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WiP Thermal rewrite

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This commit is contained in:
Ben V. Brown
2024-12-07 12:50:16 +11:00
committed by Ben V. Brown
parent 4fb95a6576
commit 6cc8b8184e
2 changed files with 46 additions and 22 deletions
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1
.gitignore vendored
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@@ -215,3 +215,4 @@ Logo GUI/TS100 Logo Editor/TS100 Logo Editor/bin/
# Tests/linters/sanitizers # Tests/linters/sanitizers
source/check-style.log source/check-style.log
.ash_history

67
source/Core/Threads/PIDThread.cpp
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@@ -30,7 +30,7 @@ int32_t powerSupplyWattageLimit = 0;
bool heaterThermalRunaway = false; bool heaterThermalRunaway = false;
static int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t current_value); static int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t current_value);
static void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const TemperatureType_t tError); static void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut) ;
static void setOutputx10WattsViaFilters(int32_t x10Watts); static void setOutputx10WattsViaFilters(int32_t x10Watts);
static int32_t getX10WattageLimits(); static int32_t getX10WattageLimits();
@@ -92,8 +92,8 @@ void startPIDTask(void const *argument __unused) {
PIDTempTarget = TipThermoModel::getTipMaxInC(); PIDTempTarget = TipThermoModel::getTipMaxInC();
} }
detectThermalRunaway(currentTipTempInC, PIDTempTarget - currentTipTempInC);
x10WattsOut = getPIDResultX10Watts(PIDTempTarget, currentTipTempInC); x10WattsOut = getPIDResultX10Watts(PIDTempTarget, currentTipTempInC);
detectThermalRunaway(currentTipTempInC,x10WattsOut);
} else { } else {
detectThermalRunaway(currentTipTempInC, 0); detectThermalRunaway(currentTipTempInC, 0);
} }
@@ -228,31 +228,54 @@ int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t curr
#endif #endif
} }
void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const TemperatureType_t tError) { /*
static TemperatureType_t tipTempCRunawayTemp = 0; * Detection of thermal runaway
static TickType_t runawaylastChangeTime = 0; * The goal of this is to handle cases where something has gone wrong
* 1. The tip MOSFET is broken, so power is being constantly applied to the tip
* a. This can show as temp being stuck at max
* b. Or temp rising when the heater is off
* 2. Broken temperature sense
* a. Temp is stuck at a value
* These boil down to either a constantly rising temperature or a temperature that is stuck at a value
* These are both covered; but looking at the eye/delta between min and max temp seen
*/
void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut) {
// Check for thermal runaway, where it has been x seconds with negligible (y) temp rise static TemperatureType_t tiptempMin = 0xFFFF; // Min tip temp seen
// While trying to actively heat static TemperatureType_t tipTempMax = 0; // Max tip temp seen while heater is on
bool thisCycleIsHeating = x10WattsOut > 0;
static TickType_t heatCycleStart = 0;
// If we are more than 20C below the setpoint static bool haveSeenDelta = false;
if ((tError > THERMAL_RUNAWAY_TEMP_C)) {
// If we have heated up by more than 20C since last sample point, snapshot time and tip temp if (haveSeenDelta) {
TemperatureType_t delta = currentTipTempInC - tipTempCRunawayTemp; return;
if (delta > THERMAL_RUNAWAY_TEMP_C) { }
// We have heated up more than the threshold, reset the timer
tipTempCRunawayTemp = currentTipTempInC; if (currentTipTempInC < tiptempMin) {
runawaylastChangeTime = xTaskGetTickCount(); tiptempMin = currentTipTempInC;
} else { }
if ((xTaskGetTickCount() - runawaylastChangeTime) > (THERMAL_RUNAWAY_TIME_SEC * TICKS_SECOND)) { if (thisCycleIsHeating && currentTipTempInC > tipTempMax) {
// It has taken too long to rise tipTempMax = currentTipTempInC;
}
if (thisCycleIsHeating) {
if (heatCycleStart == 0) {
heatCycleStart = xTaskGetTickCount();
}
} else {
heatCycleStart = 0;
}
if ((xTaskGetTickCount() - heatCycleStart) > (THERMAL_RUNAWAY_TIME_SEC * TICKS_SECOND)) {
if (tipTempMax > tiptempMin) {
// Have been heating for min seconds, check if the delta is large enough
TemperatureType_t delta = tipTempMax - tiptempMin;
haveSeenDelta = true;
if (delta < THERMAL_RUNAWAY_TEMP_C) {
heaterThermalRunaway = true; heaterThermalRunaway = true;
} }
} }
} else {
tipTempCRunawayTemp = currentTipTempInC;
runawaylastChangeTime = xTaskGetTickCount();
} }
} }
@@ -308,4 +331,4 @@ void setOutputx10WattsViaFilters(int32_t x10WattsOut) {
#endif #endif
setTipX10Watts(x10WattsOut); setTipX10Watts(x10WattsOut);
resetWatchdog(); resetWatchdog();
} }