Software/Embedded_SW/Embedded/Modules/Heaters/Heaters_init.c


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             xmlns="http://schemas.microsoft.com/winfx/2006/xaml/presentation"
             xmlns:x="http://schemas.microsoft.com/winfx/2006/xaml">
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            <ResourceDictionary.MergedDictionaries>
                <ResourceDictionary Source="pack://application:,,,/Tango.MachineStudio.Common;component/Resources/MaterialDesign.xaml" />
                <ResourceDictionary Source="pack://application:,,,/Tango.MachineStudio.Common;component/Themes/LightThemeColors.xaml" />
            </ResourceDictionary.MergedDictionaries>
        </ResourceDictionary>
    </Application.Resources>
</Application>
/************************************************************************************************************************
 * Heaters_init.c
 **************************************************************************************************************************/

////////////////////////////////State machine operation////////////////////////////////////
//the state machine operation is used to operate in runtime correct profile flow execution
//by recieved esign flow of the user from the UI
///////////////////////////////////////////////////////////////////////////////////////////
#include "include.h"

#include "PMR/Hardware/HardwarePidControl.pb-c.h"
#include "PMR/Hardware/HardwarePidControlType.pb-c.h"
#include "PMR/common/MessageContainer.pb-c.h"
#include "PMR/Stubs/StubHeatingTestRequest.pb-c.h"
#include "PMR/Stubs/StubHeatingTestResponse.pb-c.h"
#include "PMR/Stubs/StubHeatingTestPollRequest.pb-c.h"
#include "PMR/Stubs/StubHeatingTestPollResponse.pb-c.h"

#include "../control/control.h"
#include "../control/pidalgo.h"
#include "include.h"
#include <driverlib/timer.h>
#include <DataDef.h>
#include "heaters_ex.h"
#include "heaters.h"
#include "Drivers/Heater/Heater.h"
#include "Drivers/Heater/TemperatureSensor.h"


/******************** STRUCTURES AND ENUMs  ********************************************/
typedef enum {
    HeatersInitialState,
    HeatersInit,
    HeatersControlledOp,
    HeatersShutdown,
    HeatersTest,
    MaxHeatersStates
}HEATERS_STATES_ENUM;
typedef enum {
    HeatersCold,
    HeatersAtPIDStrip,
    HeatersOverHeat,
    HeatersOnTest
}HEATERS_EVENTS_ENUM;

/******************** GLOBAL PARAMETERS  ********************************************/
HeaterPIDControlConfig HeaterControl[MAX_HEATERS_NUM] = {0,0,0,0,0,0,0,0,0,0,0,0};
HeaterControlConfig_t  HeaterPIDConfig[MAX_HEATERS_NUM] = {0,0,0,0,0,0,0,0,0,0,0,0};
bool AcHeaterConfigured[MAX_AC_HEATERS] = {0,0,0};

int      NumberOFSlicesInUse = 0;
uint32_t MillisecondsPerChange = 0;

bool FastHeating = 1;
/******************** CODE  ********************************************/
/*
 * HeatersInit
 * called by: General Hardware Init
 * initialized all global data
 */
uint32_t Heaters_Init(void)
{
    //ROM_TimerDisable(Heater_timerBase, TIMER_A);
    FPGA_SensorInitConfig();
    return OK;
}
char stubToken[37] = {0};
void HeatingStopReporting(void)
{
    stubToken[0] = 0;
}

void HeatingTestRequest(MessageContainer* requestContainer)
{
//#ifdef DEBUG_TEST_FUNCTIONS
    MessageContainer responseContainer;
    uint8_t* container_buffer;
    uint32_t status = 0;
    HardwarePidControlType HeaterId1,HeaterId2;

    StubHeatingTestRequest* request = stub_heating_test_request__unpack(NULL, requestContainer->data.len, requestContainer->data.data);
    HeaterId1 = request->hardwarepidcontrol1->hardwarepidcontroltype;
    status += HeaterConfigRequestMessage(request->hardwarepidcontrol1);
    HeaterId2 = request->hardwarepidcontrol2->hardwarepidcontroltype;
    status += HeaterConfigRequestMessage(request->hardwarepidcontrol2);

    if (request->has_dryerzone1temp)
    {
        if (request->dryerzone1temp)
            status |= HeaterCommandRequestMessage(
                    HeaterId1, true,
                    request->dryerzone1temp);
        else
            status |= HeaterCommandRequestMessage(
                    HeaterId1, false,
                    request->dryerzone1temp);
    }
    if (request->has_dryerzone2temp)
    {
        if (request->dryerzone2temp)
            status |= HeaterCommandRequestMessage(
                    HeaterId2, true,
                    request->dryerzone2temp);
        else
            status |= HeaterCommandRequestMessage(
                    HeaterId2, false,
                    request->dryerzone2temp);
    }
    ControlStart();
    StubHeatingTestResponse response = STUB_HEATING_TEST_RESPONSE__INIT;

