ignition controller detects rising edge on voltage (#3636)

* ignition controller detects rising edge on voltage

* update test

* comment

* ignore negative transients

* tweak

* test

firmware/controllers/actuators/fuel_pump.cpp

@@ -4,10 +4,10 @@
 #include "fuel_pump.h"
 
 void FuelPumpController::onSlowCallback() {
-	auto uptime = getTimeNowSeconds();
+	auto timeSinceIgn = m_ignOnTimer.getElapsedSeconds();
 
-	// If the ECU just started, turn on the fuel pump to prime
-	isPrime = uptime >= 0 && uptime < engineConfiguration->startUpFuelPumpDuration;
+	// If the ignition just turned on, turn on the fuel pump to prime
+	isPrime = timeSinceIgn >= 0 && timeSinceIgn < engineConfiguration->startUpFuelPumpDuration;
 
 	// If there was a trigger event recently, turn on the pump, the engine is running!
 	auto timeSinceTrigger = engine->triggerCentral.getTimeSinceTriggerEvent(getTimeNowNt());
@@ -21,3 +21,9 @@ void FuelPumpController::onSlowCallback() {
 	engine->outputChannels.isFuelPumpOn = isPumpOn;
 #endif
 }
+
+void FuelPumpController::onIgnitionStateChanged(bool ignitionOn) {
+	if (ignitionOn) {
+		m_ignOnTimer.reset();
+	}
+}

firmware/controllers/actuators/fuel_pump.h

@@ -3,6 +3,11 @@
 #include "engine_module.h"
 #include "fuel_pump_generated.h"
 
-struct FuelPumpController : public EngineModule, public fuel_pump_control_s {
+class FuelPumpController : public EngineModule, public fuel_pump_control_s {
+public:
 	void onSlowCallback() override;
+	void onIgnitionStateChanged(bool ignitionOn) override;
+
+private:
+	Timer m_ignOnTimer;
 };

firmware/controllers/actuators/main_relay.cpp

@@ -6,8 +6,6 @@ void MainRelayController::onSlowCallback() {
 	isBenchTest = engine->isInMainRelayBench();
 
 #if EFI_MAIN_RELAY_CONTROL
-	hasIgnitionVoltage = Sensor::getOrZero(SensorType::BatteryVoltage) > 5;
-
 	mainRelayState = isBenchTest | hasIgnitionVoltage;
 #else // not EFI_MAIN_RELAY_CONTROL
 	mainRelayState = !isBenchTest;
@@ -15,3 +13,7 @@ void MainRelayController::onSlowCallback() {
 
 	enginePins.mainRelay.setValue(mainRelayState);
 }
+
+void MainRelayController::onIgnitionStateChanged(bool ignitionOn) {
+	hasIgnitionVoltage = ignitionOn;
+}

firmware/controllers/actuators/main_relay.h

@@ -5,4 +5,5 @@
 
 struct MainRelayController : public EngineModule, public main_relay_s {
 	void onSlowCallback() override;
+	void onIgnitionStateChanged(bool ignitionOn) override;
 };

firmware/controllers/algo/engine.h

@@ -34,6 +34,7 @@
 #include "ac_control.h"
 #include "type_list.h"
 #include "boost_control.h"
+#include "ignition_controller.h"
 #include "alternator_controller.h"
 
 #ifndef EFI_UNIT_TEST
@@ -154,6 +155,7 @@ public:
 #endif /* EFI_ALTERNATOR_CONTROL */
 		FuelPumpController,
 		MainRelayController,
+		IgnitionController,
 		AcController,
 		EngineModule // dummy placeholder so the previous entries can all have commas
 		> engineModules;

firmware/controllers/controllers.mk

@@ -21,6 +21,7 @@ CONTROLLERS_SRC_CPP = \
 	$(CONTROLLERS_DIR)/actuators/idle_thread_io.cpp \
 	$(CONTROLLERS_DIR)/actuators/idle_hardware.cpp \
 	$(CONTROLLERS_DIR)/actuators/idle_thread.cpp \
+	$(CONTROLLERS_DIR)/actuators/ignition_controller.cpp \
 	$(CONTROLLERS_DIR)/actuators/main_relay.cpp \
 	$(CONTROLLERS_DIR)/actuators/pwm_tester.cpp \
 	$(CONTROLLERS_DIR)/actuators/vvt.cpp \

firmware/controllers/core/engine_module.h

@@ -10,4 +10,7 @@ public:
 
