hard coded fan logic (#2805)

* remove fsio

* hard code impl

* test it

* enable fan with AC

* make commented stuff match

firmware/controllers/actuators/fan_control.cpp

@@ -0,0 +1,38 @@
+#include "fan_control.h"
+#include "engine.h"
+
+#include "bench_test.h"
+#include "efi_gpio.h"
+#include "sensor.h"
+
+EXTERN_ENGINE;
+
+static void fanControl(OutputPin& pin, int8_t fanOnTemp, int8_t fanOffTemp, bool enableWithAc DECLARE_ENGINE_PARAMETER_SUFFIX) {
+	auto [cltValid, clt] = Sensor::get(SensorType::Clt);
+
+	if (!cltValid) {
+		// If CLT is broken, turn the fan on
+		pin.setValue(true);
+	} else if (enableWithAc && ENGINE(acSwitchState)) {
+		pin.setValue(true);
+	} else if (clt > fanOnTemp) {
+		// If hot, turn the fan on
+		pin.setValue(true);
+	} else if (clt < fanOffTemp) {
+		// If cold, turn the fan off
+		pin.setValue(false);
+	} else {
+		// no condition met, maintain previous state
+	}
+}
+
+void updateFans(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
+#if EFI_PROD_CODE
+	if (isRunningBenchTest()) {
+		return; // let's not mess with bench testing
+	}
+#endif
+
+	fanControl(enginePins.fanRelay, CONFIG(fanOnTemperature), CONFIG(fanOffTemperature), CONFIG(enableFan1WithAc) PASS_ENGINE_PARAMETER_SUFFIX);
+	//fanControl(enginePins.fanRelay2, CONFIG(fan2OnTemperature), CONFIG(fan2OffTemperature), CONFIG(enableFan2WithAc) PASS_ENGINE_PARAMETER_SUFFIX);
+}

firmware/controllers/actuators/fan_control.h

@@ -0,0 +1,5 @@
+#pragma once
+
+#include "engine_ptr.h"
+
+void updateFans(DECLARE_ENGINE_PARAMETER_SIGNATURE);

firmware/controllers/algo/engine.cpp

@@ -34,6 +34,7 @@
 #include "tachometer.h"
 #include "dynoview.h"
 #include "boost_control.h"
+#include "fan_control.h"
 #if EFI_MC33816
  #include "mc33816.h"
 #endif // EFI_MC33816
@@ -228,6 +229,8 @@ void Engine::periodicSlowCallback(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	runHardcodedFsio(PASS_ENGINE_PARAMETER_SIGNATURE);
 #endif /* EFI_FSIO */
 
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+
 	updateGppwm();
 
 	updateIdleControl();

firmware/controllers/controllers.mk

@@ -15,6 +15,7 @@ CONTROLLERS_SRC_CPP = \
 	$(CONTROLLERS_DIR)/actuators/alternator_controller.cpp \
 	$(CONTROLLERS_DIR)/actuators/boost_control.cpp \
 	$(CONTROLLERS_DIR)/actuators/dc_motors.cpp \
+	$(CONTROLLERS_DIR)/actuators/fan_control.cpp \
 	$(CONTROLLERS_DIR)/actuators/idle_hardware.cpp \
 	$(CONTROLLERS_DIR)/actuators/idle_thread.cpp \
 	$(CONTROLLERS_DIR)/actuators/pwm_tester.cpp \

firmware/controllers/core/fsio_impl.cpp

@@ -107,7 +107,6 @@ static FsioPointers state;
 
 static LEElement * acRelayLogic;
 static LEElement * fuelPumpLogic;
-static LEElement * radiatorFanLogic;
 static LEElement * alternatorLogic;
 static LEElement * starterRelayDisableLogic;
 
@@ -507,10 +506,6 @@ void runFsio(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 //		setPinState("alternator", &enginePins.alternatorField, alternatorLogic, engine PASS_ENGINE_PARAMETER_SUFFIX);
 //	}
 
-	if (isBrainPinValid(CONFIG(fanPin))) {
-		setPinState("fan", &enginePins.fanRelay, radiatorFanLogic PASS_ENGINE_PARAMETER_SUFFIX);
-	}
-
 #if EFI_ENABLE_ENGINE_WARNING
 	if (engineConfiguration->useFSIO4ForSeriousEngineWarning) {
 		updateValueOrWarning(MAGIC_OFFSET_FOR_ENGINE_WARNING, "eng warning", &ENGINE(fsioState.isEngineWarning) PASS_ENGINE_PARAMETER_SUFFIX);
@@ -579,7 +574,6 @@ static void showFsioInfo(void) {
 	efiPrintf("sys used %d/user used %d", sysPool.getSize(), userPool.getSize());
 	showFsio("a/c", acRelayLogic);
 	showFsio("fuel", fuelPumpLogic);
-	showFsio("fan", radiatorFanLogic);
 	showFsio("alt", alternatorLogic);
 
 	for (int i = 0; i < CAM_INPUTS_COUNT ; i++) {
@@ -703,7 +697,6 @@ void initFsioImpl(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 #endif /* EFI_FUEL_PUMP */
 
 	acRelayLogic = sysPool.parseExpression(AC_RELAY_LOGIC);
-	radiatorFanLogic = sysPool.parseExpression(FAN_CONTROL_LOGIC);
 
 	alternatorLogic = sysPool.parseExpression(ALTERNATOR_LOGIC);
 	
