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i think we're basically done

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This commit is contained in:
Thaddeus Hughes
2026-04-27 17:22:34 -05:00
parent 9f4362b5fd
commit f47a29205e
35 changed files with 14893 additions and 1687 deletions
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65
main/power_mgmt.c
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@@ -143,16 +143,11 @@ esp_err_t drive_relays(relay_port_t relay_state) {
BRIDGE_TRANSITION_LOGIC(JACK)
BRIDGE_TRANSITION_LOGIC(AUX)
/* Sensor rail (P10) powered only when FSM is actively doing something.
* In STATE_IDLE we cut it to save power. Overrides energize a motor
* while FSM is technically IDLE — keep the rail up in that case too
* so overrides that consult sensor state (e.g. JACK_DOWN, which checks
* SENSOR_JACK) still work. */
bool motor_requested = (relay_state.bridges.DRIVE != BRIDGE_OFF ||
relay_state.bridges.JACK != BRIDGE_OFF ||
relay_state.bridges.AUX != BRIDGE_OFF);
relay_state.bridges.SENSORS =
(fsm_get_state() != STATE_IDLE || motor_requested) ? 1 : 0;
/* Sensor rail (P10) is on whenever the device is awake — including
* STATE_IDLE — so the SAFETY input can be observed continuously.
* It is dropped only in soft_idle_enter() (sleep) via i2c_relays_sleep,
* and toggled explicitly by the bring-up tool's BU.RELAY SENSORS cmd. */
relay_state.bridges.SENSORS = 1;
if (!get_is_safe())
relay_state.bridges.DRIVE = 0;
@@ -287,6 +282,20 @@ float get_raw_battery_voltage(void) {
return voltage_mv * get_param_value_t(PARAM_V_SENS_K).f32 + get_param_value_t(PARAM_V_SENS_OFFSET).f32; // same as / 1000.0 * 1150.0 / 150.0;
}
void reset_battery_ema(void)
{
/* Next process_battery_voltage() call re-seeds from raw. Also refresh
* immediately from a fresh raw read so callers that read get_battery_V()
* before the FSM ticks again (e.g. during bringup) see the new value. */
float raw = get_raw_battery_voltage();
if (!isnan(raw)) {
ema_battery = raw;
ema_battery_init = true;
} else {
ema_battery_init = false;
}
}
esp_err_t process_battery_voltage(void)
{
float raw = get_raw_battery_voltage();
@@ -364,6 +373,20 @@ static bool v5_any_bridge_active(void) {
v5_bridge_is_active(BRIDGE_JACK) ||
v5_bridge_is_active(BRIDGE_AUX);
}
/* True if any currently-active bridge is still inside its INRUSH_US window.
* The shared ACS reading is unattributable per-bridge during a co-active
* inrush — the full combined current is attributed to each active bridge in
* process_bridge_current(), so a quieter bridge (e.g. AUX during DRIVE start)
* sees an inflated I_norm and would spuriously instant-trip on KINST. */
static bool v5_any_bridge_in_inrush(void) {
int64_t inrush_us = (int64_t)get_param_value_t(PARAM_EFUSE_INRUSH_US).u32;
for (bridge_t b = 0; b < N_BRIDGES; b++) {
if (!v5_bridge_is_active(b)) continue;
if (fsm_now < isens[b].on_us + inrush_us) return true;
}
return false;
}
#endif
esp_err_t process_bridge_current(bridge_t bridge) {
@@ -440,10 +463,11 @@ esp_err_t process_bridge_current(bridge_t bridge) {
} else {
float alpha = get_param_value_t(PARAM_ADC_ALPHA_ISENS).f32;
if (isnan(channel->raw_current)) {
//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
channel->ema_current = NAN;
} else {
if (isnan(ema_battery) || isnan(alpha)) {
/* Reset the per-bridge EMA if it (or alpha) is NaN — using
* the per-bridge value, not the unrelated battery EMA. */
if (isnan(channel->ema_current) || isnan(alpha)) {
channel->ema_current = channel->raw_current;
} else {
channel->ema_current = alpha * channel->raw_current + (1.0f - alpha) * channel->ema_current;
@@ -470,9 +494,10 @@ esp_err_t process_bridge_current(bridge_t bridge) {
} else {
float alpha = get_param_value_t(PARAM_ADC_ALPHA_IAZ).f32;
if (isnan(channel->raw_current)) {
//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
/* skip — no fresh sample */
} else {
if (isnan(ema_battery) || isnan(alpha)) {
/* Reset the autozero offset if it (or alpha) is NaN. */
if (isnan(channel->az_offset) || isnan(alpha)) {
channel->az_offset = channel->ema_current;
} else {
channel->az_offset = alpha * channel->ema_current +
@@ -512,9 +537,17 @@ esp_err_t process_bridge_current(bridge_t bridge) {
// Normalize the current as a fraction of rated current
float I_norm = fabsf(channel->current / I_nominal);
// Instant trip on extreme overcurrent
// Instant trip on extreme overcurrent. On V5, also require that no
// *other* active bridge is still in its inrush window — during a
// co-active inrush the shared ACS reading is attributed to each
// active bridge, which inflates the quieter bridge's I_norm and
// would otherwise cause a spurious instant-trip there.
if (fsm_now > channel->on_us + get_param_value_t(PARAM_EFUSE_INRUSH_US).u32
&& I_norm >= get_param_value_t(PARAM_EFUSE_KINST).f32) {
&& I_norm >= get_param_value_t(PARAM_EFUSE_KINST).f32
#ifdef BOARD_V5
&& !v5_any_bridge_in_inrush()
#endif
) {
// Check if overcurrent has persisted long enough
channel->tripped = true;
channel->trip_time = fsm_now;