Gear detection improvements (#4047)

* gear detect improvements

* ui

* ui for gear ratios

* ui

firmware/console/status_loop.cpp

@@ -548,11 +548,8 @@ static void updateVvtSensors() {
 
 static void updateVehicleSpeed(int rpm) {
 #if EFI_VEHICLE_SPEED
-	float vehicleSpeedKph = Sensor::getOrZero(SensorType::VehicleSpeed);
-	float wheelRPM = vehicleSpeedKph * 1000 / 60 / (2 * CONST_PI * engineConfiguration->wheelDiameter);
-	float driveshaftRpm = wheelRPM * engineConfiguration->finalGearRatio;
-	engine->outputChannels.vehicleSpeedKph = vehicleSpeedKph;
-	engine->outputChannels.speedToRpmRatio = rpm / driveshaftRpm;
+	engine->outputChannels.vehicleSpeedKph = Sensor::getOrZero(SensorType::VehicleSpeed);
+	engine->outputChannels.speedToRpmRatio = engine->module<GearDetector>()->getGearboxRatio();
 #endif /* EFI_VEHICLE_SPEED */
 }
 

firmware/controllers/algo/algo.mk

@@ -13,6 +13,7 @@ CONTROLLERS_ALGO_SRC_CPP = $(PROJECT_DIR)/controllers/algo/advance_map.cpp \
 	$(PROJECT_DIR)/controllers/algo/engine_configuration.cpp \
 	$(PROJECT_DIR)/controllers/algo/engine.cpp \
 	$(PROJECT_DIR)/controllers/algo/engine2.cpp \
+	$(PROJECT_DIR)/controllers/algo/gear_detector.cpp \
 	$(PROJECT_DIR)/controllers/gauges/lcd_menu_tree.cpp \
 	$(PROJECT_DIR)/controllers/algo/event_registry.cpp \
 	$(PROJECT_DIR)/controllers/algo/airmass/airmass.cpp \

firmware/controllers/algo/engine.h

@@ -37,6 +37,7 @@
 #include "ignition_controller.h"
 #include "alternator_controller.h"
 #include "dfco.h"
+#include "gear_detector.h"
 
 #ifndef EFI_UNIT_TEST
 #error EFI_UNIT_TEST must be defined!
@@ -185,6 +186,9 @@ public:
 		PrimeController,
 		DfcoController,
 		Mockable<WallFuelController>,
+#if EFI_VEHICLE_SPEED
+		GearDetector,
+#endif // EFI_VEHICLE_SPEED
 		EngineModule // dummy placeholder so the previous entries can all have commas
 		> engineModules;
 

firmware/controllers/algo/gear_detector.cpp

@@ -0,0 +1,33 @@
+#include "pch.h"
+
+void GearDetector::onSlowCallback() {
+	m_gearboxRatio = computeGearboxRatio();
+
+	// TODO: solve for which gear this is
+}
+
+float GearDetector::computeGearboxRatio() const {
+	auto vssKph = Sensor::getOrZero(SensorType::VehicleSpeed);
+
+	if (vssKph < 5) {
+		// Vehicle too slow to determine gearbox ratio, avoid div/0
+		return 0;
+	}
+
+	auto engineRpm = Sensor::getOrZero(SensorType::Rpm);
+
+	// Convert to wheel RPM
+	//                 km                        rev                        1 hr
+	//               ------ *               ------------              *  __________
+	//                 hr                        km                        60 min
+	float wheelRpm = vssKph * engineConfiguration->driveWheelRevPerKm * (1 / 60.0f);
+
+	// Convert to driveshaft RPM
+	auto driveshaftRpm = wheelRpm * engineConfiguration->finalGearRatio;
+
+	return engineRpm / driveshaftRpm;
+}
+
+float GearDetector::getGearboxRatio() const {
+	return m_gearboxRatio;
+}

firmware/controllers/algo/gear_detector.h

@@ -0,0 +1,12 @@
+
+class GearDetector : public EngineModule {
+public:
+	void onSlowCallback() override;
+
+	float getGearboxRatio() const;
+
+private:
+	float computeGearboxRatio() const;
+
+	float m_gearboxRatio = 0;
+};

firmware/integration/rusefi_config.txt

@@ -724,8 +724,8 @@ custom adc_channel_mode_e 4 bits, U32, @OFFSET@, [0:1], "Off", "Slow", "Fast"
 pin_input_mode_e throttlePedalUpPinMode;
 	uint8_t acIdleExtraOffset;+Additional idle % while A/C is active;"%", 1, 0, 0, 100, 0
 
