Impl. faster engine spin-up mode (alpha-version) (#567)

* Impl. faster engine spin-up mode (alpha-version)

* A comment for RPM_LOW_THRESHOLD

* Faster engine stop detection

* Safety check for instant RPM on spinning-up

* rusefi.xml

* unit-tests & relevant fixes

firmware/config/boards/Prometheus/efifeatures.h

@@ -106,7 +106,8 @@
 #undef EFI_CJ125_DIRECTLY_CONNECTED_UR
 #define EFI_CJ125_DIRECTLY_CONNECTED_UR TRUE
 
-#define RPM_LOW_THRESHOLD 60
+#define RPM_LOW_THRESHOLD 8				// RPM=8 is an empirical lower sensitivity threshold of MAX9926 for 60-2
+#define NO_RPM_EVENTS_TIMEOUT_SECS 5	// (RPM < 12)
 
 #define EFI_PRINT_ERRORS_AS_WARNINGS TRUE
 

firmware/controllers/algo/engine.cpp

@@ -376,9 +376,6 @@ void Engine::watchdog() {
 		return;
 	}
 	efitick_t nowNt = getTimeNowNt();
-#ifndef RPM_LOW_THRESHOLD
-#define RPM_LOW_THRESHOLD 240
-#endif
 // note that we are ignoring the number of tooth here - we
 // check for duration between tooth as if we only have one tooth per revolution which is not the case
 #define REVOLUTION_TIME_HIGH_THRESHOLD (60 * 1000000LL / RPM_LOW_THRESHOLD)

firmware/controllers/math/engine_math.cpp

@@ -35,6 +35,9 @@ EXTERN_ENGINE
 
 extern EnginePins enginePins;
 
+// Store current ignition mode for prepareIgnitionPinIndices()
+static ignition_mode_e ignitionModeForPinIndices;
+
 floatms_t getEngineCycleDuration(int rpm DECLARE_ENGINE_PARAMETER_SUFFIX) {
 	return getCrankshaftRevolutionTimeMs(rpm) * (engineConfiguration->operationMode == TWO_STROKE ? 1 : 2);
 }
@@ -461,7 +464,7 @@ int getCylinderId(int index DECLARE_ENGINE_PARAMETER_SUFFIX) {
 }
 
 static int getIgnitionPinForIndex(int i DECLARE_ENGINE_PARAMETER_SUFFIX) {
-	switch (CONFIG(ignitionMode)) {
+	switch (getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE)) {
 	case IM_ONE_COIL:
 		return 0;
 		break;
@@ -479,6 +482,25 @@ static int getIgnitionPinForIndex(int i DECLARE_ENGINE_PARAMETER_SUFFIX) {
 	}
 }
 
+void prepareIgnitionPinIndices(ignition_mode_e ignitionMode DECLARE_ENGINE_PARAMETER_SUFFIX) {
+	if (ignitionMode != ignitionModeForPinIndices) {
+#if EFI_ENGINE_CONTROL || defined(__DOXYGEN__)
+		for (int i = 0; i < CONFIG(specs.cylindersCount); i++) {
+			ENGINE(ignitionPin[i]) = getIgnitionPinForIndex(i PASS_ENGINE_PARAMETER_SUFFIX);
+		}
+#endif /* EFI_ENGINE_CONTROL */
+		ignitionModeForPinIndices = ignitionMode;
+	}
+}
+
+ignition_mode_e getIgnitionMode(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+	ignition_mode_e ignitionMode = CONFIG(ignitionMode);
+	// In spin-up cranking mode we don't have full phase sync. info yet, so wasted spark mode is better
+	if (ignitionMode == IM_INDIVIDUAL_COILS && ENGINE(rpmCalculator.isSpinningUp(PASS_ENGINE_PARAMETER_SIGNATURE)))
+		ignitionMode = IM_WASTED_SPARK;
+	return ignitionMode;
+}
+
 void TriggerShape::prepareShape(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	int engineCycleInt = (int) getEngineCycle(CONFIG(operationMode));
 	for (int angle = 0; angle < engineCycleInt; angle++) {
@@ -515,9 +537,10 @@ void prepareOutputSignals(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 
 	for (int i = 0; i < CONFIG(specs.cylindersCount); i++) {
 		ENGINE(angleExtra[i])= ENGINE(engineCycle) * i / CONFIG(specs.cylindersCount);
-		ENGINE(ignitionPin[i]) = getIgnitionPinForIndex(i PASS_ENGINE_PARAMETER_SUFFIX);
 	}
 
