Improved pwr firmware

diff --git a/src/pwr/config.h b/src/pwr/config.h
index 19ccc3bf1a4689e3be9c5554949594b2d095e517..0da6d6c2782de7905b5f8c2c4d9b3ebac64e0f9b 100644 (file)
--- a/src/pwr/config.h
+++ b/src/pwr/config.h
@@ -84,7 +84,6 @@ enum {
 #define VOLTAGE_SETTLE_PERIOD 20 // ms
 #define VOLTAGE_SETTLE_TOLERANCE 0.01
 #define VOLTAGE_EXP 0.01
-#define FAULT_TIMEOUT 5000 // ms
 
 #define SHUNT_WATTS 5
 #define SHUNT_OHMS 10
@@ -121,7 +120,9 @@ typedef enum {
 
 
 enum {
-  UNDER_VOLTAGE_FLAG = 1 << 0,
-  OVER_VOLTAGE_FLAG  = 1 << 1,
-  OVER_CURRENT_FLAG  = 1 << 2,
+  UNDER_VOLTAGE_FLAG     = 1 << 0,
+  OVER_VOLTAGE_FLAG      = 1 << 1,
+  OVER_CURRENT_FLAG      = 1 << 2,
+  MEASUREMENT_ERROR_FLAG = 1 << 3,
+  SHUNT_OVERLOAD_FLAG    = 1 << 4,
 };

diff --git a/src/pwr/main.c b/src/pwr/main.c
index 4c9c4d52a08933fe3ac7e4477a9c40318373957c..9a81ae2167a093849c3acda6859f75947a3d761d 100644 (file)
--- a/src/pwr/main.c
+++ b/src/pwr/main.c
@@ -44,12 +44,12 @@ static const uint8_t ch_schedule[] = {
   CS2_ADC,  VOUT_ADC,
   CS3_ADC,  VOUT_ADC,
   CS4_ADC,  VOUT_ADC,
-  0
 };
 
 
 static volatile uint16_t regs[NUM_REGS] = {0};
 static volatile uint64_t time = 0; // ms
+static volatile bool shunt_overload = false;
 static volatile float shunt_ms_power = 0;
 static volatile float vnom = 0;
 
@@ -128,19 +128,11 @@ static void update_shunt() {
 
   // Remove power dissipation credit
   watts -= shunt_ms_power;
-  if (watts < 0) watts = 0;
+  if (watts < 0) shunt_overload = true;
 
-  // Enable shunt output when requested if allowed
-  if (shunt_ms_power) {
-    IO_DDR_SET(SHUNT_PIN); // Enable shunt output
-
-    if (watts) IO_DDR_SET(MOTOR_PIN); // Enable motor output
-    else IO_DDR_CLR(MOTOR_PIN); // Disable motor output
-
-  } else {
-    IO_DDR_CLR(SHUNT_PIN); // Disable output
-    IO_DDR_SET(MOTOR_PIN); // Enable motor output
-  }
+  // Enable shunt when requested
+  if (shunt_ms_power) IO_DDR_SET(SHUNT_PIN); // Enable
+  else IO_DDR_CLR(SHUNT_PIN);                // Disable
 }
 
 
@@ -217,7 +209,7 @@ static void adc_conversion() {
   static int i = 0;
 
   read_conversion(ch_schedule[i]);
-  if (!ch_schedule[++i]) i = 0;
+  if (++i == sizeof(ch_schedule)) i = 0;
 
   // Start next conversion
   ADMUX = (ADMUX & 0xf0) | ch_schedule[i];
@@ -256,7 +248,7 @@ static void validate_input_voltage() {
 static void charge_caps() {
   TCCR0A |= (1 << COM0A1) | (0 << COM0A0); // Clear on compare match
   IO_PORT_CLR(MOTOR_PIN); // Motor voltage off
-  IO_DDR_SET(MOTOR_PIN); // Output
+  IO_DDR_SET(MOTOR_PIN);  // Output
 
   uint64_t now = time;
   for (int i = 0; i < CAP_CHARGE_TIME; i++) {
@@ -321,6 +313,37 @@ void init() {
 }
 
 
+static void shutdown(uint16_t flags) {
+  regs[FLAGS_REG] = flags;
+
+  // Disable timers
+  TCCR0B = TCCR1B = 0;
+
+  // Disable outputs
+  IO_DDR_CLR(SHUNT_PIN);
+  IO_DDR_CLR(MOTOR_PIN);
+  IO_PORT_CLR(LOAD1_PIN);
+  IO_PORT_CLR(LOAD2_PIN);
+  IO_DDR_SET(LOAD1_PIN);
+  IO_DDR_SET(LOAD2_PIN);
+
+  while (true) continue;
+}
+
+
+static void validate_measurements() {
+  const float max_voltage = 0.99 * convert_voltage(0x3ff);
+  const float max_current = 0.99 * convert_current(0x3ff);
+
+  if (max_voltage < regs[VOUT_REG]  ||
+      max_current < regs[MOTOR_REG] ||
+      max_current < regs[LOAD1_REG] ||
+      max_current < regs[LOAD2_REG] ||
+      max_current < regs[VDD_REG])
+    shutdown(MEASUREMENT_ERROR_FLAG);
+}
+
+
 int main() {
   wdt_enable(WDTO_8S);
 
