rusefi/firmware/hw_layer/sensors/CJ125.cpp

/*
 * @file CJ125.cpp
 *
 * @date: Jun 24, 2016
 * @author Andrey Belomutskiy, (c) 2012-2018
 *
 */

#include "engine.h"
#include "CJ125.h"
#include "pwm_generator.h"
#include "rpm_calculator.h"
#include "pid.h"

#if EFI_CJ125 || defined(__DOXYGEN__)

// looks like 3v range should be enough, divider not needed
#define EFI_CJ125_DIRECTLY_CONNECTED_UR TRUE

#include "pin_repository.h"
#include "hardware.h"
#include "adc_inputs.h"
#include "backup_ram.h"


#define CJ125_DEBUG
//#define CJ125_DEBUG_SPI

EXTERN_ENGINE;

#if ! EFI_UNIT_TEST || defined(__DOXYGEN__)
extern TunerStudioOutputChannels tsOutputChannels;
#endif

static SimplePwm wboHeaterControl;
static OutputPin wboHeaterPin;
static OutputPin cj125Cs;
static Logging *logger;
static unsigned char tx_buff[2];
static unsigned char rx_buff[1];

static pid_s heaterPidConfig;
static Pid heaterPid(&heaterPidConfig);
static float heaterDuty = 0.0f;

static THD_WORKING_AREA(cjThreadStack, UTILITY_THREAD_STACK_SIZE);

static SPIDriver *driver;


static SPIConfig cj125spicfg = { NULL,
	/* HW dependent part.*/
	NULL, 0, SPI_CR1_MSTR | SPI_CR1_CPHA | SPI_CR1_BR_0 | SPI_CR1_BR_1 | SPI_CR1_BR_2 };

// Used by CJ125 driver state machine
static volatile cj125_state_e state = CJ125_IDLE;
// Chip diagnostics register contents
static volatile int diag = 0;
// Last Error code
static volatile cj125_error_e errorCode = CJ125_ERROR_NONE;

// Current values
static volatile float vUa = 0.0f, vUr = 0.0f;
// Calibration values
static volatile float vUaCal = 0.0f, vUrCal = 0.0f;

static volatile int lastSlowAdcCounter = 0;

static volatile cj125_mode_e mode = CJ125_MODE_NONE;
// Amplification coefficient, needed by cjGetAfr()
static volatile float amplCoeff = 0.0f;
// Calculated Lambda-value
static volatile float lambda = 1.0f;

// LSU conversion tables. See cj125_sensor_type_e
// For LSU4.2, See http://www.bosch-motorsport.com/media/catalog_resources/Lambda_Sensor_LSU_42_Datasheet_51_en_2779111435pdf.pdf
// See LSU4.9, See http://www.bosch-motorsport.com/media/catalog_resources/Lambda_Sensor_LSU_49_Datasheet_51_en_2779147659pdf.pdf
static const int CJ125_LSU_CURVE_SIZE = 16;
// This is a number of bins for each sensor type (should be < CJ125_LSU_CURVE_SIZE)
static const float cjLSUTableSize[2] = {
	9, 15,
};
// Pump current, mA
static const float cjLSUBins[2][CJ125_LSU_CURVE_SIZE] = {	{ 
	// LSU 4.2
	-1.85f, -1.08f, -0.76f, -0.47f, 0.0f, 0.34f, 0.68f, 0.95f, 1.4f }, { 
	// LSU 4.9
	-2.0f, -1.602f, -1.243f, -0.927f, -0.8f, -0.652f, -0.405f, -0.183f, -0.106f, -0.04f, 0, 0.015f, 0.097f, 0.193f, 0.250f },
};
// Lambda value
static const float cjLSULambda[2][CJ125_LSU_CURVE_SIZE] = { {
	// LSU 4.2
	0.7f, 0.8f, 0.85f, 0.9f, 1.009f, 1.18f, 1.43f, 1.7f, 2.42f }, {
	// LSU 4.9
	0.65f, 0.7f, 0.75f, 0.8f, 0.822f, 0.85f, 0.9f, 0.95f, 0.97f, 0.99f, 1.003f, 1.01f, 1.05f, 1.1f, 1.132f },
};

static int cjReadRegister(unsigned char regAddr) {
	spiSelect(driver);
	tx_buff[0] = regAddr;
	spiSend(driver, 1, tx_buff);
	// safety?
	chThdSleepMilliseconds(10);
	
	rx_buff[0] = 0;
	spiReceive(driver, 1, rx_buff);
	spiUnselect(driver);