    responseContainer = createContainer(MESSAGE_TYPE__StubHeatingTestResponse, requestContainer->token, false, &response, &stub_heating_test_response__pack, &stub_heating_test_response__get_packed_size);
    container_buffer = malloc(message_container__get_packed_size(&responseContainer));


    if (status)
    {
        responseContainer.has_error = true;
        responseContainer.error = (ErrorCode)status;
    }
    size_t container_size = message_container__pack(&responseContainer, container_buffer);
    free(responseContainer.data.data);
    //USBCDCD_sendData(container_buffer, container_size,10);
    SendChars(container_buffer, container_size);
    //free(container_buffer);
    //free(requestContainer);
    stub_heating_test_request__free_unpacked(request,NULL);

//#else
//    LOG_ERROR (-1, "Heating Control not on debug");
//    return ERROR;
//#endif
}
void HeatingTestPollRequest(MessageContainer* requestContainer)
{
    //uint8_t* container_buffer;

    StubHeatingTestPollRequest* request = stub_heating_test_poll_request__unpack(NULL, requestContainer->data.len, requestContainer->data.data);
    ustrncpy (stubToken, requestContainer->token,36);

/*    StubHeatingTestPollResponse response = STUB_HEATING_TEST_POLL_RESPONSE__INIT;

    responseContainer = createContainer(MESSAGE_TYPE__StubHeatingTestPollResponse, requestContainer->token, false, &response, &stub_heating_test_poll_response__pack, &stub_heating_test_poll_response__get_packed_size);
    container_buffer = malloc(message_container__get_packed_size(&responseContainer));


    if (status)
    {
        responseContainer.has_error = true;
        responseContainer.error = (ErrorCode)status;
    }
    size_t container_size = message_container__pack(&responseContainer, container_buffer);
    free(responseContainer.data.data);
    SendChars(container_buffer, container_size);
    //free(container_buffer);*/
//    free(requestContainer);
//    free(request);
    stub_heating_test_poll_request__free_unpacked(request,NULL);
}

void HeatingTestSendResonse(uint32_t status, bool last,bool heater1Active,bool heater2Active, int temperature1, int temperature2,int Heater1Percentage,int Heater2Percentage, char* Message)
{
    MessageContainer responseContainer;
    uint8_t* container_buffer;
//    uint8_t container_buffer[50];
    if (stubToken[0] == 0)
        return;
    StubHeatingTestPollResponse response = STUB_HEATING_TEST_POLL_RESPONSE__INIT;

    /*
      protobuf_c_boolean has_heatergroupid;
      uint32_t heatergroupid;
      protobuf_c_boolean has_zone1temp;
      uint32_t zone1temp;
      protobuf_c_boolean has_zone2temp;
      uint32_t zone2temp;
      protobuf_c_boolean has_heater1active;
      protobuf_c_boolean heater1active;
      protobuf_c_boolean has_heater2active;
      protobuf_c_boolean heater2active;
      protobuf_c_boolean has_heater1percentage;
      uint32_t heater1percentage;
      protobuf_c_boolean has_heater2percentage;
      uint32_t heater2percentage;
    void HeatingTestSendResonse(uint32_t status, bool last,bool heater1Active,bool heater2Active, int temperature1, int temperature2,int Heater1Percentage,int Heater2Percentage)
     */
response.has_heater1active = true;
response.heater1active = heater1Active;
response.has_heater1percentage = true;
response.heater1percentage = Heater1Percentage;
response.has_zone1temp = true;
response.zone1temp = temperature1;
response.has_heater2active = true;
response.heater2active = heater2Active;
response.has_heater2percentage = true;
response.heater2percentage = Heater2Percentage;
response.has_zone2temp = true;
response.zone2temp = temperature2;
response.infomessage = Message;
responseContainer = createContainer(MESSAGE_TYPE__StubHeatingTestPollResponse, stubToken, last, &response, &stub_heating_test_poll_response__pack, &stub_heating_test_poll_response__get_packed_size);
//setContainerContinuous
responseContainer.continuous = true;
container_buffer = malloc(message_container__get_packed_size(&responseContainer));

    if (status)
    {
        responseContainer.has_error = true;
        responseContainer.error = (ErrorCode)status;
    }
    size_t container_size = message_container__pack(&responseContainer, container_buffer);
    free(responseContainer.data.data);
    //USBCDCD_sendData(container_buffer, container_size,10);
    SendChars(container_buffer, container_size);
    //free(container_buffer);
//    stubToken[0] = 0;
}


uint32_t HeaterConfigRequestMessage(HardwarePidControl* request)
{
    //uint32_t status = OK;
    HardwarePidControlType HeaterId;

