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SC-F001/main/power_mgmt.c

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/*
* power_mgmt.c
*
* 1 kHz power-management task:
* • Samples all three H-bridge current sensors (DRIVE, AUX, JACK)
* • Samples battery voltage (BAT)
* • Applies EMA filtering on every channel
* • Updates shared volatile globals for the control FSM
* • Handles over-current spike protection
*
* Updated to modern ESP-IDF ADC API (line fitting)
* All variables now defined locally
*
* Created on: Nov 10, 2025
*/
#include <math.h>
#include <stdint.h>
#include <stdbool.h>
#include "driver/rtc_io.h"
#include "esp_log.h"
#include "esp_task_wdt.h"
#include "freertos/FreeRTOS.h"
#include "freertos/task.h"
#include "esp_adc/adc_oneshot.h"
#include "esp_adc/adc_cali.h"
#include "esp_adc/adc_cali_scheme.h"
#include "esp_timer.h"
#include "driver/gpio.h"
#include "control_fsm.h"
#include "i2c.h"
#include "sensors.h"
#include "soc/rtc_io_reg.h"
#include "power_mgmt.h"
#include "storage.h"
#include "rtc.h"
#define TAG "POWER"
// === GPIO Pin Definitions ===
#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
#define PIN_V_SENS_BAT PIN_V_BATTERY
// map from relay number to bridge
/*bridge_t bridge_map[] = {
-1,
BRIDGE_AUX,
BRIDGE_AUX,
BRIDGE_AUX,
BRIDGE_JACK,
BRIDGE_JACK,
BRIDGE_DRIVE,
BRIDGE_DRIVE };*/
// update time
#define UPDATE_MS 20
#define UPDATE_S 0.02f
extern int64_t fsm_now; // us
// E-fuse data
typedef struct {
int64_t az_enable_time; // Timestamp to enable autozeroing at (negative to disable)
float az_offset; // Accumulated zero offset
bool az_initialized; // First valid zero established
float raw_current;
bool ema_init;
float ema_current;
float current; // with all the corrections applied
float current_spike;
float heat;
efuse_trip_t tripped;
int64_t trip_time;
int64_t on_us;
int64_t off_us;
} isens_channel_t;
static isens_channel_t isens[N_BRIDGES] = {0};
/**** DRIVE RELAYS ****/
bool relay_states[8] = {false};
//int64_t bridge_transitions_on[NUM_BRIDGES] = {-1}; // last time relay turned on (used to ignore inrush)
//int64_t bridge_transitions_off[NUM_BRIDGES] = {-1}; // last time relay turned off (used to enable autozero)
relay_port_t last_relay_state;
// actually write relay states, taking note of transitions, and debouncing transitions to on.
#define BRIDGE_TRANSITION_LOGIC(BRIDGE_NAME) \
if (relay_state.bridges.BRIDGE_NAME == last_relay_state.bridges.BRIDGE_NAME) { \
/* no change; no need to do anything */ \
if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "NO CHANGE"); \
} \
else if (last_relay_state.bridges.BRIDGE_NAME != BRIDGE_OFF && relay_state.bridges.BRIDGE_NAME == BRIDGE_OFF) { \
isens[BRIDGE_##BRIDGE_NAME].off_us = fsm_now; \
if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "ON -> OFF"); \
} \
else if (last_relay_state.bridges.BRIDGE_NAME == BRIDGE_OFF && relay_state.bridges.BRIDGE_NAME != BRIDGE_OFF) { \
if (fsm_now > isens[BRIDGE_##BRIDGE_NAME].off_us + 2*get_param_value_t(PARAM_EFUSE_INRUSH_US).u32) { \
isens[BRIDGE_##BRIDGE_NAME].on_us = fsm_now; \
if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "OFF -> ON"); \
} else { \
relay_state.bridges.BRIDGE_NAME = BRIDGE_OFF; \
if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "NOT YET; -> OFF"); \
} \
} \
else { \
if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGE(TAG, "TOO FAST OF TRANSITION"); \
isens[BRIDGE_##BRIDGE_NAME].off_us = fsm_now; \
relay_state.bridges.BRIDGE_NAME = BRIDGE_OFF; \
}
esp_err_t driveRelays(relay_port_t relay_state) {
// Four types of transitions.
// Not a transition: this does nothing
// Anything -> off: always allowed. Record the transition time
// off -> anything: has debouncing; set & record transition if fsm_now > bridge_transitions_off + debounce, otherwise keep bridge off.
// fwd/rev/on -> fwd/rev/on: not allowed. Actually go to 0. Record the transition time.
