Version 1.4.6.35 - Pack Mid alpha

============================
Arc head - activate arc heaters gradually
stop FPGA Reinit after 20 trials
Head cleaning - move actuators (with stub - 0xAD7)
fix RML PID support
head open prevent job - (with stub - 0xAD6)
add stub to overrule cone missing - 0xAD8

6 files changed, 105 insertions, 92 deletions

diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread.h b/Software/Embedded_SW/Embedded/Modules/Thread/Thread.h
index d1d23598f..3a7045a6e 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread.h
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread.h
@@ -76,7 +76,6 @@ extern int MotorSpeedSamplePointer[MAX_THREAD_MOTORS_NUM];
 uint32_t InternalWinderConfigMessage(HardwareWinder* request);
 uint32_t MotorsConfigMessage( HardwareConfiguration* HW_request);
 uint32_t InternalWindingConfigMessage(JobSpool* request);
-uint32_t ThreadInitialTestStub(HardwareMotor * request);
 uint32_t MotorPidRequestMessage(HardwarePidControl* request);
 void     SetKeepWindingCone(bool value);
 void SetWinderBackToBaseTime(uint32_t value);
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c b/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c
index 2b65ca806..f5bc45d85 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c
@@ -204,6 +204,7 @@
             strcpy(LoadErrorMsg,"Thread_Load_Reduce_Heat failed");
             LoadStatus = ERROR;
             TryAgain = true;
+            //ThreadLoadButton(LoadStages);
         }
         else
         {
@@ -300,6 +301,7 @@
                     LoadStatus = ERROR;
                     ThreadLoadingReport();
                     TryAgain = true;
+                    //ThreadLoadButton(LoadStages);
                 }
                 else
                 {
@@ -544,6 +546,7 @@
                 LoadStatus = ERROR;
                 ThreadLoadingReport();
                 TryAgain = true;
+                //ThreadLoadButton(LoadStages);
             }
         }
 
@@ -647,6 +650,7 @@
             Report("Total Feeder load",__FILE__,__LINE__,dryerbufferCentimeters,RpMessage,TotalLoadedLen,0);
 
             ThreadLoadingReport();
+            //ThreadLoadButton(LoadStages);
         }
         return OK;
     }
@@ -857,6 +861,7 @@
             LoadStatus = ERROR;
             TryAgain = true;
             ThreadLoadingReport();
+            //ThreadLoadButton(LoadStages);
         }
         return OK;
     }
@@ -971,7 +976,7 @@
     uint32_t ThreadLoadStateMachine( THREAD_LOAD_STAGES_ENUM ReadValue)
     {
         REPORT_MSG(ReadValue,"ThreadLoadStateMachine");
-        ThreadLoaded();
+        //ThreadLoaded();
         ThreadLoadingReport();
 
         if (LoadStages!=ReadValue)
@@ -1089,7 +1094,7 @@ uint32_t ThreadLoadButton(THREAD_LOAD_STAGES_ENUM ReadValue)
             Report("Calling State machine",__FILE__,LoadStages,LoadStatus,RpMessage,SecondTry,0);
             ThreadLoadStateMachine(LoadStages);
         }
-        else
+        else if (SecondTry == true)
         {
             SecondTry = false;
             Report("Calling State machine",__FILE__,LoadStages,LoadStatus,RpMessage,SecondTry,0);
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c
index 80ca05cb7..92b953db5 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_Winder.c
@@ -54,7 +54,7 @@ double   ScrewRunningTime = 0;
 uint32_t ScrewNumberOfSteps = 0;     //holds the current number of steps for the next screw run - will be used to build the cone
 bool     SCREW_TimerActivated = false;
 uint32_t ScrewControlId = 0xFF;
-
+bool IgnoreConeMissing = false;
 
 
 static bool KeepWindingCone = false;
@@ -156,10 +156,13 @@ uint32_t Winder_Prepare(void *JobDetails)
         REPORT_MSG(LIMIT, "No cone in winder");
         if (Is_PP_Machine())
         {
-            JobEndReason = JOB_THREAD_BREAK;
-            PrepareReady(Module_Winder,ModuleFail);
-            AlarmHandlingSetAlarm(EVENT_TYPE__WINDER_CONE_DOES_NOT_EXIST,true);
-            return ERROR;
+            if (IgnoreConeMissing == false)
+            {
+                JobEndReason = JOB_THREAD_BREAK;
+                PrepareReady(Module_Winder,ModuleFail);
+                AlarmHandlingSetAlarm(EVENT_TYPE__WINDER_CONE_DOES_NOT_EXIST,true);
+                return ERROR;
+            }
         }
     }
 
