Version 1.3.0.5: break sensor debounce (10 msec default). temperature spikes ignored in heating control. thread winding improved.

4 files changed, 58 insertions, 42 deletions

diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c
index 2b6d3aaea..6915cc657 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c
@@ -180,7 +180,7 @@ double WinderReferenceSpeed=0;
 int32_t  TotalWinderSpeed=0;
 uint32_t Screw100msecDirectionChange(uint32_t deviceID, uint32_t BusyFlag)
 {
-    uint32_t Steps,i;
+    uint32_t Steps;
     double temp;
     double screw_horizontal_speed = 0;
     double RotationsPerSecond;
@@ -232,6 +232,7 @@ uint32_t Screw100msecDirectionChange(uint32_t deviceID, uint32_t BusyFlag)
     }
     screw_horizontal_speed = ScrewNumberOfSteps /  InternalWinderCfg.NumberOfRotationPerPassage;
     RotationsPerSecond =  WinderReferenceSpeed / (double)MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_WINDER].pulseperround;
+    ROM_IntMasterDisable();
     ScrewSpeed = screw_horizontal_speed*RotationsPerSecond;
     CurrentControlledSpeed[SCREW_MOTOR] = ScrewSpeed;
     temp = SYS_CLK_FREQ;
@@ -239,6 +240,8 @@ uint32_t Screw100msecDirectionChange(uint32_t deviceID, uint32_t BusyFlag)
     temp /= ScrewSpeed;
     if (ScrewRunningTime != temp)
     {
+        ScrewRunningTime = temp;//(SYS_CLK_FREQ*Steps)/ScrewSpeed;
+        ROM_IntMasterEnable();
         //usnprintf(TempScrewStr, 100, "Winder: Horizon,Rotation, PPR, RPP{ %d, %d ,%d, %d} ",(int)screw_horizontal_speed,(int)RotationsPerSecond,(int)InternalWinderCfg.NumberOfRotationPerPassage,(int)MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_WINDER].pulseperround);
         usnprintf(ScrewStr, 100, "Winder: Steps,Speed, Time, WinderSpeed{ %d, %d ,%d, %d} ",(int)ScrewNumberOfSteps,(int)ScrewSpeed,(int)temp,(int)WinderReferenceSpeed);
         //        Report(logmsg[index],__FILE__,__LINE__,index,RpWarning,index,  Counter[index]);
@@ -248,9 +251,9 @@ uint32_t Screw100msecDirectionChange(uint32_t deviceID, uint32_t BusyFlag)
         //REPORT_MSG(temp , "new winder speed");
         //Report("new winder speed",__FILE__,__LINE__,temp,RpWarning,ScrewSpeed,0);
     }
-    ScrewRunningTime = temp;//(SYS_CLK_FREQ*Steps)/ScrewSpeed;
 
     /********************************************************************************/
+    ROM_IntMasterEnable();
     return OK;
 
 }
@@ -409,7 +412,7 @@ void ScrewTimerInterrupt(int ARG0)
     {
         TimerDisable(Screw_timerBase, TIMER_A);
     }
-    //Report("ScrewTimerInterrupt dir, duration, speed", __FILE__,ScrewCurrentDirection,ScrewRunningTime, RpMessage, ScrewSpeed, 0);
+    Report("ScrewTimerInterrupt dir, duration, speed", __FILE__,ScrewCurrentDirection,ScrewRunningTime, RpMessage, ScrewSpeed, 0);
     //
     // Enable all interrupts.
     //
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h
index c5e3edc85..34be77177 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h
@@ -29,7 +29,7 @@ uint32_t ThreadConfigBreakSensor(void *request);
 uint32_t ThreadGetMotorSpeed(threadMotorsEnum MotorId);
 double ThreadGetMotorCalculatedError(int DancerId);
 uint32_t ThreadPrepareState(void *JobDetails);
-uint32_t ThreadPreSegmentState(void *JobDetails);
+uint32_t ThreadPreSegmentState(void *JobDetails, uint32_t SegmentId);
 uint32_t ThreadSegmentState(void *JobDetails, int SegmentId);
 uint32_t ThreadDistanceToSpoolState(void);
 uint32_t ThreadEndState(void *JobDetails);
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c
index 41daa4002..f641737ee 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c
@@ -21,8 +21,10 @@ double NormalizedErrorCoEfficient[MAX_THREAD_MOTORS_NUM] = {0};
 int DancerStopActivityLimit[MAX_THREAD_MOTORS_NUM] = {0};
 HardwareDancer DancersCfg[MAX_SYSTEM_DANCERS] = {0};
 