    HeaterId = request->hardwarepidcontroltype;
    int ValidationError = 0;

    if (HeaterId< MAX_HEATERS_NUM)
    {
        HeaterControl[HeaterId].configured = true;
        HeaterControl[HeaterId].id = HeaterId;
        //strncpy (HeaterControl[HeaterId].name, request->name, 20);
        HeaterControl[HeaterId].outputproportionalpowerlimit = request->outputproportionalpowerlimit;
        HeaterControl[HeaterId].outputproportionalband = request->outputproportionalband;
        HeaterControl[HeaterId].integraltime = request->integraltime;
        HeaterControl[HeaterId].derivativetime = request->derivativetime;
        HeaterControl[HeaterId].sensorcorrectionadjustment = request->sensorcorrectionadjustment;
        //sensorminvalue,sensormaxvalue are used for the dryer heater as internal heater control
        if (HeaterId == HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w)
        {
            HeaterControl[HeaterId].sensormaxvalue = request->sensormaxvalue;
            HeaterControl[HeaterId].sensorminvalue = request->sensorminvalue;
        }
        //HeaterControl[HeaterId].sensortypeandsetpointlimits = request->sensortypeandsetpointlimits;
        HeaterControl[HeaterId].setpointramprateorsoftstartramp = request->setpointramprateorsoftstartramp;
        HeaterControl[HeaterId].setpointcontroloutputrate = request->setpointcontroloutputrate;
        HeaterControl[HeaterId].controloutputtype = request->controloutputtype;
        HeaterControl[HeaterId].ssrcontroloutputtype = request->ssrcontroloutputtype;
        HeaterControl[HeaterId].outputonoffhysteresisvalues = request->outputonoffhysteresisvalue;
        HeaterControl[HeaterId].processvariablesamplingrate = request->processvariablesamplingrate;
        HeaterControl[HeaterId].pvinputfilterfactormode = request->pvinputfilterfactormode;
        //HeaterControl[HeaterId].kp = 0.5;
        //HeaterControl[HeaterId].ki = 0.1;
        //HeaterControl[HeaterId].kd = 0.0;
        HeaterControl[HeaterId].kp = request->proportionalgain;
        HeaterControl[HeaterId].ki = request->integraltime;
        HeaterControl[HeaterId].kd = request->derivativetime;

        if (HeaterId < MAX_AC_HEATERS)
            AcHeaterConfigured[HeaterId] = true;

        //check if all A/C heaters are defined. if they are - validate the configuration
        if (((HeaterId == HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w)||(HeaterId == HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1))
                &&HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w].configured
                &&HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1].configured
                /*&&HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater200w2].id*/)
        {
            if (HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w].outputproportionalpowerlimit
                    + HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1].outputproportionalpowerlimit
                    /*+ HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater200w2].outputproportionalpowerlimit*/> 100)
                ValidationError += 2;
            if (ValidationError)
                {
                    LOG_ERROR (ValidationError, "Validation Error in Heaters Control");
                    return ERROR;
                }
            else
            {
            }
        }
        return OK;
    }

    return ERROR;

}

/*
 * HeaterConfigSetSharedHeatersParams - prepare the time slices for A/C heaters co-ordinated operation
 * called by the general hardware HWConfigurationFunc
 * parameters - the cycle time for the coordinated operation, the size (in MCU cycles) of a single step.
 */
uint32_t HeaterConfigSetSharedHeatersParams(uint32_t outputproportionalcycletime, uint32_t outputproportionalsinglestep)
{
   int Slice_i;
   int Heater1000Slices,Heater200aSlices /*,Heater200bSlices Currently both 200W heaters will work together*/;

   //A/C Heaters Cycle time in milliseconds - one for all heaters
   OutputProportionalCycleTime = outputproportionalcycletime;

   //A/C Heaters step size from one decision point to another - in cpu clocks. 120000 = 1 millisecod
   OutputProportionalSingleStep = outputproportionalsinglestep;

   // calculate how many milliseconds is in each operating cycle (should be an integer number)
   MillisecondsPerChange = OutputProportionalSingleStep/120000;

   // calculate how many time slices are used. the total cycle time / the length of one operating cycle. (one added to put a time gap??? TBD)
   NumberOFSlicesInUse = (OutputProportionalCycleTime/MillisecondsPerChange);

   if (NumberOFSlicesInUse > MAX_TIMESLICES )
   {
       LOG_ERROR (NumberOFSlicesInUse, "NumberOFSlicesInUse too high");
       return ERROR;//NumberOFSlicesInUse = MAX_TIMESLICES;
   }

