Merge pull request #1592 from dalathegreat/improvement/stark-BMS-on-by-default

Stark CMR: Make BMS power on by default

Software/Software.cpp

@@ -34,7 +34,7 @@
 #endif
 
 // The current software version, shown on webserver
-const char* version_number = "9.1.1";
+const char* version_number = "9.2.dev";
 
 // Interval timers
 volatile unsigned long currentMillis = 0;

Software/src/battery/TESLA-BATTERY.cpp

@@ -483,11 +483,24 @@ void TeslaBattery::
   } else {
     clear_event(EVENT_BATTERY_FUSE);
   }
+  // Raise any Tesla BMS events in BE
+  // Events: Informational
+  if (BMS_a145_SW_SOC_Change) {                             // BMS has newly recalibrated pack SOC
+    set_event_latched(EVENT_BATTERY_SOC_RECALIBRATION, 0);  // