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Merge branch 'devel-overload' into devel

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This commit is contained in:
Harald Barth 2023-07-07 21:52:55 +02:00
commit 7ce1618a9c
9 changed files with 215 additions and 125 deletions
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4
DCCEXParser.cpp
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@ -487,9 +487,9 @@ void DCCEXParser::parseOne(Print *stream, byte *com, RingStream * ringStream)
#endif
else break; // will reply <X>
}
TrackManager::setJoin(join);
if (main) TrackManager::setMainPower(POWERMODE::ON);
if (prog) TrackManager::setProgPower(POWERMODE::ON);
TrackManager::setJoin(join);
CommandDistributor::broadcastPower();
return;
@ -516,12 +516,12 @@ void DCCEXParser::parseOne(Print *stream, byte *com, RingStream * ringStream)
else break; // will reply <X>
}
TrackManager::setJoin(false);
if (main) TrackManager::setMainPower(POWERMODE::OFF);
if (prog) {
TrackManager::progTrackBoosted=false; // Prog track boost mode will not outlive prog track off
TrackManager::setProgPower(POWERMODE::OFF);
}
TrackManager::setJoin(false);
CommandDistributor::broadcastPower();
return;

4
DCCRMT.cpp
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@ -194,8 +194,10 @@ int RMTChannel::RMTfillData(const byte buffer[], byte byteCount, byte repeatCoun
setDCCBit1(data + bitcounter-1); // overwrite previous zero bit with one bit
setEOT(data + bitcounter++); // EOT marker
dataLen = bitcounter;
noInterrupts(); // keep dataReady and dataRepeat consistnet to each other
dataReady = true;
dataRepeat = repeatCount+1; // repeatCount of 0 means send once
interrupts();
return 0;
}
@ -212,6 +214,8 @@ void IRAM_ATTR RMTChannel::RMTinterrupt() {
if (dataReady) { // if we have new data, fill while preamble is running
rmt_fill_tx_items(channel, data, dataLen, preambleLen-1);
dataReady = false;
if (dataRepeat == 0) // all data should go out at least once
DIAG(F("Channel %d DCC signal lost data"), channel);
}
if (dataRepeat > 0) // if a repeat count was specified, work on that
dataRepeat--;

3
DCCWaveform.cpp
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@ -247,6 +247,9 @@ void DCCWaveform::schedulePacket(const byte buffer[], byte byteCount, byte repea
pendingPacket[byteCount] = checksum;
pendingLength = byteCount + 1;
pendingRepeats = repeats;
// DIAG repeated commands (accesories)
// if (pendingRepeats > 0)
// DIAG(F("Repeats=%d on %s track"), pendingRepeats, isMainTrack ? "MAIN" : "PROG");
// The resets will be zero not only now but as well repeats packets into the future
clearResets(repeats+1);
{

2
GITHUB_SHA.h
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@ -1 +1 @@
#define GITHUB_SHA "devel-202306261801Z"
#define GITHUB_SHA "devel-overcurrent-202307061457Z"

