Move AC logic out of FSIO (#2872)

* new impl

* remove fsio

* inject "is ac active" to fan

* include the correct code

* include

* test

* more AC features

* AC switch vs. actual AC indicators

* include

* duh

firmware/console/binary/tunerstudio_outputs.h

@@ -71,7 +71,7 @@ struct TunerStudioOutputChannels {
 	unsigned int isCltError : 1; // bit 19
 	unsigned int isMapError : 1; // bit 20
 	unsigned int isIatError : 1; // bit 21
-	unsigned int unusedAt22 : 1; // bit 22
+	unsigned int acState : 1; // bit 22 - 1 if AC is engaged, 0 otherwise
 	unsigned int isTriggerError : 1; // bit 23
 	unsigned int hasCriticalError : 1; // bit 24
 	unsigned int isWarnNow : 1; // bit 25

firmware/console/status_loop.cpp

@@ -729,7 +729,6 @@ void updateTunerStudioState(TunerStudioOutputChannels *tsOutputChannels DECLARE_
 	tsOutputChannels->clutchUpState = engine->clutchUpState;
 	tsOutputChannels->clutchDownState = engine->clutchDownState;
 	tsOutputChannels->brakePedalState = engine->brakePedalState;
-	tsOutputChannels->acSwitchState = engine->acSwitchState;
 
 #if EFI_ENGINE_CONTROL
 	// tCharge depends on the previous state, so we should use the stored value.

firmware/controllers/actuators/ac_control.cpp

@@ -0,0 +1,72 @@
+#include "ac_control.h"
+#include "engine.h"
+
+#include "deadband.h"
+#include "efi_gpio.h"
+#include "sensor.h"
+#include "tunerstudio_outputs.h"
+
+EXTERN_ENGINE;
+
+// Deadbands to prevent rapid switching on/off of AC
+static Deadband<200> maxRpmDeadband;
+static Deadband<5> maxCltDeadband;
+static Deadband<5> maxTpsDeadband;
+
+static bool getAcState(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+	auto rpm = Sensor::get(SensorType::Rpm).value_or(0);
+
+	// Engine too slow, disable
+	if (rpm < 500) {
+		return false;
+	}
+
+	// Engine too fast, disable
+	auto maxRpm = CONFIG(maxAcRpm);
+	if (maxRpm != 0) {
+		if (maxRpmDeadband.gt(rpm, maxRpm)) {
+			return false;
+		}
+	}
+
+	auto clt = Sensor::get(SensorType::Clt);
+
+	// No AC with failed CLT
+	if (!clt) {
+		return false;
+	}
+
+	// Engine too hot, disable
+	auto maxClt = CONFIG(maxAcClt);
+	if (maxClt != 0) {
+		if (maxCltDeadband.gt(maxClt, clt.Value)) {
+			return false;
+		}
+	}
+
+	// TPS too high, disable
+	auto maxTps = CONFIG(maxAcTps);
+	if (maxTps != 0) {
+		auto tps = Sensor::get(SensorType::Tps1).value_or(0);
+
+		if (maxTpsDeadband.gt(maxTps, tps)) {
+			return false;
+		}
+	}
+
+	// All conditions allow AC, simply pass thru switch
+	return ENGINE(acSwitchState);
+}
+
+bool updateAc(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+	bool isEnabled = getAcState(PASS_ENGINE_PARAMETER_SIGNATURE);
+
+	enginePins.acRelay.setValue(isEnabled);
+
+#if EFI_TUNER_STUDIO
+	tsOutputChannels.acSwitchState = engine->acSwitchState;
+	tsOutputChannels.acState = isEnabled;
+#endif // EFI_TUNER_STUDIO
+
+	return isEnabled;
+}

firmware/controllers/actuators/ac_control.h

@@ -0,0 +1,6 @@
+#pragma once
+
+#include "engine_ptr.h"
+
+// Returns true if AC is currently active
+bool updateAc(DECLARE_ENGINE_PARAMETER_SIGNATURE);

firmware/controllers/actuators/fan_control.cpp

@@ -7,13 +7,13 @@
 
 EXTERN_ENGINE;
 