 	// Called approx 200Hz
 	virtual void onFastCallback() { }
+
+	// Called whenever the ignition switch state changes
+	virtual void onIgnitionStateChanged(bool ignitionOn) { }
 };

firmware/controllers/ignition_controller.cpp

@@ -0,0 +1,26 @@
+#include "pch.h"
+
+void IgnitionController::onSlowCallback() {
+	// default to 0 if failed sensor to prevent accidental ign-on if battery
+	// input misconfigured (or the ADC hasn't started yet)
+	auto hasIgnVoltage = Sensor::get(SensorType::BatteryVoltage).value_or(0) > 5;
+
+	if (hasIgnVoltage) {
+		m_timeSinceIgnVoltage.reset();
+	}
+
+	if (hasIgnVoltage == m_lastState) {
+		// nothing to do, states match
+		return;
+	}
+
+	// Ignore low voltage transients - we may see this at the start of cranking
+	// and we don't want to 
+	if (!hasIgnVoltage && !m_timeSinceIgnVoltage.hasElapsedSec(0.2f)) {
+		return;
+	}
+
+	// Store state and notify other modules of the change
+	m_lastState = hasIgnVoltage;
+	engine->engineModules.apply_all([&](auto& m) { m.onIgnitionStateChanged(hasIgnVoltage); });
+}

firmware/controllers/ignition_controller.h

@@ -0,0 +1,14 @@
+#pragma once
+
+#include "engine_module.h"
+
+#include "timer.h"
+
+class IgnitionController : public EngineModule {
+public:
+	void onSlowCallback() override;
+
+private:
+	Timer m_timeSinceIgnVoltage;
+	bool m_lastState = false;
+};

unit_tests/tests/test_logic_expression.cpp

@@ -254,9 +254,10 @@ TEST(fsio, testLogicExpressions) {
 extern int timeNowUs;
 
 TEST(fsio, fuelPump) {
-	// this will init fuel pump fsio logic
 	EngineTestHelper eth(TEST_ENGINE);
 
+	FuelPumpController dut;
+
 	// Mock a fuel pump pin
 	engineConfiguration->fuelPumpPin = GPIOA_0;
 	// Re-init so it picks up the new config
@@ -264,27 +265,30 @@ TEST(fsio, fuelPump) {
 
 	// ECU just started, haven't seen trigger yet
 	timeNowUs = 0.5e6;
-	engine->module<FuelPumpController>().unmock().onSlowCallback();
+	dut.onIgnitionStateChanged(true);
+	dut.onSlowCallback();
 	// Pump should be on!
 	EXPECT_TRUE(efiReadPin(GPIOA_0));
 
 	// Long time since ecu start, haven't seen trigger yet
-	timeNowUs = 60e6;
-	engine->module<FuelPumpController>().unmock().onSlowCallback();
+	dut.onIgnitionStateChanged(true);
+	timeNowUs += 10e6;
+	dut.onSlowCallback();
 	// Pump should be off!
 	EXPECT_FALSE(efiReadPin(GPIOA_0));
 
 	// Long time since ecu start, just saw a trigger!
-	timeNowUs = 10e6;
+	dut.onIgnitionStateChanged(true);
+	timeNowUs += 10e6;
 	engine->triggerCentral.handleShaftSignal(SHAFT_PRIMARY_FALLING, timeNowUs * US_TO_NT_MULTIPLIER);
-	engine->module<FuelPumpController>().unmock().onSlowCallback();
+	dut.onSlowCallback();
 	// Pump should be on!
 	EXPECT_TRUE(efiReadPin(GPIOA_0));
 
 	// ECU just started, and we just saw a trigger!
-	timeNowUs = 10e6;
+	dut.onIgnitionStateChanged(true);
 	engine->triggerCentral.handleShaftSignal(SHAFT_PRIMARY_FALLING, timeNowUs * US_TO_NT_MULTIPLIER);
-	engine->module<FuelPumpController>().unmock().onSlowCallback();
+	dut.onSlowCallback();
 	// Pump should be on!
 	EXPECT_TRUE(efiReadPin(GPIOA_0));
 }

unit_tests/tests/test_main_relay.cpp

@@ -7,13 +7,13 @@ TEST(MainRelay, mr) {
 
 	MainRelayController dut;
 
-	// Low battery voltage, MR is off
-	Sensor::setMockValue(SensorType::BatteryVoltage, 1);
+	// Ignition is off, MR is off
+	dut.onIgnitionStateChanged(false);
 	dut.onSlowCallback();
 	EXPECT_EQ(enginePins.mainRelay.getLogicValue(), false);
 
 	// Ignition is now on, MR is on
-	Sensor::setMockValue(SensorType::BatteryVoltage, 12);
+	dut.onIgnitionStateChanged(true);
 	dut.onSlowCallback();
 	EXPECT_EQ(enginePins.mainRelay.getLogicValue(), true);
 }