+#define BREAK_SENSOR_LIMIT 10
+
 bool BreakSensorenabled;
-int32_t BreakSensordebouncetimemilli;
+int32_t BreakSensordebouncetimemilli = BREAK_SENSOR_LIMIT;
 
 HardwarePidControlType ThreadMotorIdToControlId[MAX_THREAD_MOTORS_NUM] = {HARDWARE_PID_CONTROL_TYPE__MotorFeeder,HARDWARE_PID_CONTROL_TYPE__MotorDryer,HARDWARE_PID_CONTROL_TYPE__MotorPooler,HARDWARE_PID_CONTROL_TYPE__MotorWinder,0};
 
@@ -116,7 +118,10 @@ uint32_t ThreadConfigBreakSensor(void *request)
     if (SensorCfg)
     {
         BreakSensorenabled = SensorCfg->enabled;
-        BreakSensordebouncetimemilli = SensorCfg->debouncetimemilli;
+        if (SensorCfg->debouncetimemilli)
+        {
+            BreakSensordebouncetimemilli = SensorCfg->debouncetimemilli;
+        }
         return OK;
     }
     return ERROR;
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
index 0e0a9f987..72391e3a9 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
@@ -355,6 +355,8 @@ void testDancersControl()
 bool dancerinvalid = false;
 int MotorFailedSample[MAX_THREAD_MOTORS_NUM] = {0,0,0,0,0};
 char Message[60];
+uint16_t BreakSensorCounter = 0;
+uint16_t BreakSensorLatchCounter = 0;
 uint32_t ThreadControlCBFunction(uint32_t IfIndex, uint32_t ReadValue)
 {
 //#define MAX_CONTROL_SAMPLES 6
@@ -425,16 +427,29 @@ uint32_t ThreadControlCBFunction(uint32_t IfIndex, uint32_t ReadValue)
                 {
                     if (ReadBreakSensor()==ERROR)
                     {
-                        //consider applying the debouce parameters later
-                        //BreakSensordebouncetimemilli
-                        JobEndReason = JOB_THREAD_BREAK;
-                        ThreadControlActive = false;
-                        SendJobProgress(0.0,0,false, "ReadBreakSensor Error");
-                        SegmentReady(Module_Thread,ModuleFail);
-                        AlarmHandlingSetAlarm(EVENT_TYPE__ThreadBreak,true);
-                        //EndState(CurrentJob,"ReadBreakSensor Error" );
-                        LOG_ERROR(index, "ReadBreakSensor Error");
-                        return OK;
+                        BreakSensorCounter++;
+                        BreakSensorLatchCounter++;
+                        if (BreakSensorCounter>=BreakSensordebouncetimemilli)
+                        {
+                            //consider applying the debouce parameters later
+                            //BreakSensordebouncetimemilli
+                            JobEndReason = JOB_THREAD_BREAK;
+                            ThreadControlActive = false;
+                            SendJobProgress(0.0,0,false, "ReadBreakSensor Error");
+                            SegmentReady(Module_Thread,ModuleFail);
+                            AlarmHandlingSetAlarm(EVENT_TYPE__ThreadBreak,true);
+                            //EndState(CurrentJob,"ReadBreakSensor Error" );
+                            LOG_ERROR(index, "ReadBreakSensor Error");
+                            return OK;
+                        } //passed limit
+                    }//ReadBreakSensor()==ERROR
+                    else //reset counter - we are looking for consequent calls
+                    {
+                        if (BreakSensorCounter)
+                        {
+                            LOG_ERROR(BreakSensorCounter, "ReadBreakSensor Spike");
+                        }
+                        BreakSensorCounter = 0;
                     }
                 }
             }
@@ -525,7 +540,7 @@ uint32_t ThreadInitialTestStub(HardwareMotor * request)
 
