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_HD_BP_FLOW_SENSOR_ERROR, ( flowErrorCtr != lastBloodFlowCommErrorCount ) ) ) { @@ -596,14 +614,11 @@ else if ( bloodPumpPWMDutyCyclePctSet >= bloodPumpPWMDutyCyclePct ) { resetBloodFlowMovingAverage(); + bloodPumpPWMDutyCyclePctSet = bloodPumpPWMDutyCyclePct; resetPIController( PI_CONTROLLER_ID_BLOOD_FLOW, bloodPumpPWMDutyCyclePctSet ); bloodPumpControlModeSet = bloodPumpControlMode; - // If open loop mode, set PWM to requested duty cycle where it will stay during control state - if ( bloodPumpControlModeSet == PUMP_CONTROL_MODE_OPEN_LOOP ) - { - bloodPumpPWMDutyCyclePctSet = bloodPumpPWMDutyCyclePct; - setBloodPumpControlSignalPWM( bloodPumpPWMDutyCyclePct ); - } + setBloodPumpControlSignalPWM( bloodPumpPWMDutyCyclePctSet ); + bpControlTimerCounter = 0; result = BLOOD_PUMP_CONTROL_TO_TARGET_STATE; } // Continue ramp up @@ -638,14 +653,11 @@ else if ( bloodPumpPWMDutyCyclePctSet <= bloodPumpPWMDutyCyclePct ) { resetBloodFlowMovingAverage(); + bloodPumpPWMDutyCyclePctSet = bloodPumpPWMDutyCyclePct; resetPIController( PI_CONTROLLER_ID_BLOOD_FLOW, bloodPumpPWMDutyCyclePctSet ); bloodPumpControlModeSet = bloodPumpControlMode; - // If open loop mode, set PWM to requested duty cycle where it will stay during control state - if ( bloodPumpControlModeSet == PUMP_CONTROL_MODE_OPEN_LOOP ) - { - bloodPumpPWMDutyCyclePctSet = bloodPumpPWMDutyCyclePct; - setBloodPumpControlSignalPWM( bloodPumpPWMDutyCyclePct ); - } + setBloodPumpControlSignalPWM( bloodPumpPWMDutyCyclePctSet ); + bpControlTimerCounter = 0; result = BLOOD_PUMP_CONTROL_TO_TARGET_STATE; } // Continue ramp down @@ -713,7 +725,7 @@ static void stopBloodPump( void ) { isBloodPumpOn = FALSE; - bloodPumpPWMDutyCyclePctSet = 0.0; + bloodPumpPWMDutyCyclePctSet = BP_PWM_ZERO_OFFSET; etpwmSetCmpA( etpwmREG1, 0 ); SET_BP_STOP(); } @@ -761,33 +773,13 @@ /*********************************************************************//** * @brief - * The getPublishBloodFlowDataInterval function gets the blood flow data - * publication interval. - * @details Inputs: bloodFlowDataPublishInterval - * @details Outputs: none - * @return the current blood flow data publication interval (in task intervals). - *************************************************************************/ -U32 getPublishBloodFlowDataInterval( void ) -{ - U32 result = bloodFlowDataPublishInterval.data; - - if ( OVERRIDE_KEY == bloodFlowDataPublishInterval.override ) - { - result = bloodFlowDataPublishInterval.ovData; - } - - return result; -} - -/*********************************************************************//** - * @brief * The getMeasuredBloodFlowRate function gets the measured blood flow * rate. * @details Inputs: measuredBloodFlowRate * @details Outputs: none * @return the current blood flow rate (in mL/min). *************************************************************************/ -F32 getMeasuredBloodFlowRate( void ) +F32 getMeasuredBloodFlowRate( void ) { F32 result = measuredBloodFlowRate.data; @@ -827,7 +819,7 @@ * @details Outputs: none * @return the current blood flow rate (in mL/min). *************************************************************************/ -F32 getMeasuredBloodPumpRotorSpeed( void ) +F32 getMeasuredBloodPumpRotorSpeed( void ) { F32 result = bloodPumpRotorSpeedRPM.data; @@ -847,7 +839,7 @@ * @details Outputs: none * @return the current blood flow rate (in mL/min). *************************************************************************/ -F32 getMeasuredBloodPumpSpeed( void ) +F32 getMeasuredBloodPumpSpeed( void ) { F32 result = bloodPumpSpeedRPM.data; @@ -867,7 +859,7 @@ * @details Outputs: none * @return the current blood pump speed (in RPM). *************************************************************************/ -F32 getMeasuredBloodPumpMCSpeed( void ) +F32 getMeasuredBloodPumpMCSpeed( void ) { F32 result = adcBloodPumpMCSpeedRPM.data; @@ -887,7 +879,7 @@ * @details Outputs: none * @return the current blood pump current (in mA). *************************************************************************/ -F32 getMeasuredBloodPumpMCCurrent( void ) +F32 getMeasuredBloodPumpMCCurrent( void ) { F32 result = adcBloodPumpMCCurrentmA.data; @@ -911,7 +903,7 @@ static void publishBloodFlowData( void ) { // Publish blood flow data on interval - if ( ++bloodFlowDataPublicationTimerCounter >= getPublishBloodFlowDataInterval() ) + if ( ++bloodFlowDataPublicationTimerCounter >= getU32OverrideValue( &bloodFlowDataPublishInterval ) ) { BLOOD_PUMP_STATUS_PAYLOAD_T payload; @@ -1034,17 +1026,10 @@ // TODO - alarm??? } - // Ensure rotor speed below maximum - if ( rotorSpeed > BP_MAX_ROTOR_SPEED_RPM ) - { - if ( ++errorBloodPumpRotorTooFastPersistTimerCtr >= BP_MAX_ROTOR_SPEED_ERROR_PERSIST ) - { - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_TOO_HIGH, rotorSpeed ) - } - } - else + // Ensure rotor speed below maximum + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_TOO_HIGH, rotorSpeed > BP_MAX_ROTOR_SPEED_RPM ) ) { - errorBloodPumpRotorTooFastPersistTimerCtr = 0; + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_TOO_HIGH, rotorSpeed ) } // If pump is stopped or running very slowly, set rotor speed to zero @@ -1067,6 +1052,7 @@ if ( BLOOD_PUMP_CONTROL_TO_TARGET_STATE == bloodPumpState ) { MOTOR_DIR_T bpMCDir, bpDir; + BOOL isDirIncorrect; U08 dirErrorCnt = getFPGABloodPumpHallSensorStatus() & PUMP_DIR_ERROR_COUNT_MASK; // Check pump direction error count @@ -1079,35 +1065,26 @@ bpMCDir = ( getMeasuredBloodPumpMCSpeed() >= 0.0 ? MOTOR_DIR_FORWARD : MOTOR_DIR_REVERSE ); bpDir = ( getMeasuredBloodPumpSpeed() >= 0.0 ? MOTOR_DIR_FORWARD : MOTOR_DIR_REVERSE ); - // Check set direction vs. direction from hall sensors - if ( bloodPumpDirectionSet != bpDir ) - { - if ( ++errorBloodPumpDirectionPersistTimerCtr >= BP_DIRECTION_ERROR_PERSIST ) - { -#ifndef DISABLE_PUMP_DIRECTION_CHECKS - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_BLOOD_PUMP_MC_DIRECTION_CHECK, (U32)bloodPumpDirectionSet, (U32)bpDir ) -#endif - } - } - // Check set direction vs. direction from sign of motor controller speed - else if ( bloodPumpDirectionSet != bpMCDir ) + // Check set direction vs. direction from hall sensors vs. direction from sign of motor controller speed + isDirIncorrect = ( bloodPumpDirectionSet != bpDir ) || ( bloodPumpDirectionSet != bpMCDir ); + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_MC_DIRECTION_CHECK, isDirIncorrect ) ) { - if ( ++errorBloodPumpDirectionPersistTimerCtr >= BP_DIRECTION_ERROR_PERSIST ) - { #ifndef DISABLE_PUMP_DIRECTION_CHECKS + if ( bloodPumpDirectionSet != bpDir ) + { + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_BLOOD_PUMP_MC_DIRECTION_CHECK, (U32)bloodPumpDirectionSet, (U32)bpDir ) + } + else + { SET_ALARM_WITH_2_U32_DATA( ALARM_ID_BLOOD_PUMP_MC_DIRECTION_CHECK, (U32)bloodPumpDirectionSet, (U32)bpMCDir ) -#endif } +#endif } - else - { - errorBloodPumpDirectionPersistTimerCtr = 0; - } } else { - errorBloodPumpDirectionPersistTimerCtr = 0; - } + resetPersistentAlarmTimer( ALARM_ID_BLOOD_PUMP_MC_DIRECTION_CHECK ); + } } /*********************************************************************//** @@ -1125,74 +1102,49 @@ static void checkBloodPumpSpeeds( void ) { F32 measMotorSpeed = fabs( getMeasuredBloodPumpSpeed() ); - S32 cmdRate = targetBloodFlowRate; + F32 measMCMotorSpeed = fabs( getMeasuredBloodPumpMCSpeed() ); // Check for pump running while commanded off - if ( 0 == cmdRate ) - { - if ( measMotorSpeed > BP_MAX_MOTOR_SPEED_WHILE_OFF_RPM ) - { - if ( ++errorBloodMotorOffPersistTimerCtr >= BP_OFF_ERROR_PERSIST ) - { + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_OFF_CHECK, ( 0 == targetBloodFlowRate ) && ( measMotorSpeed > BP_MAX_MOTOR_SPEED_WHILE_OFF_RPM ) ) ) + { #ifndef DISABLE_PUMP_SPEED_CHECKS - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_OFF_CHECK, measMotorSpeed ); - activateSafetyShutdown(); + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_OFF_CHECK, measMotorSpeed ); + activateSafetyShutdown(); #endif - } - } - else - { - errorBloodMotorOffPersistTimerCtr = 0; - } } - else - { - errorBloodMotorOffPersistTimerCtr = 0; - } + // Checks that only occur when pump is running (and beyond ramp). if ( BLOOD_PUMP_CONTROL_TO_TARGET_STATE == bloodPumpState ) { - F32 cmdMotorSpeed = ( (F32)cmdRate / (F32)ML_PER_LITER ) * BP_REV_PER_LITER * BP_GEAR_RATIO; - F32 deltaMotorSpeed = fabs( measMotorSpeed - cmdMotorSpeed ); + F32 cmdMotorSpeed = BP_PWM_TO_MOTOR_SPEED_RPM( bloodPumpPWMDutyCyclePctSet ); + F32 deltaMotorSpeed = fabs( measMotorSpeed - cmdMotorSpeed ); + F32 deltaMCMotorSpeed = fabs( measMCMotorSpeed - cmdMotorSpeed ); F32 measRotorSpeed = getMeasuredBloodPumpRotorSpeed(); F32 measMotorSpeedInRotorRPM = measMotorSpeed / BP_GEAR_RATIO; F32 deltaRotorSpeed = fabs( measRotorSpeed - measMotorSpeedInRotorRPM ); - // Check measured motor speed vs. commanded motor speed while controlling to target - if ( deltaMotorSpeed > BP_MAX_MOTOR_SPEED_ERROR_RPM ) - { - if ( ++errorBloodMotorSpeedPersistTimerCtr >= BP_MOTOR_SPEED_ERROR_PERSIST ) - { -#ifndef DISABLE_PUMP_SPEED_CHECKS - SET_ALARM_WITH_2_F32_DATA( ALARM_ID_BLOOD_PUMP_MOTOR_SPEED_CHECK, (F32)cmdRate, measMotorSpeed ); + // Check measured motor speed vs. commanded motor speed while controlling to target + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_MOTOR_SPEED_CHECK, + ( deltaMotorSpeed > BP_MAX_MOTOR_SPEED_ERROR_RPM ) || ( deltaMCMotorSpeed > BP_MAX_MOTOR_SPEED_ERROR_RPM ) ) ) + { +#ifndef DISABLE_PUMP_SPEED_CHECKS + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_BLOOD_PUMP_MOTOR_SPEED_CHECK, cmdMotorSpeed, measMotorSpeed ); #endif - } } - else - { - errorBloodMotorSpeedPersistTimerCtr = 0; - } - // Check measured rotor speed vs. measured motor speed while controlling to target - if ( deltaRotorSpeed > BP_MAX_ROTOR_VS_MOTOR_DIFF_RPM ) - { - if ( ++errorBloodRotorSpeedPersistTimerCtr >= BP_ROTOR_SPEED_ERROR_PERSIST ) - { -#ifndef DISABLE_PUMP_SPEED_CHECKS - SET_ALARM_WITH_2_F32_DATA( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_CHECK, measRotorSpeed, measMotorSpeed ); + // Check measured rotor speed vs. measured motor speed while controlling to target + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_CHECK, deltaRotorSpeed > BP_MAX_ROTOR_VS_MOTOR_DIFF_RPM ) ) + { +#ifndef DISABLE_PUMP_SPEED_CHECKS + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_CHECK, measRotorSpeed, measMotorSpeed ); #endif - } } - else - { - errorBloodRotorSpeedPersistTimerCtr = 0; - } + } + else + { + resetPersistentAlarmTimer( ALARM_ID_BLOOD_PUMP_MOTOR_SPEED_CHECK ); + resetPersistentAlarmTimer( ALARM_ID_BLOOD_PUMP_ROTOR_SPEED_CHECK ); } - else - { - errorBloodMotorSpeedPersistTimerCtr = 0; - errorBloodRotorSpeedPersistTimerCtr = 0; - } } /*********************************************************************//** @@ -1201,38 +1153,40 @@ * against the implied flow of the measured pump speed when in treatment mode * and controlling to target flow. If