Index: firmware/App/Controllers/DialOutFlow.c =================================================================== diff -u -r6463655c18b173e335b6d475ac7289336f1bf092 -rb5756e5b5041288a2e95585990cce5a93756d693 --- firmware/App/Controllers/DialOutFlow.c (.../DialOutFlow.c) (revision 6463655c18b173e335b6d475ac7289336f1bf092) +++ firmware/App/Controllers/DialOutFlow.c (.../DialOutFlow.c) (revision b5756e5b5041288a2e95585990cce5a93756d693) @@ -43,15 +43,29 @@ #define MAX_DIAL_OUT_FLOW_RATE 650 ///< Maximum dialysate outlet pump flow rate in mL/min. #define MIN_DIAL_OUT_FLOW_RATE 100 ///< Minimum dialysate outlet pump flow rate in mL/min. +#define DPO_FLOW_ADJ_DUE_TO_HIGHER_INLET_PRES 0.875 ///< Adjustment factor to account for higher pump inlet pressure (than DPi pump inlet). -#define MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE 0.01 ///< Maximum duty cycle change when ramping. +#define MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE 0.0133 ///< Maximum duty cycle change when ramping up ~ 200 mL/min/s. +#define MAX_DIAL_OUT_PUMP_PWM_STEP_DN_CHANGE 0.02 ///< Maximum duty cycle change when ramping down ~ 300 mL/min/s. #define MAX_DIAL_OUT_PUMP_PWM_DUTY_CYCLE 0.88 ///< Controller will error if PWM duty cycle > 90%, so set max to 88%. #define MIN_DIAL_OUT_PUMP_PWM_DUTY_CYCLE 0.12 ///< Controller will error if PWM duty cycle < 10%, so set min to 12%. #define DOP_CONTROL_INTERVAL ( 1000 / TASK_GENERAL_INTERVAL ) ///< Interval (ms/task time) at which the dialysate outlet pump is controlled. #define DOP_P_COEFFICIENT 0.0050 ///< P term for dialysate outlet pump control. #define DOP_I_COEFFICIENT 0.0001 ///< I term for dialysate outlet pump control. +#define DOP_HOME_RATE 100 ///< target pump speed (in estimate mL/min) for homing. +#define DOP_HOME_TIMEOUT_MS 10000 ///< maximum time allowed for homing to complete (in ms). +#define DOP_SPEED_CALC_INTERVAL ( MS_PER_SECOND / TASK_PRIORITY_INTERVAL ) ///< interval (ms/task time) at which the dialysate outlet pump speed is calculated. +#define DOP_HALL_EDGE_COUNTS_PER_REV 48 ///< number of hall sensor edge counts per motor revolution. + +#define DOP_MAX_MOTOR_SPEED_WHILE_OFF_RPM 100.0 ///< maximum motor speed (RPM) while motor is commanded off. +#define DOP_MAX_ROTOR_VS_MOTOR_DIFF_RPM 5.0 ///< maximum difference in speed between motor and rotor (in rotor RPM). +#define DOP_MAX_MOTOR_SPEED_ERROR_RPM 300.0 ///< maximum difference in speed between measured and commanded RPM. +#define DOP_OFF_ERROR_PERSIST ((5 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL) ///< persist time (task intervals) for motor off error condition. +#define DOP_MOTOR_SPEED_ERROR_PERSIST ((5 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL) ///< persist time (task intervals) motor speed error condition. +#define DOP_ROTOR_SPEED_ERROR_PERSIST ((12 * MS_PER_SECOND) / TASK_PRIORITY_INTERVAL) ///< persist time (task intervals) rotor speed error condition. + #define DOP_MAX_CURR_WHEN_STOPPED_MA 150.0 ///< Motor controller current should not exceed this when pump should be stopped. #define DOP_MIN_CURR_WHEN_RUNNING_MA 150.0 ///< Motor controller current should always exceed this when pump should be running. #define DOP_MAX_CURR_WHEN_RUNNING_MA 1000.0 ///< Motor controller current should not exceed this when pump should be running. @@ -60,7 +74,7 @@ #define DOP_SPEED_ADC_TO_RPM_FACTOR 1.280938 ///< Conversion factor from ADC counts to RPM for dialysate outlet pump motor. #define DOP_CURRENT_ADC_TO_MA_FACTOR 3.002 ///< Conversion factor from ADC counts to mA for dialysate outlet