-    uint16_t autoscale finalGearRatio;;"ratio", 0.1, 0, 0, 100, 2
-	uint16_t autoscale wheelDiameter;;"m", 0.001, 0, 0, 20, 2
+    uint16_t autoscale finalGearRatio;Ratio between the wheels and your transmission output. ;"ratio", 0.01, 0, 0, 10, 2
+	uint16_t autoscale unused722;;"", 1, 0, 0, 0, 0
 	uint16_t wastegatePositionMin;+Voltage when the wastegate is closed.\nYou probably don't have one of these!;"mv", 1, 0, 0, 5000, 0
 	uint16_t wastegatePositionMax;+Voltage when the wastegate is fully open.\nYou probably don't have one of these!\n1 volt = 1000 units;"mv", 1, 0, 0, 5000, 0
 	uint16_t idlePositionMin;+Voltage when the idle valve is closed.\nYou probably don't have one of these!;"mv", 1, 0, 0, 5000, 0
@@ -1177,7 +1177,7 @@ int16_t tps2Max;Full throttle#2. tpsMax value as 10 bit ADC value. Not Voltage!\
 	float tpsAccelEnrichmentThreshold;+Maximum change delta of TPS percentage over the 'length'. Actual TPS change has to be above this value in order for TPS/TPS acceleration to kick in.;"roc", 1, 0, 0, 200, 1
 
     brain_input_pin_e[2 iterate] auxSpeedSensorInputPin;
-	uint8_t totalGearsCount;;"", 1, 0, 0, 1, 0
+	uint8_t totalGearsCount;;"", 1, 0, 1, @@GEARS_COUNT@@, 0
 	uint8_t unused16962;;"", 1, 0, 0, 1, 0
 
 	uint32_t uartConsoleSerialSpeed;Band rate for primary TTL;"BPs", 1, 0, 0, 1000000, 0
@@ -1500,7 +1500,7 @@ int8_t[MAX_CYLINDER_COUNT iterate] fuelTrim;;"Percent", @@PERCENT_TRIM_BYTE_PACK
 
 	output_pin_e[4 iterate] stepper_raw_output;
 
-    uint16_t[GEARS_COUNT iterate] autoscale gearRatio;;"ratio", 0.01, 0, 0, 650, 0
+    uint16_t[GEARS_COUNT iterate] autoscale gearRatio;;"ratio", 0.01, 0, 0, 10, 2
 
 uint16_t vvtActivationDelayMs;We need to give engine time to build oil pressure without diverting it to VVT;"ms", 1, 0, 0, 65000, 0
 uint16_t unusedShort;;"RPM", 1, 0, 0, 65000, 0

firmware/tunerstudio/rusefi.input

@@ -1463,6 +1463,7 @@ menuDialog = main
 
 	menu = "&Advanced"
 		subMenu = ignitionCylExtra,			"Cylinder offsets", 0
+		subMenu = gearDetection,			"Gear detection", 0
 
 		subMenu = std_separator
 		subMenu = boostDialog,          "Boost Control"
@@ -3102,30 +3103,41 @@ cmd_set_engine_type_default					= "@@TS_IO_TEST_COMMAND_char@@\x00\x31\x00\x00"
 		panel = alternator
 		panel = startStopDialog
 
-	dialog = speedSensorAnalog
+	dialog = speedSensorAnalog, "Speed sensor"
 		field = "Input pin",					vehicleSpeedSensorInputPin
-		field = "Wheel revolutions per kilometer",		driveWheelRevPerKm
+		field = "Filter Reciprocal",				vssFilterReciprocal, { vehicleSpeedSensorInputPin != @@ADC_CHANNEL_NONE@@ }
+
 ;
 ; We prefer quantities that users can actually measure or inspect without math, so we have
 ; two separate natural settings here without one 'sensor tooth to wheel revolution' ratio
 ;
-		field = "Speed sensor gear ratio",				vssGearRatio
-		field = "Speed sensor tooth count",				vssToothCount
+		field = "Wheel revolutions per kilometer",	driveWheelRevPerKm
+		field = "Speed sensor gear ratio",	vssGearRatio, { vehicleSpeedSensorInputPin != @@ADC_CHANNEL_NONE@@ }
+		field = "Speed sensor tooth count",	vssToothCount, { vehicleSpeedSensorInputPin != @@ADC_CHANNEL_NONE@@ }
 