a sufficient difference persists, a * flow vs. motor speed check error is triggered. - * @details Inputs: measuredBloodFlowRate, bloodPumpSpeedRPM, errorBloodFlowVsMotorSpeedPersistTimerCtr + * @details Inputs: measuredBloodFlowRate, bloodPumpSpeedRPM * @details Outputs: alarm may be triggered * @return none *************************************************************************/ static void checkBloodPumpFlowAgainstSpeed( void ) { - // Check only performed while in treatment mode and while we are in control to target state + F32 flow = getMeasuredBloodFlowRate(); + + // Range check on measure BP flow rate. +#ifndef DISABLE_PUMP_FLOW_CHECKS + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_HD_BLOOD_FLOW_OUT_OF_RANGE, ( flow > BP_MAX_FLOW_RATE ) || ( flow < BP_MIN_FLOW_RATE ) ) ) + { + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_HD_BLOOD_FLOW_OUT_OF_RANGE, flow ); + } +#endif + + // Flow vs. speed check only performed while in treatment mode and while we are in control to target state if ( ( MODE_TREA == getCurrentOperationMode() ) && ( BLOOD_PUMP_CONTROL_TO_TARGET_STATE == bloodPumpState ) ) { - F32 flow = getMeasuredBloodFlowRate(); F32 speed = getMeasuredBloodPumpSpeed(); F32 impliedSpeed = ( flow / (F32)ML_PER_LITER ) * BP_REV_PER_LITER * BP_GEAR_RATIO; F32 delta = fabs( speed - impliedSpeed ); - - if ( delta > BP_MAX_FLOW_VS_SPEED_DIFF_RPM ) - { - if ( ++errorBloodFlowVsMotorSpeedPersistTimerCtr >= BP_FLOW_VS_SPEED_PERSIST ) - { -#ifndef DISABLE_PUMP_FLOW_CHECKS - SET_ALARM_WITH_2_F32_DATA( ALARM_ID_BLOOD_PUMP_FLOW_VS_MOTOR_SPEED_CHECK, flow, speed ); -#endif - } + + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_FLOW_VS_MOTOR_SPEED_CHECK, delta > BP_MAX_FLOW_VS_SPEED_DIFF_RPM ) ) + { +#ifndef DISABLE_PUMP_SPEED_CHECKS + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_BLOOD_PUMP_FLOW_VS_MOTOR_SPEED_CHECK, flow, speed ); +#endif } - else - { - errorBloodFlowVsMotorSpeedPersistTimerCtr = 0; - } + } + else + { + resetPersistentAlarmTimer( ALARM_ID_BLOOD_PUMP_FLOW_VS_MOTOR_SPEED_CHECK ); } - else - { - errorBloodFlowVsMotorSpeedPersistTimerCtr = 0; - } } /*********************************************************************//** @@ -1245,46 +1199,18 @@ *************************************************************************/ static void checkBloodPumpMCCurrent( void ) { - F32 bpCurr; - - // Blood pump should be off - if ( BLOOD_PUMP_OFF_STATE == bloodPumpState ) - { - bpCurr = fabs( getMeasuredBloodPumpMCCurrent() ); - if ( bpCurr > BP_MAX_CURR_WHEN_STOPPED_MA ) - { - bpCurrErrorDurationCtr += TASK_PRIORITY_INTERVAL; - if ( bpCurrErrorDurationCtr > BP_MAX_CURR_ERROR_DURATION_MS ) - { -#ifndef DISABLE_MOTOR_CURRENT_CHECKS - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_MC_CURRENT_CHECK, getMeasuredBloodPumpMCCurrent() ); -#endif - } - } - else - { - bpCurrErrorDurationCtr = 0; - } + F32 const bpCurr = fabs( getMeasuredBloodPumpMCCurrent() ); + // Check blood pump current during off state + BOOL const isOffMCCurrentBad = ( BLOOD_PUMP_OFF_STATE == bloodPumpState ) && ( bpCurr > BP_MAX_CURR_WHEN_STOPPED_MA ); + // Check blood pump current during running state + BOOL const isRunningMCCurrentBad = ( BLOOD_PUMP_OFF_STATE != bloodPumpState ) && ( bpCurr > BP_MAX_CURR_WHEN_RUNNING_MA ); + + if ( TRUE == isPersistentAlarmTriggered( ALARM_ID_BLOOD_PUMP_FLOW_VS_MOTOR_SPEED_CHECK, isOffMCCurrentBad || isRunningMCCurrentBad ) ) + { +#ifndef DISABLE_MOTOR_CURRENT_CHECKS + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_MC_CURRENT_CHECK, bpCurr ); +#endif } - // Blood pump should be running - else - { - bpCurr = fabs( getMeasuredBloodPumpMCCurrent() ); - if ( bpCurr > BP_MAX_CURR_WHEN_RUNNING_MA ) - { - bpCurrErrorDurationCtr += TASK_PRIORITY_INTERVAL; - if ( bpCurrErrorDurationCtr > BP_MAX_CURR_ERROR_DURATION_MS ) - { -#ifndef DISABLE_MOTOR_CURRENT_CHECKS - SET_ALARM_WITH_1_F32_DATA( ALARM_ID_BLOOD_PUMP_MC_CURRENT_CHECK, getMeasuredBloodPumpMCCurrent() ); -#endif - } - } - else - { - bpCurrErrorDurationCtr = 0; - } - } } /*********************************************************************//** @@ -1312,6 +1238,52 @@ } } #endif +} + +/*********************************************************************//** + * @brief + * 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: bloodFlowCalRecord + * @return TRUE if the calibration record is valid, otherwise FALSE + *************************************************************************/ +static BOOL processCalibrationData( void ) +{ + BOOL status = TRUE; + + // Get the calibration record from NVDataMgmt + HD_FLOW_SENSORS_CAL_RECORD_T calData = getHDFlowSensorsCalibrationRecord(); + + // 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 blood flow sensors data is not stored in the NV memory or it was corrupted. + if ( 0 == calData.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].calibrationTime ) + { +#ifndef SKIP_CAL_CHECK + activateAlarmNoData( ALARM_ID_HD_BLOOD_FLOW_INVALID_CAL_RECORD ); + status = FALSE; +#endif + } + + // The calibration data was valid, update the local copy + bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].fourthOrderCoeff = + calData.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].fourthOrderCoeff; + + bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].thirdOrderCoeff = + calData.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].thirdOrderCoeff; + + bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].secondOrderCoeff = + calData.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].secondOrderCoeff; + + bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].gain = + calData.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].gain; + + bloodFlowCalRecord.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].offset = + calData.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].offset; + + return status; } /*********************************************************************//** @@ -1324,22 +1296,25 @@ *************************************************************************/ SELF_TEST_STATUS_T execBloodFlowTest( void ) { - SELF_TEST_STATUS_T result = SELF_TEST_STATUS_FAILED; + SELF_TEST_STATUS_T result = SELF_TEST_STATUS_IN_PROGRESS; U08 const bfmStatus = getFPGABloodFlowMeterStatus(); - // Get the flow sensors calibration record - HD_FLOW_SENSORS_CAL_RECORD_T cal = getHDFlowSensorsCalibrationRecord(); - // Retrieve blood flow sensor calibration data and check for sensor connected status if ( BFM_SENSOR_PARAM_CORRUPT_STATUS != bfmStatus ) { - bloodFlowCalGain = cal.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].gain; - bloodFlowCalOffset = cal.hdFlowSensors[ CAL_DATA_HD_BLOOD_FLOW_SENSOR ].offset; - result = SELF_TEST_STATUS_PASSED; + BOOL calStatus = processCalibrationData(); + + if ( TRUE == calStatus ) + { + result = SELF_TEST_STATUS_PASSED; + } + else + { + result = SELF_TEST_STATUS_FAILED; + } } else { - result = SELF_TEST_STATUS_FAILED; SET_ALARM_WITH_1_U32_DATA( ALARM_ID_HD_BLOOD_FLOW_STATUS_SELF_TEST_FAILURE, (U32)bfmStatus ); } @@ -1351,6 +1326,7 @@ * TEST SUPPORT FUNCTIONS *************************************************************************/ + /*********************************************************************//** * @brief * The testSetBloodFlowDataPublishIntervalOverride function overrides the