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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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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;
}