#ifdef CJ125_DEBUG_SPI
	scheduleMsg(logger, "cjReadRegister: addr=%d answer=%d", regAddr, rx_buff[0]);
#endif
	return rx_buff[0];
}

static void cjWriteRegister(unsigned char regAddr, unsigned char regValue) {
#ifdef CJ125_DEBUG_SPI
	scheduleMsg(logger, "cjWriteRegister: addr=%d value=%d", regAddr, regValue);
#endif
	spiSelect(driver);
	tx_buff[0] = regAddr;
	tx_buff[1] = regValue;
	spiSend(driver, 2, tx_buff);
	spiUnselect(driver);
}

static float getUr() {
	if (CONFIG(cj125ur) != EFI_ADC_NONE) {
#ifdef EFI_CJ125_DIRECTLY_CONNECTED_UR
		// in case of directly connected Ur signal from CJ125 to the ADC pin of MCU
		return getVoltage("cj125ur", CONFIG(cj125ur));
#else
		// if a standard voltage division scheme with OpAmp is used
		return getVoltageDivided("cj125ur", CONFIG(cj125ur));
#endif
	}
	return 0.0f;
}

static float getUa() {
	if (CONFIG(cj125ua) != EFI_ADC_NONE)
		return getVoltageDivided("cj125ua", CONFIG(cj125ua));
	return 0.0f;
}

static float getVoltageFrom16bit(uint32_t stored) {
	return ((float)stored) / CJ125_VOLTAGE_TO_16BIT_FACTOR;
}

static uint32_t get16bitFromVoltage(float v) {
	return (uint32_t)(v * CJ125_VOLTAGE_TO_16BIT_FACTOR);
}

static void cjPrintData(void) {
#ifdef CJ125_DEBUG
	scheduleMsg(logger, "cj125: state=%d diag=0x%x (vUa=%.3f vUr=%.3f) (vUaCal=%.3f vUrCal=%.3f)", state, diag, vUa, vUr, vUaCal, vUrCal);
#endif
}

static void cjPrintErrorCode(cj125_error_e errCode) {
	const char *errString = nullptr;
	switch (errCode) {
	case CJ125_ERROR_HEATER_MALFUNCTION:
		errString = "Heater malfunction (Too long preheat)"; 
		break;
	case CJ125_ERROR_OVERHEAT:
		errString = "Sensor overheating";
		break;
	case CJ125_ERROR_NONE:
		errString = "N/A";
		break;
	}
	scheduleMsg(logger, "cj125 ERROR: %s.", errString);
}

static void cjSetMode(cj125_mode_e m) {
	if (mode == m)
		return;
	switch (m) {
	case CJ125_MODE_NORMAL_8:
		cjWriteRegister(INIT_REG1_WR, CJ125_INIT1_NORMAL_8);
		amplCoeff = 1.0f / 8.0f;
		break;
	case CJ125_MODE_NORMAL_17:
		cjWriteRegister(INIT_REG1_WR, CJ125_INIT1_NORMAL_17);
		amplCoeff = 1.0f / 17.0f;
		break;
	case CJ125_MODE_CALIBRATION:
		cjWriteRegister(INIT_REG1_WR, CJ125_INIT1_CALBRT);
		amplCoeff = 0.0f;
		break;
	default:
		;
	}
	mode = m;
}

static void cjIdentify(void) {
	// read Ident register
	int ident = cjReadRegister(IDENT_REG_RD) & CJ125_IDENT_MASK;

