version

DCCEXParser.cpp

@@ -467,7 +467,7 @@ void DCCEXParser::parseOne(Print *stream, byte *com, RingStream * ringStream)
         bool prog=false;
         bool join=false;
         if (params > 1) break;
-        if (params==0 || MotorDriver::commonFaultPin) { // <1> or tracks can not be handled individually
+        if (params==0) { // All
             main=true;
             prog=true;
         }
@@ -500,7 +500,7 @@ void DCCEXParser::parseOne(Print *stream, byte *com, RingStream * ringStream)
         bool main=false;
         bool prog=false;
         if (params > 1) break;
-        if (params==0 || MotorDriver::commonFaultPin) { // <0> or tracks can not be handled individually
+        if (params==0) { // All
 	  main=true;
 	  prog=true;
         }

GITHUB_SHA.h

@@ -1 +1 @@
-#define GITHUB_SHA "devel-202306182208Z"
+#define GITHUB_SHA "devel-202306210849Z"

MotorDriver.cpp

@@ -27,7 +27,7 @@
 #include "DCCTimer.h"
 #include "DIAG.h"
 
-bool MotorDriver::commonFaultPin=false;
+unsigned long MotorDriver::globalOverloadStart = 0;
 
 volatile portreg_t shadowPORTA;
 volatile portreg_t shadowPORTB;
@@ -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 +369,112 @@ 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;
+	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
+	// We have a fault pin condition to take care of
-	  lastCurrent = -lastCurrent;
+	if (!overloadNow) {
-	  setPower(POWERMODE::OVERLOAD); // Turn off, decide later how fast to turn on again
+	  // turn on overload condition as fault pin has gone active
-	  if (commonFaultPin) {
+	  // DIAG(F("OVERLOAD FPIN ON"));
-	      if (lastCurrent < tripValue) {
+	  overloadNow=true;
-		      setPower(POWERMODE::ON); // maybe other track
+	  setLastPowerChangeOverload();
-	      }
+	}
-	      // Write this after the fact as we want to turn on as fast as possible
+	lastCurrent = -lastCurrent;
-	      // because we don't know which output actually triggered the fault pin
+	{
-	      DIAG(F("COMMON FAULT PIN ACTIVE: POWERTOGGLE TRACK %c"), trackno + 'A');
+	  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 {
-	    DIAG(F("TRACK %c FAULT PIN ACTIVE - OVERLOAD"), trackno + 'A');
+	    if (power_sample_overload_wait <= POWER_SAMPLE_OVERLOAD_WAIT &&   // virgin
-	      if (lastCurrent < tripValue) {
+		microsSinceLastPowerChange() < POWER_SAMPLE_IGNORE_FAULT_HIGH) {
-		  lastCurrent = tripValue; // exaggerate
+              // 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');
+	}
       }
-      if (lastCurrent < tripValue) {
+      // // //
-        sampleDelay = POWER_SAMPLE_ON_WAIT;
+      // above we looked at fault pin, below we look at current
-	if(power_good_counter<100)
+      // // //
-	  power_good_counter++;
+      if (lastCurrent < tripValue) { // see above (*)
-	else
+	if (overloadNow) {
-	  if (power_sample_overload_wait>POWER_SAMPLE_OVERLOAD_WAIT) power_sample_overload_wait=POWER_SAMPLE_OVERLOAD_WAIT;
+	  // 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;
+	}
       } else {
-        setPower(POWERMODE::OVERLOAD);
+	// too much current
-        unsigned int mA=raw2mA(lastCurrent);
+	if (!overloadNow) {
-        unsigned int maxmA=raw2mA(tripValue);
+	  // current is over trip value, turn on overload condition
-	      power_good_counter=0;
+	  // DIAG(F("OVERLOAD PON ON"));
-        sampleDelay = power_sample_overload_wait;
+	  overloadNow=true;
-        DIAG(F("TRACK %c POWER OVERLOAD %dmA (limit %dmA) shutdown for %dms"), trackno + 'A', mA, maxmA, sampleDelay);
+	  setLastPowerChange();
-	if (power_sample_overload_wait >= 10000)
+	}
-	    power_sample_overload_wait = 10000;
+	unsigned long uSecs = microsSinceLastPowerChange();
-	else
+	if (power_sample_overload_wait > POWER_SAMPLE_OVERLOAD_WAIT ||    // not virgin
-	    power_sample_overload_wait *= 2;
+	    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);
+	}
       }
       break;
-    case POWERMODE::OVERLOAD:
+  case POWERMODE::OVERLOAD:
-      // Try setting it back on after the OVERLOAD_WAIT
+  {
+    // Try setting it back on after the OVERLOAD_WAIT
+    unsigned long mslpc = (commonFaultPin ? (micros() - globalOverloadStart) : microsSinceLastPowerChange());
+    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);
-      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.
-      break;
+      overloadNow=false;
-    default:
+      setLastPowerChange();
-      sampleDelay = 999; // cant get here..meaningless statement to avoid compiler warning.
+      DIAG(F("TRACK %c POWER RESTORE (after %4M)"), trackno + 'A', mslpc);
+    }
+  }
+  break;
+  default:
+    break;
   }
 }

