Embedded SW Release note - Version 1.4.6.34 - Pack 2+

=============================================================
Validate IFS and cartridge location on manual waste handling - bug #3033
better handling of powerstep01 configuration and motors clocks
waste level: logs, fixed reading during waste filling,
fix PT100 reading in WHS                                                                                                                                                                                                 //important, OK
improve diespensers reading in I2C timing                                                                                                                                            //important OK
alarm handling: fix report (mid tank empty)
diagnostics - waste level in liters
Heating and process - avoid activating all heaters at once. tested for flat head.
Heating - remove alarms when colling dwn due to change of RML or idle mode
Thread - improve feeder tension handling
system: hold initalization process after 3 failures to enable code / parameters change and debugging

7 files changed, 78 insertions, 30 deletions

diff --git a/Software/Embedded_SW/Embedded/Modules/AlarmHandling/AlarmHandling.c b/Software/Embedded_SW/Embedded/Modules/AlarmHandling/AlarmHandling.c
index 356f192a3..1c2b6662d 100644
--- a/Software/Embedded_SW/Embedded/Modules/AlarmHandling/AlarmHandling.c
+++ b/Software/Embedded_SW/Embedded/Modules/AlarmHandling/AlarmHandling.c
@@ -652,6 +652,9 @@ JobEndReasonEnum getEndReason(uint32_t AlarmId)
                 usnprintf(AlarmReasonStr, 100, "Alarm %d type %d caused a job stop",AlarmId,AlarmItem[AlarmId].EventType);
                 return JOB_OTHER_ALARM;
             }
+        case ALARM_SOURCE_TYPE__FluidLevelAlarm:
+            usnprintf(AlarmReasonStr, 100, "Midtank %d is empty",AlarmItem[AlarmId].DeviceId);
+            return JOB_OUT_OF_DYE;
         default:
             usnprintf(AlarmReasonStr, 100, "Alarm %d type %d caused a job stop",AlarmId,AlarmItem[AlarmId].EventType);
             return JOB_OTHER_ALARM;
@@ -993,6 +996,8 @@ JobEndReasonEnum AlarmHandlingPrepareJob(void *CurrentJob)
     if (FoundReason != JOB_OK)
     {
         JobEndReason = getEndReason(AlarmId);
+        if (JobEndReason!=FoundReason)
+            ReportWithPackageFilter(AlarmFilter,"end reason mismatch!!!", __FILE__,AlarmId,JobEndReason, RpMessage, FoundReason, 0);
         //AbortJob(AlarmReasonStr);
         //PrepareReady(Module_Alarms,ModuleFail);
         ReportWithPackageFilter(AlarmFilter,AlarmReasonStr, __FILE__,__LINE__,AlarmId, RpMessage, DEBUG_LOG_CATEGORY__Error, 0);
diff --git a/Software/Embedded_SW/Embedded/Modules/Diagnostics/Diagnostics.c b/Software/Embedded_SW/Embedded/Modules/Diagnostics/Diagnostics.c
index 849d1cd9b..8e01fe18e 100644
--- a/Software/Embedded_SW/Embedded/Modules/Diagnostics/Diagnostics.c
+++ b/Software/Embedded_SW/Embedded/Modules/Diagnostics/Diagnostics.c
@@ -115,7 +115,7 @@ double dispenserinklevel[MAX_SYSTEM_DISPENSERS][1];
 double midtankinklevel[MAX_SYSTEM_DISPENSERS][1];
 double MidTankpressure[MAX_SYSTEM_DISPENSERS][1];
 double HeadFlowMeter;
-double tempFlow = 0.0;
+//double tempFlow = 0.0;
 double DrierFlowMeter;
 double AcVoltage;
 double WasteLevel = 0.0;
@@ -819,11 +819,11 @@ void DiagnosticOneMinuteCollection(void)
     DiagnosticsMonitor.dryerairflow = &DrierFlowMeter;
 