	// set initial registers
	cjWriteRegister(INIT_REG1_WR, CJ125_INIT1_NORMAL_17);
	cjWriteRegister(INIT_REG2_WR, CJ125_INIT2_DIAG);
	// check if regs are ok
	int init1 = cjReadRegister(INIT_REG1_RD);
	int init2 = cjReadRegister(INIT_REG2_RD);

	diag = cjReadRegister(DIAG_REG_RD);
	scheduleMsg(logger, "cj125: Check ident=0x%x diag=0x%x init1=0x%x init2=0x%x", ident, diag, init1, init2);
	if (ident != CJ125_IDENT) {
		scheduleMsg(logger, "cj125: Error! Wrong ident! Cannot communicate with CJ125!");
	}
	if (init1 != CJ125_INIT1_NORMAL_17 || init2 != CJ125_INIT2_DIAG) {
		scheduleMsg(logger, "cj125: Error! Cannot set init registers! Cannot communicate with CJ125!");
	}
#if 0
	if (diag != CJ125_DIAG_NORM) {
		scheduleMsg(logger, "cj125: Diag error!");
	}
#endif
}

static void cjUpdateAnalogValues(void) {
	waitForSlowAdc(lastSlowAdcCounter);
    vUr = getUr();
    vUa = getUa();
    lastSlowAdcCounter = getSlowAdcCounter();
}

static void cjCalibrate(void) {
	cjIdentify();

	scheduleMsg(logger, "cj125: Starting calibration...");
	cjSetMode(CJ125_MODE_CALIBRATION);
	int init1 = cjReadRegister(INIT_REG1_RD);
	// check if our command has been accepted
	if (init1 != CJ125_INIT1_CALBRT) {
		scheduleMsg(logger, "cj125: Calibration error (init1=0x%02x)! Failed!", init1);
		cjSetMode(CJ125_MODE_NORMAL_17);
		return;
	}
	// wait for the start of the calibration
	chThdSleepMilliseconds(CJ125_CALIBRATION_DELAY);
	vUaCal = 0.0f;
	vUrCal = 0.0f;
	// wait for some more ADC samples
	for (int i = 0; i < CJ125_CALIBRATE_NUM_SAMPLES; i++) {
		cjUpdateAnalogValues();
		cjPrintData();
		cjPostState(&tsOutputChannels);
		vUaCal += vUa;
		vUrCal += vUr;
	}
	// find average
	vUaCal /= (float)CJ125_CALIBRATE_NUM_SAMPLES;
	vUrCal /= (float)CJ125_CALIBRATE_NUM_SAMPLES;
	// restore normal mode
	cjSetMode(CJ125_MODE_NORMAL_17);
	chThdSleepMilliseconds(CJ125_CALIBRATION_DELAY);
	// check if everything is ok
	diag = cjReadRegister(DIAG_REG_RD);
	cjUpdateAnalogValues();
	cjPrintData();

	// store new calibration data
	uint32_t storedLambda = get16bitFromVoltage(vUaCal);
	uint32_t storedHeater = get16bitFromVoltage(vUrCal);
	scheduleMsg(logger, "cj125: Done! Saving calibration data (%d %d).", storedLambda, storedHeater);
	backupRamSave(BACKUP_CJ125_CALIBRATION_LAMBDA, storedLambda);
	backupRamSave(BACKUP_CJ125_CALIBRATION_HEATER, storedHeater);

	state = CJ125_IDLE;
}

static void cjStart(void) {
	if (!boardConfiguration->isCJ125Enabled) {
		scheduleMsg(logger, "cj125 is disabled.");
		return;
	}
	
	cjIdentify();