+	prepareIgnitionPinIndices(CONFIG(ignitionMode) PASS_ENGINE_PARAMETER_SUFFIX);
+
 	TRIGGER_SHAPE(prepareShape(PASS_ENGINE_PARAMETER_SIGNATURE));
 }
 

firmware/controllers/math/engine_math.h

@@ -73,6 +73,14 @@ float getEngineLoadT(DECLARE_ENGINE_PARAMETER_SIGNATURE);
 
 floatms_t getSparkDwell(int rpm DECLARE_ENGINE_PARAMETER_SUFFIX);
 
+ignition_mode_e getIgnitionMode(DECLARE_ENGINE_PARAMETER_SIGNATURE);
+
+/**
+ * This lightweight method is invoked in case of a configuration change or initialization.
+ * But also it's used for "Spinning-up to Cranking" transition.
+ */
+void prepareIgnitionPinIndices(ignition_mode_e ignitionMode DECLARE_ENGINE_PARAMETER_SUFFIX);
+
 int getCylinderId(int index DECLARE_ENGINE_PARAMETER_SUFFIX);
 
 void setFuelRpmBin(float from, float to DECLARE_ENGINE_PARAMETER_SUFFIX);

firmware/controllers/trigger/main_trigger_callback.cpp

@@ -478,8 +478,9 @@ void mainTriggerCallback(trigger_event_e ckpSignalType, uint32_t trgEventIndex D
 		if (checkIfTriggerConfigChanged()) {
 			engine->ignitionEvents.isReady = false; // we need to rebuild ignition schedule
 			engine->injectionEvents.isReady = false;
-			// todo: move 'triggerIndexByAngle' change into trigger initialization, why is it invoked from here if it's only about trigger shape & optimization?
+			// moved 'triggerIndexByAngle' into trigger initialization (why was it invoked from here if it's only about trigger shape & optimization?)
-			prepareOutputSignals(PASS_ENGINE_PARAMETER_SIGNATURE);
+			// see initializeTriggerShape() -> prepareOutputSignals(PASS_ENGINE_PARAMETER_SIGNATURE)
+
 			// we need this to apply new 'triggerIndexByAngle' values
 			engine->periodicFastCallback(PASS_ENGINE_PARAMETER_SIGNATURE);
 		}

firmware/controllers/trigger/rpm_calculator.cpp

@@ -58,6 +58,7 @@ RpmCalculator::RpmCalculator() {
 	previousRpmValue = rpmValue = 0;
 	oneDegreeUs = NAN;
 	state = STOPPED;
+	isSpinning = false;
 
 	// we need this initial to have not_running at first invocation
 	lastRpmEventTimeNt = (efitime_t) -10 * US2NT(US_PER_SECOND_LL);
@@ -69,11 +70,17 @@ RpmCalculator::RpmCalculator() {
 }
 
 bool RpmCalculator::isStopped(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
-	return state == STOPPED;
+	// Spinning-up with zero RPM means that the engine is not ready yet, and is treated as 'stopped'.
+	return state == STOPPED || (state == SPINNING_UP && rpmValue == 0);
+}
+
+bool RpmCalculator::isSpinningUp(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+	return state == SPINNING_UP;
 }
 
 bool RpmCalculator::isCranking(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
-	return state == CRANKING;
+	// Spinning-up with non-zero RPM is suitable for all engine math, as good as cranking
+	return state == CRANKING || (state == SPINNING_UP && rpmValue > 0);
 }
 
 /**
@@ -103,8 +110,12 @@ bool RpmCalculator::checkIfSpinning(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	 * we have a trigger event between the time we've invoked 'getTimeNow' and here
 	 */
 	bool noRpmEventsForTooLong = nowNt - lastRpmEventTimeNt >= US2NT(NO_RPM_EVENTS_TIMEOUT_SECS * US_PER_SECOND_LL); // Anything below 60 rpm is not running
-	if (noRpmEventsForTooLong) {
+	/**
-		setStopped(PASS_ENGINE_PARAMETER_SIGNATURE);
+	 * Also check if there were no trigger events
+	 */
+	bool noTriggerEventsForTooLong = nowNt - engine->triggerCentral.previousShaftEventTimeNt >= US2NT(US_PER_SECOND_LL);
+	if (noRpmEventsForTooLong || noTriggerEventsForTooLong) {
+		setStopSpinning(PASS_ENGINE_PARAMETER_SIGNATURE);
 		return false;
 	}
 
@@ -118,29 +129,42 @@ void RpmCalculator::assignRpmValue(int value DECLARE_ENGINE_PARAMETER_SUFFIX) {
 		oneDegreeUs = NAN;
 	} else {
 		oneDegreeUs = getOneDegreeTimeUs(rpmValue);
+		if (previousRpmValue == 0) {
+			/**
+			 * this would make sure that we have good numbers for first cranking revolution
+			 * #275 cranking could be improved
+			 */
+			ENGINE(periodicFastCallback(PASS_ENGINE_PARAMETER_SIGNATURE));
+		}
 	}
 }
 
 void RpmCalculator::setRpmValue(int value DECLARE_ENGINE_PARAMETER_SUFFIX) {
 	assignRpmValue(value PASS_ENGINE_PARAMETER_SUFFIX);
-	if (previousRpmValue == 0 && rpmValue > 0) {
+	spinning_state_e oldState = state;
-		/**
+	// Change state
-		 * this would make sure that we have good numbers for first cranking revolution
-		 * #275 cranking could be improved
-		 */
-		ENGINE(periodicFastCallback(PASS_ENGINE_PARAMETER_SIGNATURE));
-	}
 	if (rpmValue == 0) {
 		state = STOPPED;
 	} else if (rpmValue >= CONFIG(cranking.rpm)) {
 		state = RUNNING;
-	} else if (state == STOPPED) {
+	} else if (state == STOPPED || state == SPINNING_UP) {
 		/**
 		 * We are here if RPM is above zero but we have not seen running RPM yet.
 		 * This gives us cranking hysteresis - a drop of RPM during running is still running, not cranking.
 		 */
 		state = CRANKING;
 	}
+#if EFI_ENGINE_CONTROL || defined(__DOXYGEN__)
+	// This presumably fixes injection mode change for cranking-to-running transition.
+	// 'isSimultanious' flag should be updated for events if injection modes differ for cranking and running.
+	if (state != oldState) {
+		engine->injectionEvents.addFuelEvents(PASS_ENGINE_PARAMETER_SIGNATURE);
+	}
+#endif
+}
+
+spinning_state_e RpmCalculator::getState(void) {
+	return state;
 }
 
 void RpmCalculator::onNewEngineCycle() {
@@ -172,6 +196,27 @@ void RpmCalculator::setStopped(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	state = STOPPED;
 }
 
+void RpmCalculator::setStopSpinning(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+	isSpinning = false;
+	setStopped(PASS_ENGINE_PARAMETER_SIGNATURE);
+}
+
+void RpmCalculator::setSpinningUp(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX) {
+	if (!boardConfiguration->isFasterEngineSpinUpEnabled)
+		return;
+	// Only a completely stopped and non-spinning engine can enter the spinning-up state.
+	if (isStopped(PASS_ENGINE_PARAMETER_SIGNATURE) && !isSpinning) {
+		state = SPINNING_UP;
+		isSpinning = true;
+	}
+	// update variables needed by early instant RPM calc.
+	if (isSpinningUp(PASS_ENGINE_PARAMETER_SIGNATURE)) {
+		engine->triggerCentral.triggerState.setLastEventTimeForInstantRpm(nowNt PASS_ENGINE_PARAMETER_SUFFIX);
+	}
+	// Update ignition pin indices if needed
+	prepareIgnitionPinIndices(getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE) PASS_ENGINE_PARAMETER_SUFFIX);
+}
+
 /**
  * WARNING: this is a heavy method because 'getRpm()' is relatively heavy
  *
@@ -202,9 +247,10 @@ void rpmShaftPositionCallback(trigger_event_e ckpSignalType,
 	efiAssertVoid(getRemainingStack(chThdGetSelfX()) > 256, "lowstckRCL");
 #endif
 
+	RpmCalculator *rpmState = &engine->rpmCalculator;
+
 	if (index == 0) {
 		ENGINE(m.beforeRpmCb) = GET_TIMESTAMP();
-		RpmCalculator *rpmState = &engine->rpmCalculator;
 
 		bool hadRpmRecently = rpmState->checkIfSpinning(PASS_ENGINE_PARAMETER_SIGNATURE);
 
@@ -241,6 +287,17 @@ void rpmShaftPositionCallback(trigger_event_e ckpSignalType,
 	}
 #endif
 
+	// Replace 'normal' RPM with instant RPM for the initial spin-up period
+	if (rpmState->isSpinningUp(PASS_ENGINE_PARAMETER_SIGNATURE)) {
+		int prevIndex;
+		int iRpm = engine->triggerCentral.triggerState.calculateInstantRpm(&prevIndex, nowNt PASS_ENGINE_PARAMETER_SUFFIX);
+		// validate instant RPM - we shouldn't skip the cranking state
+		iRpm = minI(iRpm, CONFIG(cranking.rpm) - 1);
+		rpmState->assignRpmValue(iRpm PASS_ENGINE_PARAMETER_SUFFIX);
+#if 0
+		scheduleMsg(logger, "** RPM: idx=%d sig=%d iRPM=%d", index, ckpSignalType, iRpm);
+#endif
+	}
 }
 
 static scheduling_s tdcScheduler[2];

firmware/controllers/trigger/rpm_calculator.h

@@ -29,6 +29,10 @@
 #define NOISY_RPM -1
 #define UNREALISTIC_RPM 30000
 
+#ifndef RPM_LOW_THRESHOLD
+#define RPM_LOW_THRESHOLD 240
+#endif
+
 #ifdef __cplusplus
 
 typedef enum {
@@ -66,7 +70,11 @@ public:
 	 */
 	bool isStopped(DECLARE_ENGINE_PARAMETER_SIGNATURE);
 	/**
-	 * Returns true if the engine is cranking
+	 * Returns true if the engine is spinning up
+	 */
+	bool isSpinningUp(DECLARE_ENGINE_PARAMETER_SIGNATURE);
+	/**
+	 * Returns true if the engine is cranking OR spinning up
 	 */
 	bool isCranking(DECLARE_ENGINE_PARAMETER_SIGNATURE);
 	/**
@@ -76,6 +84,20 @@ public:
 
 	bool checkIfSpinning(DECLARE_ENGINE_PARAMETER_SIGNATURE);
 
+	/**
+	 * This accessor is used in unit-tests.
+	 */
+	spinning_state_e getState(void);
+
+	/**
+	 * Should be called on every trigger event when the engine is just starting to spin up.
+	 */
+	void setSpinningUp(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX);
+	/**
+	 * Called if the synchronization is lost due to a trigger timeout.
+	 */
+	void setStopSpinning(DECLARE_ENGINE_PARAMETER_SIGNATURE);
+
 	int getRpm(DECLARE_ENGINE_PARAMETER_SIGNATURE);
 	/**
 	 * This method is invoked once per engine cycle right after we calculate new RPM value
@@ -83,6 +105,11 @@ public:
 	void onNewEngineCycle();
 	uint32_t getRevolutionCounter(void);
 	void setRpmValue(int value DECLARE_ENGINE_PARAMETER_SUFFIX);
+	/**
+	 * The same as setRpmValue() but without state change.
+	 * We need this to be public because of calling rpmState->assignRpmValue() from rpmShaftPositionCallback()
+	 */
+	void assignRpmValue(int value DECLARE_ENGINE_PARAMETER_SUFFIX);
 	uint32_t getRevolutionCounterSinceStart(void);
 	/**
 	 * RPM rate of change between current RPM and RPM measured during previous engine cycle
@@ -110,10 +137,6 @@ private:
 	 */
 	void setStopped(DECLARE_ENGINE_PARAMETER_SIGNATURE);
 
-	/**
-	 * The same as setRpmValue() but without state change
-	 */
-	void assignRpmValue(int value DECLARE_ENGINE_PARAMETER_SUFFIX);
 	/**
 	 * This counter is incremented with each revolution of one of the shafts. Could be
 	 * crankshaft could be camshaft.
@@ -125,6 +148,12 @@ private:
 	volatile uint32_t revolutionCounterSinceStart;
 
 	spinning_state_e state;
+
+	/**
+	 * True if the engine is spinning (regardless of its state), i.e. if shaft position changes.
+	 * Needed by spinning-up logic.
+	 */
+	bool isSpinning;
 };
 
 /**

firmware/controllers/trigger/spark_logic.cpp

@@ -81,7 +81,7 @@ static void turnSparkPinHigh2(IgnitionEvent *event, IgnitionOutputPin *output) {
 #if ! EFI_UNIT_TEST || defined(__DOXYGEN__)
 	if (GET_RPM() > 2 * engineConfiguration->cranking.rpm) {
 		const char *outputName = output->name;
-		if (prevSparkName == outputName && engineConfiguration->ignitionMode != IM_ONE_COIL) {
+		if (prevSparkName == outputName && getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE) != IM_ONE_COIL) {
 			warning(CUSTOM_OBD_SKIPPED_SPARK, "looks like skipped spark event %d %s", getRevolutionCounter(), outputName);
 		}
 		prevSparkName = outputName;
@@ -230,7 +230,7 @@ void prepareIgnitionSchedule(IgnitionEvent *event DECLARE_ENGINE_PARAMETER_SUFFI
 	IgnitionOutputPin *output = &enginePins.coils[coilIndex];
 
 	IgnitionOutputPin *secondOutput;
-	if (CONFIG(ignitionMode) == IM_WASTED_SPARK && CONFIG(twoWireBatchIgnition)) {
+	if (getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE) == IM_WASTED_SPARK && CONFIG(twoWireBatchIgnition)) {
 		int secondIndex = index + CONFIG(specs.cylindersCount) / 2;
 		int secondCoilIndex = ID2INDEX(getCylinderId(secondIndex PASS_ENGINE_PARAMETER_SUFFIX));
 		secondOutput = &enginePins.coils[secondCoilIndex];
@@ -288,7 +288,7 @@ static ALWAYS_INLINE void prepareIgnitionSchedule(DECLARE_ENGINE_PARAMETER_SIGNA
 	 */
 	float maxAllowedDwellAngle = (int) (getEngineCycle(engineConfiguration->operationMode) / 2); // the cast is about making Coverity happy
 
-	if (engineConfiguration->ignitionMode == IM_ONE_COIL) {
+	if (getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE) == IM_ONE_COIL) {
 		maxAllowedDwellAngle = getEngineCycle(engineConfiguration->operationMode) / engineConfiguration->specs.cylindersCount / 1.1;
 	}
 
@@ -381,7 +381,7 @@ int getNumberOfSparks(ignition_mode_e mode DECLARE_ENGINE_PARAMETER_SUFFIX) {
  * @see getInjectorDutyCycle
  */
 percent_t getCoilDutyCycle(int rpm DECLARE_ENGINE_PARAMETER_SUFFIX) {
-	floatms_t totalPerCycle = 1/**getInjectionDuration(rpm PASS_ENGINE_PARAMETER_SUFFIX)*/ * getNumberOfSparks(engineConfiguration->ignitionMode PASS_ENGINE_PARAMETER_SUFFIX);
+	floatms_t totalPerCycle = 1/**getInjectionDuration(rpm PASS_ENGINE_PARAMETER_SUFFIX)*/ * getNumberOfSparks(getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE) PASS_ENGINE_PARAMETER_SUFFIX);
 	floatms_t engineCycleDuration = getCrankshaftRevolutionTimeMs(rpm) * (engineConfiguration->operationMode == TWO_STROKE ? 1 : 2);
 	return 100 * totalPerCycle / engineCycleDuration;
 }

firmware/controllers/trigger/trigger_central.cpp

@@ -602,6 +602,10 @@ bool readIfTriggerConfigChangedForUnitTest(void) {
 	return isTriggerConfigChanged;
 }
 
+void resetTriggerConfigChangedForUnitTest(void) {
+	isTriggerConfigChanged = false;
+}
+
 void initTriggerCentral(Logging *sharedLogger) {
 	logger = sharedLogger;
 	strcpy((char*) shaft_signal_msg_index, "x_");

firmware/controllers/trigger/trigger_central.h

@@ -66,5 +66,6 @@ void resetMaxValues();
 void onConfigurationChangeTriggerCallback(engine_configuration_s *previousConfiguration DECLARE_ENGINE_PARAMETER_SUFFIX);
 bool checkIfTriggerConfigChanged(void);
 bool readIfTriggerConfigChangedForUnitTest(void);
+void resetTriggerConfigChangedForUnitTest(void);
 
 #endif /* TRIGGER_CENTRAL_H_ */

firmware/controllers/trigger/trigger_decoder.cpp

@@ -169,6 +169,8 @@ void TriggerState::resetCurrentCycleState() {
 
 void TriggerState::onSynchronizationLost(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	shaft_is_synchronized = false;
+	// Needed for early instant-RPM detection
+	engine->rpmCalculator.setStopSpinning(PASS_ENGINE_PARAMETER_SIGNATURE);
 }
 
 /**
@@ -436,6 +438,10 @@ void TriggerState::decodeTriggerEvent(trigger_event_e const signal, efitime_t no
 
 	runtimeStatistics(nowNt PASS_ENGINE_PARAMETER_SUFFIX);
 
+	// Needed for early instant-RPM detection
+	if (!isInitializingTrigger) {
+		engine->rpmCalculator.setSpinningUp(nowNt PASS_ENGINE_PARAMETER_SUFFIX);
+	}
 }
 
 /**
@@ -644,6 +650,9 @@ void TriggerShape::initializeTriggerShape(Logging *logger DECLARE_ENGINE_PARAMET
 		unlockAnyContext();
 	}
 #endif
+
+	// Moved here from mainTriggerCallback()
+	prepareOutputSignals(PASS_ENGINE_PARAMETER_SIGNATURE);
 }
 
 static void onFindIndexCallback(TriggerState *state) {

firmware/controllers/trigger/trigger_decoder.h

@@ -134,8 +134,17 @@ public:
 	 * instant RPM calculated at this trigger wheel tooth
 	 */
 	float instantRpmValue[PWM_PHASE_MAX_COUNT];
+	/**
+	 * Stores last non-zero instant RPM value to fix early instability
+	 */
+	float prevInstantRpmValue;
 	float calculateInstantRpm(int *prevIndex, efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX);
 	virtual void runtimeStatistics(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX);
+	/**
+	 * Update timeOfLastEvent[] on every trigger event - even without synchronization
+	 * Needed for early spin-up RPM detection.
+	 */
+	void setLastEventTimeForInstantRpm(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX);
 };
 
 angle_t getEngineCycle(operation_mode_e operationMode);

firmware/controllers/trigger/trigger_structure.cpp

@@ -182,6 +182,12 @@ void TriggerState::runtimeStatistics(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SU
 
 TriggerStateWithRunningStatistics::TriggerStateWithRunningStatistics() {
 	instantRpm = 0;
+	prevInstantRpmValue = 0;
+	// avoid ill-defined instant RPM when the data is not gathered yet
+	efitime_t nowNt = getTimeNowNt();
+	for (int i = 0; i < PWM_PHASE_MAX_COUNT; i++) {
+		timeOfLastEvent[i] = nowNt;
+	}
 }
 
 float TriggerStateWithRunningStatistics::calculateInstantRpm(int *prevIndex, efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX) {
@@ -203,13 +209,26 @@ float TriggerStateWithRunningStatistics::calculateInstantRpm(int *prevIndex, efi
 	// todo: angle diff should be pre-calculated
 	fixAngle(angleDiff, "angleDiff");
 
+	// just for safety
+	if (time == 0)
+		return prevInstantRpmValue;
+
 	float instantRpm = (60000000.0 / 360 * US_TO_NT_MULTIPLIER) * angleDiff / time;
 	instantRpmValue[current_index] = instantRpm;
 	timeOfLastEvent[current_index] = nowNt;
 
+	// This fixes early RPM instability based on incomplete data
+	if (instantRpm < RPM_LOW_THRESHOLD)
+		return prevInstantRpmValue;
+	prevInstantRpmValue = instantRpm;
+
 	return instantRpm;
 }
 
+void TriggerStateWithRunningStatistics::setLastEventTimeForInstantRpm(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX) {
+	timeOfLastEvent[currentCycle.current_index] = nowNt;
+}
+
 void TriggerStateWithRunningStatistics::runtimeStatistics(efitime_t nowNt DECLARE_ENGINE_PARAMETER_SUFFIX) {
 	if (engineConfiguration->debugMode == DBG_INSTANT_RPM) {
 		int prevIndex;

unit_tests/engine_test_helper.cpp

@@ -70,6 +70,7 @@ EngineTestHelper::EngineTestHelper(engine_type_e engineType) : engine (&persiste
 	engine->triggerCentral.triggerShape.initializeTriggerShape(NULL PASS_ENGINE_PARAMETER_SUFFIX);
 	engine->triggerCentral.addEventListener(rpmShaftPositionCallback, "rpm reporter", engine);
 	engine->triggerCentral.addEventListener(mainTriggerCallback, "main loop", engine);
+	resetTriggerConfigChangedForUnitTest();
 }
 
 void EngineTestHelper::firePrimaryTriggerRise() {

unit_tests/main.cpp

@@ -29,6 +29,7 @@
 #include "test_signal_executor.h"
 #include "trigger_central.h"
 #include "test_startOfCrankingPrimingPulse.h"
+#include "test_fasterEngineSpinningUp.h"
 #include "test_util.h"
 #include "map_resize.h"
 #include "engine_math.h"
@@ -74,6 +75,7 @@ int main(void) {
 	testFindIndex();
 	testPlainCrankingWithoutAdvancedFeatures();
 	testStartOfCrankingPrimingPulse();
+	testFasterEngineSpinningUp();
 	testInterpolate2d();
 	testGpsParser();
 	testMisc();

unit_tests/test.mk

@@ -5,6 +5,7 @@ TEST_SRC_CPP = test_util.cpp \
 	test_basic_math/test_interpolation_3d.cpp \
 	test_data_structures/test_engine_math.cpp \
 	test_startOfCrankingPrimingPulse.cpp \
+	test_fasterEngineSpinningUp.cpp \
 	test_idle_controller.cpp \
 	test_trigger_decoder.cpp \
 	test_fuel_map.cpp \