@@ -782,12 +775,6 @@ void runHardcodedFsio(DECLARE_ENGINE_PARAMETER_SIGNATURE) {
 	if (isBrainPinValid(CONFIG(starterRelayDisablePin))) {
 		enginePins.starterRelayDisable.setValue(engine->rpmCalculator.getRpm() < engineConfiguration->cranking.rpm);
 	}
-	// see FAN_CONTROL_LOGIC
-	if (isBrainPinValid(CONFIG(fanPin))) {
-		auto clt = Sensor::get(SensorType::Clt);
-		enginePins.fanRelay.setValue(!clt.Valid || (enginePins.fanRelay.getLogicValue() && (clt.Value > engineConfiguration->fanOffTemperature)) || 
-			(clt.Value > engineConfiguration->fanOnTemperature) || !clt.Valid);
-	}
 	// see AC_RELAY_LOGIC
 	if (isBrainPinValid(CONFIG(acRelayPin))) {
 		enginePins.acRelay.setValue(getAcToggle(PASS_ENGINE_PARAMETER_SIGNATURE) && engine->rpmCalculator.getRpm() > 850);

firmware/controllers/system_fsio.h

@@ -15,9 +15,6 @@
 // different way to have the same result would be using "self"
 // (self and (coolant > fan_off_setting)) | (coolant > fan_on_setting) | is_clt_broken
 
-// Human-readable: (fan and (coolant > cfg_fanOffTemperature)) | (coolant > cfg_fanOnTemperature) | is_clt_broken
-#define FAN_CONTROL_LOGIC "fan coolant cfg_fanofftemperature > and coolant cfg_fanontemperature > | is_clt_broken |"
-
 // Human-readable: ((time_since_boot >= 0) & (time_since_boot < startup_fuel_pump_duration)) | (time_since_trigger < 1)
 #define FUEL_PUMP_LOGIC "time_since_boot 0 >= time_since_boot startup_fuel_pump_duration < & time_since_trigger 1 < |"
 

firmware/controllers/system_fsio.txt

@@ -9,10 +9,6 @@
 # Andrey Belomutskiy, (c) 2012-2017
 #
 
-# different way to have the same result would be using "self"
-# (self and (coolant > fan_off_setting)) | (coolant > fan_on_setting) | is_clt_broken
-FAN_CONTROL_LOGIC=(fan and (coolant > cfg_fanOffTemperature)) | (coolant > cfg_fanOnTemperature) | is_clt_broken
-
 FUEL_PUMP_LOGIC=((time_since_boot >= 0) & (time_since_boot < startup_fuel_pump_duration)) | (time_since_trigger < 1)
 
 ALTERNATOR_LOGIC=vbatt < 14.5

firmware/integration/rusefi_config.txt

@@ -528,8 +528,8 @@ bit isForcedInduction
 bit useFordRedundantTps;+On Ford vehicles one of the sensors is not linear on the full range, i.e. in the specific range of the positions we effectively have only one sensor.
 bit isVerboseAuxPid1
 bit overrideTriggerGaps
-bit unused_294_4
+bit enableFan1WithAc;+Turn on this fan when AC is on.
-bit unused_294_5
+bit enableFan2WithAc;+Turn on this fan when AC is on.
 bit unused_294_6
 bit unused_294_7
 bit unused_294_8
@@ -637,8 +637,8 @@ angle_t globalTriggerAngleOffset;+Angle between Top Dead Center (TDC) and the fi
 float analogInputDividerCoefficient;+Ratio/coefficient of input voltage dividers on your PCB. For example, use '2' if your board divides 5v into 2.5v. Use '1.66' if your board divides 5v into 3v.;"coef",    1,      0,    0.01,  10.0,   2
 float vbattDividerCoeff;+This is the ratio of the resistors for the battery voltage, measure the voltage at the battery and then adjust this number until the gauge matches the reading.;"coef",    1,      0,    0.01,  99.0,        2
 