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h
index 4081b53f2..4339c5312 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_ex.h
@@ -24,6 +24,7 @@ typedef enum threadMotorsEnum
 extern double TotalProcessedLength;
 extern double PoolerTotalProcessedLength;
 extern int SecondFeederCorrection;
+extern bool SkipOpenLids,IgnoreConeMissing;
 
 void ThreadSetBreakSensorLimit(int limit);
 
@@ -37,7 +38,6 @@ uint32_t ThreadPreSegmentState(void *SegmentDetails, uint32_t SegmentId);
 uint32_t ThreadSegmentState(void *SegmentDetails, int SegmentId);
 uint32_t ThreadDistanceToSpoolState(void);
 uint32_t ThreadEndState();
-uint32_t ThreadInitialTestStub();
 
 bool Set_Thread_Rockers_Bypass (int value);
 
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c
index 760a0726b..e1f887303 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_init.c
@@ -112,8 +112,6 @@ uint32_t MotorsConfigMessage(HardwareConfiguration * HWrequest)
             {
                 IDS_Dispenser_Init(Motor_i-HARDWARE_MOTOR_TYPE__MOTO_DISPENSER_1);
             }
-//        if (Motor_i == MOTOR_RDRIVING)
-//            ThreadInitialTestStub(request);
     }
         return status;
 
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
index d762e507f..42a56ae8a 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
@@ -423,7 +423,67 @@ uint32_t ThreadControlSpeedReadFunction(uint32_t IfIndex, uint32_t ReadValue)
     }
     return OK;
 }
+uint16_t BreakSensorCounter = 0;
+uint16_t BreakSensorLatchCounter = 0;
+char TMessage[150];
 
+uint32_t checkBreakSensor(uint32_t index)
+{
+    if (BreakSensorenabled == true)
+    {
+        if (JobCounter > eOneSecond)
+        {
+            if (ReadBreakSensor()==ERROR)
+            {
+                BreakSensorCounter++;
+                BreakSensorLatchCounter++;
+                if (BreakSensorCounter>=BreakSensordebouncetimemilli)
+                {
+                    //consider applying the debouce parameters later
+                    usnprintf(TMessage, 60, "ReadBreakSensor Error");
+                    //BreakSensordebouncetimemilli
+                    JobEndReason = JOB_THREAD_BREAK;
+                    ThreadControlActive = false;
+                    SendJobProgress(0.0,0,false, TMessage);
+                    SendSegmentFail();
+                    //AlarmHandlingSetAlarm(EVENT_TYPE__THREAD_BREAK,true);
+                    //EndState(CurrentJob,"ReadBreakSensor Error" );
+                    ReportWithPackageFilter(ThreadFilter,"ReadBreakSensor Error",__FILE__,BreakSensorCounter,(int)index,RpError,(int)JobCounter,0);
+                    return ERROR;
+                } //passed limit
+            }//ReadBreakSensor()==ERROR
+            else //reset counter - we are looking for consequent calls
+            {
+                if (BreakSensorCounter)
+                {
+                    ReportWithPackageFilter(ThreadFilter,"ReadBreakSensor Spike",__FILE__,BreakSensorCounter,(int)index,RpError,(int)JobCounter,0);
+                }
+                BreakSensorCounter = 0;
+            }
+            if (CurrentControlledSpeed[index] < (OriginalMotorSpd_2PPS[index]/3))
+            {
+                BreakSensorCounter++;
+                BreakSensorLatchCounter++;
+                if (BreakSensorCounter>=BreakSensordebouncetimemilli)
+                {
+                    //consider applying the debouce parameters later
+                    usnprintf(TMessage, 60, "thread speed too low");
+                    JobEndReason = JOB_THREAD_BREAK;
+                    ThreadControlActive = false;
+                    SendJobProgress(0.0,0,false, TMessage);
+                    SendSegmentFail();
+                    //AlarmHandlingSetAlarm(EVENT_TYPE__THREAD_BREAK,true);
+                    //EndState(CurrentJob,"ReadBreakSensor Error" );
+                    ReportWithPackageFilter(ThreadFilter,"thread speed too low Error",__FILE__,BreakSensorCounter,(int)index,RpError,(int)JobCounter,0);
+                    return ERROR;
+                }
+            }
+
+        }
+    }
+    return OK;
+
+}
 int controlIndex = 0;
 bool keepdata = true;
 int32_t KeepReadValue = 0;
@@ -477,10 +537,7 @@ void testDancersControl()
 }
 #endif
 int MotorFailedSample[MAX_THREAD_MOTORS_NUM] = {0,0,0,0,0};
-char TMessage[150];
 //char time[150];
-uint16_t BreakSensorCounter = 0;
-uint16_t BreakSensorLatchCounter = 0;
 bool FirstCalcInJob = true;
 uint32_t ThreadControlCBFunction(uint32_t IfIndex, uint32_t ReadValue)
 {
@@ -510,6 +567,11 @@ uint32_t ThreadControlCBFunction(uint32_t IfIndex, uint32_t ReadValue)
     }
     index = IfIndex&0xFF;
 