unit_tests/test_fasterEngineSpinningUp.cpp

@@ -0,0 +1,107 @@
+/*
+ * test_fasterEngineSpinningUp.cpp
+ *
+ *  Created on: Mar 6, 2018
+ */
+
+#include "engine_math.h"
+#include "test_fasterEngineSpinningUp.h"
+#include "test_trigger_decoder.h"
+#include "event_queue.h"
+#include "unit_test_framework.h"
+
+extern EventQueue schedulingQueue;
+extern int timeNowUs;
+extern EnginePins enginePins;
+
+void testFasterEngineSpinningUp() {
+	// this is just a reference unit test implementation
+	printf("*************************************************** testFasterEngineSpinningUp\r\n");
+
+	EngineTestHelper eth(TEST_ENGINE);
+	EXPAND_EngineTestHelper
+
+	// turn on FasterEngineSpinUp mode
+	engineConfiguration->bc.isFasterEngineSpinUpEnabled = true;
+	// set ignition mode
+	engineConfiguration->ignitionMode = IM_INDIVIDUAL_COILS;
+	// set cranking threshold (used below)
+	engineConfiguration->cranking.rpm = 999;
+	// set sequential injection mode to test auto-change to simultaneous when spinning-up
+	setupSimpleTestEngineWithMafAndTT_ONE_trigger(&eth, IM_SEQUENTIAL);
+
+	// check if it's true
+	assertEquals(IM_SEQUENTIAL, engine->getCurrentInjectionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	assertEquals(IM_INDIVIDUAL_COILS, getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// check if the engine has the right state
+	assertEquals(STOPPED, engine->rpmCalculator.getState());
+	// check RPM
+	assertEqualsM("RPM=0", 0, engine->rpmCalculator.getRpm(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// the queue should be empty, no trigger events yet
+	assertEqualsM("plain#1", 0, schedulingQueue.size());
+
+	// check all events starting from now
+	int timeStartUs = timeNowUs;
+	// advance 1 revolution
+	timeNowUs += MS2US(200);
+	eth.firePrimaryTriggerRise();
+
+	// check if the mode is changed
+	assertEquals(SPINNING_UP, engine->rpmCalculator.getState());
+	// due to isFasterEngineSpinUp=true, we should have already detected RPM!
+	assertEqualsM("RPM#1", 300, engine->rpmCalculator.getRpm(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// two simultaneous injections
+	assertEqualsM("plain#1", 4, schedulingQueue.size());
+	// test if they are simultaneous
+	assertEquals(IM_SIMULTANEOUS, engine->getCurrentInjectionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// test if ignition mode is temporary changed to wasted spark, if set to ind.coils
+	assertEquals(IM_WASTED_SPARK, getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// check real events
+	assertEvent5("inj start#1", 0, (void*)startSimultaniousInjection, timeStartUs, MS2US(200) + 97975);
+	assertEvent5("inj end#1", 1, (void*)endSimultaniousInjection, timeStartUs, MS2US(200) + 100000);
+
+	// skip the rest of the cycle
+	timeNowUs += MS2US(200);
+	eth.firePrimaryTriggerFall();
+
+	// now clear and advance more
+	eth.clearQueue();
+	timeNowUs += MS2US(200);
+	eth.firePrimaryTriggerRise();
+
+	// check if the mode is changed when fully synched
+	assertEquals(CRANKING, engine->rpmCalculator.getState());
+	// check RPM
+	assertEqualsM("RPM#2", 300, engine->rpmCalculator.getRpm(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// test if they are simultaneous in cranking mode too
+	assertEquals(IM_SIMULTANEOUS, engine->getCurrentInjectionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// test if ignition mode is restored to ind.coils
+	assertEquals(IM_INDIVIDUAL_COILS, getIgnitionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// two simultaneous injections
+	assertEqualsM("plain#2", 4, schedulingQueue.size());
+	// check real events
+	assertEvent5("inj start#2", 0, (void*)startSimultaniousInjection, timeNowUs, 97975);
+	assertEvent5("inj end#2", 1, (void*)endSimultaniousInjection, timeNowUs, 100000);
+
+	// skip, clear & advance 1 more revolution at higher RPM
+	timeNowUs += MS2US(60);
+	eth.firePrimaryTriggerFall();
+
+	eth.clearQueue();
+	timeStartUs = timeNowUs;
+	eth.fireTriggerEvents2(1, MS2US(60));
+
+	// check if the mode is now changed to 'running' at higher RPM
+	assertEquals(RUNNING, engine->rpmCalculator.getState());
+	// check RPM
+	assertEqualsM("RPM#3", 1000, engine->rpmCalculator.getRpm(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// check if the injection mode is back to sequential now
+	assertEquals(IM_SEQUENTIAL, engine->getCurrentInjectionMode(PASS_ENGINE_PARAMETER_SIGNATURE));
+	// 4 sequential injections for the full cycle
+	assertEqualsM("plain#3", 8, schedulingQueue.size());
+
+	// check real events for sequential injection
+	// Note: See addFuelEvents() fix inside setRpmValue()!
+	assertEvent5("inj start#3", 0, (void*)seTurnPinHigh, timeStartUs, MS2US(60) + 27974);
+	assertEvent5("inj end#3", 1, (void*)seTurnPinLow, timeStartUs, MS2US(60) + 27974 + 3000);
+}