-float fsio_visible fanOnTemperature;+Cooling fan turn-on temperature threshold, in Celsius;"*C",    1,      0,       0,  1000.0,        0
+float fanOnTemperature;+Cooling fan turn-on temperature threshold, in Celsius;"deg C", 1, 0, 0, 150, 0
-float fsio_visible fanOffTemperature;+Cooling fan turn-off temperature threshold, in Celsius;"*C",    1,      0,       0,  1000.0,        0
+float fanOffTemperature;+Cooling fan turn-off temperature threshold, in Celsius;"deg C", 1, 0, 0, 150, 0
 
 
 float vehicleSpeedCoef;+This coefficient translates vehicle speed input frequency (in Hz) into vehicle speed, km/h;"coef",    1,      0,    0.01,  2000.0,        2

firmware/tunerstudio/rusefi.input

@@ -2669,15 +2669,29 @@ cmd_set_engine_type_default					= "@@TS_IO_TEST_COMMAND_char@@\x00\x31\x00\x00"
 		field = "#Use debug mode 'Timing' to view idle timing adjustment"
 
 ;			Engine->Fan Settings
-	dialog = fanSetting, "Fan Settings"
+	dialog = fan1Settings, "Fan 1"
 		field = "Pin",								fanPin
 		field = "Pin mode",							fanPinMode
 		field = "On temperature",					fanOnTemperature
 		field = "Off temperature",					fanOffTemperature
-; this one has build-in FSIO logic
+		field = "Enable with AC",					enableFan1WithAc
+
+	;dialog = fan2Settings, "Fan 2"
+	;	field = "Pin",								fan2Pin
+	;	field = "Pin mode",							fan2PinMode
+	;	field = "On temperature",					fan2OnTemperature
+	;	field = "Off temperature",					fan2OffTemperature
+	;	field = "Enable with AC",					enableFan2WithAc
+
+	dialog = acSettings, "A/C Settings"
 		field = "A/C Relay",						acRelayPin
 		field = "A/C Relay Mode",					acRelayPinMode
 
+	dialog = fanSetting, "Fan Settings"
+		panel = fan1Settings
+		;panel = fan2Settings
+		panel = acSettings
+
 	dialog = fuelPump, "Fuel Pump"
 		field = "Pin",						fuelPumpPin
 		field = "Pin mode",         	        fuelPumpPinMode

unit_tests/tests/test_fan_control.cpp

@@ -0,0 +1,49 @@
+#include "efi_gpio.h"
+#include "engine_test_helper.h"
+#include "fan_control.h"
+#include "sensor.h"
+
+TEST(FanControl, fan1) {
+	WITH_ENGINE_TEST_HELPER(TEST_ENGINE);
+
+	engineConfiguration->fanOnTemperature = 90;
+	engineConfiguration->fanOffTemperature = 80;
+	engineConfiguration->enableFan1WithAc = false;
+	engine->acSwitchState = false;
+
+	// Cold, fan should be off
+	Sensor::setMockValue(SensorType::Clt, 75);
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
+
+	// Between thresholds, should still be off
+	Sensor::setMockValue(SensorType::Clt, 85);
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
+
+	// Hot, fan should turn on
+	Sensor::setMockValue(SensorType::Clt, 95);
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(true, enginePins.fanRelay.getLogicValue());
+
+	// Between thresholds, should stay on
+	Sensor::setMockValue(SensorType::Clt, 85);
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(true, enginePins.fanRelay.getLogicValue());
+
+	// Below threshold, should turn off
+	Sensor::setMockValue(SensorType::Clt, 75);
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
+
+	engineConfiguration->enableFan1WithAc = true;
+	// Now AC is on, fan should turn on!
+	engine->acSwitchState = true;
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(true, enginePins.fanRelay.getLogicValue());
+
+	// Turn off AC, fan should turn off too.
+	engine->acSwitchState = false;
+	updateFans(PASS_ENGINE_PARAMETER_SIGNATURE);
+	EXPECT_EQ(false, enginePins.fanRelay.getLogicValue());
+}

unit_tests/tests/test_logic_expression.cpp

@@ -248,16 +248,6 @@ TEST(fsio, testLogicExpressions) {
 		ASSERT_EQ(0, c.calcLogValue[0]);
 	}
 
-	{
-		WITH_ENGINE_TEST_HELPER_SENS(FORD_INLINE_6_1995, sensorVals);
-		engineConfiguration->fanOnTemperature = 0;
-		engineConfiguration->fanOffTemperature = 0;
-
-		testExpression2(0, "cfg_fanOffTemperature", 0, engine);
-		testExpression2(0, FAN_CONTROL_LOGIC, 1, engine);
-		testExpression2(0, "coolant cfg_fanOffTemperature >", 1, engine);
-	}
-
 	{
 		WITH_ENGINE_TEST_HELPER_SENS(FORD_INLINE_6_1995, sensorVals);
 		engine->fsioState.mockRpm = 900;

unit_tests/tests/tests.mk

@@ -35,6 +35,7 @@ TESTS_SRC_CPP = \
 	tests/test_idle_controller.cpp \
 	tests/test_issue_898.cpp \
 	tests/test_etb.cpp \
+	tests/test_fan_control.cpp \
 	tests/test_vvt.cpp \
 	tests/test_launch.cpp \
 	tests/test_fuel_map.cpp \