-static void fanControl(OutputPin& pin, int8_t fanOnTemp, int8_t fanOffTemp, bool enableWithAc DECLARE_ENGINE_PARAMETER_SUFFIX) {
+static void fanControl(bool acActive, OutputPin& pin, int8_t fanOnTemp, int8_t fanOffTemp, bool enableWithAc DECLARE_ENGINE_PARAMETER_SUFFIX) {
 	auto [cltValid, clt] = Sensor::get(SensorType::Clt);
 
 	if (!cltValid) {
 		// If CLT is broken, turn the fan on
 		pin.setValue(true);
-	} else if (enableWithAc && ENGINE(acSwitchState)) {
+	} else if (enableWithAc && acActive) {
 		pin.setValue(true);
 	} else if (clt > fanOnTemp) {
 		// If hot, turn the fan on
@@ -26,13 +26,13 @@ static void fanControl(OutputPin& pin, int8_t fanOnTemp, int8_t fanOffTemp, bool
 	}
 }
 
-void updateFans(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+void updateFans(bool acActive DECLARE_ENGINE_PARAMETER_SUFFIX) {
 #if EFI_PROD_CODE
 	if (isRunningBenchTest()) {
 		return; // let's not mess with bench testing
 	}
 #endif
 
-	fanControl(enginePins.fanRelay, CONFIG(fanOnTemperature), CONFIG(fanOffTemperature), CONFIG(enableFan1WithAc) PASS_ENGINE_PARAMETER_SUFFIX);
-	fanControl(enginePins.fanRelay2, CONFIG(fan2OnTemperature), CONFIG(fan2OffTemperature), CONFIG(enableFan2WithAc) PASS_ENGINE_PARAMETER_SUFFIX);
+	fanControl(acActive, enginePins.fanRelay, CONFIG(fanOnTemperature), CONFIG(fanOffTemperature), CONFIG(enableFan1WithAc) PASS_ENGINE_PARAMETER_SUFFIX);
+	fanControl(acActive, enginePins.fanRelay2, CONFIG(fan2OnTemperature), CONFIG(fan2OffTemperature), CONFIG(enableFan2WithAc) PASS_ENGINE_PARAMETER_SUFFIX);
 }

firmware/controllers/actuators/fan_control.h

@@ -2,4 +2,4 @@
 
 #include "engine_ptr.h"
 
-void updateFans(DECLARE_ENGINE_PARAMETER_SIGNATURE);
+void updateFans(bool acActive DECLARE_ENGINE_PARAMETER_SUFFIX);

firmware/controllers/algo/engine.cpp

@@ -35,6 +35,7 @@
 #include "dynoview.h"
 #include "boost_control.h"
 #include "fan_control.h"
+#include "ac_control.h"
 #if EFI_MC33816
  #include "mc33816.h"
 #endif // EFI_MC33816
@@ -229,7 +230,8 @@ void Engine::periodicSlowCallback(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	runHardcodedFsio(PASS_ENGINE_PARAMETER_SIGNATURE);
 #endif /* EFI_FSIO */
 
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	bool acActive = updateAc(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(acActive PASS_ENGINE_PARAMETER_SUFFIX);
 
 	updateGppwm();
 

firmware/controllers/controllers.mk

@@ -12,6 +12,7 @@ CONTROLLERSSRC =
 	
 CONTROLLERS_SRC_CPP = \
 	$(CONTROLLERS_DIR)/actuators/electronic_throttle.cpp \
+	$(CONTROLLERS_DIR)/actuators/ac_control.cpp \
 	$(CONTROLLERS_DIR)/actuators/alternator_controller.cpp \
 	$(CONTROLLERS_DIR)/actuators/boost_control.cpp \
 	$(CONTROLLERS_DIR)/actuators/dc_motors.cpp \

firmware/controllers/core/fsio_impl.cpp

@@ -105,7 +105,6 @@ FsioPointers::FsioPointers() : fsioLogics() {
 
 static FsioPointers state;
 
-static LEElement * acRelayLogic;
 static LEElement * fuelPumpLogic;
 static LEElement * starterRelayDisableLogic;
 
@@ -497,10 +496,6 @@ void runFsio(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	 */
 	enginePins.o2heater.setValue(engine->rpmCalculator.isRunning());
 