MotorDriver.h

@@ -175,7 +175,10 @@ class MotorDriver {
     bool isPWMCapable();
     bool canMeasureCurrent();
     bool trackPWM = false; // this track uses PWM timer to generate the DCC waveform
-    static bool commonFaultPin; // This is a stupid motor shield which has only a common fault pin for both outputs
+    bool commonFaultPin = false; // This is a stupid motor shield which has only a common fault pin for both outputs
+    inline byte setCommonFaultPin() {
+      return commonFaultPin = true;
+    }
     inline byte getFaultPin() {
 	return faultPin;
     }
@@ -186,6 +189,27 @@ 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;
+    };
+    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();
@@ -217,8 +241,10 @@ class MotorDriver {
     int rawCurrentTripValue;
     // current sampling
     POWERMODE powerMode;
-    unsigned long lastSampleTaken;
+    bool overloadNow = false;
-    unsigned int sampleDelay;
+    unsigned long lastPowerChange;            // timestamp in microseconds
+    // used to sync restore time when common Fault pin detected
+    static unsigned long globalOverloadStart; // timestamp in microseconds
     int progTripValue;
     int  lastCurrent;
 #ifdef ANALOG_READ_INTERRUPT
@@ -228,10 +254,19 @@ 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.

StringFormatter.cpp

@@ -117,6 +117,24 @@ void StringFormatter::send2(Print * stream,const FSH* format, va_list args) {
       case 'o': stream->print(va_arg(args, int), OCT); break;
       case 'x': stream->print((unsigned int)va_arg(args, unsigned int), HEX); break;
       case 'X': stream->print((unsigned long)va_arg(args, unsigned long), HEX); break;
+      case 'M':
+      { // this prints a unsigned long microseconds time in readable format
+	unsigned long time = va_arg(args, long);
+	if (time >= 2000) {
+	  time = time / 1000;
+	  if (time >= 2000) {
+	    printPadded(stream, time/1000, formatWidth, formatLeft);
+	    stream->print(F("sec"));
+	  } else {
+	    printPadded(stream,time, formatWidth, formatLeft);
+	    stream->print(F("msec"));
+	  }
+	} else {
+	  printPadded(stream,time, formatWidth, formatLeft);
+	  stream->print(F("usec"));
+	}
+      }
+      break;
       //case 'f': stream->print(va_arg(args, double), 2); break;
       //format width prefix
       case '-': 

TrackManager.cpp

@@ -123,9 +123,17 @@ void TrackManager::Setup(const FSH * shieldname,
     setTrackMode(1,TRACK_MODE_MAIN);
 #endif
   
-  // TODO Fault pin config for odd motor boards (example pololu)
+  // Fault pin config for odd motor boards (example pololu)
-  // MotorDriver::commonFaultPin = ((mainDriver->getFaultPin() == progDriver->getFaultPin())
+  FOR_EACH_TRACK(t) {
-  //				 && (mainDriver->getFaultPin() != UNUSED_PIN));
+    for (byte s=t+1;s<=lastTrack;s++) {
+      if (track[t]->getFaultPin() != UNUSED_PIN &&
+	  track[t]->getFaultPin() == track[s]->getFaultPin()) {
+	track[t]->setCommonFaultPin();
+	track[s]->setCommonFaultPin();
+	DIAG(F("Common Fault pin tracks %c and %c"), t+'A', s+'A');
+      }
+    }
+  }
   DCC::begin(shieldname);   
 }
 

version.h

@@ -4,7 +4,9 @@
 #include "StringFormatter.h"
 
 
-#define VERSION "4.2.56"
+#define VERSION "4.2.57"
+// 4.2.57 - New overload handling (faster and handles commonFaultPin again)
+//        - Optimize analog read STM32
 // 4.2.56 - Update IO_RotaryEncoder.h:
 //        - Improved I2C communication, non-blocking reads
 //        - Enable sending positions to the encoder from EXRAIL via SERVO()