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bigger partitions, port to -v5 boards

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This commit is contained in:
Thaddeus Hughes
2026-04-21 15:14:14 -05:00
parent b0b317a0fe
commit a775999c87
60 changed files with 1164 additions and 22 deletions
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162
main/power_mgmt.c
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@@ -27,6 +27,7 @@
#include "esp_adc/adc_cali_scheme.h"
#include "esp_timer.h"
#include "driver/gpio.h"
#include "board_config.h"
#include "control_fsm.h"
#include "i2c.h"
#include "sensors.h"
@@ -38,11 +39,23 @@
#define TAG "POWER"
// === GPIO Pin Definitions ===
// === GPIO Pin Definitions ===
#ifdef BOARD_V5
// V5: single ACS37220LEZATR-100B3 for all motors.
// GPIO34 (ADC1_CH6) = VOUT (main current reading)
// GPIO36 / VP (ADC1_CH0) = VOC (OC-threshold sense, diagnostic)
// GPIO39 / VN = FAULT (digital, active-low, open-drain — external pull-up on board)
// GPIO35 (ADC1_CH7) = battery voltage (moved from GPIO39)
#define PIN_V_ISENS_MAIN ADC_CHANNEL_6 // GPIO34
#define PIN_V_VOC ADC_CHANNEL_0 // GPIO36 / VP
#define PIN_V_BATTERY ADC_CHANNEL_7 // GPIO35
#define PIN_FAULT_GPIO GPIO_NUM_39 // digital input
#else // BOARD_V4
#define PIN_V_ISENS1 ADC_CHANNEL_0 // GPIO36 / VP
#define PIN_V_ISENS2 ADC_CHANNEL_6 // GPIO34
#define PIN_V_ISENS3 ADC_CHANNEL_7 // GPIO35
#define PIN_V_BATTERY ADC_CHANNEL_3 // GPIO39 / VN
#endif
#define PIN_V_SENS_BAT PIN_V_BATTERY
// map from relay number to bridge
@@ -163,10 +176,27 @@ esp_err_t adc_init() {
.bitwidth = ADC_BITWIDTH_12,
};
#ifdef BOARD_V5
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS_MAIN, &chan_cfg));
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_VOC, &chan_cfg));
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_SENS_BAT, &chan_cfg));
// FAULT is open-drain on the sensor; ESP32 GPIO39 has no internal pull —
// V5 board MUST provide an external pull-up to VDD.
gpio_config_t fault_cfg = {
.pin_bit_mask = 1ULL << PIN_FAULT_GPIO,
.mode = GPIO_MODE_INPUT,
.pull_up_en = GPIO_PULLUP_DISABLE,
.pull_down_en = GPIO_PULLDOWN_DISABLE,
.intr_type = GPIO_INTR_DISABLE,
};
ESP_ERROR_CHECK(gpio_config(&fault_cfg));
#else
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS1, &chan_cfg));
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS2, &chan_cfg));
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS3, &chan_cfg));
ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_SENS_BAT, &chan_cfg));
#endif
// Line fitting calibration (modern scheme)
adc_cali_line_fitting_config_t cali_cfg = {
@@ -176,16 +206,32 @@ esp_err_t adc_init() {
};
ESP_ERROR_CHECK(adc_cali_create_scheme_line_fitting(&cali_cfg, &adc_cali_handle));
#ifdef BOARD_V5
// Diagnostic: log configured VOC — resistor on board sets OC threshold.