-	if (isBrainPinValid(CONFIG(acRelayPin))) {
-		setPinState("A/C", &enginePins.acRelay, acRelayLogic PASS_ENGINE_PARAMETER_SUFFIX);
-	}
-
 #if EFI_ENABLE_ENGINE_WARNING
 	if (engineConfiguration->useFSIO4ForSeriousEngineWarning) {
 		updateValueOrWarning(MAGIC_OFFSET_FOR_ENGINE_WARNING, "eng warning", &ENGINE(fsioState.isEngineWarning) PASS_ENGINE_PARAMETER_SUFFIX);
@@ -567,7 +562,6 @@ static void showFsio(const char *msg, LEElement *element) {
 static void showFsioInfo(void) {
 #if EFI_PROD_CODE || EFI_SIMULATOR
 	efiPrintf("sys used %d/user used %d", sysPool.getSize(), userPool.getSize());
-	showFsio("a/c", acRelayLogic);
 	showFsio("fuel", fuelPumpLogic);
 
 	for (int i = 0; i < CAM_INPUTS_COUNT ; i++) {
@@ -690,8 +684,6 @@ void initFsioImpl(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	fuelPumpLogic = sysPool.parseExpression(FUEL_PUMP_LOGIC);
 #endif /* EFI_FUEL_PUMP */
 
-	acRelayLogic = sysPool.parseExpression(AC_RELAY_LOGIC);
-
 #if EFI_MAIN_RELAY_CONTROL
 	if (isBrainPinValid(CONFIG(mainRelayPin)))
 		mainRelayLogic = sysPool.parseExpression(MAIN_RELAY_LOGIC);
@@ -767,10 +759,6 @@ void runHardcodedFsio(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	if (isBrainPinValid(CONFIG(starterRelayDisablePin))) {
 		enginePins.starterRelayDisable.setValue(engine->rpmCalculator.getRpm() < engineConfiguration->cranking.rpm);
 	}
-	// see AC_RELAY_LOGIC
-	if (isBrainPinValid(CONFIG(acRelayPin))) {
-		enginePins.acRelay.setValue(getAcToggle(PASS_ENGINE_PARAMETER_SIGNATURE) && engine->rpmCalculator.getRpm() > 850);
-	}
 	// see FUEL_PUMP_LOGIC
 	if (isBrainPinValid(CONFIG(fuelPumpPin))) {
 		enginePins.fuelPumpRelay.setValue((getTimeNowSeconds() < engine->triggerActivitySecond + engineConfiguration->startUpFuelPumpDuration) || (engine->rpmCalculator.getRpm() > 0));

firmware/controllers/system_fsio.h

@@ -21,8 +21,6 @@
 // Human-readable: coolant > 120
 #define TOO_HOT_LOGIC "coolant 120 >"
 
-// Human-readable: ac_on_switch & (rpm > 850)
-#define AC_RELAY_LOGIC "ac_on_switch rpm 850 > &"
 // Combined RPM, CLT and VBATT warning light
 
 // Human-readable: (rpm > fsio_setting(2)) | ((coolant > fsio_setting(3)) | (vbatt < fsio_setting(4)))

firmware/controllers/system_fsio.txt

@@ -13,8 +13,6 @@ FUEL_PUMP_LOGIC=((time_since_boot >= 0) & (time_since_boot < startup_fuel_pump_d
 
 TOO_HOT_LOGIC=coolant > 120
 
-AC_RELAY_LOGIC=ac_on_switch & (rpm > 850)
-
 # Combined RPM, CLT and VBATT warning light
 COMBINED_WARNING_LIGHT=(rpm > fsio_setting(2)) | ((coolant > fsio_setting(3)) | (vbatt < fsio_setting(4)))
 

firmware/integration/rusefi_config.txt

@@ -1182,7 +1182,10 @@ custom pin_mode_e 1 bits, U08, @OFFSET@, [0:6], @@pin_mode_e_enum@@
 	
 ! todo: rename field remove 'ms' since unusual case of dual-purpose field - it could be either ms or percent	
 	float tachPulseDuractionMs;;"", 1, 0, 0, 100, 2
-	int unused1708;;"units", 1, 0, -20, 100, 0
+	uint16_t maxAcRpm;+Above this RPM, disable AC. Set to 0 to disable check.;"rpm", 1, 0, 0, 10000, 0
+	uint8_t maxAcTps;+Above this TPS, disable AC. Set to 0 to disable check.;"%", 1, 0, 0, 100, 0
+	uint8_t maxAcClt;+Above this CLT, disable AC to prevent overheating the engine. Set to 0 to disable check.;"deg C", 1, 0, 0, 150, 0
+	
 	