245
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("Track %c POWERMODE=%d"), trackLetter, (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
@ -372,112 +376,165 @@ void MotorDriver::getFastPin(const FSH* type,int pin, bool input, FASTPIN & res
// DIAG(F(" port=0x%x, inoutpin=0x%x, isinput=%d, mask=0x%x"),port, result.inout,input,result.maskHIGH);
}
///////////////////////////////////////////////////////////////////////////////////////////
// checkPowerOverload(useProgLimit, trackno)
// bool useProgLimit: Trackmanager knows if this track is in prog mode or in main mode
// byte trackno: trackmanager knows it's number (could be skipped?)
//
// Short ciruit handling strategy:
//
// There are the following power states: ON ALERT OVERLOAD OFF
// OFF state is only changed to/from manually. Power is on
// during ON and ALERT. Power is off during OVERLOAD and OFF.
// The overload mechanism changes between the other states like
//
// ON -1-> ALERT -2-> OVERLOAD -3-> ALERT -4-> ON
// or
// ON -1-> ALERT -4-> ON
//
// Times are in class MotorDriver (MotorDriver.h).
//
// 1. ON to ALERT:
// Transition on fault pin condition or current overload
//
// 2. ALERT to OVERLOAD:
// Transition happens if different timeouts have elapsed.
// If only the fault pin is active, timeout is
// POWER_SAMPLE_IGNORE_FAULT_LOW (100ms)
// If only overcurrent is detected, timeout is
// POWER_SAMPLE_IGNORE_CURRENT (100ms)
// If fault pin and overcurrent are active, timeout is
// POWER_SAMPLE_IGNORE_FAULT_HIGH (5ms)
// Transition to OVERLOAD turns off power to the affected
// output (unless fault pins are shared)
// If the transition conditions are not fullfilled,
// transition according to 4 is tested.
//
// 3. OVERLOAD to ALERT
// Transiton happens when timeout has elapsed, timeout
// is named power_sample_overload_wait. It is started
// at POWER_SAMPLE_OVERLOAD_WAIT (40ms) at first entry
// to OVERLOAD and then increased by a factor of 2
// at further entries to the OVERLOAD condition. This
// happens until POWER_SAMPLE_RETRY_MAX (10sec) is reached.
// power_sample_overload_wait is reset by a poweroff or
// a POWER_SAMPLE_ALL_GOOD (5sec) period during ON.
// After timeout power is turned on again and state
// goes back to ALERT.
//
// 4. ALERT to ON
// Transition happens by watching the current and fault pin
// samples during POWER_SAMPLE_ALERT_GOOD (20ms) time. If
// values have been good during that time, transition is
// made back to ON. Note that even if state is back to ON,
// the power_sample_overload_wait time is first reset
// later (see above).
//
// The time keeping is handled by timestamps lastPowerChange[]
// which are set by each power change and by lastBadSample which
// keeps track if conditions during ALERT have been good enough
// to go back to ON. The time differences are calculated by
// microsSinceLastPowerChange().
//
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;
}
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"), 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) {
// 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;
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;
}

52
MotorDriver.h
View File

@ -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;
@ -256,15 +260,17 @@ class MotorDriver {
// Times for overload management. Unit: microseconds.
// Base for wait time until power is turned on again
static const unsigned long POWER_SAMPLE_OVERLOAD_WAIT = 100UL;
static const unsigned long POWER_SAMPLE_OVERLOAD_WAIT = 40000UL;
// 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;
static const unsigned long POWER_SAMPLE_IGNORE_FAULT_LOW = 100000UL;
// 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;
static const unsigned long POWER_SAMPLE_IGNORE_CURRENT = 100000UL;
// Upper limit for retry period
static const unsigned long POWER_SAMPLE_RETRY_MAX = 10000000UL;

2
defines.h
View File

@ -205,7 +205,7 @@
#define WIFI_SERIAL_LINK_SPEED 115200
#if __has_include ( "myAutomation.h")
#if defined(HAS_ENOUGH_MEMORY) || defined(DISABLE_EEPROM)
#if defined(HAS_ENOUGH_MEMORY) || defined(DISABLE_EEPROM) || defined(DISABLE_PROG)
#define EXRAIL_ACTIVE
#else
#define EXRAIL_WARNING

23
installer.sh
View File

@ -1,7 +1,7 @@
#!/bin/bash
#
# © 2022 Harald Barth
# © 2022,2023 Harald Barth
#
# This file is part of CommandStation-EX
#
@ -29,14 +29,33 @@ ACLI="./bin/arduino-cli"
function need () {
type -p $1 > /dev/null && return
dpkg -l $1 2>&1 | egrep ^ii >/dev/null && return
sudo apt-get install $1
type -p $1 > /dev/null && return
echo "Could not install $1, abort"
exit 255
}
need git
if cat /etc/issue | egrep '^Raspbian' 2>&1 >/dev/null ; then
# we are on a raspi where we do not support graphical
unset DISPLAY
fi
if [ x$DISPLAY != x ] ; then
# we have DISPLAY, do the graphic thing
need python3-tk
need python3.8-venv
mkdir -p ~/ex-installer/venv
python3 -m venv ~/ex-installer/venv
cd ~/ex-installer/venv || exit 255
source ./bin/activate
git clone https://github.com/DCC-EX/EX-Installer
cd EX-Installer || exit 255
pip3 install -r requirements.txt
exec python3 -m ex_installer
fi
if test -d `basename "$DCCEXGITURL"` ; then
: assume we are almost there
cd `basename "$DCCEXGITURL"` || exit 255

5
version.h
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@ -3,8 +3,9 @@
#include "StringFormatter.h"
#define VERSION "4.2.62"
#define VERSION "4.2.63"
// 4.2.63 - completely new overcurrent detection
// - ESP32 protect from race in RMT code
// 4.2.62 - Update IO_RotaryEncoder.h to ignore sending current position
// - Update IO_EXTurntable.h to remove forced I2C clock speed
// - Show device offline if EX-Turntable not connected