Merge pull request #457 from amarofarinha/feature/pause-battery-before-ota

Add Battery Pause Feature (Max Charge/Discharge Power) and OTA Update Optimization

Software/src/devboard/mqtt/mqtt.cpp

@@ -56,6 +56,7 @@ SensorConfig sensorConfigs[] = {
     {"max_charge_power", "Battery Emulator Battery Max Charge Power", "{{ value_json.max_charge_power }}", "W",
      "power"},
     {"bms_status", "Battery Emulator BMS Status", "{{ value_json.bms_status }}", "", ""},
+    {"pause_status", "Battery Emulator Pause Status", "{{ value_json.pause_status }}", "", ""},
 
 };
 
@@ -112,25 +113,30 @@ static void publish_common_info(void) {
 
   } else {
 #endif  // HA_AUTODISCOVERY
-    doc["SOC"] = ((float)datalayer.battery.status.reported_soc) / 100.0;
-    doc["SOC_real"] = ((float)datalayer.battery.status.real_soc) / 100.0;
-    doc["state_of_health"] = ((float)datalayer.battery.status.soh_pptt) / 100.0;
-    doc["temperature_min"] = ((float)((int16_t)datalayer.battery.status.temperature_min_dC)) / 10.0;
-    doc["temperature_max"] = ((float)((int16_t)datalayer.battery.status.temperature_max_dC)) / 10.0;
-    doc["stat_batt_power"] = ((float)((int32_t)datalayer.battery.status.active_power_W));
-    doc["battery_current"] = ((float)((int16_t)datalayer.battery.status.current_dA)) / 10.0;
-    doc["battery_voltage"] = ((float)datalayer.battery.status.voltage_dV) / 10.0;
-    // publish only if cell voltages have been populated...
-    if (datalayer.battery.info.number_of_cells != 0u &&
-        datalayer.battery.status.cell_voltages_mV[datalayer.battery.info.number_of_cells - 1] != 0u) {
-      doc["cell_max_voltage"] = ((float)datalayer.battery.status.cell_max_voltage_mV) / 1000.0;
-      doc["cell_min_voltage"] = ((float)datalayer.battery.status.cell_min_voltage_mV) / 1000.0;
-    }
-    doc["total_capacity"] = ((float)datalayer.battery.info.total_capacity_Wh);
-    doc["remaining_capacity"] = ((float)datalayer.battery.status.remaining_capacity_Wh);
-    doc["max_discharge_power"] = ((float)datalayer.battery.status.max_discharge_power_W);
-    doc["max_charge_power"] = ((float)datalayer.battery.status.max_charge_power_W);
     doc["bms_status"] = getBMSStatus(datalayer.battery.status.bms_status);
+    doc["pause_status"] = get_emulator_pause_status();
+
+    //only publish these values if BMS is active and we are comunication  with the battery (can send CAN messages to the battery)
+    if (datalayer.battery.status.bms_status == ACTIVE && can_send_CAN && millis() > BOOTUP_TIME) {
+      doc["SOC"] = ((float)datalayer.battery.status.reported_soc) / 100.0;
+      doc["SOC_real"] = ((float)datalayer.battery.status.real_soc) / 100.0;
+      doc["state_of_health"] = ((float)datalayer.battery.status.soh_pptt) / 100.0;
+      doc["temperature_min"] = ((float)((int16_t)datalayer.battery.status.temperature_min_dC)) / 10.0;
+      doc["temperature_max"] = ((float)((int16_t)datalayer.battery.status.temperature_max_dC)) / 10.0;
+      doc["stat_batt_power"] = ((float)((int32_t)datalayer.battery.status.active_power_W));
+      doc["battery_current"] = ((float)((int16_t)datalayer.battery.status.current_dA)) / 10.0;
+      doc["battery_voltage"] = ((float)datalayer.battery.status.voltage_dV) / 10.0;
+      // publish only if cell voltages have been populated...
+      if (datalayer.battery.info.number_of_cells != 0u &&
+          datalayer.battery.status.cell_voltages_mV[datalayer.battery.info.number_of_cells - 1] != 0u) {
+        doc["cell_max_voltage"] = ((float)datalayer.battery.status.cell_max_voltage_mV) / 1000.0;
+        doc["cell_min_voltage"] = ((float)datalayer.battery.status.cell_min_voltage_mV) / 1000.0;
+      }
+      doc["total_capacity"] = ((float)datalayer.battery.info.total_capacity_Wh);
+      doc["remaining_capacity"] = ((float)datalayer.battery.status.remaining_capacity_Wh);
+      doc["max_discharge_power"] = ((float)datalayer.battery.status.max_discharge_power_W);
+      doc["max_charge_power"] = ((float)datalayer.battery.status.max_charge_power_W);
+    }
 
     serializeJson(doc, mqtt_msg);
     if (!mqtt_publish(state_topic.c_str(), mqtt_msg, false)) {