     HeadFlowMeter = GetWHSAirFlow(HEAD_FLOW_METER);
-    if (fabs(tempFlow - HeadFlowMeter)>0.05)
+    /*if (fabs(tempFlow - HeadFlowMeter)>0.05)
     {
         Report("Head flow change 1m",__FILE__,(int)diagvoltage,(int)(tempFlow*1000),RpWarning,(int)(HeadFlowMeter*1000),0);
         tempFlow = HeadFlowMeter;
-    }
+    }*/
     DiagnosticsMonitor.n_headairflow = 1;
     DiagnosticsMonitor.headairflow = &HeadFlowMeter;
 
@@ -858,11 +858,11 @@ void DiagnosticOneSecCollection(void)
         HeadFlowMeter = GetWHSAirFlow(HEAD_FLOW_METER);
         DiagnosticsMonitor.n_headairflow = 1;
         DiagnosticsMonitor.headairflow = &HeadFlowMeter;
-        if (fabs(tempFlow - HeadFlowMeter)>0.25)
+        /*if (fabs(tempFlow - HeadFlowMeter)>0.25)
         {
             Report("Head flow change 1s",__FILE__,(int)diagvoltage,(int)(tempFlow*1000),RpWarning,(int)(HeadFlowMeter*1000),0);
             tempFlow = HeadFlowMeter;
-        }
+        }*/
         WasteLevel = GetWHSWasteTankLevelMiliLiter()/1000;//change from ml to litter
         static double InitCounter = 0;
         if (GetMachineState()<MACHINE_STATE_NO_PROCESS_PARAMS)
diff --git a/Software/Embedded_SW/Embedded/Modules/General/process.c b/Software/Embedded_SW/Embedded/Modules/General/process.c
index 968522e48..bf7d761dd 100644
--- a/Software/Embedded_SW/Embedded/Modules/General/process.c
+++ b/Software/Embedded_SW/Embedded/Modules/General/process.c
@@ -200,6 +200,7 @@ uint32_t HandleProcessParameters(ProcessParameters* ProcessParams,bool saveData)
     }
     if(Head_Type != HEAD_TYPE_STAPLE_SPUN)
     {
+        Trigger_HeaterWriting();
         if (ProcessParams->headzone4temp>1)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ4, true,ProcessParams->headzone4temp);
@@ -239,6 +240,7 @@ uint32_t HandleProcessParameters(ProcessParameters* ProcessParams,bool saveData)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ7, false,ProcessParams->headzone7temp);
         }
+        Trigger_HeaterWriting();
         if (ProcessParams->headzone8temp>1)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ8, true,ProcessParams->headzone8temp);
@@ -263,6 +265,7 @@ uint32_t HandleProcessParameters(ProcessParameters* ProcessParams,bool saveData)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ10, false,ProcessParams->headzone10temp);
         }
+        Trigger_HeaterWriting();
         if (ProcessParams->headzone11temp>1)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ11, true,ProcessParams->headzone11temp);
@@ -282,6 +285,7 @@ uint32_t HandleProcessParameters(ProcessParameters* ProcessParams,bool saveData)
     }
     if(Head_Type == HEAD_TYPE_STAPLE_SPUN)
     {
+        Trigger_HeaterWriting();
         if (ProcessParams->rblowertemp>1)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadCoverHeater1, true,ProcessParams->rblowertemp);
@@ -290,6 +294,7 @@ uint32_t HandleProcessParameters(ProcessParameters* ProcessParams,bool saveData)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadCoverHeater1, false,ProcessParams->rblowertemp);
         }
+        Trigger_HeaterWriting();
         if (ProcessParams->lblowertemp>1)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadCoverHeater2, true,ProcessParams->lblowertemp);
@@ -298,6 +303,7 @@ uint32_t HandleProcessParameters(ProcessParameters* ProcessParams,bool saveData)
         {
