heater disaster handling

2 files changed, 70 insertions, 23 deletions

diff --git a/Software/Embedded_SW/Embedded/Drivers/Heater/Heater.c b/Software/Embedded_SW/Embedded/Drivers/Heater/Heater.c
index 2010e50cc..bceb89735 100644
--- a/Software/Embedded_SW/Embedded/Drivers/Heater/Heater.c
+++ b/Software/Embedded_SW/Embedded/Drivers/Heater/Heater.c
@@ -44,7 +44,7 @@ extern F3_GPO_01_REG F3_GPO_01_Reg;
 
 static GPIOIntPortMap portMap[MAX_HEATERS_NUM] =
 {
-    //{DRYER_SSR3_CTRL,    false},  // HARDWARE_PID_CONTROL_TYPE__DryerAirTemperature  **** Not connected ****
+    {SPARE_SSR12_CTRL,    false},  // HARDWARE_PID_CONTROL_TYPE__DryerAirTemperature  **** Not connected ****
     {DRYER_SSR1_CTRL,    false},  // HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain
     {DRYER_SSR2_CTRL,    false},  // HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary
     {DYEINGH_SSR8_CTRL,  false},  // HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ1 - Head Heater #1 - rightmost
diff --git a/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c b/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c
index fd4d2b39b..1a7a60c19 100644
--- a/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c
+++ b/Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_print.c
@@ -82,7 +82,7 @@ uint32_t    OverHeatCounter [MAX_HEATERS_NUM] = {0,0,0,0,0,0,0,0,0,0};
 uint32_t    UnderHeatCounter [MAX_HEATERS_NUM] = {0,0,0,0,0,0,0,0,0,0};
 uint32_t    MainDryerHeaterMaxTempControl = 0xFF;
 uint32_t    SecondDryerHeaterMaxTempControl = 0xFF;
-
+uint32_t    DisasterControlId = 0xFF;
 #define DRYER_AIR_PT100  TEMP_SENSE_ANALOG_DRYER_TEMP1
 #define DRYER_MAIN_PT100 TEMP_SENSE_ANALOG_DRYER_TEMP2
 #define DRYER_SECONDARY_PT100 TEMP_SENSE_ANALOG_DRYER_TEMP3
@@ -123,11 +123,16 @@ EventType HeaterUnderEventType_B[MAX_HEATERS_NUM] = {EVENT_TYPE__DRYER_ZONE_1_UN
                                               EVENT_TYPE__DYEING_HEAD_ZONE_3_UNDERTEMPERATURE_B,EVENT_TYPE__DYEING_HEAD_ZONE_4_UNDERTEMPERATURE_B,EVENT_TYPE__DYEING_HEAD_ZONE_5_UNDERTEMPERATURE_B,EVENT_TYPE__DYEING_HEAD_ZONE_6_UNDERTEMPERATURE_B,
                                               EVENT_TYPE__MIXER_UNDERTEMPERATURE_B};
 
+int HeaterDisasterCounter[HARDWARE_PID_CONTROL_TYPE__MixerHeater+1] = {0,0,0,0,0,0,0,0,0,0};
+#define DISASTER_COUNTER_LIMIT 10
+
 /******************** FUNCTIONS  ********************************************/
 uint32_t HeaterMaxTempCBFunction(uint32_t IfIndex, uint32_t readValue);
 uint32_t DcHeaterMaxTempCBFunction(uint32_t IfIndex, uint32_t readValue);
 uint32_t HeaterControlCBFunction(uint32_t deviceID, uint32_t readValue);
 uint32_t DCHeaterControlCBFunction(uint32_t IfIndex, uint32_t readValue);
+uint32_t HeatersDisasterControl(uint32_t x,uint32_t y);
+
 uint32_t PrepareHeater(int HeaterId, uint32_t SetTemperatue);
 void HeatersStartControlTimer (void);
 
