mirror of
https://github.com/dalathegreat/Battery-Emulator.git
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Merge pull request #619 from dalathegreat/feature/double-automatic-contactor
Feature: Double contactor support + NC support
This commit is contained in:
Daniel Öster
GitHub
commit
9e74fcd032
6 changed files with 120 additions and 90 deletions
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@ -57,7 +57,7 @@ const char* version_number = "7.8.dev";
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// Interval settings
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uint16_t intervalUpdateValues = INTERVAL_1_S; // Interval at which to update inverter values / Modbus registers
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unsigned long previousMillis10ms = 50;
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unsigned long previousMillis10ms = 0;
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unsigned long previousMillisUpdateVal = 0;
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// CAN parameters
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@ -118,6 +118,16 @@ MyTimer check_pause_2s(INTERVAL_2_S);
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enum State { DISCONNECTED, PRECHARGE, NEGATIVE, POSITIVE, PRECHARGE_OFF, COMPLETED, SHUTDOWN_REQUESTED };
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State contactorStatus = DISCONNECTED;
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#define ON 1
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#define OFF 0
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#ifdef NC_CONTACTORS //Normally closed contactors use inverted logic
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#undef ON
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#define ON 0
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#undef OFF
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#define OFF 1
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#endif
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#define MAX_ALLOWED_FAULT_TICKS 1000
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/* NOTE: modify the precharge time constant below to account for the resistance and capacitance of the target system.
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* t=3RC at minimum, t=5RC ideally
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@ -125,20 +135,32 @@ State contactorStatus = DISCONNECTED;
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#define PRECHARGE_TIME_MS 160
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#define NEGATIVE_CONTACTOR_TIME_MS 1000
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#define POSITIVE_CONTACTOR_TIME_MS 2000
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#ifdef PWM_CONTACTOR_CONTROL
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#define PWM_Freq 20000 // 20 kHz frequency, beyond audible range
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#define PWM_Res 10 // 10 Bit resolution 0 to 1023, maps 'nicely' to 0% 100%
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#define PWM_Hold_Duty 250
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#define PWM_Off_Duty 0
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#define PWM_On_Duty 1023
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#define PWM_HOLD_DUTY 250
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#define PWM_OFF_DUTY 0
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#define PWM_ON_DUTY 1023
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#define POSITIVE_PWM_Ch 0
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#define NEGATIVE_PWM_Ch 1
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#endif
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unsigned long prechargeStartTime = 0;
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unsigned long negativeStartTime = 0;
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unsigned long timeSpentInFaultedMode = 0;
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#endif
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void set(uint8_t pin, bool direction, uint32_t pwm_freq = 0xFFFFFFFFFF) {
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#ifdef PWM_CONTACTOR_CONTROL
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if (pwm_freq != 0xFFFFFFFFFF) {
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ledcWrite(pin, pwm_freq);
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return;
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}
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#endif
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if (direction == 1) {
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digitalWrite(pin, HIGH);
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} else { // 0
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digitalWrite(pin, LOW);
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}
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}
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#ifdef EQUIPMENT_STOP_BUTTON
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const unsigned long equipment_button_long_press_duration =
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15000; // 15 seconds for long press in case of MOMENTARY_SWITCH
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@ -280,9 +302,6 @@ void core_loop(void* task_time_us) {
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previousMillis10ms = millis();
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led_exe();
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handle_contactors(); // Take care of startup precharge/contactor closing
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#ifdef DOUBLE_BATTERY
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check_interconnect_available();
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#endif
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}
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END_TIME_MEASUREMENT_MAX(time_10ms, datalayer.system.status.time_10ms_us);
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@ -292,6 +311,7 @@ void core_loop(void* task_time_us) {
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update_values_battery(); // Fetch battery values
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#ifdef DOUBLE_BATTERY
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update_values_battery2();
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check_interconnect_available();
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#endif
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update_calculated_values();
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#ifndef SERIAL_LINK_RECEIVER
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@ -497,27 +517,34 @@ void init_CAN() {
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void init_contactors() {
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// Init contactor pins
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#ifdef CONTACTOR_CONTROL
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#ifndef PWM_CONTACTOR_CONTROL
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pinMode(POSITIVE_CONTACTOR_PIN, OUTPUT);
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digitalWrite(POSITIVE_CONTACTOR_PIN, LOW);
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pinMode(NEGATIVE_CONTACTOR_PIN, OUTPUT);
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digitalWrite(NEGATIVE_CONTACTOR_PIN, LOW);
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#else
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#ifdef PWM_CONTACTOR_CONTROL
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ledcAttachChannel(POSITIVE_CONTACTOR_PIN, PWM_Freq, PWM_Res,
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POSITIVE_PWM_Ch); // Setup PWM Channel Frequency and Resolution
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ledcAttachChannel(NEGATIVE_CONTACTOR_PIN, PWM_Freq, PWM_Res,
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NEGATIVE_PWM_Ch); // Setup PWM Channel Frequency and Resolution
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ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Off_Duty); // Set Positive PWM to 0%
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ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Off_Duty); // Set Negative PWM to 0%
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ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_OFF_DUTY); // Set Positive PWM to 0%
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ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_OFF_DUTY); // Set Negative PWM to 0%
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#else //Normal CONTACTOR_CONTROL
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pinMode(POSITIVE_CONTACTOR_PIN, OUTPUT);
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set(POSITIVE_CONTACTOR_PIN, OFF);
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pinMode(NEGATIVE_CONTACTOR_PIN, OUTPUT);
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set(NEGATIVE_CONTACTOR_PIN, OFF);
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#endif
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pinMode(PRECHARGE_PIN, OUTPUT);
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digitalWrite(PRECHARGE_PIN, LOW);
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#endif
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set(PRECHARGE_PIN, OFF);
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#endif //CONTACTOR_CONTROL
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#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY
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pinMode(SECOND_POSITIVE_CONTACTOR_PIN, OUTPUT);
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set(SECOND_POSITIVE_CONTACTOR_PIN, OFF);
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pinMode(SECOND_NEGATIVE_CONTACTOR_PIN, OUTPUT);
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set(SECOND_NEGATIVE_CONTACTOR_PIN, OFF);
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#endif //CONTACTOR_CONTROL_DOUBLE_BATTERY
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// Init BMS contactor
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#ifdef HW_STARK // TODO: Rewrite this so LilyGo can also handle this BMS contactor
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pinMode(BMS_POWER, OUTPUT);
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digitalWrite(BMS_POWER, HIGH);
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#endif
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#endif //HW_STARK
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}
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void init_rs485() {
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@ -695,14 +722,18 @@ void check_interconnect_available() {
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return; // Both voltage values need to be available to start check
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}
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if (abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) < 30) { // If we are within 3.0V
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uint16_t voltage_diff = abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV);
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if (voltage_diff <= 30) { // If we are within 3.0V between the batteries
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clear_event(EVENT_VOLTAGE_DIFFERENCE);
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if (datalayer.battery.status.bms_status != FAULT) { // Only proceed if we are not in faulted state
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if (datalayer.battery.status.bms_status == FAULT) {
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// If main battery is in fault state, disengage the second battery
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datalayer.system.status.battery2_allows_contactor_closing = false;
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} else { // If main battery is OK, allow second battery to join
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datalayer.system.status.battery2_allows_contactor_closing = true;
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}
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} else { //We are over 3.0V diff
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set_event(EVENT_VOLTAGE_DIFFERENCE,
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(uint8_t)(abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) / 10));
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} else { //Voltage between the two packs is too large
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set_event(EVENT_VOLTAGE_DIFFERENCE, (uint8_t)(voltage_diff / 10));
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}
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}
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#endif //DOUBLE_BATTERY
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@ -712,6 +743,10 @@ void handle_contactors() {
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datalayer.system.status.inverter_allows_contactor_closing = digitalRead(INVERTER_CONTACTOR_ENABLE_PIN);
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#endif
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#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY
