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preliminary heater sanity check code, disabled by default until tested

This commit is contained in:
Michael Moon 2010-11-11 00:51:25 +11:00
parent 4298f7553f
commit 2b1fbe38db
2 changed files with 93 additions and 28 deletions
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11
config.h.dist
View File

@ -182,19 +182,21 @@
\***************************************************************************/
/*
TEMP_HYSTERESIS: actual temperature must be target +/- hysteresis before target temperature can be achieved
TEMP_HYSTERESIS: actual temperature must be target +/- hysteresis before target temperature can be achieved.
NOTE: format is 30.2 fixed point, so value of 20 actually means +/- 5 degrees
TEMP_RESIDENCY_TIME: actual temperature must be close to target for this long before target is achieved
temperature is "achieved" for purposes of M109 and friends when actual temperature is within [hysteresis] of target for [residency] seconds
*/
#define TEMP_HYSTERESIS 5
#define TEMP_HYSTERESIS 20
#define TEMP_RESIDENCY_TIME 60
// which temperature sensors are you using? (intercom is the gen3-style separate extruder board)
// #define TEMP_MAX6675
// #define TEMP_THERMISTOR
// #define TEMP_AD595
// #define TEMP_INTERCOM
#define TEMP_INTERCOM
// if you selected thermistor or AD595, what pin is it on? (this value only used to fill ANALOG_MASK for you)
#define TEMP_PIN_CHANNEL AIO0_PIN
@ -245,6 +247,9 @@ struct {
// number of heaters- for GEN3, set to zero as extruder manages the heater by itself
#define NUM_HEATERS 0
// check if heater responds to changes in target temperature, disable and spit errors if not
// #define HEATER_SANITY_CHECK
/***************************************************************************\
* *
* Fill in the following struct according to your hardware *