Software/src/devboard/safety/safety.cpp

@@ -9,9 +9,23 @@ static bool battery_empty_event_fired = false;
 
 #define MAX_SOH_DEVIATION_PPTT 2500
 
+//battery pause status begin
+bool emulator_pause_request_ON = false;
+bool emulator_pause_CAN_send_ON = false;
+bool can_send_CAN = true;
+
+battery_pause_status emulator_pause_status = NORMAL;
+//battery pause status end
+
 void update_machineryprotection() {
   // Start checking that the battery is within reason. Incase we see any funny business, raise an event!
 
+  // Pause function is on
+  if (emulator_pause_request_ON) {
+    datalayer.battery.status.max_discharge_power_W = 0;
+    datalayer.battery.status.max_charge_power_W = 0;
+  }
+
   // Battery is overheated!
   if (datalayer.battery.status.temperature_max_dC > 500) {
     set_event(EVENT_BATTERY_OVERHEAT, datalayer.battery.status.temperature_max_dC);
@@ -138,6 +152,13 @@ void update_machineryprotection() {
 
 #ifdef DOUBLE_BATTERY  // Additional Double-Battery safeties are checked here
   // Check if the Battery 2 BMS is still sending CAN messages. If we go 60s without messages we raise an error
+
+  // Pause function is on
+  if (emulator_pause_request_ON) {
+    datalayer.battery2.status.max_discharge_power_W = 0;
+    datalayer.battery2.status.max_charge_power_W = 0;
+  }
+
   if (!datalayer.battery2.status.CAN_battery_still_alive) {
     set_event(EVENT_CAN2_RX_FAILURE, 0);
   } else {
@@ -171,3 +192,67 @@ void update_machineryprotection() {
 
 #endif  // DOUBLE_BATTERY
 }
+
+//battery pause status begin
+void setBatteryPause(bool pause_battery, bool pause_CAN) {
+
+  emulator_pause_CAN_send_ON = pause_CAN;
+
+  if (pause_battery) {
+
+    set_event(EVENT_PAUSE_BEGIN, 1);
+    emulator_pause_request_ON = true;
+    emulator_pause_status = PAUSING;
+    datalayer.battery.status.max_discharge_power_W = 0;
+    datalayer.battery.status.max_charge_power_W = 0;
+#ifdef DOUBLE_BATTERY
+    datalayer.battery2.status.max_discharge_power_W = 0;
+    datalayer.battery2.status.max_charge_power_W = 0;
+#endif
+
+  } else {
+    clear_event(EVENT_PAUSE_BEGIN);
+    set_event(EVENT_PAUSE_END, 0);
+    emulator_pause_request_ON = false;
+    emulator_pause_CAN_send_ON = false;
+    emulator_pause_status = RESUMING;
+    clear_event(EVENT_PAUSE_END);
+  }
+}
+
+/// @brief handle emulator pause status
+/// @return true if CAN messages should be sent to battery, false if not
+void emulator_pause_state_send_CAN_battery() {
+
+  if (emulator_pause_status == NORMAL)
+    can_send_CAN = true;
+
+  // in some inverters this values are not accurate, so we need to check if we are consider 1.8 amps as the limit
+  if (emulator_pause_request_ON && emulator_pause_status == PAUSING && datalayer.battery.status.current_dA < 18 &&
+      datalayer.battery.status.current_dA > -18) {
+    emulator_pause_status = PAUSED;
+  }
+
+  if (!emulator_pause_request_ON && emulator_pause_status == RESUMING) {
+    emulator_pause_status = NORMAL;
+    can_send_CAN = true;
+  }
+
+  can_send_CAN = (!emulator_pause_CAN_send_ON || emulator_pause_status == NORMAL);
+}
+
+std::string get_emulator_pause_status() {
+  switch (emulator_pause_status) {
+    case NORMAL:
+      return "RUNNING";
+    case PAUSING:
+      return "PAUSING";
+    case PAUSED:
+      return "PAUSED";
+    case RESUMING:
+      return "RESUMING";
+    default:
+      return "UNKNOWN";
+  }
+}
+//battery pause status