unit_tests/test_fasterEngineSpinningUp.h

@@ -0,0 +1,14 @@
+/*
+ * test_fasterEngineSpinningUp.h
+ *
+ *  Created on: Mar 6, 2018
+ */
+
+#ifndef TEST_FASTERENGINESPINNINGUP_H_
+#define TEST_FASTERENGINESPINNINGUP_H_
+
+#include "main.h"
+
+void testFasterEngineSpinningUp();
+
+#endif /* TEST_FASTERENGINESPINNINGUP_H_ */

unit_tests/test_trigger_decoder.cpp

@@ -315,8 +315,9 @@ void testRpmCalculator(void) {
 	timeNowUs = 0;
 	assertEquals(0, eth.engine.rpmCalculator.getRpm(PASS_ENGINE_PARAMETER_SIGNATURE));
 
-	assertEquals(4, TRIGGER_SHAPE(triggerIndexByAngle[240]));
+	// triggerIndexByAngle update is now fixed! prepareOutputSignals() wasn't reliably called
-	assertEquals(4, TRIGGER_SHAPE(triggerIndexByAngle[241]));
+	assertEquals(5, TRIGGER_SHAPE(triggerIndexByAngle[240]));
+	assertEquals(5, TRIGGER_SHAPE(triggerIndexByAngle[241]));
 
 	eth.fireTriggerEvents(48);
 
@@ -619,7 +620,7 @@ static void assertInjectionEvent(const char *msg, InjectionEvent *ev, int inject
 	assertEqualsM4(msg, " event offset", angleOffset, ev->injectionStart.angleOffset);
 }
 
-void setupSimpleTestEngineWithMafAndTT_ONE_trigger(EngineTestHelper *eth) {
+void setupSimpleTestEngineWithMafAndTT_ONE_trigger(EngineTestHelper *eth, injection_mode_e injMode) {
 	Engine *engine = &eth->engine;
 	EXPAND_Engine
 
@@ -629,7 +630,10 @@ void setupSimpleTestEngineWithMafAndTT_ONE_trigger(EngineTestHelper *eth) {
 	assertEquals(LM_PLAIN_MAF, engineConfiguration->fuelAlgorithm);
 	engineConfiguration->isIgnitionEnabled = false; // let's focus on injection
 	engineConfiguration->specs.cylindersCount = 4;
-	engineConfiguration->injectionMode = IM_BATCH;
+	// a bit of flexibility - the mode may be changed by some tests
+	engineConfiguration->injectionMode = injMode;
+	// set cranking mode (it's used by getCurrentInjectionMode())
+	engineConfiguration->crankingInjectionMode = IM_SIMULTANEOUS;
 
 	setArrayValues(config->cltFuelCorrBins, CLT_CURVE_SIZE, 1);
 	setArrayValues(engineConfiguration->injector.battLagCorr, VBAT_INJECTOR_CURVE_SIZE, 0);

unit_tests/test_trigger_decoder.h

@@ -20,6 +20,6 @@ void testRpmCalculator(void);
 void testStartupFuelPumping(void);
 void test1995FordInline6TriggerDecoder(void);
 void testTriggerDecoder2(const char *msg, engine_type_e type, int synchPointIndex, float channel1duty, float channel2duty);
-void setupSimpleTestEngineWithMafAndTT_ONE_trigger(EngineTestHelper *eth);
+void setupSimpleTestEngineWithMafAndTT_ONE_trigger(EngineTestHelper *eth, injection_mode_e injMode = IM_BATCH);
 
 #endif /* TEST_TRIGGER_DECODER_H_ */