             status |= HeaterCommandRequestMessage(HARDWARE_PID_CONTROL_TYPE__HeadCoverHeater2, false,ProcessParams->lblowertemp);
         }
+        Trigger_HeaterWriting();
         Trigger_Head_Fan_Control(HEAD_FAN_RIGHT,ProcessParams->rblowerflow);
         Trigger_Head_Fan_Control(HEAD_FAN_LEFT,ProcessParams->lblowerflow);
     }
diff --git a/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c b/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c
index 309eada85..73da7924b 100644
--- a/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c
+++ b/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c
@@ -1110,6 +1110,7 @@ uint32_t DcHeaterMaxTempCBFunction(uint32_t IfIndex, uint32_t readValue)
     }
     return ERROR;
 }
+bool IncreaseBlower = false;
 uint32_t HeaterControlCBFunction(uint32_t IfIndex, uint32_t readValue)
 {
     int index=HEATER_TYPE_MAX_HEATERS;
@@ -1259,23 +1260,29 @@ uint32_t HeaterControlCBFunction(uint32_t IfIndex, uint32_t readValue)
                 ReportWithPackageFilter(HeatersFilter,"AC Ready",__FILE__,index,readValue,RpWarning,(HeaterCmd[index].targettemperatue), 0);
                 HeaterAtTemp[index] = true;
                 HeaterPrepareReady();
+                IncreaseBlower = false;
             }
     }
     if    (   (readValue >  (HeaterCmd[index].targettemperatue * ((100-HeaterControl[index].outputproportionalband+2)/100)))
           &&  (readValue < (HeaterCmd[index].targettemperatue *  ((100+HeaterControl[index].outputproportionalband)/100))))
     {
-        if (BlowerCfg.enabled == true)
+        if (IncreaseBlower == false)
         {
-            if(Head_Type > HEAD_TYPE_SYLKO_WITHOUT_CARD)
-            {
-                WHS_Set_SetPoint_Q_value(headairflow);
-            }
-            else
+            IncreaseBlower = true;
+            if (BlowerCfg.enabled == true)
             {
-                Turn_the_Blower_On();//Turn on with the Default_Voltage
-                if (BlowerCfg.voltage)
-                    Control_Voltage_To_Blower(BlowerCfg.voltage);
+                if(Head_Type > HEAD_TYPE_SYLKO_WITHOUT_CARD)
+                {
+                    WHS_Set_SetPoint_Q_value(headairflow);
+                }
+                else
+                {
+                    Turn_the_Blower_On();//Turn on with the Default_Voltage
+                    if (BlowerCfg.voltage)
+                        Control_Voltage_To_Blower(BlowerCfg.voltage);
+                }
             }
+
         }
     }
     if(HeaterPIDConfig[index].m_isEnabled && (HeaterPIDConfig[index].m_SetParam != 0))
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c b/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c
index 965ea30da..2b65ca806 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/ThreadLoad.c
@@ -863,7 +863,7 @@
     uint32_t Thread_Load_Dryer_UnLoading(void)
     {
         uint32_t temp;
-        REPORT_MSG(LoadStages, "Thread UnLoad State Machine step");
+        REPORT_MSG(LoadStages, "Thread Load State Machine step Dryer Unloading");
         //LoadArmRounds = 0;
         //uint32_t numberOfSteps = 0;
         //Start Feeder Pid, Rotate Loading Arm Counter Thread Direction X Circles According To Rml. Feeder Speed Is 40
@@ -1258,7 +1258,7 @@ uint32_t ThreadLoadControlCBFunction(uint32_t IfIndex, uint32_t ReadValue)
 }
 bool ThreadLoaded(void)
 {
-    uint32_t ReadValue;
+   /* uint32_t ReadValue;
 
     int32_t PoolerValue,WinderValue,FeederValue;
     //this function tests if there is a thread in the machine. all dancers are in lowermost position then there is no thread.
@@ -1280,7 +1280,7 @@ bool ThreadLoaded(void)
         Report("Thread is out",__FILE__,(-1*PoolerValue),(-1*WinderValue),RpWarning,(-1*FeederValue),0);
         return true;
     }
-    else
+    else*/
         return false;
 }
 void ThreadLoadRequest(MessageContainer* requestContainer)
diff --git a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
index 8a4960433..d762e507f 100644
--- a/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
+++ b/Software/Embedded_SW/Embedded/Modules/Thread/Thread_print.c
@@ -217,7 +217,7 @@ uint32_t ThreadLengthCBFunction(uint32_t IfIndex, uint32_t ReadValue)
         }
 
     }
-    FeederSpeedStore[FeederSpeedIndex++] = length;
+    /*FeederSpeedStore[FeederSpeedIndex++] = length;
     if (FeederSpeedIndex>=SPEED_STORE_SIZE)
     {
         FeederSpeedIndex = 0;
@@ -225,8 +225,8 @@ uint32_t ThreadLengthCBFunction(uint32_t IfIndex, uint32_t ReadValue)
         for (Speed_i = 0;Speed_i<SPEED_STORE_SIZE;Speed_i++)
             FeederSpeedAverage+=FeederSpeedStore[Speed_i];
         FeederSpeedAverage = FeederSpeedAverage/SPEED_STORE_SIZE;
-        ReportWithPackageFilter(ThreadFilter,"Average Speed 2 second",__FILE__,__LINE__,(int)(FeederSpeedAverage*100),RpWarning,(int)(PullerSpeedAverage*100),0);
-    }
+        ReportWithPackageFilter(ThreadFilter,"Avg len 100ms last 2 sec",__FILE__,(int)PoolerTotalProcessedLength,(int)(FeederSpeedAverage*1000),RpWarning,(int)(PullerSpeedAverage*1000),0);
+    }*/
     TotalProcessedLength += (length/100);
     TempTotalProcessedLength = TotalProcessedLength;
 #ifdef FEEDER_LENGTH_CALCULATION
@@ -317,7 +317,7 @@ uint32_t PoolerThreadLengthCBFunction(uint32_t IfIndex, uint32_t ReadValue)
             length = 0;
 
         }
-        PullerSpeedStore[PullerSpeedIndex++] = length;
+        /*PullerSpeedStore[PullerSpeedIndex++] = length;
         if (PullerSpeedIndex>=SPEED_STORE_SIZE)
         {
             PullerSpeedIndex = 0;
@@ -326,7 +326,7 @@ uint32_t PoolerThreadLengthCBFunction(uint32_t IfIndex, uint32_t ReadValue)
                 PullerSpeedAverage+=PullerSpeedStore[Speed_i];
             PullerSpeedAverage = PullerSpeedAverage/SPEED_STORE_SIZE;
             //ReportWithPackageFilter(ThreadFilter,"Average Speed 2 second",__FILE__,__LINE__,(int)(FeederSpeedAverage*100),RpWarning,(int)(PullerSpeedAverage*100),0);
-        }
+        }**/
 
     //}
 
diff --git a/Software/Embedded_SW/Embedded/Modules/Waste/Waste_init.c b/Software/Embedded_SW/Embedded/Modules/Waste/Waste_init.c
index cf9fb3b7b..03ee73daf 100644
--- a/Software/Embedded_SW/Embedded/Modules/Waste/Waste_init.c
+++ b/Software/Embedded_SW/Embedded/Modules/Waste/Waste_init.c
@@ -20,6 +20,7 @@
 #include <Drivers/I2C_Communication/I2C_Task.h>
 #include <Drivers/I2C_Communication/WHS_Card/D_MAX11614_ADC/WHS_MAX11614_A2D.h>
 #include <Drivers/I2C_Communication/WHS_Card/D_Max5805_ADC_Blower/WHS_Blower.h>
+#include <Drivers/I2C_Communication/RFID_NFC/I2C_IFS_Mux.h>
 //
 //#define CARTRIDGE_INK_TIMEOUT           60
 //#define CARTRIDGE_INK_TIMEOUTx2         120
@@ -231,11 +232,11 @@ bool RdCartridgeParam(cartridge_name cart_name)
     {
     case waste_cartridge1:
         WHS_info.cartridge_1.serial_number = temp_funcion; //to do
-        WHS_info.cartridge_1.status = temp_funcion; // to do
+        WHS_info.cartridge_1.status = WasteEmpty; // to do
         break;
     case waste_cartridge2:
         WHS_info.cartridge_2.serial_number = temp_funcion;
-        WHS_info.cartridge_2.status = temp_funcion;
+        WHS_info.cartridge_2.status = WasteEmpty;
         break;
     case INK_cartridge:
         ReadCartridgeData(cart_name);
@@ -313,6 +314,12 @@ U8 set_cartridge_2(U8 cartridge_status)
 
