mirror of
https://github.com/Ralim/IronOS.git
synced 2025-07-23 12:23:06 +02:00
347 lines
14 KiB
C++
347 lines
14 KiB
C++
/*
|
|
* PIDThread.cpp
|
|
*
|
|
* Created on: 29 May 2020
|
|
* Author: Ralim
|
|
*/
|
|
|
|
#include "BSP.h"
|
|
#include "FreeRTOS.h"
|
|
#include "Settings.h"
|
|
#include "TipThermoModel.h"
|
|
#include "cmsis_os.h"
|
|
#include "configuration.h"
|
|
#include "history.hpp"
|
|
#include "main.hpp"
|
|
#include "power.hpp"
|
|
#include "task.h"
|
|
|
|
#ifdef POW_PD
|
|
#if POW_PD == 1
|
|
#include "USBPD.h"
|
|
#endif
|
|
#endif
|
|
|
|
static TickType_t powerPulseWaitUnit = 25 * TICKS_100MS; // 2.5 s
|
|
static TickType_t powerPulseDurationUnit = (5 * TICKS_100MS) / 2; // 250 ms
|
|
TaskHandle_t pidTaskNotification = NULL;
|
|
volatile TemperatureType_t currentTempTargetDegC = 0; // Current temperature target in C
|
|
int32_t powerSupplyWattageLimit = 0;
|
|
uint8_t heaterThermalRunawayCounter = 0;
|
|
|
|
static int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t current_value);
|
|
static void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut);
|
|
static void setOutputx10WattsViaFilters(int32_t x10Watts);
|
|
static int32_t getX10WattageLimits();
|
|
|
|
/* StartPIDTask function */
|
|
void startPIDTask(void const *argument __unused) {
|
|
/*
|
|
* We take the current tip temperature & evaluate the next step for the tip
|
|
* control PWM.
|
|
*/
|
|
setTipX10Watts(0); // disable the output at startup
|
|
|
|
currentTempTargetDegC = 0; // Force start with no output (off). If in sleep / soldering this will
|
|
// be over-ridden rapidly
|
|
|
|
pidTaskNotification = xTaskGetCurrentTaskHandle();
|
|
|
|
TemperatureType_t PIDTempTarget = 0;
|
|
// Pre-seed the adc filters
|
|
for (int i = 0; i < 32; i++) {
|
|
ulTaskNotifyTake(pdTRUE, 5);
|
|
TipThermoModel::getTipInC(true);
|
|
getInputVoltageX10(getSettingValue(SettingsOptions::VoltageDiv), 1);
|
|
}
|
|
|
|
while (preStartChecks() == 0) {
|
|
resetWatchdog();
|
|
ulTaskNotifyTake(pdTRUE, 2000);
|
|
}
|
|
// Wait for PD if its in the middle of negotiation
|
|
#ifdef POW_PD
|
|
#if POW_PD == 1
|
|
// This is an FUSB based PD capable device
|
|
// Wait up to 3 seconds for USB-PD to settle
|
|
while (USBPowerDelivery::negotiationInProgress() && xTaskGetTickCount() < (TICKS_SECOND * 3)) {
|
|
resetWatchdog();
|
|
ulTaskNotifyTake(pdTRUE, TICKS_100MS);
|
|
}
|
|
#endif
|
|
#endif
|
|
|
|
int32_t x10WattsOut = 0;
|
|
TickType_t lastThermalRunawayDecay = xTaskGetTickCount();
|
|
|
|
for (;;) {
|
|
x10WattsOut = 0;
|
|
// This is a call to block this thread until the ADC does its samples
|
|
if (ulTaskNotifyTake(pdTRUE, TICKS_SECOND * 2)) {
|
|
// Do the reading here to keep the temp calculations churning along
|
|
TemperatureType_t currentTipTempInC = TipThermoModel::getTipInC(true);
|
|
|
|
PIDTempTarget = currentTempTargetDegC;
|
|
if (PIDTempTarget > 0) {
|
|
// Cap the max set point to 450C
|
|
if (PIDTempTarget > 450) {
|
|
// Maximum allowed output
|
|
PIDTempTarget = 450;