+    if (index == POOLER_MOTOR) //move break sensor handling up to ensure handling even if tiing control is > 1 msec
+    {
+        if (checkBreakSensor(index) == ERROR)
+            return OK;
+    }
     if (MotorTiming[index]>1)
     {
         MotorTimer[index]++;
@@ -571,61 +633,6 @@ uint32_t ThreadControlCBFunction(uint32_t IfIndex, uint32_t ReadValue)
             avreageSampleValue += MotorSamples[index][i];
         avreageSampleValue = avreageSampleValue / (int)MotorsControl[index].pvinputfilterfactormode;
 
-        if (BreakSensorenabled == true)
-        {
-            if (index == POOLER_MOTOR)
-            {
-                if (JobCounter > eOneSecond)
-                {
-                    if (ReadBreakSensor()==ERROR)
-                    {
-                        BreakSensorCounter++;
-                        BreakSensorLatchCounter++;
-                        if (BreakSensorCounter>=BreakSensordebouncetimemilli)
-                        {
-                            //consider applying the debouce parameters later
-                            usnprintf(TMessage, 60, "ReadBreakSensor Error");
-                            //BreakSensordebouncetimemilli
-                            JobEndReason = JOB_THREAD_BREAK;
-                            ThreadControlActive = false;
-                            SendJobProgress(0.0,0,false, TMessage);
-                            SendSegmentFail();
-                            //AlarmHandlingSetAlarm(EVENT_TYPE__THREAD_BREAK,true);
-                            //EndState(CurrentJob,"ReadBreakSensor Error" );
-                            ReportWithPackageFilter(ThreadFilter,"ReadBreakSensor Error",__FILE__,BreakSensorCounter,(int)index,RpError,(int)JobCounter,0);
-                            return OK;
-                        } //passed limit
-                    }//ReadBreakSensor()==ERROR
-                    else //reset counter - we are looking for consequent calls
-                    {
-                        if (BreakSensorCounter)
-                        {
-                            ReportWithPackageFilter(ThreadFilter,"ReadBreakSensor Spike",__FILE__,BreakSensorCounter,(int)index,RpError,(int)JobCounter,0);
-                        }
-                        BreakSensorCounter = 0;
-                    }
-                    if (CurrentControlledSpeed[index] < (OriginalMotorSpd_2PPS[index]/3))
-                    {
-                        BreakSensorCounter++;
-                        BreakSensorLatchCounter++;
-                        if (BreakSensorCounter>=BreakSensordebouncetimemilli)
-                        {
-	                        //consider applying the debouce parameters later
-	                        usnprintf(TMessage, 60, "thread speed too low");
-	                        JobEndReason = JOB_THREAD_BREAK;
-	                        ThreadControlActive = false;
-	                        SendJobProgress(0.0,0,false, TMessage);
-	                        SendSegmentFail();
-	                        //AlarmHandlingSetAlarm(EVENT_TYPE__THREAD_BREAK,true);
-	                        //EndState(CurrentJob,"ReadBreakSensor Error" );
-                            ReportWithPackageFilter(ThreadFilter,"thread speed too low Error",__FILE__,BreakSensorCounter,(int)index,RpError,(int)JobCounter,0);
-	                        return OK;
-						}
-                    }
-
-                }
-            }
-        }
 
         //Stop Execution if the dancer moves too much
         if ((abs(avreageSampleValue)> DancerStopActivityLimit[index])&&(JobCounter > eOneSecond))
@@ -783,15 +790,6 @@ double ThreadGetMotorCalculatedError(int DancerId)
 }
 
 //********************************************************************************************************************
-uint32_t ThreadInitialTestStub(HardwareMotor * request)
-{
-
-
-    //MotorsConfigMessage(request);
-     ThreadPrepareState(request);
-     ThreadPreSegmentState(request,0);
-    return OK;
-}
 uint32_t HandleJobThreadControlParameters(ThreadParameters* ThreadParams)
 {
     if (ThreadParams == NULL)
@@ -799,21 +797,21 @@ uint32_t HandleJobThreadControlParameters(ThreadParameters* ThreadParams)
         return OK;
     }
     if(ThreadParams->feederp)
-        MotorControlConfig[FEEDER_MOTOR].m_params.Kd = ThreadParams->feederp;
+        MotorControlConfig[FEEDER_MOTOR].m_params.Kp = ThreadParams->feederp;
     if(ThreadParams->feederi)
         MotorControlConfig[FEEDER_MOTOR].m_params.Ki = ThreadParams->feederi;
     if(ThreadParams->feederd)
         MotorControlConfig[FEEDER_MOTOR].m_params.Kd = ThreadParams->feederd;
 
     if(ThreadParams->pullerp)
-        MotorControlConfig[POOLER_MOTOR].m_params.Kd = ThreadParams->pullerp;
+        MotorControlConfig[POOLER_MOTOR].m_params.Kp = ThreadParams->pullerp;
     if(ThreadParams->pulleri)
         MotorControlConfig[POOLER_MOTOR].m_params.Ki = ThreadParams->pulleri;
     if(ThreadParams->pullerd)
         MotorControlConfig[POOLER_MOTOR].m_params.Kd = ThreadParams->pullerd;
 
     if(ThreadParams->winderp)
-        MotorControlConfig[WINDER_MOTOR].m_params.Kd = ThreadParams->winderp;
+        MotorControlConfig[WINDER_MOTOR].m_params.Kp = ThreadParams->winderp;
     if(ThreadParams->winderi)
         MotorControlConfig[WINDER_MOTOR].m_params.Ki = ThreadParams->winderi;
     if(ThreadParams->winderd)
@@ -951,7 +949,8 @@ uint32_t ThreadPrepare_Tension (int DancerId, double tension)
     return status;
 }
 //********************************************************************************************************************
- uint32_t ThreadPrepareState(void *JobDetails)
+bool SkipOpenLids = true;
+uint32_t ThreadPrepareState(void *JobDetails)
 {
     int Motor_i,i, HW_Motor_Id, Pid_Id;
     JobTicket* JobTicket = JobDetails;
@@ -1016,22 +1015,30 @@ uint32_t ThreadPrepare_Tension (int DancerId, double tension)
         //return ERROR;
     }*/
 
