aboutsummaryrefslogtreecommitdiffhomepage
diff options
context:
space:
mode:
authorDavid P Hilton <[email protected]>2018-10-28 20:46:55 -0600
committerDavid P Hilton <[email protected]>2018-10-28 21:47:58 -0600
commit76b460cd779aba8aee15e6a6a1232d8bfb4b81ca (patch)
tree12df7b3cae7620a19de121852d6230ef01d15346
parentfebf55ad43fd9cf0cbf7794f380c624eae002aea (diff)
downloadIronOS-76b460cd779aba8aee15e6a6a1232d8bfb4b81ca.tar.gz
IronOS-76b460cd779aba8aee15e6a6a1232d8bfb4b81ca.zip
PID rework - use watts
-rw-r--r--workspace/TS100/inc/hardware.h7
-rw-r--r--workspace/TS100/inc/history.hpp41
-rw-r--r--workspace/TS100/inc/power.hpp21
-rw-r--r--workspace/TS100/src/gui.cpp16
-rw-r--r--workspace/TS100/src/hardware.c52
-rw-r--r--workspace/TS100/src/main.cpp147
-rw-r--r--workspace/TS100/src/power.cpp48
7 files changed, 194 insertions, 138 deletions
diff --git a/workspace/TS100/inc/hardware.h b/workspace/TS100/inc/hardware.h
index 0b70f227..fb129b1f 100644
--- a/workspace/TS100/inc/hardware.h
+++ b/workspace/TS100/inc/hardware.h
@@ -116,9 +116,8 @@ enum TipType {
#endif
uint16_t getHandleTemperature();
-uint16_t getTipRawTemp(uint8_t instant);
+uint16_t getTipRawTemp(uint8_t refresh);
uint16_t getInputVoltageX10(uint16_t divisor);
-uint16_t getTipInstantTemperature();
uint8_t getTipPWM();
void setTipPWM(uint8_t pulse);
uint16_t ctoTipMeasurement(uint16_t temp);
@@ -128,8 +127,8 @@ uint16_t tipMeasurementToF(uint16_t raw);
void seekQC(int16_t Vx10,uint16_t divisor);
void setCalibrationOffset(int16_t offSet);
void setTipType(enum TipType tipType, uint8_t manualCalGain);
-uint32_t calculateTipR(uint8_t useFilter);
-int16_t calculateMaxVoltage(uint8_t useFilter, uint8_t useHP);
+uint32_t calculateTipR();
+int16_t calculateMaxVoltage(uint8_t useHP);
void startQC(uint16_t divisor); // Tries to negotiate QC for highest voltage, must be run after
// RToS
// This will try for 12V, failing that 9V, failing that 5V
diff --git a/workspace/TS100/inc/history.hpp b/workspace/TS100/inc/history.hpp
new file mode 100644
index 00000000..856f6536
--- /dev/null
+++ b/workspace/TS100/inc/history.hpp
@@ -0,0 +1,41 @@
+/*
+ * history.hpp
+ *
+ * Created on: 28 Oct, 2018
+ * Authors: Ben V. Brown, David Hilton
+ */
+
+#ifndef HISTORY_HPP_
+#define HISTORY_HPP_
+
+#include <stdint.h>
+
+// max size = 127
+template <class T=uint16_t, uint8_t SIZE=15>
+struct history {
+ static const uint8_t size = SIZE;
+ T buf[size];
+ int32_t sum;
+ uint8_t loc;
+
+ void update(T const val) {
+ // step backwards so i+1 is the previous value.
+ loc = (size+loc-1) % size;
+
+ sum -= buf[loc];
+ sum += val;
+ buf[loc] = val;
+ }
+
+ T operator[] (uint8_t i) const {
+ // 0 = newest, size-1 = oldest.
