Merge branch 'devel-overcurrent' into devel

GITHUB_SHA.h

@@ -1 +1 @@
-#define GITHUB_SHA "devel-202306182208Z"
+#define GITHUB_SHA "devel-202306190642Z"

MotorDriver.cpp

@@ -159,11 +159,7 @@ MotorDriver::MotorDriver(int16_t power_pin, byte signal_pin, byte signal_pin2, i
     //   senseFactorInternal, raw2mA(1000),mA2raw(1000));
   }
 
-  // prepare values for current detection
-  sampleDelay = 0;
-  lastSampleTaken = millis();
   progTripValue = mA2raw(TRIP_CURRENT_PROG); 
-
 }
 
 bool MotorDriver::isPWMCapable() {
@@ -172,6 +168,7 @@ bool MotorDriver::isPWMCapable() {
 
 
 void MotorDriver::setPower(POWERMODE mode) {
+  if (powerMode == mode) return;
   bool on=mode==POWERMODE::ON;
   if (on) {
     // when switching a track On, we need to check the crrentOffset with the pin OFF
@@ -372,63 +369,123 @@ void  MotorDriver::getFastPin(const FSH* type,int pin, bool input, FASTPIN & res
 }
 
 void MotorDriver::checkPowerOverload(bool useProgLimit, byte trackno) {
-  if (millis() - lastSampleTaken  < sampleDelay) return;
-  lastSampleTaken = millis();
   int tripValue= useProgLimit?progTripValue:getRawCurrentTripValue();
 
-  // Trackname for diag messages later
   switch (powerMode) {
     case POWERMODE::OFF:
-      sampleDelay = POWER_SAMPLE_OFF_WAIT;
+      if (overloadNow) {
+	// reset overload condition as we have just turned off power
+	// DIAG(F("OVERLOAD POFF OFF"));
+	overloadNow=false;
+	lastPowerChange = micros();
+      }
+      if (microsSinceLastPowerChange() > POWER_SAMPLE_ALL_GOOD) {
+	power_sample_overload_wait = POWER_SAMPLE_OVERLOAD_WAIT;
+      }
       break;
     case POWERMODE::ON:
       // Check current
       lastCurrent=getCurrentRaw();
       if (lastCurrent < 0) {
 	// We have a fault pin condition to take care of
+	if (!overloadNow) {
+	  // turn on overload condition as fault pin has gone active
+	  // DIAG(F("OVERLOAD FPIN ON"));
+	  overloadNow=true;
+	  lastPowerChange = micros();
+	}
 	lastCurrent = -lastCurrent;
-	  setPower(POWERMODE::OVERLOAD); // Turn off, decide later how fast to turn on again
 	if (commonFaultPin) {
 	  if (lastCurrent < tripValue) {
+	    // probably other track, do a fast toggle.
+	    setPower(POWERMODE::OVERLOAD); // Turn off, decide later how fast to turn on again
 	    setPower(POWERMODE::ON); // maybe other track
-	      }
 	    // Write this after the fact as we want to turn on as fast as possible
 	    // because we don't know which output actually triggered the fault pin
 	    DIAG(F("COMMON FAULT PIN ACTIVE: POWERTOGGLE TRACK %c"), trackno + 'A');
+	  }
 	} else {
-	    DIAG(F("TRACK %c FAULT PIN ACTIVE - OVERLOAD"), trackno + 'A');
 	  if (lastCurrent < tripValue) {
-		  lastCurrent = tripValue; // exaggerate
+	    if (power_sample_overload_wait <= (POWER_SAMPLE_OVERLOAD_WAIT * 10) &&    // almost virgin
+		microsSinceLastPowerChange() < POWER_SAMPLE_IGNORE_FAULT_LOW) {
+	      // Ignore 50ms fault pin if no current
+	      DIAG(F("TRACK %c FAULT PIN 50ms ignore"), trackno + 'A');
+	      break;
 	    }
-	  }
+	    lastCurrent = tripValue; // exaggerate so condition below (*) is true
-      }
-      if (lastCurrent < tripValue) {
-        sampleDelay = POWER_SAMPLE_ON_WAIT;
-	if(power_good_counter<100)
-	  power_good_counter++;
-	else
-	  if (power_sample_overload_wait>POWER_SAMPLE_OVERLOAD_WAIT) power_sample_overload_wait=POWER_SAMPLE_OVERLOAD_WAIT;
 	  } else {
+	    if (power_sample_overload_wait <= POWER_SAMPLE_OVERLOAD_WAIT &&   // virgin
+		microsSinceLastPowerChange() < POWER_SAMPLE_IGNORE_FAULT_HIGH) {
+              // Ignore 5ms fault pin if we see current
+	      DIAG(F("TRACK %c FAULT PIN 5ms ignore"), trackno + 'A');
+	      break;
+	    }
+	  }
+	  DIAG(F("TRACK %c FAULT PIN ACTIVE"), trackno + 'A');
+	}
+      }
+      // // //
+      // above we looked at fault pin, below we look at current
+      // // //
+      if (lastCurrent < tripValue) { // see above (*)
+	if (overloadNow) {
+	  // current is below trip value, turn off overload condition
+	  // DIAG(F("OVERLOAD PON OFF"));
+	  overloadNow=false;
+	  lastPowerChange = micros();
+	}
+	if (microsSinceLastPowerChange() > POWER_SAMPLE_ALL_GOOD) {
+	  power_sample_overload_wait = POWER_SAMPLE_OVERLOAD_WAIT;
+	}
+      } else {
+	// too much current
+	if (!overloadNow) {
+	  // current is over trip value, turn on overload condition
+	  // DIAG(F("OVERLOAD PON ON"));
+	  overloadNow=true;
+	  lastPowerChange = micros();
+	}
+	unsigned long uSecs = microsSinceLastPowerChange();
+	if (power_sample_overload_wait > POWER_SAMPLE_OVERLOAD_WAIT ||    // not virgin
+	    uSecs > POWER_SAMPLE_OFF_DELAY) {
+	  // Overload has existed longer than delay (typ. 10ms)
 	  setPower(POWERMODE::OVERLOAD);
+	  if (overloadNow) {
+	    // the setPower just turned off, so overload is now gone
+	    // DIAG(F("OVERLOAD PON OFF"));
+	    overloadNow=false;
+	    lastPowerChange = micros();
+	  }
 	  unsigned int mA=raw2mA(lastCurrent);
 	  unsigned int maxmA=raw2mA(tripValue);
-	      power_good_counter=0;
+	  DIAG(F("TRACK %c POWER OVERLOAD %dmA (limit %dmA) shutdown after %lus for %lus"),
-        sampleDelay = power_sample_overload_wait;
+	       trackno + 'A', mA, maxmA, uSecs, power_sample_overload_wait);
-        DIAG(F("TRACK %c POWER OVERLOAD %dmA (limit %dmA) shutdown for %dms"), trackno + 'A', mA, maxmA, sampleDelay);
+	}
-	if (power_sample_overload_wait >= 10000)
-	    power_sample_overload_wait = 10000;
-	else
-	    power_sample_overload_wait *= 2;
       }
       break;
   case POWERMODE::OVERLOAD:
+    if (overloadNow) {
+      // state overload mode means power is off, turn off overload condition flag as well
+      // DIAG(F("OVERLOAD POVER OFF"));
+      overloadNow=false;
+      lastPowerChange = micros();
+    }
     // Try setting it back on after the OVERLOAD_WAIT
+    if (microsSinceLastPowerChange() > power_sample_overload_wait) {
+      // adjust next wait time
+      power_sample_overload_wait *= 2;
+      if (power_sample_overload_wait > POWER_SAMPLE_RETRY_MAX)
+	power_sample_overload_wait = POWER_SAMPLE_RETRY_MAX;
+      // power on test
       setPower(POWERMODE::ON);
-      sampleDelay = POWER_SAMPLE_ON_WAIT;
+      // here we change power but not the overloadNow as that was
-      // Debug code....
+      // already changed to false when we entered POWERMODE::OVERLOAD
-      DIAG(F("TRACK %c POWER RESTORE (check %dms)"), trackno + 'A', sampleDelay);
+      // so we need to set the lastPowerChange anyway.
+      lastPowerChange = micros();
+      DIAG(F("TRACK %c POWER RESTORE (was off %lus)"), trackno + 'A', power_sample_overload_wait);
+    }
     break;
   default:
-      sampleDelay = 999; // cant get here..meaningless statement to avoid compiler warning.
+    break;
   }
 }