@@ -478,6 +483,9 @@ void PrepareACHeater(int HeaterId,uint32_t Frequency, uint32_t SetTemperatue)
  */
 int PrepareDCHeater(int HeaterId, uint32_t Frequency, uint32_t SetTemperatue)
 {
+    if (DisasterControlId = 0xFF)
+        DisasterControlId = AddControlCallback( HeatersDisasterControl, eOneSecond,TemplateDataReadCBFunction,0,0, 0);
+
     if (ControlIdtoHeaterId [HeaterId] == 0xFF)
     ControlIdtoHeaterId [HeaterId] = AddControlCallback( DCHeaterControlCBFunction, Frequency/*eOneSecond*/,MillisecGetTemperatures,(IfTypeHeaters*0x100+HeaterId),HeaterId2PT100Id[HeaterId],0);
     //HeaterPIDConfig[HeaterId].m_params.dt *=10;
@@ -702,7 +710,7 @@ uint32_t DcHeaterMaxTempCBFunction(uint32_t IfIndex, uint32_t readValue)
         if(OverHeatCounter[index]++ >=Overheat_Count_Limit)
         {
             OverHeatCounter[index] = Overheat_Count_Limit;
-            HeaterReady[index] = false;
+            //?????HeaterReady[index] = false;
             if (JobIsActive()&&(HeaterReady[index]==true))
             {
                 JobEndReason = JOB_TEMPERATURE_ALARM;
@@ -725,7 +733,7 @@ uint32_t DcHeaterMaxTempCBFunction(uint32_t IfIndex, uint32_t readValue)
         if(UnderHeatCounter[index]++ >=Underheat_Count_Limit)
         {
             UnderHeatCounter[index] = Underheat_Count_Limit;
-            HeaterReady[index] = false;
+            //???HeaterReady[index] = false;
             if (JobIsActive()&&(HeaterReady[index]==true))
             {
                 JobEndReason = JOB_TEMPERATURE_ALARM;
@@ -808,6 +816,15 @@ uint32_t HeaterControlCBFunction(uint32_t IfIndex, uint32_t readValue)
         }
         return ERROR;
     }
+    if (HeaterDisasterCounter[index] >= DISASTER_COUNTER_LIMIT)
+    {
+        Report("AC Temperature disaster",__FILE__,index,HeaterPreviousRead[index],RpWarning,readValue, index);
+        DeActivateHeater(HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary);
+        DeActivateHeater(HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain);
+        HeaterRecalculateSharedHeatersParams(HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain,0);
+        HeaterRecalculateSharedHeatersParams(HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary,0);
+        return ERROR;
+    }
     HeaterPreviousRead[index] = readValue;
 
     // check if the read value is within the proportional band
@@ -936,9 +953,15 @@ uint32_t DCHeaterControlCBFunction(uint32_t IfIndex, uint32_t readValue)
             DeActivateHeater(index);
             HeaterRecalculateHeaterParams(index, 0);
         }
-        return ERROR;
     }
     HeaterPreviousRead[index] = readValue;
+    if (HeaterDisasterCounter[index] >= DISASTER_COUNTER_LIMIT)
+    {
+        Report("DC Temperature disaster",__FILE__,index,HeaterPreviousRead[index],RpWarning,readValue, index);
+        DeActivateHeater (index);
+        return ERROR;
+    }
+
     // check if the read value is within the proportional band
     if (HeaterReady[index]==false)
     {
@@ -1052,28 +1075,61 @@ void EightMilliSecondHeatersInterrupt(UArg arg0)
 }
 
