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completely new overcurrent detection

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This commit is contained in:
Harald Barth 2023-07-02 01:33:41 +02:00
parent 7c41ec7c25
commit 70d4c016ef
4 changed files with 121 additions and 125 deletions
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2
GITHUB_SHA.h
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@ -1 +1 @@
#define GITHUB_SHA "devel-overcurrent-202306300005Z"
#define GITHUB_SHA "devel-overcurrent-202307012332Z"

193
MotorDriver.cpp
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@ -173,7 +173,11 @@ bool MotorDriver::isPWMCapable() {
void MotorDriver::setPower(POWERMODE mode) {
if (powerMode == mode) return;
bool on=mode==POWERMODE::ON;
//DIAG(F("POWERMODE=%d"), (int)mode);
lastPowerChange[(int)mode] = micros();
if (mode == POWERMODE::OVERLOAD)
globalOverloadStart = lastPowerChange[(int)mode];
bool on=(mode==POWERMODE::ON || mode ==POWERMODE::ALERT);
if (on) {
// when switching a track On, we need to check the crrentOffset with the pin OFF
if (powerMode==POWERMODE::OFF && currentPin!=UNUSED_PIN) {
@ -213,8 +217,8 @@ bool MotorDriver::canMeasureCurrent() {
return currentPin!=UNUSED_PIN;
}
/*
* Return the current reading as pin reading 0 to 1023. If the fault
* pin is activated return a negative current to show active fault pin.
* Return the current reading as pin reading 0 to max resolution (1024 or 4096).
* If the fault pin is activated return a negative current to show active fault pin.
* As there is no -0, cheat a little and return -1 in that case.
*
* senseOffset handles the case where a shield returns values above or below
@ -373,118 +377,103 @@ void MotorDriver::getFastPin(const FSH* type,int pin, bool input, FASTPIN & res
}
void MotorDriver::checkPowerOverload(bool useProgLimit, byte trackno) {
int tripValue= useProgLimit?progTripValue:getRawCurrentTripValue();
switch (powerMode) {
case POWERMODE::OFF:
if (overloadNow) {
// reset overload condition as we have just turned off power
// DIAG(F("OVERLOAD POFF OFF"));
overloadNow=false;
setLastPowerChange();
}
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;
setLastPowerChangeOverload();
}
lastCurrent = -lastCurrent;
{
if (lastCurrent < tripValue) {
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;
}
setPower(POWERMODE::OVERLOAD);
overloadNow=false;
DIAG(F("TRACK %c FAULT PIN"), trackno + 'A');
break;
//lastCurrent = tripValue; // exaggerate so condition below (*) is true
} 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 AND OVERCURRENT"), 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;
setLastPowerChange();
}
if (microsSinceLastPowerChange() > POWER_SAMPLE_ALL_GOOD) {
power_sample_overload_wait = POWER_SAMPLE_OVERLOAD_WAIT;
}
case POWERMODE::OFF: {
lastPowerMode = POWERMODE::OFF;
power_sample_overload_wait = POWER_SAMPLE_OVERLOAD_WAIT;
break;
}
case POWERMODE::ON: {
lastPowerMode = POWERMODE::ON;
bool cF = checkFault();
bool cC = checkCurrent(useProgLimit);
if(cF || cC ) {
if (cC) {
unsigned int mA=raw2mA(lastCurrent);
DIAG(F("TRACK %c ALERT %s %dmA"), trackno + 'A',
cF ? "FAULT" : "",
mA);
} else {
// too much current
if (!overloadNow) {
// current is over trip value, turn on overload condition
// DIAG(F("OVERLOAD PON ON"));
overloadNow=true;