pump motor. #define DOP_ADC_FULL_SCALE_V 3.0 ///< DPo analog signals are 0-3V (while int. ADC ref V may be different). -#define DOP_ADC_ZERO ( (F32)( INT_ADC_ZERO ) * ( DOP_ADC_FULL_SCALE_V / INT_ADC_REF_V ) ) ///< Mid-point (zero) for ADC readings. +#define DOP_ADC_ZERO 1998 ///< Mid-point (zero) for ADC readings. #define SIGN_FROM_12_BIT_VALUE(v) ( (S16)(v) - (S16)DOP_ADC_ZERO ) ///< Macro converts a 12-bit ADC reading to a signed 16-bit value. @@ -94,15 +108,15 @@ // pin assignments and macros for pump stop and direction outputs #define STOP_DO_PUMP_MIBSPI1_PORT_MASK 0x00000400 ///< MIBSPI1 SIMO[0] - re-purposed as GPIOoutput for pump controller run/stop pin. #ifndef BREADBOARD_TARGET - #define SET_DOP_STOP() {mibspiREG1->PC3 &= ~STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to stop. - #define CLR_DOP_STOP() {mibspiREG1->PC3 |= STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to run. + #define SET_DOP_STOP() {mibspiREG1->PC3 &= ~STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to stop. + #define CLR_DOP_STOP() {mibspiREG1->PC3 |= STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to run. #else - #define SET_DOP_STOP() {mibspiREG1->PC3 |= STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to stop. - #define CLR_DOP_STOP() {mibspiREG1->PC3 &= ~STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to run. + #define SET_DOP_STOP() {mibspiREG1->PC3 |= STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to stop. + #define CLR_DOP_STOP() {mibspiREG1->PC3 &= ~STOP_DO_PUMP_MIBSPI1_PORT_MASK;} ///< Macro sets pump controller run/stop signal to run. #endif -#define STOP_DO_PUMP_GIO_PORT_PIN 6U ///< GIO port A pin used for pump controller direction pin. -#define SET_DOP_DIR() gioSetBit( gioPORTA, STOP_DO_PUMP_GIO_PORT_PIN, PIN_SIGNAL_HIGH ) ///< Macro sets pump controller direction to forward direction. -#define CLR_DOP_DIR() gioSetBit( gioPORTA, STOP_DO_PUMP_GIO_PORT_PIN, PIN_SIGNAL_LOW ) ///< Macro sets pump controller direction to reverse direction. +#define STOP_DO_PUMP_GIO_PORT_PIN 6U ///< GIO port A pin used for pump controller direction pin. +#define SET_DOP_DIR() gioSetBit( gioPORTA, STOP_DO_PUMP_GIO_PORT_PIN, PIN_SIGNAL_HIGH ) ///< Macro sets pump controller direction to forward direction. +#define CLR_DOP_DIR() gioSetBit( gioPORTA, STOP_DO_PUMP_GIO_PORT_PIN, PIN_SIGNAL_LOW ) ///< Macro sets pump controller direction to reverse direction. // ********** private data ********** @@ -129,6 +143,18 @@ static U32 dopControlTimerCounter = 0; ///< Timer counter to determine when to control dialysate outlet pump. static U32 dopCurrErrorDurationCtr = 0; ///< Timer counter for motor current error persistence. +static U32 dopRotorRevStartTime = 0; ///< dialysate outlet pump rotor rotation start time (in ms) +static BOOL dopStopAtHomePosition = FALSE; ///< stop dialysate outlet pump at next home position +static U32 dopHomeStartTime = 0; ///< when did dialysate outlet pump home command begin? (in ms) + +static U16 dopLastMotorHallSensorCount = 0; ///< last hall sensor count for the dialysate outlet pump motor +static MOTOR_DIR_T dopMotorDirectionFromHallSensors = MOTOR_DIR_FORWARD; ///< pump direction according to hall sensor count +static U32 dopMotorSpeedCalcTimerCtr = 0; ///< counter determines interval for calculating dialysate outlet pump motor speed from hall sensor count. + +static U32 errorDialOutMotorOffPersistTimerCtr = 0; ///< persistence timer counter for motor off check error condition. +static U32 errorDialOutMotorSpeedPersistTimerCtr = 0; ///< persistence timer counter