 bool SetWastePump( bool power)
 {
+    if ((IFS_Availability[1] == IFS_RECOGNIZED)&&(IFS_Availability[2] == IFS_RECOGNIZED)) //ifs installed -check cartridges
+     {
+        if ((WHS_WasteCartridgeLowerPresent() == false)&&(WHS_WasteCartridgeMiddlePresent() == false))
+            return ERROR;
+     }
+
     /*
     set the waste pump on/off
     off - :
@@ -415,6 +422,29 @@ U8 CartridgeWasteFilling(bool status)
             SetWasteLevelEmptyingLimit(GetWHSWasteTankLevelMiliLiter());
             waste_seq_step1_cont();
         }
+        switch (WHS_info.active_cartridge)
+           {
+              case waste_cartridge1:
+                  Pannel_Leds( CART_2,  MODE_ON);                //set led color
+                  cart2.color = BLINK;
+                  ReportWithPackageFilter(WasteFilter,"------------ WHS  waste_cartridge1 is used please replace it -----------------", __FILE__, __LINE__, 0, RpMessage, 0, 0);
+                  break;
+              case waste_cartridge2:
+                  Pannel_Leds( CART_3,  MODE_ON);                //set led color
+                  cart3.color = BLINK;
+                  ReportWithPackageFilter(WasteFilter,"------------ WHS  waste_cartridge2 is used please replace it -----------------", __FILE__, __LINE__, 0, RpMessage, 0, 0);
+                  break;
+              case no_waste_cartridge:
+                  ReportWithPackageFilter(WasteFilter,"------------ !!!!!WHS  No waste cartridge !!!!! -----------------", __FILE__, __LINE__, 0, RpMessage, 0, 0);
+                  ReportWithPackageFilter(WasteFilter,"------------ !!!! WHS  insert cartridge!!!! -----------------", __FILE__, __LINE__, 0, RpMessage, 0, 0);
+                  SetWastePump(CLOSE);
+                  //WHS_info.WHS_pump.time = 0;
+                  AlarmHandlingSetAlarm( EVENT_TYPE__NO_WASTE_CARTRIDGE_AVAILABLE,  true);
+                  ret = ERROR;
+                  break;
+              default:
+                  break;
+           }
         ret=OK;
     }
     else // stop Waste cartridge filling
@@ -460,9 +490,9 @@ U8 CartridgeWasteFilling(bool status)
 
 /* ------read waste tank sensors -----------  */
 #define WASTE_CARTRIDGE_SIZE 1500
-#define WASTE_LEVEL_OVERFLOW 4000
-#define WASTE_LEVEL_FULL 3500
-#define WASTE_LEVEL_EMPTY 2100
+#define WASTE_LEVEL_OVERFLOW 2700
+#define WASTE_LEVEL_FULL 2300
+#define WASTE_LEVEL_EMPTY 900
 double WasteLevelOverflow = WASTE_LEVEL_OVERFLOW;
 double WasteLevelFull = WASTE_LEVEL_FULL;
 double WasteLevelEmpty = WASTE_LEVEL_EMPTY;
@@ -727,7 +757,7 @@ bool WasteTankCBFunction()
                 ReportWithPackageFilter(WasteFilter,"------------ WHS, Cartridge cover open -------------", __FILE__, __LINE__, WHS_info.sttMachine, RpMessage, WHS_info.WHS_sensors.cartridge_cover, 0);//popup message :"Cartridge cover open"  //todo
                 if ( WHS_info.WHS_pump.status == OPEN)
                 {
-                    CartridgeWasteFilling(CLOSE);
+                    CartridgeWasteFilling(OFF);
                     pump_on_flag = OPEN;
                 }
 
@@ -759,12 +789,12 @@ bool WasteTankCBFunction()
             }
             else // CLOSE
             {
-                //if (WHS_info.sttMachine == WHS_full) CartridgeWasteFilling(OPEN);
+                if (WHS_info.sttMachine == WHS_full) CartridgeWasteFilling(ON);
                 SetActiveWastCartridge();
                 if (pump_on_flag == OPEN )
                 {
                     WHS_info.WHS_sensors.waste_tank_full_sensor =  SENSORnotFULL;  // todo
-                    //                    CartridgeWasteFilling(OPEN);
+                    CartridgeWasteFilling(OPEN);
                     pump_on_flag = CLOSE;
                 }
                 IFS_info.Cartridge_Ink_device_Id    = RemoveControlCallback(IFS_info.Cartridge_Ink_device_Id   , WasteTankCBFunction );