 int HeaterDisasterTemp[HARDWARE_PID_CONTROL_TYPE__MixerHeater+1] = {28000,28000,28000,17000,17000,17000,17000,17000,17000,11000};
+//int HeaterDisasterTemp[HARDWARE_PID_CONTROL_TYPE__MixerHeater+1] = {8100,8100,8200,8100,8100,8100,8100,8100,8100,8100};
+uint32_t HeatersDisasterControl(uint32_t x,uint32_t y)
+{
+    int HeaterId,temperature;
+
+    for ( HeaterId = HARDWARE_PID_CONTROL_TYPE__DryerAirTemperature; HeaterId<= HARDWARE_PID_CONTROL_TYPE__MixerHeater;HeaterId++)
+    {
+        temperature = MillisecGetTemperatures(HeaterId2PT100Id[HeaterId]);
+        if (temperature>=HeaterDisasterTemp[HeaterId])
+        {
+            Report("Disaster Temperature ",__FILE__,HeaterId,temperature,RpWarning,HeaterDisasterTemp[HeaterId], 0);
+            if (HeaterDisasterCounter[HeaterId]++ >= DISASTER_COUNTER_LIMIT)
+                HeaterDisasterCounter[HeaterId] = DISASTER_COUNTER_LIMIT;
+        }
+        else if (temperature<0)
+        {
+            if (HeaterDisasterCounter[HeaterId]++ <= 0)
+                HeaterDisasterCounter[HeaterId] = 0;
+        }
+        else
+        {
+            if (HeaterDisasterCounter[HeaterId]-- <= 0)
+                HeaterDisasterCounter[HeaterId] = 0;
+        }
+
+    }
+    return OK;
+
+}
 uint32_t HeatersControlLoop(uint32_t tick)
 {
     //char str[100];
     //uint8_t len = 0;
     int DcHeaterId;
+    bool AcHeaterDisaster = false;
+
     /*len = usnprintf(str, 100, "\r\n EightMilliSecondHeatersInterrupt SliceCounter %d Owner %d H1000 %d  H2000 %d"
                     ,SliceCounter,TimeSliceAllocation[SliceCounter],HeatersRestart,NumberOFSlicesInUse);
     Report(str, __FILE__,__LINE__,0, RpMessage, SliceCounter, TimeSliceAllocation[SliceCounter]);
 */
-    /*static bool first = true;
-    if (first == true)
+    if (HeaterDisasterCounter[HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain] >= DISASTER_COUNTER_LIMIT)
     {
-        first = false;
-    }*/
-    if ((MillisecGetTemperatures(HeaterId2PT100Id[HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain])>HeaterDisasterTemp[HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain])|
-            (MillisecGetTemperatures(HeaterId2PT100Id[HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary])>HeaterDisasterTemp[HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary]))
+        DeActivateHeater (HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain);
+        DeActivateHeater (HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary);
+        AcHeaterDisaster = true;
+    }
+    if (HeaterDisasterCounter[HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary] >= DISASTER_COUNTER_LIMIT)
     {
-        Report("AC Disaster Temperature ",__FILE__,HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain,MillisecGetTemperatures(HeaterId2PT100Id[HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain]),RpWarning,HeaterDisasterTemp[HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary], 0);
         DeActivateHeater (HARDWARE_PID_CONTROL_TYPE__DryerHeaterMain);
         DeActivateHeater (HARDWARE_PID_CONTROL_TYPE__DryerHeaterSecondary);
+        AcHeaterDisaster = true;
     }
-    else
+
+
+    if (AcHeaterDisaster == false)
     {
         if (HeaterReady[HARDWARE_PID_CONTROL_TYPE__DryerAirTemperature] == true)
         {
@@ -1110,17 +1166,8 @@ uint32_t HeatersControlLoop(uint32_t tick)
     }
     for ( DcHeaterId = HARDWARE_PID_CONTROL_TYPE__HeadHeaterZ1; DcHeaterId<= HARDWARE_PID_CONTROL_TYPE__MixerHeater;DcHeaterId++)
     {
-        if (MillisecGetTemperatures(HeaterId2PT100Id[DcHeaterId])>HeaterDisasterTemp[DcHeaterId])
-        {
-	        if (HeaterCmd[DcHeaterId].targettemperatue)
-	            Report("DC Disaster Temperature ",__FILE__,DcHeaterId,MillisecGetTemperatures(HeaterId2PT100Id[DcHeaterId]),RpWarning,HeaterDisasterTemp[DcHeaterId], DcHeaterId);
-            DeActivateHeater (DcHeaterId);
-            continue;
-        }
-        if (   MillisecGetTemperatures(HeaterId2PT100Id[DcHeaterId]<MINIMUM_HEATER_READ))
+        if (HeaterDisasterCounter[DcHeaterId] >= DISASTER_COUNTER_LIMIT)
         {
-            if (HeaterCmd[DcHeaterId].targettemperatue)
-                Report("DC negative Temperature ",__FILE__,DcHeaterId,MillisecGetTemperatures(HeaterId2PT100Id[DcHeaterId]),RpWarning,HeaterDisasterTemp[DcHeaterId], DcHeaterId);
             DeActivateHeater (DcHeaterId);
             continue;
         }