Cleaner hourmeter handling using a new class for each counter.

Added a warning animation to LVC, ether <12V, or 0.5V > LVC if that result is over 12V

src/Afterburner.cpp

@@ -458,8 +458,8 @@ void setup() {
 //  bCyclicEngaged = RTC_Store.getCyclicEngaged();
   DebugPort.printf("Previous cyclic active = %d\r\n", RTC_Store.getCyclicEngaged());   // state flag required for cyclic mode to persist properly after a WD reboot :-)
 
-  pHourMeter = new CHourMeter(persistentRunTime, persistentGlowTime); // persistent vars are only trustworthy with SW reboots
+  pHourMeter = new CHourMeter(persistentRunTime, persistentGlowTime); // persistent vars passed by reference so they can be valid after SW reboots
-  pHourMeter->init(bESP32PowerUpInit || RTC_Store.getBootInit());  // ensure persistent memory variable are reset after powerup, or OTA update
+  pHourMeter->init(bESP32PowerUpInit || RTC_Store.getBootInit());     // ensure persistent memory variable are reset after powerup, or OTA update
   RTC_Store.setBootInit(false);
 
   delay(1000); // just to hold the splash screeen for while
@@ -908,7 +908,7 @@ bool validateFrame(const CProtocol& frame, const char* name)
 
 void requestOn()
 {
-  if(bHasHtrData && SmartError.checkVolts(FilteredSamples.FastipVolts.getValue(), FilteredSamples.FastGlowAmps.getValue())) {
+  if(bHasHtrData && (0 == SmartError.checkVolts(FilteredSamples.FastipVolts.getValue(), FilteredSamples.FastGlowAmps.getValue()))) {
     heaterOn();
     RTC_Store.setCyclicEngaged(true);    // for cyclic mode
   }
@@ -1249,14 +1249,7 @@ void checkDebugCommands()
         ESP.restart();            // reset the esp
       }
       else if(rxVal == ('h' & 0x1f)) {   // CTRL-H hourmeter reset
-        sHourMeter FLASHmem = NVstore.getHourMeter();
+        pHourMeter->resetHard();
-        FLASHmem.RunTime = 0;
-        FLASHmem.GlowTime = 0;
-        NVstore.setHourMeter(FLASHmem);
-        RTC_Store.resetRunTime();
-        RTC_Store.resetGlowTime();
-        persistentRunTime = 0;
-        persistentGlowTime = 0;
       }
     }
 #ifdef PROTOCOL_INVESTIGATION    

src/OLED/ScreenHeader.cpp

@@ -134,9 +134,43 @@ CScreenHeader::animate()
     int xPos = X_BATT_ICON;   
     int yPos = Y_BATT_ICON;
     showTimers();
+
+    switch(_batteryCount) {
+      case 0:
+        // establish  battery icon flash pattern
+        // > 0.5 over LVC - solid
+        // < 0.5 over LVC - slow flash
+        // < LVC - fast flash
+        _batteryWarn = SmartError.checkVolts(FilteredSamples.FastipVolts.getValue(), FilteredSamples.FastGlowAmps.getValue(), false);
+        
+        showBatteryIcon(getBatteryVoltage(true));
+        break;
+      case 1:
+        if(_batteryWarn == 2)
+          _display.fillRect(xPos, yPos, BatteryIconInfo.width, BatteryIconInfo.height, BLACK);
+        break;
+      case 2:
+        if(_batteryWarn == 2)
+          showBatteryIcon(getBatteryVoltage(true));
+        break;
+      case 3:
+        if(_batteryWarn)   // works for either < LVC, or < LVC+0.5
+          _display.fillRect(xPos, yPos, BatteryIconInfo.width, BatteryIconInfo.height, BLACK);
+        break;
+      case 4:
+        if(_batteryWarn == 2)
+          showBatteryIcon(getBatteryVoltage(true));
+        break;
+      case 5:
+        if(_batteryWarn == 2)
+          _display.fillRect(xPos, yPos, BatteryIconInfo.width, BatteryIconInfo.height, BLACK);
+        break;
+
+    }
+/*    
     switch(_batteryCount) {
       case 3:
-        if(SmartError.checkVolts(FilteredSamples.FastipVolts.getValue(), FilteredSamples.FastGlowAmps.getValue(), false)) { // check but do not fault
+        if(SmartError.checkVolts(FilteredSamples.FastipVolts.getValue(), FilteredSamples.FastGlowAmps.getValue(), false) == 0) { // check but do not fault
           showBatteryIcon(getBatteryVoltage(true));
         }
         else {
@@ -147,6 +181,7 @@ CScreenHeader::animate()
         showBatteryIcon(getBatteryVoltage(true));
         break;
     }
+*/
   }
 
