Tweak logic for contactor closing

Software/Software.ino

@@ -619,9 +619,19 @@ void send_can2() {
 
 #ifdef DOUBLE_BATTERY
 void handle_CAN_contactors() {
-  if (abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) < 50) {
+  if (datalayer.battery.status.voltage_dV == 0 || datalayer.battery2.status.voltage_dV == 0) {
+    return;  // Both voltage values need to be available to start check
+  }
+
+  if (abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) < 30) {  // If we are within 3.0V
+    clear_event(EVENT_VOLTAGE_DIFFERENCE);
+    if (datalayer.battery2.status.bms_status != FAULT) {  // Only proceed if BMS on battery2 is not faulted
       datalayer.system.status.battery2_allows_contactor_closing = true;
-  }  //TODO: Shall we handle opening incase of fault here?
+    }
+  } else {  //We are over 3.0V diff
+    set_event(EVENT_VOLTAGE_DIFFERENCE,
+              (uint8_t)(abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) / 10));
+  }
 }
 #endif
 
@@ -744,7 +754,29 @@ void update_SOC() {
     datalayer.battery.status.reported_soc = calc_soc;
   } else {  // No SOC window wanted. Set scaled to same as real.
     datalayer.battery.status.reported_soc = datalayer.battery.status.real_soc;
+#ifdef DOUBLE_BATTERY
+    datalayer.battery.status.reported_soc =
+        (datalayer.battery.status.real_soc + datalayer.battery2.status.real_soc) / 2;
+#endif
   }
+#ifdef DOUBLE_BATTERY
+  datalayer.battery.status.reported_soc = (datalayer.battery.status.real_soc + datalayer.battery2.status.real_soc) / 2;
+
+  if (datalayer.battery.status.real_soc < 100) {  //If this battery is under 1.00%, use this as SOC instead of average
+    datalayer.battery.status.reported_soc = datalayer.battery.status.real_soc;
+  }
+  if (datalayer.battery2.status.real_soc < 100) {  //If this battery is under 1.00%, use this as SOC instead of average
+    datalayer.battery.status.reported_soc = datalayer.battery2.status.real_soc;
+  }
+
+  if (datalayer.battery.status.real_soc > 9900) {  //If this battery is over 99.00%, use this as SOC instead of average
+    datalayer.battery.status.reported_soc = datalayer.battery.status.real_soc;
+  }
+  if (datalayer.battery2.status.real_soc > 9900) {  //If this battery is over 99.00%, use this as SOC instead of average
+    datalayer.battery.status.reported_soc = datalayer.battery2.status.real_soc;
+  }
+
+#endif  //TODO: Constrain according to the user settings. Help wanted on algoritm to use.
 }
 