	// Load calibration values
	uint32_t storedLambda = backupRamLoad(BACKUP_CJ125_CALIBRATION_LAMBDA);
	uint32_t storedHeater = backupRamLoad(BACKUP_CJ125_CALIBRATION_HEATER);
	// if no calibration, try to calibrate now and store new values
	if (storedLambda == 0 || storedHeater == 0) {
		cjCalibrate();
	} else {
		scheduleMsg(logger, "cj125: Loading stored calibration data (%d %d)", storedLambda, storedHeater);
		vUaCal = getVoltageFrom16bit(storedLambda);
		vUrCal = getVoltageFrom16bit(storedHeater);
		// Start normal measurement mode
		cjSetMode(CJ125_MODE_NORMAL_17);
	}
	cjPrintData();

	lastSlowAdcCounter = getSlowAdcCounter();
}

static void cjSetHeater(float value) {
	// limit duty cycle for sensor safety
	float maxDuty = (engine->sensors.vBatt > CJ125_HEATER_LIMITING_VOLTAGE) ? CJ125_HEATER_LIMITING_RATE : 1.0f;
	heaterDuty = (value < CJ125_HEATER_MIN_DUTY) ? 0.0f : minF(maxF(value, 0.0f), maxDuty);
#ifdef CJ125_DEBUG
	scheduleMsg(logger, "cjSetHeater: %.2f", heaterDuty);
#endif
	// a little trick to disable PWM if needed.
	// todo: this should be moved to wboHeaterControl.setPwmDutyCycle()
	wboHeaterControl.setFrequency(heaterDuty == 0.0f ? NAN : CJ125_HEATER_PWM_FREQ);
	wboHeaterControl.setSimplePwmDutyCycle(heaterDuty);
	// This fixes pwm sticking to the last pin state
	if (heaterDuty == 0.0f)
		wboHeaterPin.setValue(false);
}

static void cjSetIdleHeater(void) {
	// small preheat for faster start & moisture anti-shock therapy for the sensor
	cjSetHeater(CJ125_HEATER_IDLE_RATE);
}

static void cjStartHeaterControl(void) {
	if (boardConfiguration->wboHeaterPin != GPIO_UNASSIGNED) {
		scheduleMsg(logger, "cj125: Starting heater control");
		// todo: use custom pin state method, turn pin off while not running
		startSimplePwmExt(&wboHeaterControl, "wboHeaterPin", boardConfiguration->wboHeaterPin,
				&wboHeaterPin, CJ125_HEATER_PWM_FREQ, 0.0f, applyPinState);
		cjSetIdleHeater();
	}
}

static void cjSetError(cj125_error_e errCode) {
	errorCode = errCode;
	state = CJ125_ERROR;
	cjPrintErrorCode(errorCode);
	// This is for safety:
	scheduleMsg(logger, "cj125: Controller Shutdown!");
	cjSetHeater(0);
	// Software-reset of CJ125
	cjWriteRegister(INIT_REG2_WR, CJ125_INIT2_RESET);
}

static bool cjIsWorkingState(void) {
	return state != CJ125_ERROR && state != CJ125_INIT && state != CJ125_IDLE;
}

static void cjInitPid(void) {
	// todo: these values are valid only for LSU 4.2
	heaterPidConfig.pFactor = CJ125_PID_LSU42_P;
	heaterPidConfig.iFactor = CJ125_PID_LSU42_I;
	heaterPidConfig.dFactor = 0.0f;
	heaterPidConfig.minValue = 0;
	heaterPidConfig.maxValue = 1;
	heaterPidConfig.offset = 0;
	// todo: period?
	heaterPidConfig.period = 1.0f;
	heaterPid.reset();
}

static void cjStartSpi(void) {
	cj125spicfg.ssport = getHwPort("cj125", boardConfiguration->cj125CsPin);
	cj125spicfg.sspad = getHwPin("cj125", boardConfiguration->cj125CsPin);

	driver = getSpiDevice(engineConfiguration->cj125SpiDevice);

	cj125Cs.initPin("cj125 CS", boardConfiguration->cj125CsPin,
			&engineConfiguration->cj125CsPinMode);

	scheduleMsg(logger, "cj125: Starting SPI driver");
	spiStart(driver, &cj125spicfg);
}

static msg_t cjThread(void)
{
	chRegSetThreadName("cj125");

	chThdSleepMilliseconds(500);

	efitick_t startHeatingNt = 0;
	efitick_t prevNt = getTimeNowNt();
	while(1) {
		efitick_t nowNt = getTimeNowNt();
		bool isStopped = engine->rpmCalculator.isStopped(PASS_ENGINE_PARAMETER_SIGNATURE);

		cjUpdateAnalogValues();
		
