Merge branch 'SmartErrors' into 'master'

Smart errors

See merge request mrjones.id.au/bluetoothheater!6

Arduino/SenderTrial2/Protocol.cpp

@@ -248,7 +248,7 @@ CProtocol::Init(int FrameMode)
     setGlowPlug_Voltage(0);
     setGlowPlug_Current(0);
     Heater.ActualPumpFreq = 0;     // fuel pump freq.: 0.1Hz / digit
-    Heater.ErrorCode = 0;          // 
+    Heater.StoredErrorCode = 0;    // 
     Heater.Unknown1 = 0;           // always 0x00
     Heater.FixedPumpFreq = 23;     // fixed mode frequency set point: 0.1Hz / digit
     Heater.Unknown2 = 100;         // always 0x64  "100 ?"

Arduino/SenderTrial2/Protocol.h

@@ -49,7 +49,7 @@ public:
       unsigned char GlowPlugCurrent_MSB; // 16 bit - big endian MSB  
       unsigned char GlowPlugCurrent_LSB; // 16 bit - big endian LSB : 10mA / digit
       unsigned char ActualPumpFreq;     // fuel pump freq.: 0.1Hz / digit
-      unsigned char ErrorCode;          // 
+      unsigned char StoredErrorCode;    // 
       unsigned char Unknown1;           // always 0x00
       unsigned char FixedPumpFreq;      // fixed mode frequency set point: 0.1Hz / digit
       unsigned char Unknown2;           // always 0x64  "100 ?"
@@ -121,6 +121,8 @@ public:
   void setRunState(unsigned char state) { Heater.RunState = state; };
   unsigned char getErrState() { return Heater.ErrState; };
   void setErrState(unsigned char state) { Heater.ErrState = state; };
+  unsigned char getStoredErrCode() { return Heater.StoredErrorCode; };
+  void setStoredErrCode(unsigned char state) { Heater.StoredErrorCode = state; };
   //
   short getVoltage_Supply();
   void setVoltage_Supply(short voltsx10);

Arduino/SenderTrial2/SenderTrial2.ino

@@ -67,6 +67,7 @@
 #include "pins.h"
 #include "NVStorage.h"
 #include "debugport.h"
+#include "SmartError.h"
 
 #define DEBUG_BTRX
   
@@ -129,13 +130,23 @@ public:
   }
 };
 
+class CModeratedFrame : public CProtocol {
+  unsigned long lastTime;
+public:
+  CModeratedFrame() { lastTime = 0; };
+  void setTime() { lastTime = millis(); };
+  unsigned long elapsedTime() { return millis() - lastTime; };
+};
 
 CommStates CommState;
 CTxManage TxManage(TxEnbPin, BlueWireSerial);
-CProtocol OEMCtrlFrame;        // data packet received from heater in response to OEM controller packet
-CProtocol HeaterFrame1;        // data packet received from heater in response to OEM controller packet
+//CProtocol OEMCtrlFrame;        // data packet received from heater in response to OEM controller packet
+//CProtocol HeaterFrame1;        // data packet received from heater in response to OEM controller packet
+CModeratedFrame OEMCtrlFrame;        // data packet received from heater in response to OEM controller packet
+CModeratedFrame HeaterFrame1;        // data packet received from heater in response to OEM controller packet
 CProtocol HeaterFrame2;        // data packet received from heater in response to our packet 
 CProtocol DefaultBTCParams(CProtocol::CtrlMode);  // defines the default parameters, used in case of no OEM controller
+CSmartError SmartError;
 long lastRxTime;        // used to observe inter character delays
 bool hasOEMController = false;
 
