428 lines
14 KiB
C
428 lines
14 KiB
C
/*
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* power_mgmt.c
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*
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* 1 kHz power-management task:
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* • Samples all three H-bridge current sensors (DRIVE, AUX, JACK)
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* • Samples battery voltage (BAT)
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* • Applies EMA filtering on every channel
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* • Updates shared volatile globals for the control FSM
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* • Handles over-current spike protection
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*
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* Updated to modern ESP-IDF ADC API (line fitting)
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* All variables now defined locally
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*
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* Created on: Nov 10, 2025
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*/
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#include <math.h>
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#include <stdint.h>
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#include <stdbool.h>
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#include "driver/rtc_io.h"
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#include "esp_log.h"
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#include "esp_task_wdt.h"
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#include "freertos/FreeRTOS.h"
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#include "freertos/task.h"
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#include "esp_adc/adc_oneshot.h"
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#include "esp_adc/adc_cali.h"
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#include "esp_adc/adc_cali_scheme.h"
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#include "esp_timer.h"
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#include "driver/gpio.h"
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#include "control_fsm.h"
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#include "i2c.h"
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#include "sensors.h"
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#include "soc/rtc_io_reg.h"
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#include "power_mgmt.h"
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#include "storage.h"
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#include "rtc.h"
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#define TAG "POWER"
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// === GPIO Pin Definitions ===
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#define PIN_V_ISENS1 ADC_CHANNEL_0 // GPIO36 / VP
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#define PIN_V_ISENS2 ADC_CHANNEL_6 // GPIO34
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#define PIN_V_ISENS3 ADC_CHANNEL_7 // GPIO35
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#define PIN_V_BATTERY ADC_CHANNEL_3 // GPIO39 / VN
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#define PIN_V_SENS_BAT PIN_V_BATTERY
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// map from relay number to bridge
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/*bridge_t bridge_map[] = {
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-1,
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BRIDGE_AUX,
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BRIDGE_AUX,
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BRIDGE_AUX,
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BRIDGE_JACK,
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BRIDGE_JACK,
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BRIDGE_DRIVE,
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BRIDGE_DRIVE };*/
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// update time
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#define UPDATE_MS 20
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#define UPDATE_S 0.02f
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extern int64_t fsm_now; // us
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// E-fuse data
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typedef struct {
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int64_t az_enable_time; // Timestamp to enable autozeroing at (negative to disable)
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float az_offset; // Accumulated zero offset
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bool az_initialized; // First valid zero established
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float raw_current;
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bool ema_init;
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float ema_current;
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float current; // with all the corrections applied
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float current_spike;
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float heat;
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efuse_trip_t tripped;
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int64_t trip_time;
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int64_t on_us;
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int64_t off_us;
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} isens_channel_t;
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static isens_channel_t isens[N_BRIDGES] = {0};
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/**** DRIVE RELAYS ****/
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bool relay_states[8] = {false};
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//int64_t bridge_transitions_on[NUM_BRIDGES] = {-1}; // last time relay turned on (used to ignore inrush)
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//int64_t bridge_transitions_off[NUM_BRIDGES] = {-1}; // last time relay turned off (used to enable autozero)
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relay_port_t last_relay_state;
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// actually write relay states, taking note of transitions, and debouncing transitions to on.
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#define BRIDGE_TRANSITION_LOGIC(BRIDGE_NAME) \
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if (relay_state.bridges.BRIDGE_NAME == last_relay_state.bridges.BRIDGE_NAME) { \
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/* no change; no need to do anything */ \
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if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "NO CHANGE"); \
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} \
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else if (last_relay_state.bridges.BRIDGE_NAME != BRIDGE_OFF && relay_state.bridges.BRIDGE_NAME == BRIDGE_OFF) { \
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isens[BRIDGE_##BRIDGE_NAME].off_us = fsm_now; \
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if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "ON -> OFF"); \
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} \
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else if (last_relay_state.bridges.BRIDGE_NAME == BRIDGE_OFF && relay_state.bridges.BRIDGE_NAME != BRIDGE_OFF) { \
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if (fsm_now > isens[BRIDGE_##BRIDGE_NAME].off_us + 2*get_param_value_t(PARAM_EFUSE_INRUSH_US).u32) { \
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isens[BRIDGE_##BRIDGE_NAME].on_us = fsm_now; \
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if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "OFF -> ON"); \
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} else { \
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relay_state.bridges.BRIDGE_NAME = BRIDGE_OFF; \
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if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGI(TAG, "NOT YET; -> OFF"); \
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} \
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} \
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else { \
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if(false) if (BRIDGE_##BRIDGE_NAME == BRIDGE_JACK) ESP_LOGE(TAG, "TOO FAST OF TRANSITION"); \
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isens[BRIDGE_##BRIDGE_NAME].off_us = fsm_now; \
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relay_state.bridges.BRIDGE_NAME = BRIDGE_OFF; \
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}
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esp_err_t drive_relays(relay_port_t relay_state) {
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// Four types of transitions.