|
|
}
|
|
// Safety check that not aiming higher than current tip can measure
|
|
if (PIDTempTarget > TipThermoModel::getTipMaxInC()) {
|
|
PIDTempTarget = TipThermoModel::getTipMaxInC();
|
|
}
|
|
|
|
x10WattsOut = getPIDResultX10Watts(PIDTempTarget, currentTipTempInC);
|
|
detectThermalRunaway(currentTipTempInC, x10WattsOut);
|
|
} else {
|
|
detectThermalRunaway(currentTipTempInC, 0);
|
|
}
|
|
setOutputx10WattsViaFilters(x10WattsOut);
|
|
} else {
|
|
// ADC interrupt timeout
|
|
setTipPWM(0, false);
|
|
}
|
|
#ifdef DEBUG_UART_OUTPUT
|
|
log_system_state(x10WattsOut);
|
|
#endif
|
|
if (xTaskGetTickCount() - lastThermalRunawayDecay > TICKS_SECOND) {
|
|
lastThermalRunawayDecay = xTaskGetTickCount();
|
|
if (heaterThermalRunawayCounter > 0) {
|
|
heaterThermalRunawayCounter--;
|
|
}
|
|
}
|
|
}
|
|
}
|
|
|
|
#ifdef TIP_CONTROL_PID
|
|
template <class T, T Kp, T Ki, T Kd, T integral_limit_scale> struct PID {
|
|
T previous_error_term;
|
|
T integration_running_sum;
|
|
|
|
T update(const T set_point, const T new_reading, const TickType_t interval_ms, const T max_output) {
|
|
const T target_delta = set_point - new_reading;
|
|
|
|
// Proportional term
|
|
const T kp_result = Kp * target_delta;
|
|
|
|
// Integral term as we use mixed sampling rates, we cant assume a constant sample interval
|
|
// Thus we multiply this out by the interval time to ~= dv/dt
|
|
// Then the shift by 1000 is ms -> Seconds
|
|
|
|
integration_running_sum += (target_delta * interval_ms * Ki) / 1000;
|
|
|
|
// We constrain integration_running_sum to limit windup
|
|
// This is not overly required for most use cases but can prevent large overshoot in constrained implementations
|
|
if (integration_running_sum > integral_limit_scale * max_output) {
|
|
integration_running_sum = integral_limit_scale * max_output;
|
|
} else if (integration_running_sum < -integral_limit_scale * max_output) {
|
|
integration_running_sum = -integral_limit_scale * max_output;
|
|
}
|
|
// Calculate the integral term, we use a shift 100 to get precision in integral as we often need small amounts
|
|
T ki_result = integration_running_sum / 100;
|
|
|
|
// Derivative term
|
|
T derivative = (target_delta - previous_error_term);
|
|
T kd_result = ((Kd * derivative) / (T)(interval_ms));
|
|
|
|
// Summation of the outputs
|
|
T output = kp_result + ki_result + kd_result;
|
|
|
|
// Restrict to max / 0
|
|
if (output > max_output) {
|
|
output = max_output;
|
|
} else if (output < 0) {
|
|
output = 0;
|
|
}
|
|
|
|
// Save target_delta to previous target_delta
|
|
previous_error_term = target_delta;
|
|
|
|
return output;
|
|
}
|
|
};
|
|
#else
|
|
template <class T = TemperatureType_t> struct Integrator {
|
|
T sum;
|
|
|
|
T update(const T val, const int32_t inertia, const int32_t gain, const int32_t rate, const int32_t limit) {
|
|
// Decay the old value. This is a simplified formula that still works with decent results
|
|
// Ideally we would have used an exponential decay but the computational effort required