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handle_contactors_battery2();
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#endif
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#ifdef CONTACTOR_CONTROL
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// First check if we have any active errors, incase we do, turn off the battery
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if (datalayer.battery.status.bms_status == FAULT) {
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@ -720,50 +755,38 @@ void handle_contactors() {
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timeSpentInFaultedMode = 0;
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}
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//handle contactor control SHUTDOWN_REQUESTED vs DISCONNECTED
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if (timeSpentInFaultedMode > MAX_ALLOWED_FAULT_TICKS ||
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(datalayer.system.settings.equipment_stop_active && contactorStatus != SHUTDOWN_REQUESTED)) {
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//handle contactor control SHUTDOWN_REQUESTED
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if (timeSpentInFaultedMode > MAX_ALLOWED_FAULT_TICKS) {
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contactorStatus = SHUTDOWN_REQUESTED;
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datalayer.system.settings.equipment_stop_active = true;
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}
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if (contactorStatus == SHUTDOWN_REQUESTED && !datalayer.system.settings.equipment_stop_active) {
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contactorStatus = DISCONNECTED;
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}
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if (contactorStatus == SHUTDOWN_REQUESTED) {
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digitalWrite(PRECHARGE_PIN, LOW);
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#ifndef PWM_CONTACTOR_CONTROL
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digitalWrite(NEGATIVE_CONTACTOR_PIN, LOW);
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digitalWrite(POSITIVE_CONTACTOR_PIN, LOW);
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#else
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ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Off_Duty);
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ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Off_Duty);
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#endif
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set(PRECHARGE_PIN, OFF);
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set(NEGATIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
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set(POSITIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
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set_event(EVENT_ERROR_OPEN_CONTACTOR, 0);
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datalayer.system.status.contactor_control_closed = false;
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datalayer.system.status.contactors_engaged = false;
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return; // A fault scenario latches the contactor control. It is not possible to recover without a powercycle (and investigation why fault occured)
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}
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// After that, check if we are OK to start turning on the battery
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if (contactorStatus == DISCONNECTED) {
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digitalWrite(PRECHARGE_PIN, LOW);
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#ifndef PWM_CONTACTOR_CONTROL
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digitalWrite(NEGATIVE_CONTACTOR_PIN, LOW);
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digitalWrite(POSITIVE_CONTACTOR_PIN, LOW);
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#else
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ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Off_Duty);
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ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Off_Duty);
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#endif
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set(PRECHARGE_PIN, OFF);
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set(NEGATIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
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set(POSITIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
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if (datalayer.system.status.battery_allows_contactor_closing &&
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datalayer.system.status.inverter_allows_contactor_closing) {
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datalayer.system.status.inverter_allows_contactor_closing && !datalayer.system.settings.equipment_stop_active) {
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contactorStatus = PRECHARGE;
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}
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}
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// In case the inverter requests contactors to open, set the state accordingly
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if (contactorStatus == COMPLETED) {
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if (!datalayer.system.status.inverter_allows_contactor_closing)
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//Incase inverter (or estop) requests contactors to open, make state machine jump to Disconnected state (recoverable)
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if (!datalayer.system.status.inverter_allows_contactor_closing || datalayer.system.settings.equipment_stop_active) {
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contactorStatus = DISCONNECTED;
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}
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// Skip running the state machine below if it has already completed
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return;
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}
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@ -772,18 +795,14 @@ void handle_contactors() {
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// Handle actual state machine. This first turns on Precharge, then Negative, then Positive, and finally turns OFF precharge
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switch (contactorStatus) {
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case PRECHARGE:
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digitalWrite(PRECHARGE_PIN, HIGH);
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set(PRECHARGE_PIN, ON);
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prechargeStartTime = currentTime;
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contactorStatus = NEGATIVE;
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break;
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case NEGATIVE:
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if (currentTime - prechargeStartTime >= PRECHARGE_TIME_MS) {
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#ifndef PWM_CONTACTOR_CONTROL
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digitalWrite(NEGATIVE_CONTACTOR_PIN, HIGH);
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#else
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ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_On_Duty);
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#endif
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set(NEGATIVE_CONTACTOR_PIN, ON, PWM_ON_DUTY);
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negativeStartTime = currentTime;
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contactorStatus = POSITIVE;
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}
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@ -791,24 +810,18 @@ void handle_contactors() {
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case POSITIVE:
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if (currentTime - negativeStartTime >= NEGATIVE_CONTACTOR_TIME_MS) {
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#ifndef PWM_CONTACTOR_CONTROL
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digitalWrite(POSITIVE_CONTACTOR_PIN, HIGH);
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#else
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ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_On_Duty);
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#endif
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set(POSITIVE_CONTACTOR_PIN, ON, PWM_ON_DUTY);
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contactorStatus = PRECHARGE_OFF;
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}
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break;
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case PRECHARGE_OFF:
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if (currentTime - negativeStartTime >= POSITIVE_CONTACTOR_TIME_MS) {
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digitalWrite(PRECHARGE_PIN, LOW);
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#ifdef PWM_CONTACTOR_CONTROL
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ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Hold_Duty);
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ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Hold_Duty);
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#endif
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set(PRECHARGE_PIN, OFF);
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set(NEGATIVE_CONTACTOR_PIN, ON, PWM_HOLD_DUTY);
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set(POSITIVE_CONTACTOR_PIN, ON, PWM_HOLD_DUTY);
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contactorStatus = COMPLETED;
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datalayer.system.status.contactor_control_closed = true;
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datalayer.system.status.contactors_engaged = true;
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}
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break;
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default:
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@ -817,6 +830,20 @@ void handle_contactors() {
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#endif // CONTACTOR_CONTROL
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}
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#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY
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void handle_contactors_battery2() {
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if ((contactorStatus == COMPLETED) && datalayer.system.status.battery2_allows_contactor_closing) {
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set(SECOND_NEGATIVE_CONTACTOR_PIN, ON);
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set(SECOND_POSITIVE_CONTACTOR_PIN, ON);
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datalayer.system.status.contactors_battery2_engaged = true;
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} else { // Closing contactors on secondary battery not allowed
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set(SECOND_NEGATIVE_CONTACTOR_PIN, OFF);
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set(SECOND_POSITIVE_CONTACTOR_PIN, OFF);
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datalayer.system.status.contactors_battery2_engaged = false;
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}
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}
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#endif //CONTACTOR_CONTROL_DOUBLE_BATTERY
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void update_calculated_values() {
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/* Calculate allowed charge/discharge currents*/
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if (datalayer.battery.status.voltage_dV > 10) {
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@ -55,12 +55,16 @@
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//#define HW_STARK
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//#define HW_3LB
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/* Contactor settings. If you have a battery that does not activate contactors via CAN, configure this section */
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//#define CONTACTOR_CONTROL //Enable this line to have the emulator handle automatic precharge/contactor+/contactor- closing sequence (See wiki for pins)
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//#define CONTACTOR_CONTROL_DOUBLE_BATTERY //Enable this line to have the emulator hardware control secondary set of contactors for double battery setups (See wiki for pins)
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//#define PWM_CONTACTOR_CONTROL //Enable this line to use PWM for CONTACTOR_CONTROL, which lowers power consumption and heat generation. CONTACTOR_CONTROL must be enabled.
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//#define NC_CONTACTORS //Enable this line to control normally closed contactors. CONTACTOR_CONTROL must be enabled for this option. Extremely rare setting!