setLastPowerChange();
}
unsigned long uSecs = microsSinceLastPowerChange();
if (/*power_sample_overload_wait > POWER_SAMPLE_OVERLOAD_WAIT || */ // not virgin
uSecs > POWER_SAMPLE_OFF_DELAY) {
/*
if (micros() - overloadStart > 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;
setLastPowerChangeOverload();
}
unsigned int mA=raw2mA(lastCurrent);
unsigned int maxmA=raw2mA(tripValue);
DIAG(F("TRACK %c POWER OVERLOAD %4dmA (max %4dmA) detected after %4M. Pause %4M"),
trackno + 'A', mA, maxmA, uSecs, power_sample_overload_wait);
}
DIAG(F("TRACK %c ALERT FAULT"), trackno + 'A');
}
setPower(POWERMODE::ALERT);
break;
case POWERMODE::OVERLOAD:
{
// Try setting it back on after the OVERLOAD_WAIT
unsigned long mslpc = (commonFaultPin ? (micros() - globalOverloadStart) : microsSinceLastPowerChange());
}
// all well
if (microsSinceLastPowerChange(POWERMODE::ON) > POWER_SAMPLE_ALL_GOOD) {
power_sample_overload_wait = POWER_SAMPLE_OVERLOAD_WAIT;
}
break;
}
case POWERMODE::ALERT: {
// set local flags that handle how much is output to diag (do not output duplicates)
bool notFromOverload = (lastPowerMode != POWERMODE::OVERLOAD);
bool newPowerMode = (powerMode != lastPowerMode);
unsigned long now = micros();
if (newPowerMode)
lastBadSample = now;
lastPowerMode = POWERMODE::ALERT;
// check how long we have been in this state
unsigned long mslpc = microsSinceLastPowerChange(POWERMODE::ALERT);
if(checkFault()) {
lastBadSample = now;
unsigned long timeout = checkCurrent(useProgLimit) ? POWER_SAMPLE_IGNORE_FAULT_HIGH : POWER_SAMPLE_IGNORE_FAULT_LOW;
if ( mslpc < timeout) {
if (newPowerMode)
DIAG(F("TRACK %c FAULT PIN (%M ignore)"), trackno + 'A', timeout);
break;
}
DIAG(F("TRACK %c FAULT PIN detected after %4M. Pause %4M)"), trackno + 'A', mslpc, power_sample_overload_wait);
setPower(POWERMODE::OVERLOAD);
break;
}
if (checkCurrent(useProgLimit)) {
lastBadSample = now;
if (mslpc < POWER_SAMPLE_IGNORE_CURRENT) {
if (newPowerMode) {
unsigned int mA=raw2mA(lastCurrent);
DIAG(F("TRACK %c CURRENT (%M ignore) %dmA"), trackno + 'A', POWER_SAMPLE_IGNORE_CURRENT, mA);
}
break;
}
unsigned int mA=raw2mA(lastCurrent);
unsigned int maxmA=raw2mA(tripValue);
DIAG(F("TRACK %c POWER OVERLOAD %4dmA (max %4dmA) detected after %4M. Pause %4M"),
trackno + 'A', mA, maxmA, mslpc, power_sample_overload_wait);
setPower(POWERMODE::OVERLOAD);
break;
}
// all well
unsigned long goodtime = micros() - lastBadSample;
if (goodtime > POWER_SAMPLE_ALERT_GOOD) {
if (true || notFromOverload) { // we did a RESTORE message XXX
unsigned int mA=raw2mA(lastCurrent);
DIAG(F("TRACK %c NORMAL (after %M/%M) %dmA"), trackno + 'A', goodtime, mslpc, mA);
}
setPower(POWERMODE::ON);
}
break;
}
case POWERMODE::OVERLOAD: {
lastPowerMode = POWERMODE::OVERLOAD;
unsigned long mslpc = (commonFaultPin ? (micros() - globalOverloadStart) : microsSinceLastPowerChange(POWERMODE::OVERLOAD));
if (mslpc > power_sample_overload_wait) {
// adjust next wait time
power_sample_overload_wait *= 2;
power_sample_overload_wait *= 4;
if (power_sample_overload_wait > POWER_SAMPLE_RETRY_MAX)
power_sample_overload_wait = POWER_SAMPLE_RETRY_MAX;
// power on test
setPower(POWERMODE::ON);
// here we change power but not the overloadNow as that was
// already changed to false when we entered POWERMODE::OVERLOAD
// so we need to set the lastPowerChange anyway.