// Datasheet: VVOC [V] = RL_VOC [Ω] × 1e-5, linear 0.33–0.66 V on 3.3V variant.
int voc_raw = 0, voc_mv = 0;
if (adc_oneshot_read(adc1_handle, PIN_V_VOC, &voc_raw) == ESP_OK &&
adc_cali_raw_to_voltage(adc_cali_handle, voc_raw, &voc_mv) == ESP_OK) {
ESP_LOGI(TAG, "ACS37220 VOC = %d mV (OC threshold config)", voc_mv);
}
#endif
return ESP_OK;
}
esp_err_t adc_post(void) {
// Read all 4 channels twice with a short delay; flag if frozen or wildly out of range
#ifdef BOARD_V5
const adc_channel_t channels[] = { PIN_V_ISENS_MAIN, PIN_V_SENS_BAT };
const char *names[] = { "ISENS", "BATTERY" };
const int n = 2;
#else
const adc_channel_t channels[] = { PIN_V_ISENS1, PIN_V_ISENS2, PIN_V_ISENS3, PIN_V_SENS_BAT };
const char *names[] = { "ISENS1", "ISENS2", "ISENS3", "BATTERY" };
const int n = 4;
#endif
int first[4], second[4];
for (int i = 0; i < 4; i++) {
for (int i = 0; i < n; i++) {
if (adc_oneshot_read(adc1_handle, channels[i], &first[i]) != ESP_OK) {
ESP_LOGE(TAG, "POST: ADC read failed on %s", names[i]);
return ESP_FAIL;
@@ -194,23 +240,28 @@ esp_err_t adc_post(void) {
vTaskDelay(pdMS_TO_TICKS(5));
for (int i = 0; i < 4; i++) {
for (int i = 0; i < n; i++) {
if (adc_oneshot_read(adc1_handle, channels[i], &second[i]) != ESP_OK) {
ESP_LOGE(TAG, "POST: ADC read failed on %s (2nd)", names[i]);
return ESP_FAIL;
}
}
// Check for frozen ADC (identical readings on noise-bearing current sense channels)
for (int i = 0; i < 3; i++) { // only current sense, not battery (battery can be stable)
// Frozen-ADC check on current-sense channels only (battery can legitimately be stable)
for (int i = 0; i < n - 1; i++) {
if (first[i] == second[i] && first[i] != 0) {
ESP_LOGW(TAG, "POST: ADC %s may be frozen (both reads = %d)", names[i], first[i]);
// Warning only — a truly stuck ADC will trip efuse protections anyway
}
}
#ifdef BOARD_V5
ESP_LOGI(TAG, "POST: ADC OK (BAT=%d/%d, I=%d/%d) FAULT=%d",
first[1], second[1], first[0], second[0],
gpio_get_level(PIN_FAULT_GPIO));
#else
ESP_LOGI(TAG, "POST: ADC OK (BAT=%d/%d, I1=%d/%d, I2=%d/%d, I3=%d/%d)",
first[3], second[3], first[0], second[0], first[1], second[1], first[2], second[2]);
#endif
return ESP_OK;
}
@@ -269,14 +320,79 @@ bool get_bridge_spike(bridge_t bridge, float threshold) {
return true;
}
#ifdef BOARD_V5
// V5 has a single current sensor shared by all bridges. Cache the read
// per fsm tick so three process_bridge_current() calls in the same tick
// don't hit the ADC three times.