Software/src/devboard/safety/safety.h

@@ -1,11 +1,26 @@
 #ifndef SAFETY_H
 #define SAFETY_H
 #include <Arduino.h>
+#include <string>
 
 #define MAX_CAN_FAILURES 50
 
 #define MAX_CHARGE_DISCHARGE_LIMIT_FAILURES 1
 
+//battery pause status begin
+enum battery_pause_status { NORMAL = 0, PAUSING = 1, PAUSED = 2, RESUMING = 3 };
+extern bool emulator_pause_request_ON;
+extern bool emulator_pause_CAN_send_ON;
+extern battery_pause_status emulator_pause_status;
+extern bool can_send_CAN;
+//battery pause status end
+
 void update_machineryprotection();
 
+//battery pause status begin
+void setBatteryPause(bool pause_battery, bool pause_CAN);
+void emulator_pause_state_send_CAN_battery();
+std::string get_emulator_pause_status();
+//battery pause status end
+
 #endif

Software/src/devboard/utils/events.cpp

@@ -198,6 +198,8 @@ void init_events(void) {
   events.entries[EVENT_RESET_EFUSE].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_RESET_PWR_GLITCH].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_RESET_CPU_LOCKUP].level = EVENT_LEVEL_WARNING;
+  events.entries[EVENT_PAUSE_BEGIN].level = EVENT_LEVEL_WARNING;
+  events.entries[EVENT_PAUSE_END].level = EVENT_LEVEL_INFO;
 
   events.entries[EVENT_EEPROM_WRITE].log = false;  // Don't log the logger...
 
@@ -367,6 +369,10 @@ const char* get_event_message_string(EVENTS_ENUM_TYPE event) {
       return "Info: The board was reset due to a detected power glitch";
     case EVENT_RESET_CPU_LOCKUP:
       return "Warning: The board was reset due to CPU lockup. Inform developers!";
+    case EVENT_PAUSE_BEGIN:
+      return "Warning: The emulator is trying to pause the battery.";
+    case EVENT_PAUSE_END:
+      return "Info: The emulator is attempting to resume battery operation from pause.";
     default:
       return "";
   }

Software/src/devboard/utils/events.h

@@ -93,6 +93,8 @@
   XX(EVENT_RESET_EFUSE)                 \
   XX(EVENT_RESET_PWR_GLITCH)            \
   XX(EVENT_RESET_CPU_LOCKUP)            \
+  XX(EVENT_PAUSE_BEGIN)                 \
+  XX(EVENT_PAUSE_END)                   \
   XX(EVENT_NOF_EVENTS)
 
 typedef enum { EVENTS_ENUM_TYPE(GENERATE_ENUM) } EVENTS_ENUM_TYPE;

Software/src/devboard/webserver/webserver.cpp

@@ -1,6 +1,7 @@
 #include "webserver.h"
 #include <Preferences.h>
 #include "../../datalayer/datalayer.h"
+#include "../../lib/bblanchon-ArduinoJson/ArduinoJson.h"
 #include "../utils/events.h"
 #include "../utils/led_handler.h"
 #include "../utils/timer.h"
@@ -34,6 +35,7 @@ unsigned const long MAX_WIFI_RETRY_INTERVAL = 90000;         // Maximum wifi ret
 unsigned long last_wifi_monitor_time = millis();             //init millis so wifi monitor doesn't run immediately
 unsigned long wifi_reconnect_interval = DEFAULT_WIFI_RECONNECT_INTERVAL;
 unsigned long last_wifi_attempt_time = millis();  //init millis so wifi monitor doesn't run immediately
+const char get_firmware_info_html[] = R"rawliteral(%X%)rawliteral";
 
 void init_webserver() {
   // Configure WiFi
@@ -53,6 +55,13 @@ void init_webserver() {
 
   server.on("/logout", HTTP_GET, [](AsyncWebServerRequest* request) { request->send(401); });
 
+  // Route for firmware info from ota update page
+  server.on("/GetFirmwareInfo", HTTP_GET, [](AsyncWebServerRequest* request) {
+    if (WEBSERVER_AUTH_REQUIRED && !request->authenticate(http_username, http_password))
+      return request->requestAuthentication();
+    request->send_P(200, "application/json", get_firmware_info_html, get_firmware_info_processor);
+  });
+
   // Route for root / web page
   server.on("/", HTTP_GET, [](AsyncWebServerRequest* request) {
     if (WEBSERVER_AUTH_REQUIRED && !request->authenticate(http_username, http_password))
@@ -159,6 +168,19 @@ void init_webserver() {
     }
   });
 