for motor speed error condition. +static U32 errorDialOutRotorSpeedPersistTimerCtr = 0; ///< persistence timer counter for rotor speed error condition. + static DIAL_OUT_PUMP_SELF_TEST_STATE_T dialOutPumpSelfTestState = DIAL_OUT_PUMP_SELF_TEST_STATE_START; ///< Current state of the dialysate outlet pump self test state machine. static U32 dialOutPumpSelfTestTimerCount = 0; ///< Timer counter for time reference during self test. @@ -149,7 +175,10 @@ static void publishDialOutFlowData( void ); +static void updateDialOutPumpSpeedAndDirectionFromHallSensors( void ); +static void checkDialOutPumpRotor( void ); static void checkDialOutPumpDirection( void ); +static void checkDialOutPumpSpeeds( void ); static void checkDialOutPumpMCCurrent( void ); static DATA_GET_PROTOTYPE( U32, getPublishDialOutDataInterval ); @@ -166,6 +195,8 @@ { U32 i; + dopLastMotorHallSensorCount = getFPGADialOutPumpHallSensorCount(); + stopDialOutPump(); setDialOutPumpDirection( MOTOR_DIR_FORWARD ); @@ -212,11 +243,13 @@ // verify flow rate if ( flowRate <= MAX_DIAL_OUT_FLOW_RATE ) { + F32 adjFlow = (F32)flowRate * DPO_FLOW_ADJ_DUE_TO_HIGHER_INLET_PRES; + lastGivenRate = flowRate; dialOutPumpDirection = dir; dialOutPumpControlMode = mode; // set PWM duty cycle target to an estimated initial target to ramp to based on target flow rate - then we'll control to flow when ramp completed - dialOutPumpPWMDutyCyclePct = DOP_PWM_FROM_ML_PER_MIN((F32)flowRate); + dialOutPumpPWMDutyCyclePct = DOP_PWM_FROM_ML_PER_MIN(adjFlow); switch ( dialOutPumpState ) { @@ -295,6 +328,55 @@ /*********************************************************************//** * @brief + * The signalDialOutPumpRotorHallSensor function handles the dialysate outlet \n + * pump rotor hall sensor detection. Calculates rotor speed (in RPM). \n + * Stops pump if there is a pending request to home the pump. + * @details + * Inputs : dopRotorRevStartTime, dopStopAtHomePosition + * Outputs : dopRotorRevStartTime, dialOutPumpRotorSpeedRPM + * @return none + *************************************************************************/ +void signalDialOutPumpRotorHallSensor( void ) +{ + U32 rotTime = getMSTimerCount(); + U32 deltaTime = calcTimeBetween( dopRotorRevStartTime, rotTime ); + + // calculate rotor speed (in RPM) + dialOutPumpRotorSpeedRPM.data = ( 1.0 / (F32)deltaTime ) * (F32)MS_PER_SECOND * (F32)SEC_PER_MIN; + dopRotorRevStartTime = rotTime; + + // if we're supposed to stop pump at home position, stop pump now. + if ( TRUE == dopStopAtHomePosition ) + { + signalDialOutPumpHardStop(); + dopStopAtHomePosition = FALSE; + } +} + +/*********************************************************************//** + * @brief + * The homeDialOutPump function initiates a dialysate outlet pump home operation. + * @details + * Inputs : dialOutPumpState + * Outputs : dopStopAtHomePosition, dopHomeStartTime, dialysate outlet pump started (slow) + * @return none + *************************************************************************/ +BOOL homeDialOutPump( void ) +{ + BOOL result = FALSE; + + if ( DIAL_OUT_PUMP_OFF_STATE == dialOutPumpState ) + { + dopStopAtHomePosition = TRUE; + dopHomeStartTime = getMSTimerCount(); + result = setDialOutPumpTargetRate( DOP_HOME_RATE, MOTOR_DIR_FORWARD, PUMP_CONTROL_MODE_OPEN_LOOP ); + } + + return result; +} + +/*********************************************************************//** + * @brief * The setDialOutUFVolumes function sets the ultrafiltration reference and \n * measured total volumes (in mL). * @details @@ -336,11 +418,20 @@ dialOutPumpMCSpeedRPM.data = (F32)(SIGN_FROM_12_BIT_VALUE(bpRPM)) * DOP_SPEED_ADC_TO_RPM_FACTOR; dialOutPumpMCCurrentmA.data = (F32)(SIGN_FROM_12_BIT_VALUE(bpmA)) * DOP_CURRENT_ADC_TO_MA_FACTOR; + // calculate dialysate outlet pump motor speed/direction from hall sensor count + updateDialOutPumpSpeedAndDirectionFromHallSensors(); + // don't start enforcing checks until out of init/POST mode if ( getCurrentOperationMode() != MODE_INIT ) { + // check pump direction checkDialOutPumpDirection(); + // check pump controller current checkDialOutPumpMCCurrent(); + // check pump speeds + checkDialOutPumpSpeeds(); + // check for home position, zero/low speed + checkDialOutPumpRotor(); } publishDialOutFlowData(); @@ -398,7 +489,7 @@ if ( lastGivenRate > 0 ) { // set initial PWM duty cycle - dialOutPumpPWMDutyCyclePctSet = DOP_PWM_ZERO_OFFSET + MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE; + dialOutPumpPWMDutyCyclePctSet = DOP_PWM_ZERO_OFFSET + MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE; setDialOutPumpControlSignalPWM( dialOutPumpPWMDutyCyclePctSet ); // allow dialOut pump to run in requested direction setDialOutPumpDirection( dialOutPumpDirection ); @@ -431,7 +522,7 @@ if ( dialOutPumpPWMDutyCyclePct < NEARLY_ZERO ) { // start ramp down to stop - dialOutPumpPWMDutyCyclePctSet -= MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE; + dialOutPumpPWMDutyCyclePctSet -= MAX_DIAL_OUT_PUMP_PWM_STEP_DN_CHANGE; setDialOutPumpControlSignalPWM( dialOutPumpPWMDutyCyclePctSet ); result = DIAL_OUT_PUMP_RAMPING_DOWN_STATE; } @@ -451,7 +542,7 @@ // continue ramp up else { - dialOutPumpPWMDutyCyclePctSet += MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE; + dialOutPumpPWMDutyCyclePctSet += MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE; setDialOutPumpControlSignalPWM( dialOutPumpPWMDutyCyclePctSet ); } @@ -472,7 +563,7 @@ DIAL_OUT_PUMP_STATE_T result = DIAL_OUT_PUMP_RAMPING_DOWN_STATE; // have we essentially reached zero speed - if ( dialOutPumpPWMDutyCyclePctSet < (MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE + DOP_PWM_ZERO_OFFSET) ) + if ( dialOutPumpPWMDutyCyclePctSet < (MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE + DOP_PWM_ZERO_OFFSET) ) { stopDialOutPump(); result = DIAL_OUT_PUMP_OFF_STATE; @@ -493,7 +584,7 @@ // continue ramp down else { - dialOutPumpPWMDutyCyclePctSet -= MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE; + dialOutPumpPWMDutyCyclePctSet -= MAX_DIAL_OUT_PUMP_PWM_STEP_DN_CHANGE; setDialOutPumpControlSignalPWM( dialOutPumpPWMDutyCyclePctSet ); } @@ -527,9 +618,9 @@ newPWM = runPIController( PI_CONTROLLER_ID_ULTRAFILTRATION, refVol, totVol ); // limit PWM change to max deltaPWM = newPWM - dialOutPumpPWMDutyCyclePctSet; - if ( FABS( deltaPWM ) > MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE ) + if ( FABS( deltaPWM ) > MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE ) { - newPWM = ( deltaPWM < 0.0 ? dialOutPumpPWMDutyCyclePctSet - MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE : dialOutPumpPWMDutyCyclePctSet + MAX_DIAL_OUT_PUMP_PWM_STEP_CHANGE ); + newPWM = ( deltaPWM < 0.0 ? dialOutPumpPWMDutyCyclePctSet - MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE : dialOutPumpPWMDutyCyclePctSet + MAX_DIAL_OUT_PUMP_PWM_STEP_UP_CHANGE ); } // set new PWM dialOutPumpPWMDutyCyclePctSet = newPWM; @@ -558,7 +649,7 @@ /*********************************************************************//** * @brief stopDialOutPump - * The stopDialOutPump function sets the dialout flow stop signal and PWM + * The stopDialOutPump function sets the dialout