-    if ((FPGA_Read_limit_Switches(Motor_Id_to_LS_IdUp[HARDWARE_MOTOR_TYPE__MOTO_DH_LID]) == LIMIT)&&(JoggingJobActive == false))
+//    if ((FPGA_Read_limit_Switches(Motor_Id_to_LS_IdUp[HARDWARE_MOTOR_TYPE__MOTO_DH_LID]) == LIMIT)&&(JoggingJobActive == false))
+    if ((FPGA_Read_limit_Switches(Motor_Id_to_LS_IdDown[HARDWARE_MOTOR_TYPE__MOTO_DH_LID]) != LIMIT)&&(JoggingJobActive == false))
     {
         if(Head_Type != HEAD_TYPE_STAPLE_SPUN)
         {
             ReportWithPackageFilter(ThreadFilter,"Dyeing head is wide open!!!",__FILE__,__LINE__,HARDWARE_MOTOR_TYPE__MOTO_DH_LID,RpError,LIMIT,0);
-            JobEndReason = JOB_LIDS_OPEN;
-            PrepareReady(Module_Thread,ModuleFail);
-            return ERROR;
+            if (SkipOpenLids == false)
+            {
+                JobEndReason = JOB_LIDS_OPEN;
+                PrepareReady(Module_Thread,ModuleFail);
+                return ERROR;
+            }
         }
     }
-    if ((FPGA_Read_limit_Switches(Motor_Id_to_LS_IdUp[HARDWARE_MOTOR_TYPE__MOTO_DRYER_LID]) == LIMIT)&&(JoggingJobActive == false))
+//    if ((FPGA_Read_limit_Switches(Motor_Id_to_LS_IdUp[HARDWARE_MOTOR_TYPE__MOTO_DRYER_LID]) == LIMIT)&&(JoggingJobActive == false))
+    if ((FPGA_Read_limit_Switches(Motor_Id_to_LS_IdDown[HARDWARE_MOTOR_TYPE__MOTO_DRYER_LID]) != LIMIT)&&(JoggingJobActive == false))
     {
         ReportWithPackageFilter(ThreadFilter,"Dryer lid is wide open!!!",__FILE__,__LINE__,HARDWARE_MOTOR_TYPE__MOTO_DRYER_LID,RpError,LIMIT,0);
-        JobEndReason = JOB_LIDS_OPEN;
-        PrepareReady(Module_Thread,ModuleFail);
-        return ERROR;
+        if (SkipOpenLids == false)
+        {
+            JobEndReason = JOB_LIDS_OPEN;
+            PrepareReady(Module_Thread,ModuleFail);
+            return ERROR;
+        }
     }
 
     //start thread control for all motors
@@ -1057,6 +1064,8 @@ uint32_t ThreadPrepare_Tension (int DancerId, double tension)
             MotorControlConfig[Motor_i].m_preError = 0;
             MotorControlConfig[Motor_i].m_SetParam = 0;//need to update SetParams on presegment stage
 
+		    HandleJobThreadControlParameters(JobTicket->threadparameters);  //OVERRIDES CONFIGURATION PARAMETERS!!!
+
             temp_dt = MotorControlConfig[Motor_i].m_params.dt/0.001;
             MotorTiming[Motor_i] = (int)temp_dt;
             if (MotorTiming[Motor_i])
@@ -1068,7 +1077,7 @@ uint32_t ThreadPrepare_Tension (int DancerId, double tension)
             for (i = 0;i < (int)MotorsControl[Motor_i].pvinputfilterfactormode; i++)
             {
                 //if (Motor_i == DRYER_MOTOR) // dryer motor is speed controlled. later a speed sensor will be utilized, but for now it will not be controlled
-                    MotorSamples[Motor_i][i] = Control_Read_Dancer_Position(ThreadMotorIdToDancerId[Motor_i],0);  //reset the samples value for control beginning
+                    MotorSamples[Motor_i][i] = 0;
                // else if ((Motor_i == POOLER_MOTOR)||(Motor_i == FEEDER_MOTOR))
                 //    MotorSamples[Motor_i][i] = DancersCfg[ThreadMotorIdToDancerId[Motor_i]].zeropoint;
                 //MotorSpeedSamples[Motor_i][i] = 0;
@@ -1148,7 +1157,6 @@ uint32_t ThreadPrepare_Tension (int DancerId, double tension)
             if (Motor_i == ThreadMotorIdToMotorId[DRYER_MOTOR]) // dryer motor is speed controlled. later a speed sensor will be utilized, but for now it will not be controlled
                 continue;
     }
-    HandleJobThreadControlParameters(JobTicket->threadparameters);  //OVERRIDES CONFIGURATION PARAMETERS!!!
 
 #ifdef TEST_PID_THREAD
     testDancersControl();