     //MotorsConfigMessage(request);
      ThreadPrepareState(request);
-     ThreadPreSegmentState(request);
+     ThreadPreSegmentState(request,0);
     return OK;
 }
 bool InitialProcess = false;
@@ -659,7 +674,7 @@ void SetOriginMotorSpeed(float process_speed)
 }
 
 //********************************************************************************************************************
-uint32_t ThreadPreSegmentState(void *JobDetails)
+uint32_t ThreadPreSegmentState(void *JobDetails, uint32_t SegmentId)
 {
 //set the speed only before the first segment, speed is constant across all job segments and intersegments
     JobTicket* JobTicket = JobDetails;
@@ -671,32 +686,25 @@ uint32_t ThreadPreSegmentState(void *JobDetails)
         return ERROR;
     }
     REPORT_MSG (dyeingspeed," ThreadPreSegmentState");
-
-    SetOriginMotorSpeed(process_speed);
-    ThreadControlActive = true;
-    PrepareState = false;
-    // set the new speed in the dryer motor to the speed of the new segment
-    MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_DRYER_DRIVING, OriginalMotorSpd_2PPS[DRYER_MOTOR]);
- //only for testing - when control works, these motors will take their speed from the dryer
-    //MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_LDRIVING, OriginalMotorSpd_2PPS[POOLER_MOTOR]);
- //only for testing - when control works, these motors will take their speed from the dryer
-    //MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_RDRIVING, OriginalMotorSpd_2PPS[FEEDER_MOTOR]);
-
-//#warning rocker disabled
-    if (MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_RLOADING].maxfrequency > 0)
+    if (SegmentId == 0) // do all this only in the beginning of the job. do not touch after that (assuming spool does not change mid job)
     {
-        MotorSetDirection((TimerMotors_t)HARDWARE_MOTOR_TYPE__MOTO_RLOADING,MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_RLOADING].directionthreadwize);
-        MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_RLOADING, 1);
-    }
-    if (MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_LLOADING].maxfrequency > 0)
-    {
-        MotorSetDirection((TimerMotors_t)HARDWARE_MOTOR_TYPE__MOTO_LLOADING,MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_LLOADING].directionthreadwize);
-        MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_LLOADING, 1);
-    }
-// #warning rocker disabled
-
-//    MotorMovetoLimitSwitch (HARDWARE_MOTOR_TYPE__MOTO_RDRIVING,MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_RDRIVING].directionthreadwize, 0, GPI_LS_RLOADMOTOR_UP, EndState); //TODO
+        SetOriginMotorSpeed(process_speed);
+        ThreadControlActive = true;
+        PrepareState = false;
+        // set the new speed in the dryer motor to the speed of the new segment
+        MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_DRYER_DRIVING, OriginalMotorSpd_2PPS[DRYER_MOTOR]);
 
+        if (MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_RLOADING].maxfrequency > 0)
+        {
+            MotorSetDirection((TimerMotors_t)HARDWARE_MOTOR_TYPE__MOTO_RLOADING,MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_RLOADING].directionthreadwize);
+            MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_RLOADING, 1);
+        }
+        if (MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_LLOADING].maxfrequency > 0)
+        {
+            MotorSetDirection((TimerMotors_t)HARDWARE_MOTOR_TYPE__MOTO_LLOADING,MotorsCfg[HARDWARE_MOTOR_TYPE__MOTO_LLOADING].directionthreadwize);
+            MotorSetSpeed(HARDWARE_MOTOR_TYPE__MOTO_LLOADING, 1);
+        }
+    }
     // activate control fr all motors
     //set speed for both rocker motors
     //wait for all motors to get to the required speed (set the target speed for the control to check)