110
heater.c
View File

@ -1,14 +1,12 @@
#include "heater.h"
#include <stdlib.h>
#include <avr/eeprom.h>
#include <avr/pgmspace.h>
#include "arduino.h"
// #include "timer.h"
#include "debug.h"
#ifdef DEBUG
#include "sersendf.h"
#endif
#include "sersendf.h"
#define HEATER_C
#include "config.h"
@ -21,21 +19,22 @@ struct {
int16_t i_limit;
} heaters_pid[NUM_HEATERS];
// this struct holds the runtime heater data- PID counters and such
// this struct holds the runtime heater data- PID integrator history, temperature history, sanity checker
struct {
int16_t heater_p;
int16_t heater_i;
int16_t heater_d;
uint8_t pid_output;
uint16_t temp_history[TH_COUNT];
uint8_t temp_history_pointer;
#ifdef HEATER_SANITY_CHECK
uint16_t sanity_counter;
uint16_t sane_temperature;
#endif
} heaters_runtime[NUM_HEATERS];
#define DEFAULT_P 8192
#define DEFAULT_I 512
#define DEFAULT_D -24576
#define DEFAULT_D 24576
#define DEFAULT_I_LIMIT 384
// this lives in the eeprom so we can save our PID settings for each heater
@ -55,9 +54,10 @@ void heater_init() {
for (i = 0; i < NUM_HEATERS; i++) {
*(heaters[i].heater_port) &= ~MASK(heaters[i].heater_pin);
// DDR is always 1 address below PORT. ugly code but saves ram and an extra field in heaters[] which will never be used anywhere but here
*((volatile uint8_t *) (heaters[i].heater_port - 1)) |= MASK(heaters[i].heater_pin);
*(heaters[i].heater_port - 1) |= MASK(heaters[i].heater_pin);
if (heaters[i].heater_pwm) {
*heaters[i].heater_pwm = 0;
// this is somewhat ugly too, but switch() won't accept pointers for reasons unknown
switch((uint16_t) heaters[i].heater_pwm) {
case (uint16_t) &OCR0A:
TCCR0A |= MASK(COM0A1);
@ -73,10 +73,11 @@ void heater_init() {
break;
}
}
}
// 0 is a "sane" temperature when we're trying to cool down
heaters_runtime[i].sane_temperature = 0;
// read factors from eeprom
for (i = 0; i < NUM_HEATERS; i++) {
heaters_pid[i].p_factor = eeprom_read_dword((uint32_t *) &EE_factors[i].EE_p_factor);
heaters_pid[i].i_factor = eeprom_read_dword((uint32_t *) &EE_factors[i].EE_i_factor);
heaters_pid[i].d_factor = eeprom_read_dword((uint32_t *) &EE_factors[i].EE_d_factor);
@ -103,15 +104,18 @@ void heater_save_settings() {
}
void heater_tick(uint8_t h, uint16_t current_temp, uint16_t target_temp) {
// now for heater stuff
int16_t t_error = target_temp - current_temp;
int16_t heater_p;
int16_t heater_d;
uint8_t pid_output;
int16_t t_error = target_temp - current_temp;
heaters_runtime[h].temp_history[heaters_runtime[h].temp_history_pointer++] = current_temp;
heaters_runtime[h].temp_history_pointer &= (TH_COUNT - 1);
// PID stuff
// proportional
heaters_runtime[h].heater_p = t_error;
heater_p = t_error;
// integral
heaters_runtime[h].heater_i += t_error;
@ -123,31 +127,87 @@ void heater_tick(uint8_t h, uint16_t current_temp, uint16_t target_temp) {
// derivative
// note: D follows temp rather than error so there's no large derivative when the target changes
heaters_runtime[h].heater_d = current_temp - heaters_runtime[h].temp_history[heaters_runtime[h].temp_history_pointer];
heater_d = heaters_runtime[h].temp_history[heaters_runtime[h].temp_history_pointer] - current_temp;
// combine factors
int32_t pid_output_intermed = (
(
(((int32_t) heaters_runtime[h].heater_p) * heaters_pid[h].p_factor) +
(((int32_t) heater_p) * heaters_pid[h].p_factor) +
(((int32_t) heaters_runtime[h].heater_i) * heaters_pid[h].i_factor) +
(((int32_t) heaters_runtime[h].heater_d) * heaters_pid[h].d_factor)
(((int32_t) heater_d) * heaters_pid[h].d_factor)
) / PID_SCALE
);
// rebase and limit factors
if (pid_output_intermed > 255)
heaters_runtime[h].pid_output = 255;
pid_output = 255;
else if (pid_output_intermed < 0)
heaters_runtime[h].pid_output = 0;
pid_output = 0;
else
heaters_runtime[h].pid_output = pid_output_intermed & 0xFF;
pid_output = pid_output_intermed & 0xFF;
#ifdef DEBUG
if (debug_flags & DEBUG_PID)
sersendf_P(PSTR("T{E:%d, P:%d * %ld = %ld / I:%d * %ld = %ld / D:%d * %ld = %ld # O: %ld = %u}\n"), t_error, heaters_runtime[h].heater_p, heaters_pid[h].p_factor, (int32_t) heaters_runtime[h].heater_p * heaters_pid[h].p_factor / PID_SCALE, heaters_runtime[h].heater_i, heaters_pid[h].i_factor, (int32_t) heaters_runtime[h].heater_i * heaters_pid[h].i_factor / PID_SCALE, heaters_runtime[h].heater_d, heaters_pid[h].d_factor, (int32_t) heaters_runtime[h].heater_d * heaters_pid[h].d_factor / PID_SCALE, pid_output_intermed, heaters_runtime[h].pid_output);
sersendf_P(PSTR("T{E:%d, P:%d * %ld = %ld / I:%d * %ld = %ld / D:%d * %ld = %ld # O: %ld = %u}\n"), t_error, heater_p, heaters_pid[h].p_factor, (int32_t) heater_p * heaters_pid[h].p_factor / PID_SCALE, heaters_runtime[h].heater_i, heaters_pid[h].i_factor, (int32_t) heaters_runtime[h].heater_i * heaters_pid[h].i_factor / PID_SCALE, heater_d, heaters_pid[h].d_factor, (int32_t) heater_d * heaters_pid[h].d_factor / PID_SCALE, pid_output_intermed, pid_output);
#endif
heater_set(h, heaters_runtime[h].pid_output);
#ifdef HEATER_SANITY_CHECK
// check heater sanity
// implementation is a moving window with some slow-down to compensate for thermal mass
if (target_temp > (current_temp + TEMP_HYSTERESIS)) {
// heating
if (current_temp > heaters_runtime[h].sane_temperature)
// hotter than sane- good since we're heating unless too hot
heaters_runtime[h].sane_temperature = current_temp;
else {
if (heaters_runtime[h].sanity_counter < 40)
heaters_runtime[h].sanity_counter++;
else {
heaters_runtime[h].sanity_counter = 0;
// ratchet up expected temp
heaters_runtime[h].sane_temperature++;
}
}
// limit to target, so if we overshoot by too much for too long an error is flagged
if (heaters_runtime[h].sane_temperature > target_temp)
heaters_runtime[h].sane_temperature = target_temp;
}
else if (target_temp < (current_temp - TEMP_HYSTERESIS)) {
// cooling
if (current_temp < heaters_runtime[h].sane_temperature)
// cooler than sane- good since we're cooling
heaters_runtime[h].sane_temperature = current_temp;
else {
if (heaters_runtime[h].sanity_counter < 125)
heaters_runtime[h].sanity_counter++;
else {
heaters_runtime[h].sanity_counter = 0;
// ratchet down expected temp
heaters_runtime[h].sane_temperature--;
}
}
// if we're at or below 60 celsius, don't freak out if we can't drop any more.
if (current_temp <= 240)
heaters_runtime[h].sane_temperature = current_temp;
// limit to target, so if we don't cool down for too long an error is flagged
else if (heaters_runtime[h].sane_temperature < target_temp)
heaters_runtime[h].sane_temperature = target_temp;
}
// we're within HYSTERESIS of our target
else {
heaters_runtime[h].sane_temperature = current_temp;
heaters_runtime[h].sanity_counter = 0;
}
// compare where we're at to where we should be
if (labs(current_temp - heaters_runtime[h].sane_temperature) > TEMP_HYSTERESIS) {
// no change, or change in wrong direction for a long time- heater is broken!
pid_output = 0;
sersendf_P(PSTR("!! heater %d broken- temp is %d.%dC, target is %d.%dC, didn't reach %d.%dC in %d0 milliseconds\n"), h, current_temp >> 2, (current_temp & 3) * 25, target_temp >> 2, (target_temp & 3) * 25, heaters_runtime[h].sane_temperature >> 2, (heaters_runtime[h].sane_temperature & 3) * 25, heaters_runtime[h].sanity_counter);
}
#endif
heater_set(h, pid_output);
}
void heater_set(uint8_t index, uint8_t value) {