@@ -328,6 +351,7 @@ int main() {
   adc_conversion(); // Start ADC
   validate_input_voltage();
   charge_caps();
+  validate_measurements();
 
   while (true) {
     wdt_reset();
@@ -340,25 +364,11 @@ int main() {
     // Check fault conditions
     uint16_t flags = 0;
     if (vin < VOLTAGE_MIN) flags |= UNDER_VOLTAGE_FLAG;
-    if (VOLTAGE_MAX < vin) flags |= OVER_VOLTAGE_FLAG;
+    if (VOLTAGE_MAX < vin || VOLTAGE_MAX < vout) flags |= OVER_VOLTAGE_FLAG;
     if (CURRENT_MAX < get_total_current()) flags |= OVER_CURRENT_FLAG;
-    regs[FLAGS_REG] = flags;
-
-    if (flags) {
-      // Disable
-      IO_PORT_CLR(MOTOR_PIN);
-      IO_PORT_CLR(LOAD1_PIN);
-      IO_PORT_CLR(LOAD2_PIN);
-      IO_DDR_SET(LOAD1_PIN);
-      IO_DDR_SET(LOAD2_PIN);
-
-      delay_ms(FAULT_TIMEOUT);
-
-      // Reenable
-      charge_caps();
-      IO_DDR_CLR(LOAD1_PIN);
-      IO_DDR_CLR(LOAD2_PIN);
-    }
+    if (shunt_overload) flags |= SHUNT_OVERLOAD_FLAG;
+
+    if (flags) shutdown(flags);
   }
 
   return 0;

diff --git a/src/py/bbctrl/Pwr.py b/src/py/bbctrl/Pwr.py
index d1659aaa6b8ecd0646922cc056e55899b902eb81..50847b05ca0474056cdbc8701a2326844e9f0e12 100644 (file)
--- a/src/py/bbctrl/Pwr.py
+++ b/src/py/bbctrl/Pwr.py
@@ -12,6 +12,16 @@ VOUT_REG        = 2
 MOTOR_REG       = 3
 LOAD1_REG       = 4
 LOAD2_REG       = 5
+VDD_REG         = 6
+FLAGS_REG       = 7
+
+UNDER_VOLTAGE_FLAG     = 1 << 0
+OVER_VOLTAGE_FLAG      = 1 << 1
+OVER_CURRENT_FLAG      = 1 << 2
+MEASUREMENT_ERROR_FLAG = 1 << 3
+SHUNT_OVERLOAD_FLAG    = 1 << 4
+
+reg_names = 'temp vin vout motor load1 load2 vdd pwr_flags'.split()
 
 
 class Pwr():
@@ -19,7 +29,7 @@ class Pwr():
         self.ctrl = ctrl
 
         self.i2c_addr = ctrl.args.pwr_addr
-        self.regs = [-1] * 6
+        self.regs = [-1] * 8
         self.lcd_page = ctrl.lcd.add_new_page()
 
         self._update()
@@ -28,6 +38,20 @@ class Pwr():
     def get_reg(self, i): return self.regs[i]
 
 
+    def error(self):
+        flags = self.regs[FLAGS_REG]
+        errors = []
+
+        if flags & UNDER_VOLTAGE_FLAG:     errors.push('under voltage')
+        if flags & OVER_VOLTAGE_FLAG:      errors.push('over voltage')
+        if flags & OVER_CURRENT_FLAG:      errors.push('over current')
+        if flags & MEASUREMENT_ERROR_FLAG: errors.push('measurement error')
+        if flags & SHUNT_OVERLOAD_FLAG:    errors.push('shunt overload')
+
+        # Report errors
+        self.ctrl.state.set('pwr_errors', errors)
+
+
     def _update(self):
         update = {}
 
@@ -38,25 +62,29 @@ class Pwr():
                 if i == TEMP_REG: value -= 273
                 else: value /= 100.0
 
-                key = ['temp', 'vin', 'vout', 'motor', 'load1', 'load2'][i]
+                key = reg_names[i]
                 self.ctrl.state.set(key, value)
 
                 if self.regs[i] != value:
                     update[key] = value
                     self.regs[i] = value
 
+                    if i == FLAGS_REG and value: self.error()
+
         except Exception as e:
             log.warning('Pwr communication failed: %s' % e)
             self.ctrl.ioloop.call_later(1, self._update)
             return
 
-        self.lcd_page.text('%3dC'       % self.regs[TEMP_REG], 0, 0)
-        self.lcd_page.text('%5.1fV In'  % self.regs[VIN_REG],  0, 1)
-        self.lcd_page.text('%5.1fV Out' % self.regs[VOUT_REG], 0, 2)
+        self.lcd_page.text('%3dC   Tmp'   % self.regs[TEMP_REG], 0, 0)
+        self.lcd_page.text('%5.1fV  In'   % self.regs[VIN_REG],  0, 1)
+        self.lcd_page.text('%5.1fV Out'   % self.regs[VOUT_REG], 0, 2)
+        self.lcd_page.text(' %02d    Flg' % self.regs[FLAGS_REG], 0, 3)
 
         self.lcd_page.text('%5.1fA Mot' % self.regs[MOTOR_REG], 10, 0)
         self.lcd_page.text('%5.1fA Ld1' % self.regs[LOAD1_REG], 10, 1)
         self.lcd_page.text('%5.1fA Ld2' % self.regs[LOAD2_REG], 10, 2)
+        self.lcd_page.text('%5.1fA Vdd' % self.regs[VDD_REG],   10, 3)
 
         if len(update): self.ctrl.state.update(update)
 

diff --git a/src/resources/config-template.json b/src/resources/config-template.json
index 6f2d802dfb23a400a5d83e99b89cc9589f512067..15f3d7e363958a01379f328617f81e4dc2324c95 100644 (file)
--- a/src/resources/config-template.json
+++ b/src/resources/config-template.json
@@ -58,7 +58,7 @@
         "type": "float",
         "min": 0,
         "unit": "m/min²",
-        "default": 100,
+        "default": 1000,
         "code": "am"
       },
       "max-jerk": {