flow stop signal and PWM \n * duty cycle to 0.0. * @details * Inputs : none @@ -587,7 +678,7 @@ } /*********************************************************************//** - * @brief setDialOutPumpDirection + * @brief * The setDialOutPumpDirection function sets the set dialOut pump direction to \n * the given direction. * @details @@ -617,7 +708,7 @@ } /*********************************************************************//** - * @brief publishDialOutFlowData + * @brief * The publishDialOutFlowData function publishes dialysate outlet data at \n * the set interval. * @details @@ -647,14 +738,79 @@ } } -/************************************************************************* +/*********************************************************************//** * @brief + * The updateDialOutPumpSpeedAndDirectionFromHallSensors function calculates \n + * the dialysate outlet pump motor speed and direction from hall sensor counter on \n + * a 1 second interval. + * @details + * Inputs : dopLastMotorHallSensorCount, dopMotorSpeedCalcTimerCtr, current count from FPGA + * Outputs : dopMotorDirectionFromHallSensors, dialOutPumpSpeedRPM + * @return none + *************************************************************************/ +static void updateDialOutPumpSpeedAndDirectionFromHallSensors( void ) +{ + if ( ++dopMotorSpeedCalcTimerCtr >= DOP_SPEED_CALC_INTERVAL ) + { + U16 dopMotorHallSensorCount = getFPGADialOutPumpHallSensorCount(); + U16 incDelta = ( dopMotorHallSensorCount >= dopLastMotorHallSensorCount ? dopMotorHallSensorCount - dopLastMotorHallSensorCount : ( HEX_64_K - dopLastMotorHallSensorCount ) + dopMotorHallSensorCount ); + U16 decDelta = HEX_64_K - incDelta; + U16 delta; + + // determine dialysate outlet pump speed/direction from delta hall sensor count since last interval + if ( incDelta < decDelta ) + { + dopMotorDirectionFromHallSensors = MOTOR_DIR_FORWARD; + delta = incDelta; + dialOutPumpSpeedRPM.data = ( (F32)delta / (F32)DOP_HALL_EDGE_COUNTS_PER_REV ) * (F32)SEC_PER_MIN; + } + else + { + dopMotorDirectionFromHallSensors = MOTOR_DIR_REVERSE; + delta = decDelta; + dialOutPumpSpeedRPM.data = ( (F32)delta / (F32)DOP_HALL_EDGE_COUNTS_PER_REV ) * (F32)SEC_PER_MIN * -1.0; + } + + // update last count for next time + dopLastMotorHallSensorCount = dopMotorHallSensorCount; + dopMotorSpeedCalcTimerCtr = 0; + } +} + +/*********************************************************************//** + * @brief + * The checkDialOutPumpRotor function checks the rotor for the dialysate outlet \n + * pump. If homing, this function will stop when hall sensor detected. If pump \n + * is off or running very slowly, rotor speed will be set to zero. + * @details + * Inputs : dopStopAtHomePosition, dopHomeStartTime, dopRotorRevStartTime + * Outputs : pump may be stopped if homing, dialOutPumpRotorSpeedRPM may be set to zero. + * @return none + *************************************************************************/ +static void checkDialOutPumpRotor( void ) +{ + // if homing, check timeout + if ( ( TRUE == dopStopAtHomePosition ) && ( TRUE == didTimeout( dopHomeStartTime, DOP_HOME_TIMEOUT_MS ) ) ) + { + signalDialOutPumpHardStop(); + dopStopAtHomePosition = FALSE; + // TODO - alarm??? + } + + // if pump is stopped or running very slowly, set rotor speed to zero + if ( TRUE == didTimeout( dopRotorRevStartTime, DOP_HOME_TIMEOUT_MS ) ) + { + dialOutPumpRotorSpeedRPM.data = 0.0; + } +} + +/*********************************************************************//** + * @brief * The checkDialOutPumpDirection function checks the set