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// Not a transition: this does nothing
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// Anything -> off: always allowed. Record the transition time
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// off -> anything: has debouncing; set & record transition if fsm_now > bridge_transitions_off + debounce, otherwise keep bridge off.
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// fwd/rev/on -> fwd/rev/on: not allowed. Actually go to 0. Record the transition time.
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BRIDGE_TRANSITION_LOGIC(DRIVE)
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BRIDGE_TRANSITION_LOGIC(JACK)
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BRIDGE_TRANSITION_LOGIC(AUX)
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relay_state.bridges.SENSORS = 1;
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if (!get_is_safe())
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relay_state.bridges.DRIVE = 0;
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last_relay_state = relay_state;
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//ESP_LOGI(TAG, "RELAY STATE: %x", state);
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return i2c_set_relays(relay_state);
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}
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/**** CURRENT / VOLTAGE MONITORING ****/
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// === ADC Handles ===
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static adc_oneshot_unit_handle_t adc1_handle = NULL;
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static adc_cali_handle_t adc_cali_handle = NULL;
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static float ema_battery = 0.0f;
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static bool ema_battery_init = false;
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esp_err_t adc_init() {
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// ADC1 oneshot mode
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adc_oneshot_unit_init_cfg_t init_cfg = {
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.unit_id = ADC_UNIT_1,
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};
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ESP_ERROR_CHECK(adc_oneshot_new_unit(&init_cfg, &adc1_handle));
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// Configure all channels
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adc_oneshot_chan_cfg_t chan_cfg = {
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.atten = ADC_ATTEN_DB_12,
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.bitwidth = ADC_BITWIDTH_12,
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};
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ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS1, &chan_cfg));
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ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS2, &chan_cfg));
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ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_ISENS3, &chan_cfg));
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ESP_ERROR_CHECK(adc_oneshot_config_channel(adc1_handle, PIN_V_SENS_BAT, &chan_cfg));
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// Line fitting calibration (modern scheme)
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adc_cali_line_fitting_config_t cali_cfg = {
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.unit_id = ADC_UNIT_1,
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.atten = ADC_ATTEN_DB_12,
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.bitwidth = ADC_BITWIDTH_12,
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};
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ESP_ERROR_CHECK(adc_cali_create_scheme_line_fitting(&cali_cfg, &adc_cali_handle));
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return ESP_OK;
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}
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float get_raw_battery_voltage(void) {
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int adc_raw = 0;
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int voltage_mv = 0;
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if (adc_oneshot_read(adc1_handle, PIN_V_SENS_BAT, &adc_raw)
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!= ESP_OK) { return NAN; }
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if (adc_cali_raw_to_voltage(adc_cali_handle, adc_raw, &voltage_mv)
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!= ESP_OK) { return NAN; }
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// Voltage divider: 150kohm to 1Mohm -> gain = 1.15 -> scale = 1150/150
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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;
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}
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esp_err_t process_battery_voltage(void)
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{
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float raw = get_raw_battery_voltage();
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if (!ema_battery_init) {
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ema_battery = (float)raw;
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ema_battery_init = true;
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} else {
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float alpha = get_param_value_t(PARAM_ADC_ALPHA_BATTERY).f32;
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if (isnan(raw)) {
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//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
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} else {
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if (isnan(ema_battery) || isnan(alpha)) {
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ema_battery = raw;
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} else {
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ema_battery = alpha * (float)raw + (1.0f - alpha) * ema_battery;
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}
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}
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}
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return ESP_OK;
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}
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void disable_autozero(bridge_t bridge) {
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// enable autozeroing for this bridge 1 second from now
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isens[bridge].az_enable_time = fsm_now+1000000;
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//ESP_LOGI(TAG, "KILLING BRIDGE %d; %lld -> %lld", bridge, (long long int) now, (long long int) isens[bridge].az_enable_time);
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}
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bool get_bridge_overcurrent(bridge_t bridge, float threshold) {
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if (bridge < 0 || bridge>=NUM_BRIDGES) return true; // I GUESS?