@@ -152,10 +163,6 @@ void PrepareTxFrame(const CProtocol& basisFrame, CProtocol& TxFrame, bool isBTCm
 
 void setup() 
 {
-  // initialize serial port to interact with the "blue wire"
-  // 25000 baud, Tx and Rx channels of Chinese heater comms interface:
-  // Tx/Rx data to/from heater, 
-  // Note special baud rate for Chinese heater controllers
   pinMode(Tx2Pin, OUTPUT);
   digitalWrite(Tx2Pin, HIGH);
   pinMode(Rx2Pin, INPUT_PULLUP);
@@ -163,6 +170,10 @@ void setup()
   pinMode(KeyPin, OUTPUT);
   digitalWrite(KeyPin, LOW);
 
+  // initialize serial port to interact with the "blue wire"
+  // 25000 baud, Tx and Rx channels of Chinese heater comms interface:
+  // Tx/Rx data to/from heater, 
+  // Note special baud rate for Chinese heater controllers
 #if defined(__arm__) || defined(__AVR__)
   BlueWireSerial.begin(25000);   
   pinMode(Rx1Pin, INPUT_PULLUP);  // required for MUX to work properly
@@ -181,7 +192,7 @@ void setup()
 
   TxManage.begin(); // ensure Tx enable pin is setup
 
-  // define defaults should heater controller be missing
+  // define defaults should OEM controller be missing
   DefaultBTCParams.setTemperature_Desired(23);
   DefaultBTCParams.setTemperature_Actual(22);
   DefaultBTCParams.Controller.OperatingVoltage = 120;
@@ -233,6 +244,16 @@ void loop()
         CommState.is(CommStates::HeaterRx1) ||  
         CommState.is(CommStates::HeaterRx2) ) {
 
+      if(CommState.is(CommStates::OEMCtrlRx)) {
+        DebugPort.println("Timeout collecting OEM controller data, returning to Idle State");
+      }
+      else if(CommState.is(CommStates::HeaterRx1)) {
+        DebugPort.println("Timeout collecting OEM heater response data, returning to Idle State");
+      }
+      else {
+        DebugPort.println("Timeout collecting BTC heater response data, returning to Idle State");
+      }
+
       CommState.set(CommStates::Idle);  // revert to idle mode
     }
   }
@@ -295,7 +316,13 @@ void loop()
   else if( CommState.is(CommStates::OEMCtrlReport) ) {  
     // filled OEM controller frame, report
     // echo received OEM controller frame over Bluetooth, using [OEM] header
-    Bluetooth_SendFrame("[OEM]", OEMCtrlFrame, true);
+    if(OEMCtrlFrame.elapsedTime() > 700) {
+      Bluetooth_SendFrame("[OEM]", OEMCtrlFrame, true);
+      OEMCtrlFrame.setTime();
+    }
+    else {
+      DebugPort.println("Suppressed delivery of OEM frame");
+    }
     CommState.set(CommStates::HeaterRx1);
   }
 
@@ -310,8 +337,19 @@ void loop()
 
   else if(CommState.is(CommStates::HeaterReport1) ) {
     // received heater frame (after controller message), report
+    
+    // do some monitoring of the heater state variable
+    // if suspicious transitions, introduce a smart error!
+    SmartError.monitor(HeaterFrame1);
+
     // echo heater reponse data to Bluetooth client
-    Bluetooth_SendFrame("[HTR]", HeaterFrame1);
+    if(HeaterFrame1.elapsedTime() > 700) {
+      Bluetooth_SendFrame("[HTR]", HeaterFrame1);
+      HeaterFrame1.setTime();
+    }
+    else {
+      DebugPort.println("Suppressed delivery of OEM heater response frame");
+    }
 
     if(digitalRead(ListenOnlyPin)) {
       bool isBTCmaster = false;
@@ -343,6 +381,11 @@ void loop()
 
