Initial Implementation of Core Emergency Stop Feature on Battery Emulator

Software/Software.ino

@@ -334,10 +334,24 @@ void init_serial() {
 }
 
 void init_stored_settings() {
+  static uint32_t temp = 0;
   settings.begin("batterySettings", false);
 
+  //allways get the emergency stop status
+  temp = settings.getBool("EMERGENGY_STOP", false);
+  datalayer.system.settings.equipment_stop_active = temp;
+  if (datalayer.system.settings.equipment_stop_active) {
+    set_event(EVENT_EMERGENCY_STOP, 1);
+  }
+
 #ifndef LOAD_SAVED_SETTINGS_ON_BOOT
   settings.clear();  // If this clear function is executed, no settings will be read from storage
+
+  //always save the emergency stop status
+  if (datalayer.system.settings.equipment_stop_active) {
+    settings.putBool("EMERGENGY_STOP", datalayer.system.settings.equipment_stop_active);
+  }
+
 #endif
 
 #ifdef WIFI
@@ -356,7 +370,6 @@ void init_stored_settings() {
   }
 #endif
 
-  static uint32_t temp = 0;
   temp = settings.getUInt("BATTERY_WH_MAX", false);
   if (temp != 0) {
     datalayer.battery.info.total_capacity_Wh = temp;
@@ -658,9 +671,14 @@ void handle_contactors() {
     timeSpentInFaultedMode = 0;
   }
 
-  if (timeSpentInFaultedMode > MAX_ALLOWED_FAULT_TICKS) {
+  //handle contactor control SHUTDOWN_REQUESTED vs DISCONNECTED
+  if (timeSpentInFaultedMode > MAX_ALLOWED_FAULT_TICKS ||
+      (datalayer.system.settings.equipment_stop_active && contactorStatus != SHUTDOWN_REQUESTED)) {
     contactorStatus = SHUTDOWN_REQUESTED;
   }
+  if (contactorStatus == SHUTDOWN_REQUESTED && !datalayer.system.settings.equipment_stop_active) {
+    contactorStatus = DISCONNECTED;
+  }
   if (contactorStatus == SHUTDOWN_REQUESTED) {
     digitalWrite(PRECHARGE_PIN, LOW);
 #ifndef PWM_CONTACTOR_CONTROL
@@ -832,6 +850,12 @@ void init_serialDataLink() {
 #endif
 }
 
+void store_settings_emergency_stop() {
+  settings.begin("batterySettings", false);
+  settings.putBool("EMERGENGY_STOP", datalayer.system.settings.equipment_stop_active);
+  settings.end();
+}
+
 void storeSettings() {
   settings.begin("batterySettings", false);
 #ifdef WIFI

Software/src/datalayer/datalayer.h

@@ -172,6 +172,7 @@ typedef struct {
 } DATALAYER_SYSTEM_STATUS_TYPE;
 
 typedef struct {
+  bool equipment_stop_active = false;
 } DATALAYER_SYSTEM_SETTINGS_TYPE;
 
 typedef struct {

Software/src/devboard/safety/safety.cpp

@@ -196,7 +196,18 @@ void update_machineryprotection() {
 }
 
 //battery pause status begin
-void setBatteryPause(bool pause_battery, bool pause_CAN) {
+void setBatteryPause(bool pause_battery, bool pause_CAN, bool emergency_stop) {
+
+  //fist handle emergency stop / resume
+  if (emergency_stop && !datalayer.system.settings.equipment_stop_active) {
+    datalayer.system.settings.equipment_stop_active = true;
+    store_settings_emergency_stop();
+    set_event(EVENT_EMERGENCY_STOP, 1);
+  } else if (!emergency_stop && datalayer.system.settings.equipment_stop_active) {
+    datalayer.system.settings.equipment_stop_active = false;
+    store_settings_emergency_stop();
+    clear_event(EVENT_EMERGENCY_STOP);
+  }
 
   emulator_pause_CAN_send_ON = pause_CAN;
 

Software/src/devboard/safety/safety.h

@@ -15,10 +15,12 @@ extern battery_pause_status emulator_pause_status;
 extern bool allowed_to_send_CAN;
 //battery pause status end
 
+extern void store_settings_emergency_stop();
+
 void update_machineryprotection();
 
 //battery pause status begin
-void setBatteryPause(bool pause_battery, bool pause_CAN);
+void setBatteryPause(bool pause_battery, bool pause_CAN, bool emergency_stop = false);
 void emulator_pause_state_send_CAN_battery();
 std::string get_emulator_pause_status();
 //battery pause status end

Software/src/devboard/utils/events.cpp

@@ -213,6 +213,7 @@ void init_events(void) {
   events.entries[EVENT_WIFI_DISCONNECT].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_MQTT_CONNECT].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_MQTT_DISCONNECT].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_EMERGENCY_STOP].level = EVENT_LEVEL_ERROR;
 
   events.entries[EVENT_EEPROM_WRITE].log = false;  // Don't log the logger...
 