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if (fsm_now < isens[bridge].on_us + get_param_value_t(PARAM_EFUSE_INRUSH_US).u32) return false;
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if (isens[bridge].raw_current < threshold) return false;
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return true;
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}
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bool get_bridge_spike(bridge_t bridge, float threshold) {
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if (bridge < 0 || bridge>=NUM_BRIDGES) return true; // I GUESS?
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if (fsm_now < isens[bridge].on_us + get_param_value_t(PARAM_EFUSE_INRUSH_US).u32) return false;
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if (isens[bridge].current_spike < threshold) return false;
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return true;
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}
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esp_err_t process_bridge_current(bridge_t bridge) {
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if (bridge < 0 || bridge >= NUM_BRIDGES) return ESP_ERR_INVALID_ARG;
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int adc_raw = 0;
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int voltage_mv = 0;
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isens_channel_t *channel = &isens[bridge];
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adc_channel_t pin;
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switch(bridge) {
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case BRIDGE_DRIVE: pin = PIN_V_ISENS1; break;
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case BRIDGE_JACK: pin = PIN_V_ISENS2; break;
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case BRIDGE_AUX: pin = PIN_V_ISENS3; break;
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default: return ESP_ERR_INVALID_ARG;
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}
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if (adc_oneshot_read(adc1_handle, pin, &adc_raw) != ESP_OK) {
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return 0;
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}
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if (adc_cali_raw_to_voltage(adc_cali_handle, adc_raw, &voltage_mv) != ESP_OK) {
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return 0;
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}
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float last_current = channel->raw_current;
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channel->raw_current = NAN;
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switch (bridge) {
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case BRIDGE_JACK:
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case BRIDGE_AUX:
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// ACS37042KLHBLT-030B3 is 30A capable and 44 mV/A
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channel->raw_current = (voltage_mv - 1650.0f) / 44.0f;
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break;
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case BRIDGE_DRIVE:
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// ACS37220LEZATR-100B3 is 100A capable and 13.2 mV/A
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channel->raw_current = -(voltage_mv - 1650.0f) / 13.2f;
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break;
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default: break;
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}
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if (!channel->ema_init) {
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channel->ema_current = channel->raw_current;
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channel->ema_init = true;
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} else {
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float alpha = get_param_value_t(PARAM_ADC_ALPHA_ISENS).f32;
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if (isnan(channel->raw_current)) {
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//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
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channel->ema_current = NAN;
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} else {
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if (isnan(ema_battery) || isnan(alpha)) {
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channel->ema_current = channel->raw_current;
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} else {
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channel->ema_current = alpha * channel->raw_current + (1.0f - alpha) * channel->ema_current;
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}
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}
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}
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// === AUTO-ZERO LEARNING PHASE ===
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if (fsm_now > channel->az_enable_time) {
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//ESP_LOGI(TAG, "AZING %d", bridge);
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float db = get_param_value_t(PARAM_ADC_DB_IAZ).f32;
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if (isnan(db) || fabsf(channel->ema_current) <= db) {
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// Valid zero sample
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if (!channel->az_initialized) {
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channel->az_offset = channel->ema_current;
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channel->az_initialized = true;
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} else {
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float alpha = get_param_value_t(PARAM_ADC_ALPHA_IAZ).f32;
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if (isnan(channel->raw_current)) {
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//ESP_LOGI(TAG, "RAW BATTERY IS NAN");
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} else {
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if (isnan(ema_battery) || isnan(alpha)) {
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channel->az_offset = channel->ema_current;
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} else {
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channel->az_offset = alpha * channel->ema_current +
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(1.0f - alpha) * channel->az_offset;
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}
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}
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}
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}
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}
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// Apply the offset
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channel->current = channel->raw_current - channel->az_offset;
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channel->raw_current = channel->raw_current - channel->az_offset;
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channel->current_spike = channel->raw_current - last_current;
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// PARAMETERS FOR E-FUSING ALGORITHM
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// PARAM_EFUSE_KINST : ratio of nominal current that should cause an immediate shutdown