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/* Other options */
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//#define DEBUG_VIA_USB //Enable this line to have the USB port output serial diagnostic data while program runs (WARNING, raises CPU load, do not use for production)
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//#define DEBUG_CAN_DATA //Enable this line to print incoming/outgoing CAN & CAN-FD messages to USB serial (WARNING, raises CPU load, do not use for production)
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//#define INTERLOCK_REQUIRED //Nissan LEAF specific setting, if enabled requires both high voltage conenctors to be seated before starting
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//#define CONTACTOR_CONTROL //Enable this line to have pins 25,32,33 handle automatic precharge/contactor+/contactor- closing sequence
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//#define PWM_CONTACTOR_CONTROL //Enable this line to use PWM for CONTACTOR_CONTROL, which lowers power consumption and heat generation. CONTACTOR_CONTROL must be enabled.
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//#define DUAL_CAN //Enable this line to activate an isolated secondary CAN Bus using add-on MCP2515 chip (Needed for some inverters / double battery)
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#define CRYSTAL_FREQUENCY_MHZ 8 //DUAL_CAN option, what is your MCP2515 add-on boards crystal frequency?
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//#define CAN_FD //Enable this line to activate an isolated secondary CAN-FD bus using add-on MCP2518FD chip / Native CANFD on Stark board
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@ -136,10 +136,10 @@ static uint16_t battery2_TEMP = 0; //Temporary value used in s
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static uint16_t battery2_Wh_Remaining = 0; //Amount of energy in battery, in Wh
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static uint16_t battery2_GIDS = 273; //Startup in 24kWh mode
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static uint16_t battery2_MAX = 0;
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static uint16_t battery2_Max_GIDS = 273; //Startup in 24kWh mode
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static uint16_t battery2_StateOfHealth = 99; //State of health %
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static uint16_t battery2_Total_Voltage2 = 740; //Battery voltage (0-450V) [0.5V/bit, so actual range 0-800]
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static int16_t battery2_Current2 = 0; //Battery current (-400-200A) [0.5A/bit, so actual range -800-400]
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static uint16_t battery2_Max_GIDS = 273; //Startup in 24kWh mode
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static uint16_t battery2_StateOfHealth = 99; //State of health %
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static uint16_t battery2_Total_Voltage2 = 0; //Battery voltage (0-450V) [0.5V/bit, so actual range 0-800]
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static int16_t battery2_Current2 = 0; //Battery current (-400-200A) [0.5A/bit, so actual range -800-400]
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static int16_t battery2_HistData_Temperature_MAX = 6; //-40 to 86*C
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static int16_t battery2_HistData_Temperature_MIN = 5; //-40 to 86*C
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static int16_t battery2_AverageTemperature = 6; //Only available on ZE0, in celcius, -40 to +55
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@ -514,11 +514,7 @@ void receive_can_battery2(CAN_frame rx_frame) {
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battery2_Relay_Cut_Request = ((rx_frame.data.u8[1] & 0x18) >> 3);
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battery2_Failsafe_Status = (rx_frame.data.u8[1] & 0x07);
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battery2_MainRelayOn_flag = (bool)((rx_frame.data.u8[3] & 0x20) >> 5);