 	float wwaeTau;+Length of time the deposited wall fuel takes to dissipate after the start of acceleration. ;"Seconds", 1, 0, 0, 3, 2
 	pid_s alternatorControl;

firmware/tunerstudio/rusefi.input

@@ -199,6 +199,7 @@ enable2ndByteCanID = false
 ;      ind_map_error   = bits,    U32,      0,  [20:20], "true", "false";
 
       ind_iat_error   = bits,    U32,      0,  [21:21], "true", "false";
+	  acState         = bits,    U32,      0,  [22:22], "true", "false";
       ind_isTriggerError = bits, U32,      0,  [23:23], "true", "false";
       ind_hasFatalError=bits,    U32,      0,  [24:24], "true", "false";
 	  ind_isWarnNow    =bits,    U32,      0,  [25:25], "true", "false";
@@ -1203,7 +1204,8 @@ gaugeCategory = DynoView
     indicator = { clutchUpState }, "clutch",   "cltch Up",   white, black, red,   black
     indicator = { clutchDownState }, "clutch",   "cltch Down",   white, black, yellow,   black
     indicator = { brakePedalIndicator }, "brake",   "brake down",   white, black, red,   black
-    indicator = { acSwitchState }, "AC off",   "AC on",   white, black, blue,   white
+    indicator = { acSwitchState }, "AC switch off", "AC switch on", white, black, blue, white
+	indicator = { acState }, "AC off", "AC on", white, black, blue, white
 	indicator = { isIdleClosedLoop }, "not idling", "idling", white, black, green, black
 	indicator = { isIdleCoasting }, "not coasting", "coasting", white, black, green, black
 
@@ -1392,6 +1394,7 @@ menuDialog = main
 		subMenu = starterRelay,				"Starter Disable relay"
 		subMenu = fuelPump,					"Fuel pump"
 		subMenu = fanSetting,				"Fan"
+		subMenu = acSettings,				"Air Conditioning"
 		subMenu = tachSettings,				"Tachometer"
 		subMenu = malfunction,				"Check engine light"
 		subMenu = statusLeds,				"Status LEDs"
@@ -2698,11 +2701,13 @@ cmd_set_engine_type_default					= "@@TS_IO_TEST_COMMAND_char@@\x00\x31\x00\x00"
 	dialog = acSettings, "A/C Settings"
 		field = "A/C Relay",						acRelayPin
 		field = "A/C Relay Mode",					acRelayPinMode
+		field = "Max RPM",						maxAcRpm
+		field = "Max CLT",						maxAcClt
+		field = "Max TPS",						maxAcTps
 
 	dialog = fanSetting, "Fan Settings"
 		panel = fan1Settings
 		panel = fan2Settings
-		panel = acSettings
 
 	dialog = fuelPump, "Fuel Pump"
 		field = "Pin",						fuelPumpPin

unit_tests/tests/test_fan_control.cpp

@@ -9,41 +9,38 @@ TEST(FanControl, fan1) {
 	engineConfiguration->fanOnTemperature = 90;
 	engineConfiguration->fanOffTemperature = 80;
 	engineConfiguration->enableFan1WithAc = false;
-	engine->acSwitchState = false;
 
 	// Cold, fan should be off
 	Sensor::setMockValue(SensorType::Clt, 75);
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(false PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
 
 	// Between thresholds, should still be off
 	Sensor::setMockValue(SensorType::Clt, 85);
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(false PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
 
 	// Hot, fan should turn on
 	Sensor::setMockValue(SensorType::Clt, 95);
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(false PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(true, enginePins.fanRelay.getLogicValue());
 
 	// Between thresholds, should stay on
 	Sensor::setMockValue(SensorType::Clt, 85);
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(false PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(true, enginePins.fanRelay.getLogicValue());
 
 	// Below threshold, should turn off
 	Sensor::setMockValue(SensorType::Clt, 75);
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(false PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
 
 	engineConfiguration->enableFan1WithAc = true;
 	// Now AC is on, fan should turn on!
-	engine->acSwitchState = true;
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(true PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(true, enginePins.fanRelay.getLogicValue());
 
 	// Turn off AC, fan should turn off too.
-	engine->acSwitchState = false;
-	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	updateFans(false PASS_ENGINE_PARAMETER_SUFFIX);
 	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
 }