		// If the controller is disabled
		if (state == CJ125_IDLE || state == CJ125_ERROR) {
			chThdSleepMilliseconds(CJ125_IDLE_TICK_DELAY);
			continue;
		}

		if (state == CJ125_CALIBRATION) {
			cjCalibrate();
			// Start normal operation
			state = CJ125_INIT;
			cjSetMode(CJ125_MODE_NORMAL_17);
		}
		
		diag = cjReadRegister(DIAG_REG_RD);

		// check heater state
		if (vUr > CJ125_UR_PREHEAT_THR || heaterDuty < CJ125_PREHEAT_MIN_DUTY) {
			// Check if RPM>0 and it's time to start pre-heating
			if (state == CJ125_INIT && !isStopped) {
				// start preheating
				state = CJ125_PREHEAT;
				startHeatingNt = prevNt = getTimeNowNt();
				cjSetMode(CJ125_MODE_NORMAL_17);
			}
		} else if (vUr > CJ125_UR_GOOD_THR) {
			state = CJ125_HEAT_UP;
		} else if (vUr < CJ125_UR_OVERHEAT_THR) {
			state = CJ125_OVERHEAT;
		} else {
			// This indicates that the heater temperature is optimal for UA measurement
			state = CJ125_READY;
		}

		if (isStopped && cjIsWorkingState()) {
			state = CJ125_INIT;
			cjSetIdleHeater();
		}

#if 0
		// Change amplification if AFR gets lean/rich for better accuracy
		cjSetMode(lambda > 1.0f ? CJ125_MODE_NORMAL_17 : CJ125_MODE_NORMAL_8);
#endif

#if 0
		// Update console output variables
		cjPostState(&tsOutputChannels);
#endif

		switch (state) {
		case CJ125_PREHEAT:
			// use constant-speed startup heat-up
			if (nowNt - prevNt >= CJ125_HEATER_PREHEAT_PERIOD) {
				float periodSecs = (float)(nowNt - prevNt) / US2NT(US_PER_SECOND_LL);
				// maintain speed at ~0.4V/sec
				float preheatDuty = heaterDuty + periodSecs * CJ125_HEATER_PREHEAT_RATE;
				cjSetHeater(preheatDuty);
				// If we are heating too long, and there's still no result, then something is wrong...
				if (nowNt - startHeatingNt > US2NT(US_PER_SECOND_LL) * CJ125_PREHEAT_TIMEOUT) {
					cjSetError(CJ125_ERROR_HEATER_MALFUNCTION);
				}
				cjPrintData();
				prevNt = nowNt;
			}
			break;
		case CJ125_HEAT_UP:
		case CJ125_READY:
			// use PID for normal heater control
			if (nowNt - prevNt >= CJ125_HEATER_CONTROL_PERIOD) {
				float duty = heaterPid.getValue(vUr, vUrCal);
				heaterPid.showPidStatus(logger, "cj");
				cjSetHeater(duty);
				cjPrintData();
				prevNt = nowNt;
			}
			break;
		case CJ125_OVERHEAT:
			if (nowNt - prevNt >= CJ125_HEATER_OVERHEAT_PERIOD) {
				cjSetError(CJ125_ERROR_OVERHEAT);
				prevNt = nowNt;
			}
		default:
			;
		}

		chThdSleepMilliseconds(CJ125_TICK_DELAY);
	}
	return -1;
}

static bool cjCheckConfig(void) {
	if (!boardConfiguration->isCJ125Enabled) {
		scheduleMsg(logger, "cj125 is disabled. Failed!");
		return false;
	}
	return true;
}

static void cjStartCalibration(void) {
	if (!cjCheckConfig())
		return;
	if (state != CJ125_IDLE) {
		// todo: change this later for the normal thread operation (auto pre-heating)
		scheduleMsg(logger, "cj125: Cannot start calibration. Please restart the board and make sure that your sensor is not heating");
		return;
	}
	state = CJ125_CALIBRATION;
}

static void cjStartTest(void) {
	if (!cjCheckConfig())
		return;
	state = CJ125_INIT;
}