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if (battery2_MainRelayOn_flag) {
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datalayer.system.status.battery2_allows_contactor_closing = true;
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} else {
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datalayer.system.status.battery2_allows_contactor_closing = false;
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}
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//battery2_allows_contactor_closing written by check_interconnect_available();
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battery2_Full_CHARGE_flag = (bool)((rx_frame.data.u8[3] & 0x10) >> 4);
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battery2_Interlock = (bool)((rx_frame.data.u8[3] & 0x08) >> 3);
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break;
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@ -192,7 +192,9 @@ typedef struct {
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bool inverter_allows_contactor_closing = true;
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#ifdef CONTACTOR_CONTROL
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/** True if the contactor controlled by battery-emulator is closed */
|
||||
bool contactor_control_closed = false;
|
||||
bool contactors_engaged = false;
|
||||
/** True if the contactor controlled by battery-emulator is closed. Determined by check_interconnect_available(); if voltage is OK */
|
||||
bool contactors_battery2_engaged = false;
|
||||
#endif
|
||||
} DATALAYER_SYSTEM_STATUS_TYPE;
|
||||
|
||||
|
|
|
|||
|
|
@ -52,9 +52,9 @@
|
|||
#define NEGATIVE_CONTACTOR_PIN 33
|
||||
#define PRECHARGE_PIN 25
|
||||
|
||||
#define 2ND_POSITIVE_CONTACTOR_PIN 13
|
||||
#define 2ND_NEGATIVE_CONTACTOR_PIN 16
|
||||
#define 2ND_PRECHARGE_PIN 18
|
||||
#define SECOND_POSITIVE_CONTACTOR_PIN 13
|
||||
#define SECOND_NEGATIVE_CONTACTOR_PIN 16
|
||||
#define SECOND_PRECHARGE_PIN 18
|
||||
|
||||
// SMA CAN contactor pins
|
||||
#define INVERTER_CONTACTOR_ENABLE_PIN 36
|
||||
|
|
|
|||
|
|
@ -642,7 +642,7 @@ String processor(const String& var) {
|
|||
|
||||
#ifdef CONTACTOR_CONTROL
|
||||
content += "<h4>Contactors controlled by Battery-Emulator: ";
|
||||
if (datalayer.system.status.contactor_control_closed) {
|
||||
if (datalayer.system.status.contactors_engaged) {
|
||||
content += "<span style='color: green;'>ON</span>";
|
||||
} else {
|
||||
content += "<span style='color: red;'>OFF</span>";
|
||||
|
|
@ -773,34 +773,35 @@ String processor(const String& var) {
|
|||
|
||||
#ifdef CONTACTOR_CONTROL
|
||||
content += "<h4>Contactors controlled by Battery-Emulator: ";
|
||||
if (datalayer.system.status.contactor_control_closed) {
|
||||
if (datalayer.system.status.contactors_battery2_engaged) {
|
||||
content += "<span style='color: green;'>ON</span>";
|
||||
} else {
|
||||
content += "<span style='color: red;'>OFF</span>";
|
||||
}
|
||||
content += "</h4>";
|
||||
|
||||
#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY
|
||||
content += "<h4>Pre Charge: ";
|
||||
if (digitalRead(PRECHARGE_PIN) == HIGH) {
|
||||
if (digitalRead(SECOND_PRECHARGE_PIN) == HIGH) {
|
||||
content += "<span style='color: green;'>✓</span>";
|
||||
} else {
|
||||
content += "<span style='color: red;'>✕</span>";
|
||||
}
|
||||
content += " Cont. Neg.: ";
|
||||
if (digitalRead(NEGATIVE_CONTACTOR_PIN) == HIGH) {
|
||||
if (digitalRead(SECOND_NEGATIVE_CONTACTOR_PIN) == HIGH) {
|
||||
content += "<span style='color: green;'>✓</span>";
|
||||
} else {
|
||||
content += "<span style='color: red;'>✕</span>";
|
||||
}
|
||||
|
||||
content += " Cont. Pos.: ";
|
||||
if (digitalRead(POSITIVE_CONTACTOR_PIN) == HIGH) {
|
||||
if (digitalRead(SECOND_POSITIVE_CONTACTOR_PIN) == HIGH) {
|
||||
content += "<span style='color: green;'>✓</span>";
|
||||
} else {
|
||||
content += "<span style='color: red;'>✕</span>";
|
||||
}
|
||||
content += "</h4>";
|
||||
#endif
|
||||
#endif // CONTACTOR_CONTROL_DOUBLE_BATTERY
|
||||
#endif // CONTACTOR_CONTROL
|
||||
|
||||
content += "</div>";
|
||||
content += "</div>";
|
||||
|
|
|
|||
Loading…
Add table
Add a link
Reference in a new issue