311 lines
9.4 KiB
C
311 lines
9.4 KiB
C
#include "heater.h"
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#include <stdlib.h>
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#include <avr/eeprom.h>
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#include <avr/pgmspace.h>
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#include "arduino.h"
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#include "debug.h"
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#ifndef EXTRUDER
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#include "sersendf.h"
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#endif
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#include "temp.h"
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typedef struct {
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volatile uint8_t *heater_port;
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uint8_t heater_pin;
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volatile uint8_t *heater_pwm;
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} heater_definition_t;
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#undef DEFINE_HEATER
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#define DEFINE_HEATER(name, port, pin, pwm) { &(port), (pin), &(pwm) },
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static const heater_definition_t heaters[NUM_HEATERS] =
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{
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#include "config.h"
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};
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#undef DEFINE_HEATER
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// this struct holds the heater PID factors that are stored in the EEPROM during poweroff
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struct {
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int32_t p_factor;
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int32_t i_factor;
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int32_t d_factor;
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int16_t i_limit;
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} heaters_pid[NUM_HEATERS];
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// this struct holds the runtime heater data- PID integrator history, temperature history, sanity checker
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struct {
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int16_t heater_i;
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uint16_t temp_history[TH_COUNT];
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uint8_t temp_history_pointer;
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#ifdef HEATER_SANITY_CHECK
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uint16_t sanity_counter;
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uint16_t sane_temperature;
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#endif
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uint8_t heater_output;
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} heaters_runtime[NUM_HEATERS];
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#define DEFAULT_P 8192
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#define DEFAULT_I 512
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#define DEFAULT_D 24576
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#define DEFAULT_I_LIMIT 384
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// this lives in the eeprom so we can save our PID settings for each heater
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typedef struct {
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int32_t EE_p_factor;
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int32_t EE_i_factor;
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int32_t EE_d_factor;
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int16_t EE_i_limit;
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} EE_factor;
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EE_factor EEMEM EE_factors[NUM_HEATERS];
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void heater_init() {
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heater_t i;
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// setup pins
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for (i = 0; i < NUM_HEATERS; i++) {
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*(heaters[i].heater_port) &= ~MASK(heaters[i].heater_pin);
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// 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
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*(heaters[i].heater_port - 1) |= MASK(heaters[i].heater_pin);
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if (heaters[i].heater_pwm) {
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*heaters[i].heater_pwm = 0;
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// this is somewhat ugly too, but switch() won't accept pointers for reasons unknown
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switch((uint16_t) heaters[i].heater_pwm) {
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case (uint16_t) &OCR0A:
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TCCR0A |= MASK(COM0A1);
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break;
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case (uint16_t) &OCR0B:
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TCCR0A |= MASK(COM0B1);
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break;
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case (uint16_t) &OCR2A:
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TCCR2A |= MASK(COM2A1);
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break;
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case (uint16_t) &OCR2B:
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TCCR2A |= MASK(COM2B1);
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break;
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}
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}
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#ifdef HEATER_SANITY_CHECK
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// 0 is a "sane" temperature when we're trying to cool down
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heaters_runtime[i].sane_temperature = 0;
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#endif
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#ifndef BANG_BANG
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// read factors from eeprom
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heaters_pid[i].p_factor = eeprom_read_dword((uint32_t *) &EE_factors[i].EE_p_factor);
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heaters_pid[i].i_factor = eeprom_read_dword((uint32_t *) &EE_factors[i].EE_i_factor);
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heaters_pid[i].d_factor = eeprom_read_dword((uint32_t *) &EE_factors[i].EE_d_factor);
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heaters_pid[i].i_limit = eeprom_read_word((uint16_t *) &EE_factors[i].EE_i_limit);
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if ((heaters_pid[i].p_factor == 0) && (heaters_pid[i].i_factor == 0) && (heaters_pid[i].d_factor == 0) && (heaters_pid[i].i_limit == 0)) {
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heaters_pid[i].p_factor = DEFAULT_P;
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heaters_pid[i].i_factor = DEFAULT_I;
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heaters_pid[i].d_factor = DEFAULT_D;
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heaters_pid[i].i_limit = DEFAULT_I_LIMIT;
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}
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#endif /* BANG_BANG */
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}
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}
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void heater_save_settings() {
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#ifndef BANG_BANG
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heater_t i;
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for (i = 0; i < NUM_HEATERS; i++) {
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eeprom_write_dword((uint32_t *) &EE_factors[i].EE_p_factor, heaters_pid[i].p_factor);
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eeprom_write_dword((uint32_t *) &EE_factors[i].EE_i_factor, heaters_pid[i].i_factor);
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eeprom_write_dword((uint32_t *) &EE_factors[i].EE_d_factor, heaters_pid[i].d_factor);
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eeprom_write_word((uint16_t *) &EE_factors[i].EE_i_limit, heaters_pid[i].i_limit);
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}
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#endif /* BANG_BANG */
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}
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void heater_tick(heater_t h, temp_sensor_t t, uint16_t current_temp, uint16_t target_temp) {
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uint8_t pid_output;
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#ifndef BANG_BANG
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int16_t heater_p;
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int16_t heater_d;
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int16_t t_error = target_temp - current_temp;
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#endif /* BANG_BANG */
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if (h >= NUM_HEATERS || t >= NUM_TEMP_SENSORS)
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return;
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#ifndef BANG_BANG
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heaters_runtime[h].temp_history[heaters_runtime[h].temp_history_pointer++] = current_temp;
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heaters_runtime[h].temp_history_pointer &= (TH_COUNT - 1);
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// PID stuff
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// proportional
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heater_p = t_error;
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// integral
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heaters_runtime[h].heater_i += t_error;
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// prevent integrator wind-up
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if (heaters_runtime[h].heater_i > heaters_pid[h].i_limit)
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heaters_runtime[h].heater_i = heaters_pid[h].i_limit;
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else if (heaters_runtime[h].heater_i < -heaters_pid[h].i_limit)
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heaters_runtime[h].heater_i = -heaters_pid[h].i_limit;
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// derivative
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// note: D follows temp rather than error so there's no large derivative when the target changes
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heater_d = heaters_runtime[h].temp_history[heaters_runtime[h].temp_history_pointer] - current_temp;