   showWifiIcon();

src/OLED/ScreenHeader.h

@@ -46,6 +46,7 @@ class CScreenHeader : public CScreen {
   bool _colon;
   uint8_t  _animateCount;
   uint8_t  _batteryCount;
+  uint8_t  _batteryWarn;
 protected:
   void showBTicon();
   void showWifiIcon();

src/Protocol/SmartError.cpp

@@ -113,7 +113,12 @@ CSmartError::monitor(uint8_t newRunState)
   _prevRunState = newRunState;
 }
 
-bool
+//
+// retval:
+// 0 - OK
+// 1 - Warning less than 12/24 (or .5V over LVC for higher LVC levels)
+// 2 - Warning less than LVC
+int
 CSmartError::checkVolts(float ipVolts, float glowI, bool throwfault)
 {
  // check for low voltage
@@ -126,10 +131,22 @@ CSmartError::checkVolts(float ipVolts, float glowI, bool throwfault)
         _Error = 2;     // +1 over displayed error code
         requestOff();
       }
-      return false;
+      return 2;
+    }
+    int alert = Thresh + 0.5;
+    if(NVstore.getHeaterTuning().sysVoltage == 120) {
+      if(alert < 12)
+        alert = 12;
+    }
+    else {
+      if(alert < 24)
+        alert = 24;
+    }
+    if(ipVolts < alert) {
+      return 1;
     }
   }
-  return true;
+  return 0;
 }
 
 

src/Protocol/SmartError.h

@@ -31,7 +31,7 @@ public:
   void inhibit();
   void monitor(const CProtocol& heaterFrame);
   void monitor(uint8_t runstate);
-  bool checkVolts(float volts, float plugI, bool throwfault=true);
+  int checkVolts(float volts, float plugI, bool throwfault=true);  // 0 = OK, 1 = within 0.5V of LVC, 2 = under LVC
   uint8_t getError();
 };
 

src/RTC/RTCStore.cpp

@@ -245,6 +245,7 @@ CRTC_Store::_PackAndSaveByte5()
 void
 CRTC_Store::_PackAndSaveByte6()
 {
+  DebugPort.printf("RTC_Store - save byte 6: Run=%d, Glow=%d\r\n", _RunTime, _GlowTime);
   uint8_t NVval = ((_GlowTime & 0x07)<<5) | (_RunTime & 0x1f);
   Clock.saveData((uint8_t*)&NVval, 1, 6);
 }
@@ -258,7 +259,7 @@ CRTC_Store::_ReadAndUnpackByte6()
     _GlowTime = (NVval >> 5) & 0x07;
     _RunTime = NVval & 0x1f;
     _accessed[3] = true;
-    DebugPort.printf("RTC_Store - read byte6: glow=%d, run=%d\r\n", _GlowTime, _RunTime);
+    DebugPort.printf("RTC_Store - read byte6: Run=%d, Glow=%d\r\n", _RunTime, _GlowTime);
   }
 }
 

src/Utility/HourMeter.cpp

@@ -31,11 +31,13 @@
 void 
 CHourMeter::init(bool poweron)
 {
-  if(poweron) {
+  // power on reset or OTA update - cannot trust persistent values - they are likely un-initialised
-    _RunTime = 0;  // definitely untrustworthy after power on or OTA updates
+  if(poweron) {       
-    _GlowTime = 0;
+    RunTime.reset();  
+    GlowTime.reset();
   }
-  if(_RunTime || _GlowTime || RTC_Store.getRunTime() || RTC_Store.getGlowTime()) {
+  // if there is a remnant time held, add it to the real NV stored value
+  if(RunTime.get() || GlowTime.get() || RTC_Store.getRunTime() || RTC_Store.getGlowTime()) {
     store();
   }
 }
@@ -45,101 +47,110 @@ CHourMeter::reset()
 {
   RTC_Store.resetRunTime();
   RTC_Store.resetGlowTime();
-  _RunTime = 0;
+  RunTime.reset();
-  _GlowTime = 0;
+  GlowTime.reset();
+}
+
+void
+CHourMeter::resetHard()
+{
+  reset();
+  sHourMeter NV = NVstore.getHourMeter();
+  NV.RunTime = 0;
+  NV.GlowTime = 0;
+  NVstore.setHourMeter(NV);
 }
 