overloadNow=false;
setLastPowerChange();
DIAG(F("TRACK %c POWER RESTORE (after %4M)"), trackno + 'A', mslpc);
setPower(POWERMODE::ALERT);
}
break;
}
break;
default:
break;
}

48
MotorDriver.h
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@ -107,7 +107,7 @@ extern volatile portreg_t shadowPORTA;
extern volatile portreg_t shadowPORTB;
extern volatile portreg_t shadowPORTC;
enum class POWERMODE : byte { OFF, ON, OVERLOAD };
enum class POWERMODE : byte { OFF, ON, OVERLOAD, ALERT };
class MotorDriver {
public:
@ -192,24 +192,13 @@ class MotorDriver {
// 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() {
inline unsigned long microsSinceLastPowerChange(POWERMODE mode) {
unsigned long now = micros();
unsigned long diff = now - lastPowerChange;
unsigned long diff = now - lastPowerChange[(int)mode];
if (diff > (1UL << (7 *sizeof(unsigned long)))) // 2^(4*7)us = 268.4 seconds
lastPowerChange = now - 30000000UL; // 30 seconds ago
lastPowerChange[(int)mode] = now - 30000000UL; // 30 seconds ago
return diff;
};
inline void setLastPowerChange() {
lastPowerChange = micros();
};
// as setLastPowerChange but sets the global timestamp as well which
// is only used to sync power restore in case of common Fault pin.
inline void setLastPowerChangeOverload() {
if (commonFaultPin)
globalOverloadStart = lastPowerChange = micros();
else
setLastPowerChange();
};
#ifdef ANALOG_READ_INTERRUPT
bool sampleCurrentFromHW();
void startCurrentFromHW();
@ -218,9 +207,22 @@ class MotorDriver {
char trackLetter = '?';
bool isProgTrack = false; // tells us if this is a prog track
void getFastPin(const FSH* type,int pin, bool input, FASTPIN & result);
void getFastPin(const FSH* type,int pin, FASTPIN & result) {
inline void getFastPin(const FSH* type,int pin, FASTPIN & result) {
getFastPin(type, pin, 0, result);
}
};
// side effect sets lastCurrent and tripValue
inline bool checkCurrent(bool useProgLimit) {
tripValue= useProgLimit?progTripValue:getRawCurrentTripValue();
lastCurrent = getCurrentRaw();
if (lastCurrent < 0)
lastCurrent = -lastCurrent;
return lastCurrent >= tripValue;
};
// side effect sets lastCurrent
inline bool checkFault() {
lastCurrent = getCurrentRaw();
return lastCurrent < 0;
};
VPIN powerPin;
byte signalPin, signalPin2, currentPin, faultPin, brakePin;
FASTPIN fastSignalPin, fastSignalPin2, fastBrakePin,fastFaultPin;
@ -241,12 +243,14 @@ class MotorDriver {
int rawCurrentTripValue;
// current sampling
POWERMODE powerMode;
bool overloadNow = false;
unsigned long lastPowerChange; // timestamp in microseconds
POWERMODE lastPowerMode;
unsigned long lastPowerChange[4]; // timestamp in microseconds
unsigned long lastBadSample; // timestamp in microseconds
// used to sync restore time when common Fault pin detected
static unsigned long globalOverloadStart; // timestamp in microseconds
int progTripValue;
int lastCurrent;
int lastCurrent; //temp value
int tripValue; //temp value
#ifdef ANALOG_READ_INTERRUPT
volatile unsigned long sampleCurrentTimestamp;
volatile uint16_t sampleCurrent;
@ -259,12 +263,14 @@ class MotorDriver {
static const unsigned long POWER_SAMPLE_OVERLOAD_WAIT = 10000UL;
// Time after we consider all faults old and forgotten
static const unsigned long POWER_SAMPLE_ALL_GOOD = 5000000UL;
// Time after which we consider a ALERT over
static const unsigned long POWER_SAMPLE_ALERT_GOOD = 20000UL;
// 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 = 100000UL;
static const unsigned long POWER_SAMPLE_IGNORE_CURRENT = 100000UL;
// Upper limit for retry period
static const unsigned long POWER_SAMPLE_RETRY_MAX = 10000000UL;

3
version.h
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@ -4,7 +4,8 @@
#include "StringFormatter.h"
#define VERSION "4.2.61"
#define VERSION "4.2.62pre1"
// 4.2.62 - completely new overcurrent detection
// 4.2.61 - MAX_CURRENT restriction (caps motor shield value)
// 4.2.60 - Add mDNS capability to ESP32 for autodiscovery
// 4.2.59 - Fix: AP SSID was DCC_ instead of DCCEX_