|
|
// by exp function is just not justified here in respect to the outcome
|
|
sum = (sum * (100 - (inertia / rate))) / 100;
|
|
// Add the new value x integration interval ( 1 / rate)
|
|
sum += (gain * val) / rate;
|
|
|
|
// constrain the output between +- our max power output, this limits windup when doing the inital heatup or when solding something large
|
|
if (sum > limit) {
|
|
sum = limit;
|
|
} else if (sum < -limit) {
|
|
sum = -limit;
|
|
}
|
|
|
|
return sum;
|
|
}
|
|
|
|
void set(T const val) { sum = val; }
|
|
|
|
T get(bool positiveOnly = true) const { return (positiveOnly) ? ((sum > 0) ? sum : 0) : sum; }
|
|
};
|
|
#endif
|
|
int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t current_reading) {
|
|
static TickType_t lastCall = 0;
|
|
|
|
#ifdef TIP_CONTROL_PID
|
|
static PID<TemperatureType_t, TIP_PID_KP, TIP_PID_KI, TIP_PID_KD, 5> pid = {0, 0};
|
|
|
|
const TickType_t interval = (xTaskGetTickCount() - lastCall);
|
|
|
|
#else
|
|
static Integrator<TemperatureType_t> powerStore = {0};
|
|
const TickType_t rate = TICKS_SECOND / (xTaskGetTickCount() - lastCall);
|
|
#endif
|
|
lastCall = xTaskGetTickCount();
|
|
// Sandman note:
|
|
// PID Challenge - we have a small thermal mass that we to want heat up as fast as possible but we don't
|
|
// want to overshot excessively (if at all) the set point temperature. In the same time we have 'imprecise'
|
|
// instant temperature measurements. The nature of temperature reading imprecision is not necessarily
|
|
// related to the sensor (thermocouple) or DAQ system, that otherwise are fairly decent. The real issue is
|
|
// the thermal inertia. We basically read the temperature in the window between two heating sessions when
|
|
// the output is off. However, the heater temperature does not dissipate instantly into the tip mass so
|
|
// at any moment right after heating, the thermocouple would sense a temperature significantly higher than
|
|
// moments later. We could use longer delays but that would slow the PID loop and that would lead to other
|
|
// negative side effects. As a result, we can only rely on the I term but with a twist. Instead of a simple
|
|
// integrator we are going to use a self decaying integrator that acts more like a dual I term / P term
|
|
// rather than a plain I term. Depending on the circumstances, like when the delta temperature is large,
|
|
// it acts more like a P term whereas on closing to set point it acts increasingly closer to a plain I term.
|
|
// So in a sense, we have a bit of both.
|
|
// So there we go...
|
|
|
|
// P = (Thermal Mass) x (Delta Temperature ) / 1sec, where thermal mass is in X10 J / °C and
|
|
// delta temperature is in °C. The result is the power in X10 W needed to raise (or decrease!) the
|
|
// tip temperature with (Delta Temperature ) °C in 1 second.
|
|
// Note on powerStore. On update, if the value is provided in X10 (W) units then inertia shall be provided
|
|
// in X10 (J / °C) units as well.