+ i = (i+loc) % size;
+ return buf[i];
+ }
+
+ T average() const {
+ return sum / size;
+ }
+};
+
+#endif /* HISTORY_HPP_ */
diff --git a/workspace/TS100/inc/power.hpp b/workspace/TS100/inc/power.hpp
new file mode 100644
index 00000000..de4c35db
--- /dev/null
+++ b/workspace/TS100/inc/power.hpp
@@ -0,0 +1,21 @@
+/*
+ * Power.hpp
+ *
+ * Created on: 28 Oct, 2018
+ * Authors: Ben V. Brown, David Hilton
+ */
+
+#include "stdint.h"
+#include <history.hpp>
+
+#ifndef POWER_HPP_
+#define POWER_HPP_
+
+extern history<uint16_t, 75> milliWattHistory;
+
+int32_t tempToMilliWatts(int32_t rawTemp, uint16_t mass, uint8_t rawC);
+void setTipMilliWatts(int32_t mw);
+uint8_t milliWattsToPWM(int32_t milliWatts, uint8_t divisor);
+int32_t PWMToMilliWatts(uint8_t pwm, uint8_t divisor);
+
+#endif /* POWER_HPP_ */
diff --git a/workspace/TS100/src/gui.cpp b/workspace/TS100/src/gui.cpp
index b57bf243..9bc11555 100644
--- a/workspace/TS100/src/gui.cpp
+++ b/workspace/TS100/src/gui.cpp
@@ -664,20 +664,8 @@ static void settings_displayTipModel(void) {
#endif
}
static void calibration_displaySimpleCal(void) { printShortDescription(18, 5); }
-static void dotDelay() {
- for (uint8_t i = 0; i < 20; i++) {
- getTipRawTemp(
- 1); // cycle through the filter a fair bit to ensure we're stable.
- OLED::clearScreen();
- OLED::setCursor(0, 0);
- for (uint8_t x = 0; x < i / 4; x++) OLED::print(".");
- OLED::refresh();
- osDelay(50);
- }
-}
static void setTipOffset() {
setCalibrationOffset(0); // turn off the current offset
- dotDelay();
// If the thermocouple at the end of the tip, and the handle are at
// equalibrium, then the output should be zero, as there is no temperature
@@ -685,8 +673,7 @@ static void setTipOffset() {
int32_t offset = 0;
for (uint8_t i = 0; i < 15; i++) {
- offset += getTipRawTemp(
- 1); // cycle through the filter a fair bit to ensure we're stable.
+ offset += getTipRawTemp(1);
OLED::clearScreen();
OLED::setCursor(0, 0);
@@ -719,7 +706,6 @@ static void calibration_enterSimpleCal(void) {
OLED::refresh();
osDelay(200);
waitForButtonPress();
- dotDelay(); // cycle the filter a bit
// Now take the three hot measurements
// Assume water is boiling at 100C
uint32_t RawTipHot = getTipRawTemp(0) * 10;
diff --git a/workspace/TS100/src/hardware.c b/workspace/TS100/src/hardware.c
index 9b281cf2..17ba5273 100644
--- a/workspace/TS100/src/hardware.c
+++ b/workspace/TS100/src/hardware.c
@@ -118,28 +118,16 @@ uint16_t lookupTipDefaultCalValue(enum TipType tipID) {
#endif
}
-uint16_t getTipRawTemp(uint8_t instant) {
- static int64_t filterFP = 0;
+uint16_t getTipRawTemp(uint8_t refresh) {
static uint16_t lastSample = 0;
- const uint8_t filterBeta = 7; // higher values smooth out more, but reduce responsiveness
-
- if (instant == 1) {
- uint16_t itemp = getTipInstantTemperature();
- filterFP = (filterFP << filterBeta) - filterFP;
- filterFP += (itemp << 9);
- filterFP = filterFP >> filterBeta;
- uint16_t temp = itemp;
- itemp += lastSample;
- itemp /= 2;
- lastSample = temp;
- return itemp;
- } else if (instant == 2) {
- filterFP = (getTipInstantTemperature() << 8);
- return filterFP >> 9;
- } else {
- return filterFP >> 9;
+
+ if (refresh) {
+ lastSample = getTipInstantTemperature();
}
+
+ return lastSample;
}
+
uint16_t getInputVoltageX10(uint16_t divisor) {
// ADC maximum is 32767 == 3.3V at input == 28.05V at VIN
// Therefore we can divide down from there
@@ -333,7 +321,7 @@ void startQC(uint16_t divisor) {
QCMode = 0;
}
// Get tip resistance in milliohms
-uint32_t calculateTipR(uint8_t useFilter) {
+uint32_t calculateTipR() {
// We inject a small current into the front end of the iron,
// By measuring the Vdrop over the tip we can calculate the resistance
// Turn PA0 into an output and drive high to inject (3.3V-0.6)/(6K8+Rtip)