direction vs. \n * the direction implied by the sign of the measured MC speed. * @details * Inputs : adcDialOutPumpMCSpeedRPM, dialOutPumpDirectionSet, dialOutPumpState * Outputs : none - * @param none * @return none *************************************************************************/ static void checkDialOutPumpDirection( void ) @@ -663,23 +819,109 @@ if ( DIAL_OUT_PUMP_CONTROL_TO_TARGET_STATE == dialOutPumpState ) { - // check set direction vs. direction from sign of motor controller speed + // check set direction vs. direction from hall sensors or sign of motor controller speed dopMCDir = ( getMeasuredDialOutPumpMCSpeed() >= 0.0 ? MOTOR_DIR_FORWARD : MOTOR_DIR_REVERSE ); - if ( dialOutPumpDirectionSet != dopMCDir ) + if ( ( dialOutPumpDirectionSet != dopMCDir ) || ( dialOutPumpDirectionSet != dopMotorDirectionFromHallSensors ) ) { - SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DIAL_OUT_PUMP_MC_DIRECTION_CHECK, (U32)dialOutPumpDirectionSet, (U32)dopMCDir ) +#ifndef DISABLE_PUMP_DIRECTION_CHECKS + SET_ALARM_WITH_2_U32_DATA( ALARM_ID_DIAL_OUT_PUMP_MC_DIRECTION_CHECK, (U32)dialOutPumpDirectionSet, (U32)dopMotorDirectionFromHallSensors ) +#endif } } } -/************************************************************************* +/*********************************************************************//** * @brief + * The checkDialOutPumpSpeeds function checks several aspects of the dialysate \n + * outlet pump speed. \n + * 1. while pump is commanded off, measured motor speed should be < limit. \n + * 2. while pump is controlling, measured motor speed should be within allowed range of measured motor controller speed. \n + * 3. measured motor speed should be within allowed range of measured rotor speed. \n + * All 3 checks have a persistence time that must be met before an alarm is triggered. + * @details + * Inputs : targetDialOutFlowRate, dialOutPumpSpeedRPM, dialOutPumpRotorSpeedRPM + * Outputs : alarm(s) may be triggered + * @return none + *************************************************************************/ +static void checkDialOutPumpSpeeds( void ) +{ + F32 measMotorSpeed = getMeasuredDialOutPumpSpeed(); + + // check for pump running while commanded off + if ( FALSE == isDialOutPumpOn ) + { + if ( measMotorSpeed > DOP_MAX_MOTOR_SPEED_WHILE_OFF_RPM ) + { + if ( ++errorDialOutMotorOffPersistTimerCtr >= DOP_OFF_ERROR_PERSIST ) + { +#ifndef DISABLE_PUMP_SPEED_CHECKS + SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DIAL_OUT_PUMP_OFF_CHECK, measMotorSpeed ); +#endif + } + } + else + { + errorDialOutMotorOffPersistTimerCtr = 0; + } + } + else + { + errorDialOutMotorOffPersistTimerCtr = 0; + } + + if ( DIAL_OUT_PUMP_CONTROL_TO_TARGET_STATE == dialOutPumpState ) + { + F32 controllerMotorSpeed = getMeasuredDialOutPumpMCSpeed(); + F32 deltaMotorSpeed = FABS( measMotorSpeed - controllerMotorSpeed ); + F32 measRotorSpeed = getMeasuredDialOutPumpRotorSpeed(); + F32 measMotorSpeedInRotorRPM = measMotorSpeed / DOP_GEAR_RATIO; + F32 deltaRotorSpeed = FABS( measRotorSpeed - measMotorSpeedInRotorRPM ); + + // check measured motor speed vs. commanded motor speed while controlling to target + if ( deltaMotorSpeed > DOP_MAX_MOTOR_SPEED_ERROR_RPM ) + { + if ( ++errorDialOutMotorSpeedPersistTimerCtr >= DOP_MOTOR_SPEED_ERROR_PERSIST ) + { +#ifndef DISABLE_PUMP_SPEED_CHECKS + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_DIAL_OUT_PUMP_MOTOR_SPEED_CHECK, controllerMotorSpeed, measMotorSpeed ); +#endif + } + } + else + { + errorDialOutMotorSpeedPersistTimerCtr = 0; + } + + // check measured rotor speed