 void summarize_battery_values() {

Software/src/battery/BMW-I3-BATTERY.cpp

@@ -16,14 +16,6 @@ static unsigned long previousMillis1000 = 0;     // will store last time a 1000m
 static unsigned long previousMillis5000 = 0;   // will store last time a 5000ms CAN Message was send
 static unsigned long previousMillis10000 = 0;  // will store last time a 10000ms CAN Message was send
 static uint8_t CANstillAlive = 12;             // counter for checking if CAN is still alive
-static unsigned long previousMillis20_2 = 0;     // will store last time a 20ms CAN Message was send
-static unsigned long previousMillis100_2 = 0;    // will store last time a 100ms CAN Message was send
-static unsigned long previousMillis200_2 = 0;    // will store last time a 200ms CAN Message was send
-static unsigned long previousMillis500_2 = 0;    // will store last time a 500ms CAN Message was send
-static unsigned long previousMillis640_2 = 0;    // will store last time a 600ms CAN Message was send
-static unsigned long previousMillis1000_2 = 0;   // will store last time a 1000ms CAN Message was send
-static unsigned long previousMillis5000_2 = 0;   // will store last time a 5000ms CAN Message was send
-static unsigned long previousMillis10000_2 = 0;  // will store last time a 10000ms CAN Message was send
 static uint8_t CAN2stillAlive = 12;            // counter for checking if CAN2 is still alive
 static uint16_t CANerror = 0;                  // counter on how many CAN errors encountered
 #define ALIVE_MAX_VALUE 14                     // BMW CAN messages contain alive counter, goes from 0...14
@@ -533,6 +525,7 @@ void update_values_battery2() {  //This function maps all the values fetched via
   if (!CAN2stillAlive) {
     set_event(EVENT_CAN2_RX_FAILURE, 2);
     datalayer.battery2.status.bms_status = FAULT;  //TODO: Refactor handling of event for battery2
+    datalayer.system.status.battery2_allows_contactor_closing = false;
   } else {
     CAN2stillAlive--;
     clear_event(EVENT_CAN2_RX_FAILURE);
@@ -788,7 +781,8 @@ void receive_can_battery2(CAN_frame_t rx_frame) {
       CAN2stillAlive = 12;  //This message is only sent if 30C (Wakeup pin on battery) is energized with 12V
       battery2_current = (rx_frame.data.u8[1] << 8 | rx_frame.data.u8[0]) - 8192;  //deciAmps (-819.2 to 819.0A)
       battery2_volts = (rx_frame.data.u8[3] << 8 | rx_frame.data.u8[2]);           //500.0 V
-      datalayer.battery2.status.voltage_dV = battery2_volts;  // Update the datalayer as soon as possible with this info
+      datalayer.battery2.status.voltage_dV =
+          battery2_volts;  // Update the datalayer as soon as possible with this info, needed for contactor control
       battery2_HVBatt_SOC = ((rx_frame.data.u8[5] & 0x0F) << 8 | rx_frame.data.u8[4]);
       battery2_request_open_contactors = (rx_frame.data.u8[5] & 0xC0) >> 6;
       battery2_request_open_contactors_instantly = (rx_frame.data.u8[6] & 0x03);

Software/src/devboard/utils/events.cpp

@@ -143,6 +143,7 @@ void init_events(void) {
   events.entries[EVENT_BATTERY_CHG_STOP_REQ].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_BATTERY_DISCHG_STOP_REQ].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_BATTERY_CHG_DISCHG_STOP_REQ].level = EVENT_LEVEL_ERROR;
+  events.entries[EVENT_VOLTAGE_DIFFERENCE].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_LOW_SOH].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_HVIL_FAILURE].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_INTERNAL_OPEN_FAULT].level = EVENT_LEVEL_ERROR;
@@ -227,6 +228,8 @@ const char* get_event_message_string(EVENTS_ENUM_TYPE event) {
       return "Info: COLD BATTERY! Battery requesting heating pads to activate!";
     case EVENT_BATTERY_WARMED_UP:
       return "Info: Battery requesting heating pads to stop. The battery is now warm enough.";
+    case EVENT_VOLTAGE_DIFFERENCE:
+      return "Info: Too large voltage diff between the batteries. Second battery cannot join the DC-link";
     case EVENT_LOW_SOH:
       return "ERROR: State of health critically low. Battery internal resistance too high to continue. Recycle "
              "battery.";

Software/src/devboard/utils/events.h

@@ -45,6 +45,7 @@
   XX(EVENT_BATTERY_CHG_DISCHG_STOP_REQ) \
   XX(EVENT_BATTERY_REQUESTS_HEAT)       \
   XX(EVENT_BATTERY_WARMED_UP)           \
+  XX(EVENT_VOLTAGE_DIFFERENCE)          \
   XX(EVENT_LOW_SOH)                     \
   XX(EVENT_HVIL_FAILURE)                \
   XX(EVENT_INTERNAL_OPEN_FAULT)         \

Software/src/devboard/webserver/webserver.cpp

@@ -599,7 +599,7 @@ String processor(const String& var) {
     socRealFloat =
         static_cast<float>(datalayer.battery2.status.real_soc) / 100.0;  // Convert to float and divide by 100
     socScaledFloat =
-        static_cast<float>(datalayer.battery2.status.reported_soc) / 100.0;     // Convert to float and divide by 100
+        static_cast<float>(datalayer.battery.status.reported_soc) / 100.0;      // Convert to float and divide by 100
     sohFloat = static_cast<float>(datalayer.battery2.status.soh_pptt) / 100.0;  // Convert to float and divide by 100
     voltageFloat =
         static_cast<float>(datalayer.battery2.status.voltage_dV) / 10.0;  // Convert to float and divide by 10