 void
 CHourMeter::store()
 {
   sHourMeter NV = NVstore.getHourMeter();
-  NV.RunTime += _RunTime + baseSeconds * RTC_Store.getRunTime();    // add any residual to the real NV stored value
+  NV.RunTime += RunTime.get() + RTC_storageInterval * RTC_Store.getRunTime();    // add any residual to the real NV stored value
-  NV.GlowTime += _GlowTime + baseSeconds * RTC_Store.getGlowTime();
+  NV.GlowTime += GlowTime.get() + RTC_storageInterval * RTC_Store.getGlowTime();
-  NVstore.setHourMeter(NV);
+  NVstore.setHourMeter(NV);  // stage new values, and setup for save (if changed)
-  reset();
+  reset();                   // zero time tracked in this class
 }
 
 void 
 CHourMeter::monitor(const CProtocol& frame)
 {
-//  long now = Clock.get().secondstime();
-  unsigned long now = millis();
   if(frame.getRunState() == 0) {
-    // heater is stopped - save remnant times to flash
+    // heater is stopped 
-    if(_lastRunTime) {
+    if(RunTime.active()) {
-      store();   // heater hass stopped - save remnant times to flash
+      store();   // initial stop of heater - save residual times to NV
     }
-    _lastRunTime = 0;
+    RunTime.stop();   // cancel time tracking
-    _lastGlowTime = 0;
+    GlowTime.stop();
   }
   else {
     // heater is running
-    if(_lastRunTime != 0) {
+    unsigned long now = millis();
-      // first sample after start is ignored
+    RunTime.recordTime(now);   // track run time of heater
-      float tDelta = float(now - _lastRunTime) * 0.001;
+    if(frame.getGlowPlug_Voltage() != 0) {
-      _RunTime += tDelta;
+      GlowTime.recordTime(now);  // track on time of glow plug
-      if(frame.getGlowPlug_Voltage() != 0) {
-        if(_lastGlowTime != 0) {
-          _GlowTime += tDelta;
-        }    
-        _lastGlowTime = now;
-      }
-      else {
-        _lastGlowTime = 0;
-      }
     }
-    _lastRunTime = now;
+    else {
+      GlowTime.stop();
+    }
+    // check for RAM counters time interval rollover
     sHourMeter NV = NVstore.getHourMeter();
-    // test for rollover of our local run time tracking
+    // rollover run time tracking?
-    if(_RunTime > baseSeconds) {
+    if(RunTime.get() > RTC_storageInterval) {
-      _RunTime -= baseSeconds;
+      RunTime.offset(-RTC_storageInterval);
-      if(RTC_Store.incRunTime()) {       // returns true if rolled back to zero
+      if(RTC_Store.incRunTime()) {       // returns true if RTC counter rolled back to zero
         // rolled RTC intermediate store - push into FLASH
-        NV.RunTime += baseSeconds * RTC_Store.getMaxRunTime();   // bump by our maximum storable time
+        NV.RunTime += RTC_storageInterval * RTC_Store.getMaxRunTime();   // bump NV by our maximum storable time
       }
     }
-    // test for rollover of our local glow time tracking
+    // rollover glow time tracking?
-    if(_GlowTime > baseSeconds) {
+    if(GlowTime.get() > RTC_storageInterval) {
-      _GlowTime -= baseSeconds;
+      GlowTime.offset(-RTC_storageInterval);
       if(RTC_Store.incGlowTime()) {       // returns true if rolled back to zero
         // rolled RTC intermediate store - push into FLASH
-        NV.GlowTime += baseSeconds * RTC_Store.getMaxGlowTime();  // bump by our maximum storable time
+        NV.GlowTime += RTC_storageInterval * RTC_Store.getMaxGlowTime();  // bump NV by our maximum storable time
       }
     }
-    NVstore.setHourMeter(NV);  // internally moderated, only actually saves if values have changed
+    NVstore.setHourMeter(NV);  // internally moderated, will only actually save if a value has changed
   }
-//    DebugPort.printf("CHourMeter %f %f\r\n", _RunTime, _GlowTime);
 }
 
 uint32_t
 CHourMeter::_getLclRunTime()
 {
-  uint32_t rt = (uint32_t)_RunTime;
+  uint32_t rt = RunTime.get();
+#ifdef DEBUG_HOURMETER
   DebugPort.printf("HrMtr _GetLclRunTime(): %d %d\r\n", rt, RTC_Store.getRunTime());
-  return  rt + baseSeconds * RTC_Store.getRunTime();
+#endif
-}
+  return  rt + RTC_storageInterval * RTC_Store.getRunTime();
-
-uint32_t
-CHourMeter::_getLclGlowTime()
-{
-  uint32_t gt = (uint32_t)_GlowTime;
-  DebugPort.printf("HrMtr _GetLclGlowTime(): %d %d\r\n", gt, RTC_Store.getGlowTime());
-  return  gt + baseSeconds * RTC_Store.getGlowTime();
 }
 