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// PARAM_EFUSE_TCOOL : cooldown timer from trip (in microseconds)
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// PARAM_EFUSE_TAUCOOL : speed of cooldown for heating (units are 1/s; bigger = faster cooldown)
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// Monitor E-fusing
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float I_nominal = NAN;
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switch(bridge) {
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case BRIDGE_DRIVE:
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I_nominal = get_param_value_t(PARAM_EFUSE_INOM_1).f32;
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break;
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case BRIDGE_JACK:
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I_nominal = get_param_value_t(PARAM_EFUSE_INOM_2).f32;
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break;
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case BRIDGE_AUX:
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I_nominal = get_param_value_t(PARAM_EFUSE_INOM_3).f32;
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break;
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default: break;
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}
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// Normalize the current as a fraction of rated current
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float I_norm = fabsf(channel->current / I_nominal);
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// Instant trip on extreme overcurrent
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if (fsm_now > channel->on_us + get_param_value_t(PARAM_EFUSE_INRUSH_US).u32
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&& I_norm >= get_param_value_t(PARAM_EFUSE_KINST).f32) {
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// Check if overcurrent has persisted long enough
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channel->tripped = true;
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channel->trip_time = fsm_now;
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//ESP_LOGI(TAG, "FUSE TRIP: Inom: %+.5f HEAT:%+2.5f", I_norm, channel->heat);
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return ESP_OK; // no more processing, if we're over, we're over
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// Still in overcurrent but within inrush tolerance window - don't trip yet
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}
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// Accumulate heat
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channel->heat += (I_norm * I_norm) * UPDATE_S;
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// Only do cooling when below threshold
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if (I_norm < 1.0f) {
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// if we are hot we radiate more heat
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// (I^2/I^2*t) * (1/t) * t = I^2/I^2*t
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channel->heat -= channel->heat * get_param_value_t(PARAM_EFUSE_TAUCOOL).f32 * UPDATE_S;
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channel->heat = fmaxf(0.0f, channel->heat); // keep it from going negative
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// channel.tripped = false; // Auto-clear if cooled (WTF why this is insane)
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}
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// If built-up heat exceeds the time limit, trip
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// Recall units of heat are (current_actual^2/current_nominal^2)*time
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// Ergo, heat is measured in seconds
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if (channel->heat > get_param_value_t(PARAM_EFUSE_HEAT_THRESH).f32) {
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channel->tripped = true;
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channel->trip_time = fsm_now;
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// If we're not overheated
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// And enough time has passed
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// Go ahead and reset the e-fuse
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} else if (channel->tripped &&
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(fsm_now - channel->trip_time) > get_param_value_t(PARAM_EFUSE_TCOOL).u32) {
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channel->tripped = false;
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// channel.heat = 0.0f // I think we should wait for the e-fuse to catch up
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}
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//if (bridge == BRIDGE_JACK) ESP_LOGI(TAG, "TIME: %lld", (long long) fsm_now);
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//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);
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return ESP_OK;
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}
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// === Public Accessors ===
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float get_bridge_A(bridge_t bridge)
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{
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if (bridge >= N_BRIDGES) return NAN;
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return isens[bridge].current;
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}
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float get_bridge_raw_A(bridge_t bridge)
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{
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if (bridge >= N_BRIDGES) return NAN;
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return isens[bridge].raw_current;
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}
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float efuse_get_heat(bridge_t bridge) {
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if (bridge >= N_BRIDGES) return NAN;
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return isens[bridge].heat;
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}
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float get_battery_V(void)
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{
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if (ema_battery_init)
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return ema_battery;
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return get_raw_battery_voltage();
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}
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efuse_trip_t efuse_get(bridge_t bridge)
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{
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if (bridge >= N_BRIDGES) return false;
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return isens[bridge].tripped;
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}
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void efuse_set(bridge_t bridge, efuse_trip_t state)
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{
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if (bridge >= N_BRIDGES) return;
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isens[bridge].tripped = state;
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isens[bridge].trip_time = fsm_now;
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} |