-	dialog = speedSensorCan
-		field = "Vss Car Type",						canVssNbcType, { enableCanVss }
+	dialog = speedSensorCan, "CAN Vehicle Speed"
+		field = "Enable CAN VSS",			enableCanVss, { canReadEnabled }
+		field = "VSS CAN message type",						canVssNbcType, { enableCanVss }
 
-	dialog = vssFilter
-		field = "Filter Reciprocal",                      vssFilterReciprocal
-
-	dialog = speedSensorLeft, "Speed sensor config", yAxis
-		panel = speedSensorCan, { enableCanVss }
+	dialog = speedSensorLeft, "", yAxis
 	    panel = speedSensorAnalog, { enableCanVss == 0 }
-		field = "Enable CANbus VSS values",			enableCanVss, { canReadEnabled }
+		panel = speedSensorCan
 		panel = vssFilter
-		field = "finalGearRatio",       finalGearRatio
-        field = "wheelDiameter",            wheelDiameter
 
+	dialog = gearDetection, "Gear Detection"
+		field = "Wheel revolutions per kilometer",	driveWheelRevPerKm
+		field = "Final drive ratio",       finalGearRatio
+		field = ""
+		field = "Forward gear count", totalGearsCount
+		field = ""
+		field = "1st gear", gearRatio1, { totalGearsCount >= 1 }
+		field = "2nd gear", gearRatio2, { totalGearsCount >= 2 }
+		field = "3rd gear", gearRatio3, { totalGearsCount >= 3 }
+		field = "4th gear", gearRatio4, { totalGearsCount >= 4 }
+		field = "5th gear", gearRatio5, { totalGearsCount >= 5 }
+		field = "6th gear", gearRatio6, { totalGearsCount >= 6 }
+		field = "7th gear", gearRatio6, { totalGearsCount >= 7 }
+		field = "8th gear", gearRatio6, { totalGearsCount >= 8 }
 
 	dialog = speedSensor, "Speed sensor", xAxis
 		panel = speedSensorLeft

unit_tests/tests/test_gear_detector.cpp

@@ -0,0 +1,28 @@
+#include "pch.h"
+
+float GetGearRatioFor(float revPerKm, float axle, float kph, float rpm) {
+	EngineTestHelper eth(TEST_ENGINE);
+
+	engineConfiguration->driveWheelRevPerKm = revPerKm;
+	engineConfiguration->finalGearRatio = axle;
+
+	Sensor::setMockValue(SensorType::VehicleSpeed, kph);
+	Sensor::setMockValue(SensorType::Rpm, rpm);
+
+	GearDetector dut;
+	dut.onSlowCallback();
+
+	return dut.getGearboxRatio();
+}
+
+TEST(GearDetector, ComputeGearRatio) {
+	// real gears from Volvo racecar
+	EXPECT_NEAR_M3(3.35f, GetGearRatioFor(507, 4.1, 29.45f / 0.6214f, 5500));
+	EXPECT_NEAR_M3(1.99f, GetGearRatioFor(507, 4.1, 49.57f / 0.6214f, 5500));
+	EXPECT_NEAR_M3(1.33f, GetGearRatioFor(507, 4.1, 74.18f / 0.6214f, 5500));
+	EXPECT_NEAR_M3(1.00f, GetGearRatioFor(507, 4.1, 98.65f / 0.6214f, 5500));
+	EXPECT_NEAR_M3(0.72f, GetGearRatioFor(507, 4.1, 137.02f / 0.6214f, 5500));
+
+	// Idling, car stopped, check no div/0
+	EXPECT_EQ(0, GetGearRatioFor(507, 4.1, 0, 800));
+}

unit_tests/tests/tests.mk

@@ -49,6 +49,7 @@ TESTS_SRC_CPP = \
 	tests/test_scattered_outputs.cpp \
 	tests/test_launch.cpp \
 	tests/test_fuel_map.cpp \
+	tests/test_gear_detector.cpp \
 	tests/ignition_injection/test_fuel_wall_wetting.cpp \
 	tests/test_one_cylinder_logic.cpp \
 	tests/test_tunerstudio.cpp \