+  // Route for pause/resume Battery emulator
+  server.on("/pause", HTTP_GET, [](AsyncWebServerRequest* request) {
+    if (WEBSERVER_AUTH_REQUIRED && !request->authenticate(http_username, http_password))
+      return request->requestAuthentication();
+    if (request->hasParam("p")) {
+      String valueStr = request->getParam("p")->value();
+      setBatteryPause(valueStr == "true" || valueStr == "1", 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))
@@ -414,10 +436,8 @@ void wifi_monitor() {
 
   if (ota_active && ota_timeout_timer.elapsed()) {
     // OTA timeout, try to restore can and clear the update event
-    ESP32Can.CANInit();
-    clear_event(EVENT_OTA_UPDATE);
     set_event(EVENT_OTA_UPDATE_TIMEOUT, 0);
-    ota_active = false;
+    onOTAEnd(false);
   }
 }
 
@@ -444,6 +464,24 @@ void init_ElegantOTA() {
   ElegantOTA.onEnd(onOTAEnd);
 }
 
+String get_firmware_info_processor(const String& var) {
+  if (var == "X") {
+    String content = "";
+    static JsonDocument doc;
+#ifdef HW_LILYGO
+    doc["hardware"] = "LilyGo T-CAN485";
+#endif  // HW_LILYGO
+#ifdef HW_STARK
+    doc["hardware"] = "Stark CMR Module";
+#endif  // HW_STARK
+
+    doc["firmware"] = String(version_number);
+    serializeJson(doc, content);
+    return content;
+  }
+  return String();
+}
+
 String processor(const String& var) {
   if (var == "X") {
     String content = "";
@@ -696,6 +734,10 @@ String processor(const String& var) {
     } else {
       content += "<span style='color: red;'>&#10005;</span></h4>";
     }
+    if (emulator_pause_status == NORMAL)
+      content += "<h4>Pause status: " + String(get_emulator_pause_status().c_str()) + " </h4>";
+    else
+      content += "<h4 style='color: red;'>Pause status: " + String(get_emulator_pause_status().c_str()) + " </h4>";
 
     // Close the block
     content += "</div>";
@@ -772,6 +814,10 @@ String processor(const String& var) {
     } else {
       content += "<span style='color: red;'>&#10005;</span></h4>";
     }
+    if (emulator_pause_status == NORMAL)
+      content += "<h4>Pause status: " + String(get_emulator_pause_status().c_str()) + " </h4>";
+    else
+      content += "<h4 style='color: red;'>Pause status: " + String(get_emulator_pause_status().c_str()) + " </h4>";
 
     content += "</div>";
     content += "</div>";
@@ -833,6 +879,11 @@ String processor(const String& var) {
     content += "</div>";
 #endif  // defined CHEVYVOLT_CHARGER || defined NISSANLEAF_CHARGER
 
+    if (emulator_pause_request_ON)
+      content += "<button onclick='PauseBattery(false)'>Resume Battery</button>";
+    else
+      content += "<button onclick='PauseBattery(true)'>Pause Battery</button>";
+
     content += "<button onclick='OTA()'>Perform OTA update</button>";
     content += " ";
     content += "<button onclick='Settings()'>Change Settings</button>";
@@ -866,6 +917,12 @@ String processor(const String& var) {
       content += "  setTimeout(function(){ window.open(\"/\",\"_self\"); }, 1000);";
       content += "}";
     }
+    content += "function PauseBattery(pause){";
+    content +=
+        "var xhr=new "
+        "XMLHttpRequest();xhr.onload=function() { "
+        "window.location.reload();};xhr.open('GET','/pause?p='+pause,true);xhr.send();";
+    content += "}";
 
     content += "</script>";
 
@@ -880,8 +937,10 @@ String processor(const String& var) {
 }
 
 void onOTAStart() {
+  //try to Pause the battery
+  setBatteryPause(true, true);
+
   // Log when OTA has started
-  ESP32Can.CANStop();
   set_event(EVENT_OTA_UPDATE, 0);
 