 uint32_t 
 CHourMeter::getRunTime()
 {
   uint32_t rt = _getLclRunTime();
+#ifdef DEBUG_HOURMETER
   DebugPort.printf("HrMtr GetRunTime(): %d %d\r\n", rt, NVstore.getHourMeter().RunTime);
+#endif
   return  rt + NVstore.getHourMeter().RunTime;
 }
 
+uint32_t
+CHourMeter::_getLclGlowTime()
+{
+  uint32_t gt = GlowTime.get();
+#ifdef DEBUG_HOURMETER
+  DebugPort.printf("HrMtr _GetLclGlowTime(): %d %d\r\n", gt, RTC_Store.getGlowTime());
+#endif
+  return  gt + RTC_storageInterval * RTC_Store.getGlowTime();
+}
+
 uint32_t 
 CHourMeter::getGlowTime()
 {
   uint32_t gt = _getLclGlowTime();
-  DebugPort.printf("HrMtr GetGlowTime(): %d %d\r\n", gt, NVstore.getHourMeter().RunTime);
+#ifdef DEBUG_HOURMETER
+  DebugPort.printf("HrMtr GetGlowTime(): %d %d\r\n", gt, NVstore.getHourMeter().GlowTime);
+#endif
   return gt + NVstore.getHourMeter().GlowTime;
 }
 

src/Utility/HourMeter.h

@@ -23,29 +23,59 @@
 #include "../RTC/RTCStore.h"
 #include "NVStorage.h"
 
+#define DEBUG_HOURMETER
+
+
 class CProtocol;
 
-class CHourMeter {
+class sRunTime {
-  const int baseSeconds = 60 * 15;  // 15 minutes
+  float& persistentVal;
+  unsigned long lastSampleTime;
+public:
+  sRunTime(float& refVal) : persistentVal(refVal) { 
+    lastSampleTime = 0; 
+  };
+  void reset() {
+    persistentVal = 0;
+  };
+  uint32_t get() const {
+    return (uint32_t)persistentVal;
+  }
+  bool active() const {
+    return lastSampleTime != 0;
+  }
+  void stop() {
+    lastSampleTime = 0;
+  }
+  float recordTime(unsigned long now) {
+    float rVal = 0;
+    if(lastSampleTime)
+      rVal = float((unsigned long)(now - lastSampleTime)) * 0.001;
+    lastSampleTime = now;
+    persistentVal += rVal;
+    return rVal;
+  } 
+  void offset(float ofs) {
+    persistentVal += ofs;
+  }
 
-  float& _RunTime;
+};
-  float& _GlowTime;
+
-  unsigned long _lastRunTime;
+class CHourMeter {
-  unsigned long _lastGlowTime;
+  const int RTC_storageInterval = 60 * 10;  // 10 minutes
+
+  sRunTime RunTime;
+  sRunTime GlowTime;
   uint32_t _getLclRunTime();    // volatile persistent variable + RTC stored rollovers
   uint32_t _getLclGlowTime();   // volatile persistent variable + RTC stored rollovers
 public:
   CHourMeter(float &runtime, float& glowtime) : 
-    _RunTime(runtime), 
+    RunTime(runtime),
-    _GlowTime(glowtime) 
+    GlowTime(glowtime) 
   {
-    _lastRunTime = 0;
+#ifdef DEBUG_HOURMETER
-    _lastGlowTime = 0;
+    DebugPort.printf("CHourMeter %d %d\r\n", RunTime.get(), GlowTime.get());
-    DebugPort.printf("CHourMeter %f %f\r\n", _RunTime, _GlowTime);
+#endif
-  };
-  void associate(float &runtime, float& glowtime) {
-    _RunTime = runtime; 
-    _GlowTime = glowtime; 
   };
   void init(bool poweron);
   void reset();
@@ -53,6 +83,7 @@ public:
   void monitor(const CProtocol& frame);
   uint32_t getRunTime();       // total time, local tracked + last NV stored value
   uint32_t getGlowTime();      // total time, local tracked + last NV stored value
+  void resetHard();
 };
 
 extern CHourMeter* pHourMeter;