vs. measured motor speed while controlling to target + if ( deltaRotorSpeed > DOP_MAX_ROTOR_VS_MOTOR_DIFF_RPM ) + { + if ( ++errorDialOutRotorSpeedPersistTimerCtr >= DOP_ROTOR_SPEED_ERROR_PERSIST ) + { +#ifndef DISABLE_PUMP_SPEED_CHECKS + SET_ALARM_WITH_2_F32_DATA( ALARM_ID_DIAL_OUT_PUMP_ROTOR_SPEED_CHECK, measRotorSpeed, measMotorSpeed ); +#endif + } + } + else + { + errorDialOutRotorSpeedPersistTimerCtr = 0; + } + + } + else + { + errorDialOutMotorSpeedPersistTimerCtr = 0; + errorDialOutRotorSpeedPersistTimerCtr = 0; + } +} + +/*********************************************************************//** + * @brief * The checkDialOutPumpMCCurrent function checks the measured MC current vs. \n * the set state of the dialOut pump (stopped or running). * @details * Inputs : dialOutPumpState, dopCurrErrorDurationCtr, adcDialOutPumpMCCurrentmA * Outputs : none - * @param none * @return none *************************************************************************/ static void checkDialOutPumpMCCurrent( void ) @@ -695,7 +937,7 @@ dopCurrErrorDurationCtr += TASK_PRIORITY_INTERVAL; if ( dopCurrErrorDurationCtr > DOP_MAX_CURR_ERROR_DURATION_MS ) { -#ifndef DISABLE_MOTOR_CURRENT_ERRORS +#ifndef DISABLE_MOTOR_CURRENT_CHECKS SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DIAL_OUT_PUMP_MC_CURRENT_CHECK, getMeasuredDialOutPumpMCCurrent() ); #endif } @@ -714,7 +956,7 @@ dopCurrErrorDurationCtr += TASK_PRIORITY_INTERVAL; if ( dopCurrErrorDurationCtr > DOP_MAX_CURR_ERROR_DURATION_MS ) { -#ifndef DISABLE_MOTOR_CURRENT_ERRORS +#ifndef DISABLE_MOTOR_CURRENT_CHECKS SET_ALARM_WITH_1_F32_DATA( ALARM_ID_DIAL_OUT_PUMP_MC_CURRENT_CHECK, getMeasuredDialOutPumpMCCurrent() ); #endif } @@ -764,6 +1006,7 @@ F32 getLoadCellWeightInGrams( U32 loadCellID ) { F32 result = 0.0; + if ( loadCellID <= NUM_OF_LOAD_CELLS - 1 ) { if ( OVERRIDE_KEY == loadCellWeightInGrams[ loadCellID ].override ) @@ -779,6 +1022,7 @@ { activateAlarmNoData( ALARM_ID_SOFTWARE_FAULT ); } + return result; } @@ -793,10 +1037,12 @@ F32 getTotalTargetDialOutUFVolumeInMl( void ) { F32 result = referenceUFVolumeInMl.data; + if ( OVERRIDE_KEY == referenceUFVolumeInMl.override ) { result = referenceUFVolumeInMl.ovData; } + return result; } @@ -811,10 +1057,12 @@ F32 getTotalMeasuredUFVolumeInMl( void ) { F32 result = totalMeasuredUFVolumeInMl.data; + if ( OVERRIDE_KEY == totalMeasuredUFVolumeInMl.override ) { result = totalMeasuredUFVolumeInMl.ovData; } + return result; } @@ -830,10 +1078,12 @@ F32 getMeasuredDialOutPumpRotorSpeed( void ) { F32 result = dialOutPumpRotorSpeedRPM.data; + if ( OVERRIDE_KEY == dialOutPumpRotorSpeedRPM.override ) { result = dialOutPumpRotorSpeedRPM.ovData; } + return result; } @@ -849,10 +1099,12 @@ F32 getMeasuredDialOutPumpSpeed( void ) { F32 result = dialOutPumpSpeedRPM.data; + if ( OVERRIDE_KEY == dialOutPumpSpeedRPM.override ) { result = dialOutPumpSpeedRPM.ovData; } + return result; } @@ -863,16 +1115,17 @@ * @details * Inputs : dialOutPumpMCSpeedRPM * Outputs : none -* @param none * @return the current dialOut pump speed (in RPM). *************************************************************************/ F32 getMeasuredDialOutPumpMCSpeed( void ) { F32 result = dialOutPumpMCSpeedRPM.data; + if ( OVERRIDE_KEY == dialOutPumpMCSpeedRPM.override ) { result = dialOutPumpMCSpeedRPM.ovData; } + return result; } @@ -888,10 +1141,12 @@ F32 getMeasuredDialOutPumpMCCurrent( void ) { F32 result = dialOutPumpMCCurrentmA.data; + if ( OVERRIDE_KEY == dialOutPumpMCCurrentmA.override ) { result = dialOutPumpMCCurrentmA.ovData; } + return result; }