static int64_t v5_isens_cache_time = INT64_MIN;
static int v5_isens_mv_cache = 0;
static bool v5_isens_cache_ok = false;
static bool v5_read_isens_mv(int *out_mv) {
if (v5_isens_cache_time != fsm_now) {
v5_isens_cache_time = fsm_now;
int raw = 0;
int mv = 0;
v5_isens_cache_ok = (adc_oneshot_read(adc1_handle, PIN_V_ISENS_MAIN, &raw) == ESP_OK) &&
(adc_cali_raw_to_voltage(adc_cali_handle, raw, &mv) == ESP_OK);
v5_isens_mv_cache = mv;
}
*out_mv = v5_isens_mv_cache;
return v5_isens_cache_ok;
}
static bool v5_bridge_is_active(bridge_t b) {
switch (b) {
case BRIDGE_DRIVE: return last_relay_state.bridges.DRIVE != BRIDGE_OFF;
case BRIDGE_JACK: return last_relay_state.bridges.JACK != BRIDGE_OFF;
case BRIDGE_AUX: return last_relay_state.bridges.AUX != BRIDGE_OFF;
default: return false;
}
}
static bool v5_any_bridge_active(void) {
return v5_bridge_is_active(BRIDGE_DRIVE) ||
v5_bridge_is_active(BRIDGE_JACK) ||
v5_bridge_is_active(BRIDGE_AUX);
}
#endif
esp_err_t process_bridge_current(bridge_t bridge) {
if (bridge < 0 || bridge >= NUM_BRIDGES) return ESP_ERR_INVALID_ARG;
isens_channel_t *channel = &isens[bridge];
#ifdef BOARD_V5
int voltage_mv = 0;
if (!v5_read_isens_mv(&voltage_mv)) {
return 0;
}
float last_current = channel->raw_current;
channel->raw_current = NAN;
// Single ACS37220LEZATR-100B3 for all motors: 13.2 mV/A, Vqvo=1.65 V.
// Sign convention matches the old V4 DRIVE wiring (ACS37220 oriented such
// that forward motor current gives negative delta from Vqvo).
float measured_A = -(voltage_mv - 1650.0f) / 13.2f;
// Per-bridge attribution:
// - bridge active and alone → it owns the entire reading
// - bridge active, others active → attribute full reading to each active
// bridge (worst-case; protects hardware). Jack/drive are mutually
// exclusive per design, so this only affects drive+aux overlap.
// - bridge OFF → no current from this bridge
// TODO(V5): better drive+aux simultaneous attribution (e.g. subtract the
// quieter bridge's nominal draw from the total).
if (v5_bridge_is_active(bridge)) {
channel->raw_current = measured_A;
} else {
channel->raw_current = 0.0f;
}
#else
int adc_raw = 0;
int voltage_mv = 0;
isens_channel_t *channel = &isens[bridge];
adc_channel_t pin;
switch(bridge) {
case BRIDGE_DRIVE: pin = PIN_V_ISENS1; break;
@@ -291,10 +407,10 @@ esp_err_t process_bridge_current(bridge_t bridge) {
if (adc_cali_raw_to_voltage(adc_cali_handle, adc_raw, &voltage_mv) != ESP_OK) {
return 0;
}
float last_current = channel->raw_current;
channel->raw_current = NAN;
switch (bridge) {
case BRIDGE_JACK:
case BRIDGE_AUX:
@@ -307,6 +423,7 @@ esp_err_t process_bridge_current(bridge_t bridge) {
break;
default: break;
}
#endif
if (!channel->ema_init) {
channel->ema_current = channel->raw_current;
@@ -326,7 +443,14 @@ esp_err_t process_bridge_current(bridge_t bridge) {
}
// === AUTO-ZERO LEARNING PHASE ===
if (fsm_now > channel->az_enable_time) {
// On V5, the single ADC reads aggregate motor current. A channel's
// "quiet" periods are when ALL bridges are off — not just this one.
#ifdef BOARD_V5
bool az_allowed = (fsm_now > channel->az_enable_time) && !v5_any_bridge_active();
#else
bool az_allowed = (fsm_now > channel->az_enable_time);
#endif
if (az_allowed) {
//ESP_LOGI(TAG, "AZING %d", bridge);
float db = get_param_value_t(PARAM_ADC_DB_IAZ).f32;
if (isnan(db) || fabsf(channel->ema_current) <= db) {
@@ -450,6 +574,16 @@ float get_battery_V(void)
return get_raw_battery_voltage();
}
bool get_hw_overcurrent_fault(void)
{
#ifdef BOARD_V5
// ACS37220 FAULT is active-low, open-drain, not latched.
return gpio_get_level(PIN_FAULT_GPIO) == 0;
#else
return false;
#endif
}
efuse_trip_t efuse_get(bridge_t bridge)
{
if (bridge >= N_BRIDGES) return false;