overdwell protection (#3220)

* cancel event

* looks like it works...

* some tests are happy

* add enable bit

* undo test changes

* Revert "add enable bit"

This reverts commit 000afadd3fc560867302557afe26f76cd9fc4ed6.

* enable bit in engine

* only turn off for one test

* Revert "undo test changes"

This reverts commit 106db49e291b5a531a94de6ac177c6584d5337f6.

firmware/controllers/algo/engine.h

@@ -88,6 +88,7 @@ public:
 	DECLARE_ENGINE_PTR;
 
 	Engine();
+	bool enableOverdwellProtection = true;
 	bool isPwmEnabled = true;
 	int triggerActivitySecond = 0;
 

firmware/controllers/engine_cycle/spark_logic.cpp

@@ -378,6 +378,8 @@ static void handleSparkEvent(bool limitedSpark, uint32_t trgEventIndex, Ignition
 
 	event->sparkId = engine->globalSparkIdCounter++;
 
+	efitick_t chargeTime = 0;
+
 	/**
 	 * The start of charge is always within the current trigger event range, so just plain time-based scheduling
 	 */
@@ -393,7 +395,7 @@ static void handleSparkEvent(bool limitedSpark, uint32_t trgEventIndex, Ignition
 		 * This way we make sure that coil dwell started while spark was enabled would fire and not burn
 		 * the coil.
 		 */
-		scheduleByAngle(&event->dwellStartTimer, edgeTimestamp, angleOffset, { &turnSparkPinHigh, event } PASS_ENGINE_PARAMETER_SUFFIX);
+		chargeTime = scheduleByAngle(&event->dwellStartTimer, edgeTimestamp, angleOffset, { &turnSparkPinHigh, event } PASS_ENGINE_PARAMETER_SUFFIX);
 
 		event->sparksRemaining = ENGINE(engineState.multispark.count);
 	} else {
@@ -418,10 +420,14 @@ static void handleSparkEvent(bool limitedSpark, uint32_t trgEventIndex, Ignition
 #if SPARK_EXTREME_LOGGING
 		efiPrintf("to queue sparkDown ind=%d %d %s now=%d for id=%d", trgEventIndex, getRevolutionCounter(), event->getOutputForLoggins()->name, (int)getTimeNowUs(), event->sparkEvent.position.triggerEventIndex);
 #endif /* SPARK_EXTREME_LOGGING */
+
+		if (!limitedSpark && engine->enableOverdwellProtection) {
+			// auto fire spark at 1.5x nominal dwell
+			efitick_t fireTime = chargeTime + MSF2NT(1.5f * dwellMs);
+			engine->executor.scheduleByTimestampNt("overdwell", &event->sparkEvent.scheduling, fireTime, { fireSparkAndPrepareNextSchedule, event });
+		}
 	}
 
-
-
 #if EFI_UNIT_TEST
 	if (verboseMode) {
 		printf("spark dwell@ %d/%d spark@ %d/%d id=%d\r\n", event->dwellPosition.triggerEventIndex, (int)event->dwellPosition.angleOffsetFromTriggerEvent,
@@ -482,7 +488,6 @@ static void prepareIgnitionSchedule(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	initializeIgnitionActions(PASS_ENGINE_PARAMETER_SIGNATURE);
 }
 
-
 static void scheduleAllSparkEventsUntilNextTriggerTooth(uint32_t trgEventIndex, efitick_t edgeTimestamp DECLARE_ENGINE_PARAMETER_SUFFIX) {
 	AngleBasedEvent *current, *tmp;
 
@@ -498,6 +503,9 @@ static void scheduleAllSparkEventsUntilNextTriggerTooth(uint32_t trgEventIndex,
 	efiPrintf("time to invoke ind=%d %d %d", trgEventIndex, getRevolutionCounter(), (int)getTimeNowUs());
 #endif /* SPARK_EXTREME_LOGGING */
 
+			// In case this event was scheduled by overdwell protection, cancel it so we can re-schedule at the correct time
+			engine->executor.cancel(sDown);
+
 			scheduleByAngle(
 				sDown,
 				edgeTimestamp,

unit_tests/tests/ignition_injection/test_ignition_scheduling.cpp

@@ -40,6 +40,9 @@ TEST(ignition, twoCoils) {
 TEST(ignition, trailingSpark) {
 	WITH_ENGINE_TEST_HELPER(TEST_ENGINE);
 
+	// TODO #3220: this feature makes this test sad, eventually remove this line (and the ability to disable it altogether)
+	engine->enableOverdwellProtection = false;
+
 	EXPECT_CALL(eth.mockAirmass, getAirmass(_))
 		.WillRepeatedly(Return(AirmassResult{0.1008f, 50.0f}));
 

unit_tests/tests/trigger/test_real_cranking_nissan_vq40.cpp

@@ -32,7 +32,8 @@ TEST(realCrankingVQ40, normalCranking) {
 	ASSERT_EQ(241, GET_RPM())<< reader.lineIndex();
 
 	// TODO: why warnings?
-	ASSERT_EQ(2, eth.recentWarnings()->getCount());
+	ASSERT_EQ(3, eth.recentWarnings()->getCount());
 	ASSERT_EQ(CUSTOM_SYNC_COUNT_MISMATCH, eth.recentWarnings()->get(0));
-	ASSERT_EQ(CUSTOM_SYNC_ERROR, eth.recentWarnings()->get(1));
+	ASSERT_EQ(CUSTOM_OUT_OF_ORDER_COIL, eth.recentWarnings()->get(1));	// this is from a coil being protected by overdwell protection
+	ASSERT_EQ(CUSTOM_SYNC_ERROR, eth.recentWarnings()->get(2));
 }

unit_tests/tests/trigger/test_trigger_decoder.cpp

@@ -1134,7 +1134,7 @@ TEST(big, testSparkReverseOrderBug319) {
 	ASSERT_EQ( 3000,  GET_RPM()) << "testSparkReverseOrderBug319: RPM";
 
 
-	ASSERT_EQ( 7,  engine->executor.size()) << "testSparkReverseOrderBug319: queue size";
+	ASSERT_EQ( 8,  engine->executor.size()) << "testSparkReverseOrderBug319: queue size";
 	eth.executeActions();
 	printf("***************************************************\r\n");