#ifdef CJ125_DEBUG
static void cjSetInit1(int v) {
	cjWriteRegister(INIT_REG1_WR, v & 0xff);
	v = cjReadRegister(INIT_REG1_RD);
	scheduleMsg(logger, "cj125 INIT_REG1=0x%02x.", v);
}

static void cjSetInit2(int v) {
	cjWriteRegister(INIT_REG2_WR, v & 0xff);
	v = cjReadRegister(INIT_REG2_RD);
	scheduleMsg(logger, "cj125 INIT_REG2=0x%02x.", v);
}
#endif /* CJ125_DEBUG */

float cjGetAfr(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
	// todo: make configurable sensor LSU type
	cj125_sensor_type_e sensorType = CJ125_LSU_42;
	
	// See CJ125 datasheet, page 6
	float pumpCurrent = (vUa - vUaCal) * amplCoeff * (CJ125_PUMP_CURRENT_FACTOR / CJ125_PUMP_SHUNT_RESISTOR);
	lambda = interpolate2d("cj125Lsu", pumpCurrent, (float *)cjLSUBins[sensorType], (float *)cjLSULambda[sensorType], cjLSUTableSize[sensorType]);
	// todo: make configurable stoich ratio
	return lambda * CJ125_STOICH_RATIO;
}

bool cjHasAfrSensor(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
	if (!boardConfiguration->isCJ125Enabled)
		return false;
	// check if controller is functioning
	if (!cjIsWorkingState())
		return false;
	// check if amplification is turned on
	if (amplCoeff == 0.0f)
		return false;
	// check if UA calibration value is valid
	if (vUaCal < CJ125_UACAL_MIN || vUaCal > CJ125_UACAL_MAX)
		return false;
	return true;
}

void cjPostState(TunerStudioOutputChannels *tsOutputChannels) {
	tsOutputChannels->debugFloatField1 = heaterDuty;
	tsOutputChannels->debugFloatField2 = heaterPid.getIntegration();
	tsOutputChannels->debugFloatField3 = heaterPid.getPrevError();
	tsOutputChannels->debugFloatField4 = vUa;
	tsOutputChannels->debugFloatField5 = vUr;
	tsOutputChannels->debugFloatField6 = vUaCal;
	tsOutputChannels->debugFloatField7 = vUrCal;
	tsOutputChannels->debugIntField1 = state;
	tsOutputChannels->debugIntField2 = diag;
}

void initCJ125(Logging *sharedLogger) {
	logger = sharedLogger;

	if (!boardConfiguration->isCJ125Enabled)
		return;

	if (CONFIG(cj125ur) == EFI_ADC_NONE || CONFIG(cj125ua) == EFI_ADC_NONE) {
		scheduleMsg(logger, "cj125 init error! cj125ur and cj125ua are required.");
		return;
	}

	if (boardConfiguration->wboHeaterPin == GPIO_UNASSIGNED) {
		scheduleMsg(logger, "cj125 init error! wboHeaterPin is required.");
		return;
	}

	cjInitPid();
	cjStartSpi();
	cjStartHeaterControl();
	cjStart();

#if 1
	state = CJ125_INIT;
#endif
	
	addConsoleAction("cj125", cjStartTest);
	addConsoleAction("cj125_calibrate", cjStartCalibration);
#ifdef CJ125_DEBUG
	addConsoleActionF("cj125_heater", cjSetHeater);
	addConsoleActionI("cj125_set_init1", cjSetInit1);
	addConsoleActionI("cj125_set_init2", cjSetInit2);
#endif /* CJ125_DEBUG */

	chThdCreateStatic(cjThreadStack, sizeof(cjThreadStack), LOWPRIO, (tfunc_t) cjThread, NULL);
}

#endif /* EFI_CJ125 */