   // If already set, make a new attempt
@@ -903,8 +962,13 @@ void onOTAProgress(size_t current, size_t final) {
 }
 
 void onOTAEnd(bool success) {
+
+  ota_active = false;
+  clear_event(EVENT_OTA_UPDATE);
+
   // Log when OTA has finished
   if (success) {
+    // a reboot will be done by the OTA library. no need to do anything here
 #ifdef DEBUG_VIA_USB
     Serial.println("OTA update finished successfully!");
 #endif  // DEBUG_VIA_USB
@@ -912,12 +976,9 @@ void onOTAEnd(bool success) {
 #ifdef DEBUG_VIA_USB
     Serial.println("There was an error during OTA update!");
 #endif  // DEBUG_VIA_USB
-
-    // If we fail without a timeout, try to restore CAN
-    ESP32Can.CANInit();
+    //try to Resume the battery pause and CAN communication
+    setBatteryPause(false, false);
   }
-  ota_active = false;
-  clear_event(EVENT_OTA_UPDATE);
 }
 
 template <typename T>  // This function makes power values appear as W when under 1000, and kW when over

Software/src/devboard/webserver/webserver.h

@@ -103,6 +103,7 @@ void init_ElegantOTA();
  * @return String
  */
 String processor(const String& var);
+String get_firmware_info_processor(const String& var);
 
 /**
  * @brief Executes on OTA start 

Software/src/lib/ayushsharma82-ElegantOTA/howtochangeHTML.txt

@@ -0,0 +1,30 @@
+Modifying HTML for the ElegantOTA Library
+
+This guide provides the necessary steps to update and modify the HTML used in the ElegantOTA library. 
+Follow these steps carefully to ensure that your changes are properly integrated.
+
+Steps to Modify the HTML:
+
+1 - Edit the CurrentPlainHTML.txt:
+
+Locate the file CurrentPlainHTML.txt in your project directory.
+Modify the HTML content as needed. This file contains the plain HTML code that will be served through the OTA interface.
+
+Convert the HTML to GZIP and Decimal Format:
+
+Copy the content of the updated CurrentPlainHTML.txt.
+Navigate to the CyberChef tool for encoding and compression.
+Apply the following recipe:
+Gzip with the "Dynamic Huffman Coding" option enabled.
+Convert to Decimal with a comma separator.
+Use this link for the process: https://gchq.github.io/CyberChef/#recipe=Gzip('Dynamic%20Huffman%20Coding','','',false)To_Decimal('Comma',false)
+
+2 - Update the ELEGANT_HTML Array:
+
+Copy the resulting decimal output from CyberChef.
+Replace the existing content of the ELEGANT_HTML array in elop.cpp with the new decimal data from CyberChef.
+
+3 - Adjust the ELEGANT_HTML Array Size:
+
+After updating the ELEGANT_HTML array in both elop.h and elop.cpp, update the array size to match the length of the new output from CyberChef.
+Ensure that the array size reflects the new length of the compressed HTML to avoid errors during compilation.

Software/src/lib/ayushsharma82-ElegantOTA/src/ElegantOTA.cpp

@@ -43,6 +43,15 @@ void ElegantOTAClass::begin(ELEGANTOTA_WEBSERVER *server, const char * username,
         return request->requestAuthentication();
       }
 
+      // Pre-OTA update callback
+      if (preUpdateCallback != NULL) preUpdateCallback();
+      
+     // Sleep for 3 seconds to allow asynchronous preUpdateCallback tasks to complete
+      unsigned long sleepStart = millis();
+      while (millis() - sleepStart < 3000) { // Sleep for 3 second
+        delay(1); // Yield to other tasks
+      }
+
       // Get header x-ota-mode value, if present
       OTA_Mode mode = OTA_MODE_FIRMWARE;
       // Get mode from arg
@@ -73,7 +82,7 @@ void ElegantOTAClass::begin(ELEGANTOTA_WEBSERVER *server, const char * username,
       #endif
 
       // Pre-OTA update callback
-      if (preUpdateCallback != NULL) preUpdateCallback();
+      //if (preUpdateCallback != NULL) preUpdateCallback();
 
       // Start update process
       #if defined(ESP8266)

Software/src/lib/ayushsharma82-ElegantOTA/src/elop.h

@@ -3,6 +3,6 @@
 
 #include <Arduino.h>
 
-extern const uint8_t ELEGANT_HTML[10214];
+extern const uint8_t ELEGANT_HTML[40500];
 
 #endif