@@ -411,6 +412,8 @@ const char* get_event_message_string(EVENTS_ENUM_TYPE event) {
       return "Info: MQTT connected.";
     case EVENT_MQTT_DISCONNECT:
       return "Info: MQTT disconnected.";
+    case EVENT_EMERGENCY_STOP:
+      return "ERROR: EMERGENCY STOP ACTIVATED!!!";
     default:
       return "";
   }

Software/src/devboard/utils/events.h

@@ -101,6 +101,7 @@
   XX(EVENT_WIFI_DISCONNECT)             \
   XX(EVENT_MQTT_CONNECT)                \
   XX(EVENT_MQTT_DISCONNECT)             \
+  XX(EVENT_EMERGENCY_STOP)              \
   XX(EVENT_NOF_EVENTS)
 
 typedef enum { EVENTS_ENUM_TYPE(GENERATE_ENUM) } EVENTS_ENUM_TYPE;

Software/src/devboard/webserver/webserver.cpp

@@ -166,6 +166,23 @@ void init_webserver() {
     }
   });
 
+  // Route for emergency stop/resume
+  server.on("/estop", HTTP_GET, [](AsyncWebServerRequest* request) {
+    if (WEBSERVER_AUTH_REQUIRED && !request->authenticate(http_username, http_password))
+      return request->requestAuthentication();
+    if (request->hasParam("stop")) {
+      String valueStr = request->getParam("stop")->value();
+      if (valueStr == "true" || valueStr == "1") {
+        setBatteryPause(true, true, true);
+      } else {
+        setBatteryPause(false, false, false);
+      }
+      request->send(200, "text/plain", "Updated successfully");
+    } else {
+      request->send(400, "text/plain", "Bad Request");
+    }
+  });
+
   // Route for editing SOCMin
   server.on("/updateSocMin", HTTP_GET, [](AsyncWebServerRequest* request) {
     if (WEBSERVER_AUTH_REQUIRED && !request->authenticate(http_username, http_password))
@@ -844,6 +861,21 @@ String processor(const String& var) {
     content += "<button onclick='askReboot()'>Reboot Emulator</button>";
     if (WEBSERVER_AUTH_REQUIRED)
       content += "<button onclick='logout()'>Logout</button>";
+    if (!datalayer.system.settings.equipment_stop_active)
+      content +=
+          "<br/><br/><button style=\"background:red;color:white;cursor:pointer;\""
+          " onclick=\""
+          "if(confirm('This action will open contactors on the battery and stop all CAN communications. Are you "
+          "sure?')) { estop(true); }\""
+          ">EQUIPMENT STOP</button><br/>";
+    else
+      content +=
+          "<br/><br/><button style=\"background:green;color:white;cursor:pointer;\""
+          "20px;font-size:16px;font-weight:bold;cursor:pointer;border-radius:5px; margin:10px;"
+          " onclick=\""
+          "if(confirm('This action will restore the battery state. Are you sure?')) { estop(false); }\""
+          ">RESUME FROM EQUIPMENT STOP</button><br/>";
+
     content += "<script>";
     content += "function OTA() { window.location.href = '/update'; }";
     content += "function Cellmon() { window.location.href = '/cellmonitor'; }";
@@ -872,7 +904,12 @@ String processor(const String& var) {
         "XMLHttpRequest();xhr.onload=function() { "
         "window.location.reload();};xhr.open('GET','/pause?p='+pause,true);xhr.send();";
     content += "}";
-
+    content += "function estop(stop){";
+    content +=
+        "var xhr=new "
+        "XMLHttpRequest();xhr.onload=function() { "
+        "window.location.reload();};xhr.open('GET','/estop?stop='+stop,true);xhr.send();";
+    content += "}";
     content += "</script>";
 
     //Script for refreshing page