|
|
|
|
#ifdef TIP_CONTROL_PID
|
|
return pid.update(set_point, current_reading, interval, getX10WattageLimits());
|
|
#else
|
|
return powerStore.update(((TemperatureType_t)getTipThermalMass()) * (set_point - current_reading), // the required power
|
|
getTipInertia(), // Inertia, smaller numbers increase dominance of the previous value
|
|
2, // gain
|
|
rate, // PID cycle frequency
|
|
getX10WattageLimits());
|
|
#endif
|
|
}
|
|
|
|
/*
|
|
* Detection of thermal runaway
|
|
* 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) {
|
|
|
|
static TemperatureType_t tiptempMin = 0xFFFF; // Min tip temp seen
|
|
static TemperatureType_t tipTempMax = 0; // Max tip temp seen while heater is on
|
|
bool thisCycleIsHeating = x10WattsOut > 0;
|
|
static TickType_t heatCycleStart = 0;
|
|
|
|
static bool haveSeenDelta = false;
|
|
|
|
// Check for readings being pegged at the top of the ADC while the heater is off
|
|
if (!thisCycleIsHeating && (getTipRawTemp(0) > (ADC_MAX_READING - 8)) && heaterThermalRunawayCounter < 255) {
|
|
heaterThermalRunawayCounter++;
|
|
}
|
|
|
|
if (haveSeenDelta) {
|
|
return;
|
|
}
|
|
|
|
if (currentTipTempInC < tiptempMin) {
|
|
tiptempMin = currentTipTempInC;
|
|
}
|
|
if (thisCycleIsHeating && currentTipTempInC > tipTempMax) {
|
|
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 && heaterThermalRunawayCounter < 255) {
|
|
heaterThermalRunawayCounter++;
|
|
}
|
|
}
|
|
}
|
|
}
|
|
|
|
int32_t getX10WattageLimits() {
|
|
int32_t limit = availableW10(0);
|
|
|
|
if (getSettingValue(SettingsOptions::PowerLimit) && limit > (getSettingValue(SettingsOptions::PowerLimit) * 10)) {
|
|
limit = getSettingValue(SettingsOptions::PowerLimit) * 10;
|
|
}
|
|
if (powerSupplyWattageLimit && limit > powerSupplyWattageLimit * 10) {
|
|
limit = powerSupplyWattageLimit * 10;
|
|
}
|
|
return limit;
|
|
}
|
|
|
|
void setOutputx10WattsViaFilters(int32_t x10WattsOut) {
|
|
static TickType_t lastPowerPulseStart = 0;
|
|
static TickType_t lastPowerPulseEnd = 0;
|
|
#ifdef SLEW_LIMIT
|
|
static int32_t x10WattsOutLast = 0;
|
|
#endif
|
|
|
|
// If the user turns on the option of using an occasional pulse to keep the power bank on
|
|
if (getSettingValue(SettingsOptions::KeepAwakePulse)) {
|
|
const TickType_t powerPulseWait = powerPulseWaitUnit * getSettingValue(SettingsOptions::KeepAwakePulseWait);
|
|
if (xTaskGetTickCount() - lastPowerPulseStart > powerPulseWait) {
|
|
const TickType_t powerPulseDuration = powerPulseDurationUnit * getSettingValue(SettingsOptions::KeepAwakePulseDuration);
|
|
lastPowerPulseStart = xTaskGetTickCount();
|
|
lastPowerPulseEnd = lastPowerPulseStart + powerPulseDuration;
|
|
}
|
|
|
|
// If current PID is less than the pulse level, check if we want to constrain to the pulse as the floor
|
|
if (x10WattsOut < getSettingValue(SettingsOptions::KeepAwakePulse) && xTaskGetTickCount() < lastPowerPulseEnd) {
|
|
x10WattsOut = getSettingValue(SettingsOptions::KeepAwakePulse);
|
|
}
|
|
}
|
|
|
|
// Secondary safety check to forcefully disable header when within ADC noise of top of ADC
|
|
if (getTipRawTemp(0) > (0x7FFF - 32)) {
|
|
x10WattsOut = 0;
|
|
}
|
|
if (heaterThermalRunawayCounter > 8) {
|
|
x10WattsOut = 0;
|
|
}
|
|
#ifdef SLEW_LIMIT
|
|
if (x10WattsOut - x10WattsOutLast > SLEW_LIMIT) {
|
|
x10WattsOut = x10WattsOutLast + SLEW_LIMIT;
|
|
}
|
|
if (x10WattsOut < 0) {
|
|
x10WattsOut = 0;
|
|
}
|
|
x10WattsOutLast = x10WattsOut;
|
|
#endif
|
|
setTipX10Watts(x10WattsOut);
|
|
resetWatchdog();
|
|
}
|