   // all numbers are rounded down. better to have carefully calculated numbers
   Heater1000Slices = HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w].outputproportionalpowerlimit * NumberOFSlicesInUse / 100;
   Heater200aSlices = HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1].outputproportionalpowerlimit * NumberOFSlicesInUse / 100;

   if ((Heater1000Slices + Heater200aSlices +2)>NumberOFSlicesInUse)
   {
       LOG_ERROR (NumberOFSlicesInUse, "proportional time slices too high too high");
       return ERROR;//NumberOFSlicesInUse = MAX_TIMESLICES;
   }

   //mark the time slices  for heaters operation as empty / Heater1000 / Heater 200
   memset (TimeSliceAllocation,0xFF,sizeof(TimeSliceAllocation));
   for (Slice_i = 0; Slice_i < Heater1000Slices;Slice_i++ ) TimeSliceAllocation[Slice_i] = HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w;
   for (Slice_i = Heater1000Slices+1; Slice_i <= Heater1000Slices+Heater200aSlices;Slice_i++ ) TimeSliceAllocation[Slice_i] = HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1;

   return OK;

}
/*
 * HeaterRecalculateSharedHeatersParams -
 *
 * parameters - the cycle time for the coordinated operation, the size (in MCU cycles) of a single step.
 */
uint32_t HeaterRecalculateSharedHeatersParams(uint32_t deviceId, uint32_t new_outputproportionalpowerlimit)
{
   int Slice_i;
   int Heater1000Slices,Heater200aSlices /*,Heater200bSlices Currently both 200W heaters will work together*/;


   if (NumberOFSlicesInUse > MAX_TIMESLICES )
   {
       LOG_ERROR (NumberOFSlicesInUse, "NumberOFSlicesInUse too high");
       return ERROR;//NumberOFSlicesInUse = MAX_TIMESLICES;
   }

   // all numbers are rounded down. better to have carefully calculated numbers
   HeaterControl[deviceId].outputproportionalpowerlimit = new_outputproportionalpowerlimit;
   Heater1000Slices = HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w].outputproportionalpowerlimit * NumberOFSlicesInUse / 100;
   Heater200aSlices = HeaterControl[HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1].outputproportionalpowerlimit * NumberOFSlicesInUse / 100;

//#warning temporary disable time slice control as we are working with one heater in run time
/*   if ((Heater1000Slices + Heater200aSlices +2)>NumberOFSlicesInUse)
   {
       LOG_ERROR (NumberOFSlicesInUse, "proportional time slices too high too high");
       return ERROR;//NumberOFSlicesInUse = MAX_TIMESLICES;
   }
*/
   //mark the time slices  for heaters operation as empty / Heater1000 / Heater 200
   memset (TimeSliceAllocation,0xFF,sizeof(TimeSliceAllocation));
   for (Slice_i = 0; Slice_i < Heater1000Slices;Slice_i++ ) TimeSliceAllocation[Slice_i] = HARDWARE_PID_CONTROL_TYPE__DryerHeater1000w;
   for (Slice_i = Heater1000Slices+1; Slice_i <= Heater1000Slices+Heater200aSlices;Slice_i++ ) TimeSliceAllocation[Slice_i] = HARDWARE_PID_CONTROL_TYPE__DryerHeater200w1;

   return OK;

}

/*
 * HeaterRecalculateHeaterParams - prepare the time slices for D/C heaters operation
 * called by the general hardware HWConfigurationFunc
 * parameters - the cycle time for the coordinated operation, the size (in MCU cycles) of a single step.
 */
uint32_t HeaterRecalculateHeaterParams(uint32_t deviceId, uint32_t new_outputproportionalpowerlimit)
{
   // calculate how many milliseconds is in each operating cycle (should be an integer number)
   //uint32_t MillisecondsPerChange = OutputProportionalSingleStep/120000;

   // calculate how many time slices are used. the total cycle time / the length of one operating cycle. (one added to put a time gap??? TBD)
   //NumberOFSlicesInUse = (OutputProportionalCycleTime/MillisecondsPerChange);

   if (NumberOFSlicesInUse > MAX_TIMESLICES )
   {
       LOG_ERROR (NumberOFSlicesInUse, "NumberOFSlicesInUse too high");
       return ERROR;//NumberOFSlicesInUse = MAX_TIMESLICES;
   }

   // all numbers are rounded down. better to have carefully calculated numbers
   HeaterControl[deviceId].outputproportionalpowerlimit = new_outputproportionalpowerlimit;

   //mark the time slices  for heaters operation as empty / Heater1000 / Heater 200
   DCTimeSliceAllocation[deviceId] = (HeaterControl[deviceId].outputproportionalpowerlimit * NumberOFSlicesInUse) / 100;


   return OK;

}