@@ -347,27 +335,19 @@ uint32_t calculateTipR(uint8_t useFilter) {
HAL_GPIO_WritePin(GPIOA, GPIO_PIN_0, GPIO_PIN_RESET); // Set low first
setTipPWM(0);
vTaskDelay(1);
- uint32_t offReading = getTipInstantTemperature();
+ uint32_t offReading = getTipRawTemp(1);
for (uint8_t i = 0; i < 24; i++) {
- if (useFilter == 0) {
- vTaskDelay(1); // delay to allow it too stabilize
- offReading += getTipInstantTemperature();
- } else {
- offReading += getTipRawTemp(0);
- }
+ vTaskDelay(1); // delay to allow it to stabilize
+ offReading += getTipRawTemp(1);
}
// Turn on
HAL_GPIO_WritePin(GPIOA, GPIO_PIN_0, GPIO_PIN_SET); // Set low first
- vTaskDelay(1); // delay to allow it too stabilize
+ vTaskDelay(1); // delay to allow it to stabilize
uint32_t onReading = getTipInstantTemperature();
for (uint8_t i = 0; i < 24; i++) {
- if (useFilter == 0) {
- vTaskDelay(1); // delay to allow it too stabilize
- onReading += getTipInstantTemperature();
- } else {
- onReading += getTipRawTemp(0);
- }
+ vTaskDelay(1); // delay to allow it to stabilize
+ onReading += getTipRawTemp(1);
}
uint32_t difference = onReading - offReading;
@@ -392,11 +372,11 @@ static unsigned int sqrt32(unsigned long n) {
g |= c;
}
}
-int16_t calculateMaxVoltage(uint8_t useFilter, uint8_t useHP) {
+int16_t calculateMaxVoltage(uint8_t useHP) {
// This measures the tip resistance, then it calculates the appropriate
// voltage To stay under ~18W. Mosfet is "9A", so no issues there
// QC3.0 supports up to 18W, which is 2A @9V and 1.5A @12V
- uint32_t milliOhms = calculateTipR(useFilter);
+ uint32_t milliOhms = calculateTipR();
// Check no tip
if (milliOhms > 10000)
return -1;
diff --git a/workspace/TS100/src/main.cpp b/workspace/TS100/src/main.cpp
index 94599d85..be365ab8 100644
--- a/workspace/TS100/src/main.cpp
+++ b/workspace/TS100/src/main.cpp
@@ -3,6 +3,8 @@
#include <gui.hpp>
#include <main.hpp>
#include "LIS2DH12.hpp"
+#include <history.hpp>
+#include <power.hpp>
#include "Settings.h"
#include "Translation.h"
#include "cmsis_os.h"
@@ -36,7 +38,7 @@ int main(void) {
HAL_Init();
Setup_HAL(); // Setup all the HAL objects
HAL_IWDG_Refresh(&hiwdg);
- setTipPWM(0); // force tip off
+ setTipMilliWatts(0); // force tip off
FRToSI2C::init(&hi2c1);
OLED::initialize(); // start up the LCD
OLED::setFont(0); // default to bigger font
@@ -87,6 +89,21 @@ int main(void) {
while (1) {
}
}
+
+void debugNumber(int32_t val) {
+ if (abs(val) > 99999) {
+ OLED::print(" OoB"); // out of bounds
+ return;
+ }
+ if (val >= 0) {
+ OLED::drawChar(' ');
+ OLED::printNumber(val, 5);
+ } else {
+ OLED::drawChar('-');
+ OLED::printNumber(-val, 5);
+ }
+}
+
void printVoltage() {
OLED::printNumber(getInputVoltageX10(systemSettings.voltageDiv) / 10, 2);
OLED::drawChar('.');
@@ -535,8 +552,10 @@ static void gui_solderingMode(uint8_t jumpToSleep) {
if (systemSettings.detailedSoldering) {
OLED::setFont(1);
OLED::print(SolderingAdvancedPowerPrompt); // Power:
- OLED::printNumber(getTipPWM(), 3);
- OLED::print("%");
+ OLED::printNumber(milliWattHistory[0] / 1000, 2);
+ OLED::drawChar('.');
+ OLED::printNumber(milliWattHistory[0] / 100 % 10, 1);
+ OLED::drawChar('W');
if (systemSettings.sensitivity && systemSettings.SleepTime) {
OLED::print(" ");
@@ -723,7 +742,7 @@ void startGUITask(void const *argument __unused) {
uint8_t tempWarningState = 0;
bool buttonLockout = false;
bool tempOnDisplay = false;
- getTipRawTemp(2); // reset filter
+ getTipRawTemp(1); // reset filter
OLED::setRotation(systemSettings.OrientationMode & 1);
uint32_t ticks = xTaskGetTickCount();
ticks += 400; // 4 seconds from now
@@ -786,8 +805,7 @@ void startGUITask(void const *argument __unused) {
#ifdef MODEL_TS80
//Here we re-check for tip presence
if (idealQCVoltage < 90)
- idealQCVoltage = calculateMaxVoltage(1,