BRIDGE_TRANSITION_LOGIC(DRIVE)
BRIDGE_TRANSITION_LOGIC(JACK)
BRIDGE_TRANSITION_LOGIC(AUX)
relay_state.bridges.SENSORS = 1;
if (!get_is_safe())
relay_state.bridges.DRIVE = 0;
last_relay_state = relay_state;
//ESP_LOGI(TAG, "RELAY STATE: %x", state);
return i2c_set_relays(relay_state);
}
/**** CURRENT / VOLTAGE MONITORING ****/
// === ADC Handles ===
static adc_oneshot_unit_handle_t adc1_handle = NULL;
static adc_cali_handle_t adc_cali_handle = NULL;
static float ema_battery = 0.0f;
static bool ema_battery_init = false;
esp_err_t adc_init() {
// ADC1 oneshot mode
adc_oneshot_unit_init_cfg_t init_cfg = {
.unit_id = ADC_UNIT_1,
};
ESP_ERROR_CHECK(adc_oneshot_new_unit(&init_cfg, &adc1_handle));
// Configure all channels
adc_oneshot_chan_cfg_t chan_cfg = {
.atten = ADC_ATTEN_DB_12,
.bitwidth = ADC_BITWIDTH_12,
};
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));
// Line fitting calibration (modern scheme)
adc_cali_line_fitting_config_t cali_cfg = {
.unit_id = ADC_UNIT_1,
.atten = ADC_ATTEN_DB_12,
.bitwidth = ADC_BITWIDTH_12,
};
ESP_ERROR_CHECK(adc_cali_create_scheme_line_fitting(&cali_cfg, &adc_cali_handle));
return ESP_OK;
}
float get_raw_battery_voltage(void) {
int adc_raw = 0;
int voltage_mv = 0;
if (adc_oneshot_read(adc1_handle, PIN_V_SENS_BAT, &adc_raw)
!= ESP_OK) { return NAN; }
if (adc_cali_raw_to_voltage(adc_cali_handle, adc_raw, &voltage_mv)
!= ESP_OK) { return NAN; }
// Voltage divider: 150kohm to 1Mohm -> gain = 1.15 -> scale = 1150/150
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;
}
esp_err_t process_battery_voltage(void)
{
float raw = get_raw_battery_voltage();
if (!ema_battery_init) {
ema_battery = (float)raw;
ema_battery_init = true;
} else {
float alpha = get_param_value_t(PARAM_ADC_ALPHA_BATTERY).f32;
if (isnan(raw)) {
//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
} else {
if (isnan(ema_battery) || isnan(alpha)) {
ema_battery = raw;
} else {
ema_battery = alpha * (float)raw + (1.0f - alpha) * ema_battery;
}
}
}
return ESP_OK;
}
void disable_autozero(bridge_t bridge) {
// enable autozeroing for this bridge 1 second from now
isens[bridge].az_enable_time = fsm_now+1000000;
//ESP_LOGI(TAG, "KILLING BRIDGE %d; %lld -> %lld", bridge, (long long int) now, (long long int) isens[bridge].az_enable_time);
}
bool get_bridge_overcurrent(bridge_t bridge, float threshold) {
if (bridge < 0 || bridge>=NUM_BRIDGES) return true; // I GUESS?
if (fsm_now < isens[bridge].on_us + get_param_value_t(PARAM_EFUSE_INRUSH_US).u32) return false;
if (isens[bridge].raw_current < threshold) return false;
return true;
}
bool get_bridge_spike(bridge_t bridge, float threshold) {
if (bridge < 0 || bridge>=NUM_BRIDGES) return true; // I GUESS?
if (fsm_now < isens[bridge].on_us + get_param_value_t(PARAM_EFUSE_INRUSH_US).u32) return false;
if (isens[bridge].current_spike < threshold) return false;
return true;
}
esp_err_t process_bridge_current(bridge_t bridge) {
if (bridge < 0 || bridge >= NUM_BRIDGES) return ESP_ERR_INVALID_ARG;
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;
case BRIDGE_JACK: pin = PIN_V_ISENS2; break;
case BRIDGE_AUX: pin = PIN_V_ISENS3; break;
default: return ESP_ERR_INVALID_ARG;
}
if (adc_oneshot_read(adc1_handle, pin, &adc_raw) != ESP_OK) {
return 0;
}
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:
// ACS37042KLHBLT-030B3 is 30A capable and 44 mV/A
channel->raw_current = (voltage_mv - 1650.0f) / 44.0f;
break;
case BRIDGE_DRIVE:
// ACS37220LEZATR-100B3 is 100A capable and 13.2 mV/A
channel->raw_current = -(voltage_mv - 1650.0f) / 13.2f;
break;
default: break;
}
if (!channel->ema_init) {
channel->ema_current = channel->raw_current;
channel->ema_init = true;
} 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)) {
channel->ema_current = channel->raw_current;
} else {
channel->ema_current = alpha * channel->raw_current + (1.0f - alpha) * channel->ema_current;
}
}
}
// === AUTO-ZERO LEARNING PHASE ===
if (fsm_now > channel->az_enable_time) {
//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) {