MotorDriver.h

@@ -186,6 +186,16 @@ class MotorDriver {
     inline void setTrackLetter(char c) {
       trackLetter = c;
     };
+    // this returns how much time has passed since the last power change. If it
+    // was really long ago (approx > 52min) advance counter approx 35 min so that
+    // we are at 18 minutes again. Times for 32 bit unsigned long.
+    inline unsigned long microsSinceLastPowerChange() {
+      unsigned long now = micros();
+      unsigned long diff = now - lastPowerChange;
+      if (diff > (1UL << (7 *sizeof(unsigned long)))) // 2^(4*7)us = 268.4 seconds
+        lastPowerChange = now - 30000000UL;           // 30 seconds ago
+      return diff;
+    };
 #ifdef ANALOG_READ_INTERRUPT
     bool sampleCurrentFromHW();
     void startCurrentFromHW();
@@ -217,8 +227,8 @@ class MotorDriver {
     int rawCurrentTripValue;
     // current sampling
     POWERMODE powerMode;
-    unsigned long lastSampleTaken;
+    bool overloadNow = false;
-    unsigned int sampleDelay;
+    unsigned long lastPowerChange; // timestamp in microseconds
     int progTripValue;
     int  lastCurrent;
 #ifdef ANALOG_READ_INTERRUPT
@@ -228,10 +238,19 @@ class MotorDriver {
     int maxmA;
     int tripmA;
 
-    // Wait times for power management. Unit: milliseconds
+    // Times for overload management. Unit: microseconds.
-    static const int  POWER_SAMPLE_ON_WAIT = 100;
+    // Base for wait time until power is turned on again
-    static const int  POWER_SAMPLE_OFF_WAIT = 1000;
+    static const unsigned long POWER_SAMPLE_OVERLOAD_WAIT =       100UL;
-    static const int  POWER_SAMPLE_OVERLOAD_WAIT = 20;
+    // Time after we consider all faults old and forgotten
+    static const unsigned long POWER_SAMPLE_ALL_GOOD =        5000000UL;
+    // How long to ignore fault pin if current is under limit
+    static const unsigned long POWER_SAMPLE_IGNORE_FAULT_LOW =  50000UL;
+    // How long to ignore fault pin if current is higher than limit
+    static const unsigned long POWER_SAMPLE_IGNORE_FAULT_HIGH =  5000UL;
+    // How long to wait between overcurrent and turning off
+    static const unsigned long POWER_SAMPLE_OFF_DELAY =         10000UL;
+    // Upper limit for retry period
+    static const unsigned long POWER_SAMPLE_RETRY_MAX =      10000000UL;
     
     // Trip current for programming track, 250mA. Change only if you really
     // need to be non-NMRA-compliant because of decoders that are not either.