- systemSettings.cutoutSetting); // 1 means use filtered values rather than do its own
+ idealQCVoltage = calculateMaxVoltage(systemSettings.cutoutSetting);
seekQC(idealQCVoltage,systemSettings.voltageDiv);
#endif
gui_solderingMode(0); // enter soldering mode
@@ -807,7 +825,7 @@ void startGUITask(void const *argument __unused) {
currentlyActiveTemperatureTarget = 0; // ensure tip is off
- uint16_t tipTemp = tipMeasurementToC(getTipRawTemp(1)); // This forces a faster update rate on the filtering
+ uint16_t tipTemp = tipMeasurementToC(getTipRawTemp(0));
if (tipTemp < 50) {
if (systemSettings.sensitivity) {
@@ -906,37 +924,15 @@ void startPIDTask(void const *argument __unused) {
* struct
*
*/
- setTipPWM(0); // disable the output driver if the output is set to be off
-#ifdef MODEL_TS100
- for (uint8_t i = 0; i < 50; i++) {
- osDelay(10);
- getTipRawTemp(1); // cycle up the tip temp filter
- HAL_IWDG_Refresh(&hiwdg);
- }
-#else
- // On the TS80 we can measure the tip resistance before cycling the filter a
- // bit
- idealQCVoltage = 0;
- idealQCVoltage = calculateMaxVoltage(0, systemSettings.cutoutSetting);
- // Rapidly cycle the filter to help converge
- HAL_IWDG_Refresh(&hiwdg);
- for (uint8_t i = 0; i < 50; i++) {
- osDelay(11);
- getTipRawTemp(1); // cycle up the tip temp filter
- }
- HAL_IWDG_Refresh(&hiwdg);
-
+ setTipMilliWatts(0); // disable the output driver if the output is set to be off
+#ifdef MODEL_TS80
+ idealQCVoltage = calculateMaxVoltage(systemSettings.cutoutSetting);
#endif
+ int32_t rawC = ctoTipMeasurement(100) - ctoTipMeasurement(101); // 1*C change in raw.
currentlyActiveTemperatureTarget = 0; // Force start with no output (off). If in sleep / soldering this will
- // be over-ridded rapidly
- int32_t integralCount = 0;
- int32_t derivativeLastValue = 0;
-
- // REMEBER ^^^^ These constants are backwards
- // They act as dividers, so to 'increase' a P term, you make the number
- // smaller.
+ // be over-ridden rapidly
+ history<int16_t> tempError = {{0}, 0, 0};
- const int32_t itermMax = 100;
pidTaskNotification = xTaskGetCurrentTaskHandle();
for (;;) {
if (ulTaskNotifyTake(pdTRUE, 50)) {
@@ -944,69 +940,54 @@ void startPIDTask(void const *argument __unused) {
// This is a call to block this thread until the ADC does its samples
uint16_t rawTemp = getTipRawTemp(1); // get instantaneous reading
if (currentlyActiveTemperatureTarget) {
- // Compute the PID loop in here
- // Because our values here are quite large for all measurements (0-32k
- // ~= 66 counts per C) P I & D are divisors, so inverse logic applies
- // (beware)
-
// Cap the max set point to 450C
if (currentlyActiveTemperatureTarget > ctoTipMeasurement(450)) {
currentlyActiveTemperatureTarget = ctoTipMeasurement(450);
}
- int32_t rawTempError = currentlyActiveTemperatureTarget
- - rawTemp;
-
- int32_t ierror = (rawTempError
- / ((int32_t) systemSettings.PID_I));
-
- integralCount += ierror;
-
- if (integralCount > (itermMax / 2))
- integralCount = itermMax / 2; // prevent too much lead
- else if (integralCount < -itermMax)
- integralCount = itermMax;
-
- int32_t dInput = (rawTemp - derivativeLastValue);
-
- /*Compute PID Output*/
- int32_t output = (rawTempError
- / ((int32_t) systemSettings.PID_P));
- if (((int32_t) systemSettings.PID_I))
- output += integralCount;
- if (((int32_t) systemSettings.PID_D))
- output -= (dInput / ((int32_t) systemSettings.PID_D));
-
- if (output > 100) {
- output = 100; // saturate
- } else if (output < 0) {
- output = 0;
- }
-
- if (currentlyActiveTemperatureTarget < rawTemp) {
- output = 0;
- integralCount = 0;
- derivativeLastValue = 0;
- }
- setTipPWM(output);
- derivativeLastValue = rawTemp; // store for next loop
-
+ // As we get close to our target, temp noise causes the system
+ // to be unstable. Use a rolling average to dampen it.