// Valid zero sample
if (!channel->az_initialized) {
channel->az_offset = channel->ema_current;
channel->az_initialized = true;
} else {
float alpha = get_param_value_t(PARAM_ADC_ALPHA_IAZ).f32;
if (isnan(channel->raw_current)) {
//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
} else {
if (isnan(ema_battery) || isnan(alpha)) {
channel->az_offset = channel->ema_current;
} else {
channel->az_offset = alpha * channel->ema_current +
(1.0f - alpha) * channel->az_offset;
}
}
}
}
}
// Apply the offset
channel->current = channel->raw_current - channel->az_offset;
channel->raw_current = channel->raw_current - channel->az_offset;
channel->current_spike = channel->raw_current - last_current;
// PARAMETERS FOR E-FUSING ALGORITHM
// PARAM_EFUSE_KINST : ratio of nominal current that should cause an immediate shutdown
// PARAM_EFUSE_TCOOL : cooldown timer from trip (in microseconds)
// PARAM_EFUSE_TAUCOOL : speed of cooldown for heating (units are 1/s; bigger = faster cooldown)
// Monitor E-fusing
float I_nominal = NAN;
switch(bridge) {
case BRIDGE_DRIVE:
I_nominal = get_param_value_t(PARAM_EFUSE_INOM_1).f32;
break;
case BRIDGE_JACK:
I_nominal = get_param_value_t(PARAM_EFUSE_INOM_2).f32;
break;
case BRIDGE_AUX:
I_nominal = get_param_value_t(PARAM_EFUSE_INOM_3).f32;
break;
default: break;
}
// Normalize the current as a fraction of rated current
float I_norm = fabsf(channel->current / I_nominal);
// Instant trip on extreme overcurrent
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) {
// Check if overcurrent has persisted long enough
channel->tripped = true;
channel->trip_time = fsm_now;
//ESP_LOGI(TAG, "FUSE TRIP: Inom: %+.5f HEAT:%+2.5f", I_norm, channel->heat);
return ESP_OK; // no more processing, if we're over, we're over
// Still in overcurrent but within inrush tolerance window - don't trip yet
}
// Accumulate heat
channel->heat += (I_norm * I_norm) * UPDATE_S;
// Only do cooling when below threshold
if (I_norm < 1.0f) {
// if we are hot we radiate more heat
// (I^2/I^2*t) * (1/t) * t = I^2/I^2*t
channel->heat -= channel->heat * get_param_value_t(PARAM_EFUSE_TAUCOOL).f32 * UPDATE_S;
channel->heat = fmaxf(0.0f, channel->heat); // keep it from going negative
// channel.tripped = false; // Auto-clear if cooled (WTF why this is insane)
}
// If built-up heat exceeds the time limit, trip
// Recall units of heat are (current_actual^2/current_nominal^2)*time
// Ergo, heat is measured in seconds
if (channel->heat > get_param_value_t(PARAM_EFUSE_HEAT_THRESH).f32) {
channel->tripped = true;
channel->trip_time = fsm_now;
// If we're not overheated
// And enough time has passed
// Go ahead and reset the e-fuse
} else if (channel->tripped &&
(fsm_now - channel->trip_time) > get_param_value_t(PARAM_EFUSE_TCOOL).u32) {
channel->tripped = false;
// channel.heat = 0.0f // I think we should wait for the e-fuse to catch up
}
//if (bridge == BRIDGE_JACK) ESP_LOGI(TAG, "TIME: %lld", (long long) fsm_now);
//if (bridge == BRIDGE_JACK) ESP_LOGI(TAG, "FUSE: trip [%d] %lld, raw_a: %+.4f cur: %+.4f Inorm: %+.5f HEAT:%+2.5f", channel->tripped, channel->trip_time, channel->raw_current, channel->current, I_norm, channel->heat);
return ESP_OK;
}
// === Public Accessors ===
float get_bridge_A(bridge_t bridge)
{
if (bridge >= N_BRIDGES) return NAN;
return isens[bridge].current;
}
float get_bridge_raw_A(bridge_t bridge)
{
if (bridge >= N_BRIDGES) return NAN;
return isens[bridge].raw_current;
}
float efuse_get_heat(bridge_t bridge) {
if (bridge >= N_BRIDGES) return NAN;
return isens[bridge].heat;
}
float get_battery_V(void)
{
if (ema_battery_init)
return ema_battery;
return get_raw_battery_voltage();
}
efuse_trip_t efuse_get(bridge_t bridge)
{
if (bridge >= N_BRIDGES) return false;
return isens[bridge].tripped;
}
void efuse_set(bridge_t bridge, efuse_trip_t state)
{
if (bridge >= N_BRIDGES) return;
isens[bridge].tripped = state;
isens[bridge].trip_time = fsm_now;
}
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