   else if( CommState.is(CommStates::HeaterReport2) ) {
     // received heater frame (after our control message), report
+
+    // do some monitoring of the heater state variable
+    // if suspicious transitions, introduce a smart error!
+    SmartError.monitor(HeaterFrame2);
+
     delay(5);
     if(!hasOEMController) {
       // only convey these frames to Bluetooth when NOT using an OEM controller!
@@ -391,10 +434,12 @@ void Command_Interpret(const char* pLine)
     if(strncmp(pLine, "ON", 2) == 0) {
       TxManage.queueOnRequest();
       DebugPort.println("Heater ON");
+      SmartError.reset();
     }
     else if(strncmp(pLine, "OFF", 3) == 0) {
       TxManage.queueOffRequest();
       DebugPort.println("Heater OFF");
+      SmartError.inhibit();
     }
     else if(strncmp(pLine, "Pmin", 4) == 0) {
       pLine += 4;

Arduino/SenderTrial2/SmartError.cpp

@@ -0,0 +1,93 @@
+#include "SmartError.h"
+
+CSmartError::CSmartError()
+{
+  reset();
+}
+
+void 
+CSmartError::reset()
+{
+  m_prevRunState = 0;
+  m_Error = 0;
+  m_bInhibit = false;
+}
+
+// we use inhibit when we manually command the heater off during preheat
+// otherwise we'll register an ignition fail event
+void
+CSmartError::inhibit()
+{
+  m_bInhibit = true;
+  m_Error = 0;
+}
+
+// accept a fresh heater frame
+// inpsect the advertised run state, tracking when and how it transitions out
+// of preheat especially.
+// abnormal transitions are registered and becoem our smart m_Error
+// In addition, the hetaer frame has the ErrState updated to track the 
+// smart error, providing no heater error exists!
+void
+CSmartError::monitor(CProtocol& heaterFrame)
+{
+  if(heaterFrame.verifyCRC()) {
+    // only accept valid heater frames!
+    monitor(heaterFrame.getRunState());
+    unsigned char HtrErr = heaterFrame.getErrState();
+    if((HtrErr & 0xfe) == 0)  {
+      // heater is Idle or Normal running state  (E-0X + 1 in protocol!!)
+      unsigned char smartErr = getError();
+      if(smartErr) {
+        heaterFrame.setErrState(smartErr);  // 10 = ign fail, 11 = retry
+        heaterFrame.setCRC();              // changed the message, fix the CRC!
+      }
+    }
+  }
+}
+
+// test the new run state value, comparing to previous
+// detect abnormal transitions
+void 
+CSmartError::monitor(unsigned char newRunState)
+{
+  // check if moving away from heater Idle state (S0)
+  // especially useful if an OEM controller exists
+  if((m_prevRunState == 0) && newRunState) {
+    // reset the smart error
+    m_Error = 0;
+    m_bInhibit = false;
+  }
+
+  if(!m_bInhibit) {
+    if(m_prevRunState == 2) {   // preheat state (S2)
+      if(newRunState == 4) {
+        // transitioned from preheat to ignited
+        // - all good!
+        m_Error = 0;
+      }
+      else if(newRunState > 5) {
+        // transitioned from preheat to post glow
+        // - second ignition attempt failed, heater is shutting down
+        m_Error = 11;
+      }
+      else if(newRunState == 3) {
+        // transitioned from preheat to retry 
+        // - first ignition attempt failed, heater will retry
+        m_Error = 12;
+      }
+    }
+  }
+
+  m_prevRunState = newRunState;
+}
+
+// return our smart error, if it exists, as the registered code
+unsigned char 
+CSmartError::getError()
+{
+  if(m_Error) {
+    return m_Error;
+  }
+  return 0;
+}

Arduino/SenderTrial2/SmartError.h

@@ -0,0 +1,14 @@
+#include "Protocol.h"
+
+class CSmartError {
+  unsigned char m_prevRunState;
+  unsigned char m_Error;
+  bool m_bInhibit;
+public: 
+  CSmartError();
+  void reset();
+  void inhibit();
+  void monitor(CProtocol& heaterFrame);
+  void monitor(unsigned char runstate);
+  unsigned char getError();
+};