+ // We overshoot by roughly 1/2 of 1 degree Fahrenheit.
+ // This helps stabilize the display.
+ tempError.update(currentlyActiveTemperatureTarget - rawTemp + rawC/4);
+
+ // Now for the PID!
+ int32_t milliWattsOut = 0;
+
+ // P term - total power needed to hit target temp next cycle.
+ // thermal mass = 1690 milliJ/*C for my tip.
+ // = Watts*Seconds to raise Temp from room temp to +100*C, divided by 100*C.
+ // divided by 4 to let I term dominate near set point.
+ const uint16_t mass = 1690 / 4;
+ int32_t milliWattsNeeded = tempToMilliWatts(tempError.average(), mass, rawC);
+ milliWattsOut += milliWattsNeeded;
+
+ // I term - energy needed to compensate for heat loss.
+ // We track energy put into the system over some window.
+ // Assuming the temp is stable, energy in = energy transfered.
+ // (If it isn't, P will dominate).
+ milliWattsOut += milliWattHistory.average();
+
+ // D term - use sudden temp change to counter fast cooling/heating.
+ // In practice, this provides an early boost if temp is dropping
+ // and counters extra power if the iron is no longer losing temp.
+ // basically: temp - lastTemp
+ // Unfortunately, our temp signal is too noisy to really help.
+
+ setTipMilliWatts(milliWattsOut);
} else {
- setTipPWM(0); // disable the output driver if the output is set to be off
- integralCount = 0;
- derivativeLastValue = 0;
+ setTipMilliWatts(0);
}
HAL_IWDG_Refresh(&hiwdg);
} else {
if (currentlyActiveTemperatureTarget == 0) {
- setTipPWM(0); // disable the output driver if the output is set to be off
- integralCount = 0;
- derivativeLastValue = 0;
+ setTipMilliWatts(0);
}
}
}
}
+
#define MOVFilter 8
void startMOVTask(void const *argument __unused) {
OLED::setRotation(false);
diff --git a/workspace/TS100/src/power.cpp b/workspace/TS100/src/power.cpp
new file mode 100644
index 00000000..a249dc14
--- /dev/null
+++ b/workspace/TS100/src/power.cpp
@@ -0,0 +1,48 @@
+/*
+ * power.cpp
+ *
+ * Created on: 28 Oct, 2018
+ * Authors: Ben V. Brown, David Hilton
+ */
+
+#include <power.hpp>
+#include <Settings.h>
+#include <hardware.h>
+
+history<uint16_t, 75> milliWattHistory = {{0}, 0, 0};
+
+const uint8_t tipResistance = 87;
+const uint8_t hz = 33;
+const uint8_t maxPWM = 100;
+
+int32_t tempToMilliWatts(int32_t rawTemp, uint16_t mass, uint8_t rawC) {
+ // mass is in milliJ/*C, rawC is raw per degree C
+ int32_t milliJoules = mass * rawTemp / rawC;
+ return milliJoules * hz;
+}
+
+void setTipMilliWatts(int32_t mw) {
+ int32_t output = milliWattsToPWM(mw, systemSettings.voltageDiv / 10);
+ setTipPWM(output);
+ uint16_t actualMilliWatts = PWMToMilliWatts(output, systemSettings.voltageDiv / 10);
+
+ milliWattHistory.update(actualMilliWatts);
+}
+
+uint8_t milliWattsToPWM(int32_t milliWatts, uint8_t divisor) {
+ int32_t v = getInputVoltageX10(divisor); // 1000 = 10v
+ int32_t availableMilliWatts = v*v / tipResistance;
+ int32_t pwm = maxPWM * milliWatts / availableMilliWatts;
+
+ if (pwm > maxPWM) {
+ pwm = maxPWM;
+ } else if (pwm < 0) {
+ pwm = 0;
+ }
+ return pwm;
+}
+
+int32_t PWMToMilliWatts(uint8_t pwm, uint8_t divisor) {
+ int32_t v = getInputVoltageX10(divisor);
+ return pwm * (v*v / tipResistance) / maxPWM;
+}