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// combine factors
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int32_t pid_output_intermed = (
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(
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(((int32_t) heater_p) * heaters_pid[h].p_factor) +
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(((int32_t) heaters_runtime[h].heater_i) * heaters_pid[h].i_factor) +
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(((int32_t) heater_d) * heaters_pid[h].d_factor)
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) / PID_SCALE
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);
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// rebase and limit factors
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if (pid_output_intermed > 255)
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pid_output = 255;
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else if (pid_output_intermed < 0)
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pid_output = 0;
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else
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pid_output = pid_output_intermed & 0xFF;
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#ifdef DEBUG
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if (debug_flags & DEBUG_PID)
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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);
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#endif
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#else
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if (current_temp >= target_temp)
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pid_output = BANG_BANG_OFF;
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else
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pid_output = BANG_BANG_ON;
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#endif
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#ifdef HEATER_SANITY_CHECK
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// check heater sanity
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// implementation is a moving window with some slow-down to compensate for thermal mass
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if (target_temp > (current_temp + TEMP_HYSTERESIS)) {
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// heating
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if (current_temp > heaters_runtime[h].sane_temperature)
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// hotter than sane- good since we're heating unless too hot
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heaters_runtime[h].sane_temperature = current_temp;
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else {
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if (heaters_runtime[h].sanity_counter < 40)
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heaters_runtime[h].sanity_counter++;
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else {
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heaters_runtime[h].sanity_counter = 0;
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// ratchet up expected temp
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heaters_runtime[h].sane_temperature++;
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}
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}
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// limit to target, so if we overshoot by too much for too long an error is flagged
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if (heaters_runtime[h].sane_temperature > target_temp)
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heaters_runtime[h].sane_temperature = target_temp;
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}
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else if (target_temp < (current_temp - TEMP_HYSTERESIS)) {
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// cooling
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if (current_temp < heaters_runtime[h].sane_temperature)
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// cooler than sane- good since we're cooling
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heaters_runtime[h].sane_temperature = current_temp;
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else {
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if (heaters_runtime[h].sanity_counter < 125)
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heaters_runtime[h].sanity_counter++;
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else {
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heaters_runtime[h].sanity_counter = 0;
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// ratchet down expected temp
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heaters_runtime[h].sane_temperature--;
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}
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}
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// if we're at or below 60 celsius, don't freak out if we can't drop any more.
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if (current_temp <= 240)
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heaters_runtime[h].sane_temperature = current_temp;
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// limit to target, so if we don't cool down for too long an error is flagged
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else if (heaters_runtime[h].sane_temperature < target_temp)
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heaters_runtime[h].sane_temperature = target_temp;
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}
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// we're within HYSTERESIS of our target
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else {
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heaters_runtime[h].sane_temperature = current_temp;
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heaters_runtime[h].sanity_counter = 0;
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}
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// compare where we're at to where we should be
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if (labs(current_temp - heaters_runtime[h].sane_temperature) > TEMP_HYSTERESIS) {
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// no change, or change in wrong direction for a long time- heater is broken!
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pid_output = 0;
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sersendf_P(PSTR("!! heater %d or temp sensor %d broken- temp is %d.%dC, target is %d.%dC, didn't reach %d.%dC in %d0 milliseconds\n"), h, t, 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);
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}
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#endif /* HEATER_SANITY_CHECK */
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heater_set(h, pid_output);
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}
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void heater_set(heater_t index, uint8_t value) {
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if (index >= NUM_HEATERS)
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return;
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heaters_runtime[index].heater_output = value;
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if (heaters[index].heater_pwm) {
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*(heaters[index].heater_pwm) = value;
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#ifdef DEBUG
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if (debug_flags & DEBUG_PID)
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sersendf_P(PSTR("PWM{%u = %u}\n"), index, OCR0A);
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#endif
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}
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else {
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if (value >= 8)
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*(heaters[index].heater_port) |= MASK(heaters[index].heater_pin);
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else
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*(heaters[index].heater_port) &= ~MASK(heaters[index].heater_pin);
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}
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}
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uint8_t heaters_all_off() {
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uint8_t i;
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for (i = 0; i < NUM_HEATERS; i++) {
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if (heaters_runtime[i].heater_output > 0)
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return 0;
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}
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return 255;
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}
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void pid_set_p(heater_t index, int32_t p) {
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#ifndef BANG_BANG
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if (index >= NUM_HEATERS)
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return;
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heaters_pid[index].p_factor = p;
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#endif /* BANG_BANG */
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}
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void pid_set_i(heater_t index, int32_t i) {
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#ifndef BANG_BANG
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if (index >= NUM_HEATERS)
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return;
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heaters_pid[index].i_factor = i;
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#endif /* BANG_BANG */
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}
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void pid_set_d(heater_t index, int32_t d) {
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#ifndef BANG_BANG
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if (index >= NUM_HEATERS)
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return;
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heaters_pid[index].d_factor = d;
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#endif /* BANG_BANG */
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}
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void pid_set_i_limit(heater_t index, int32_t i_limit) {
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#ifndef BANG_BANG
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if (index >= NUM_HEATERS)
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return;
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heaters_pid[index].i_limit = i_limit;
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#endif /* BANG_BANG */
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}
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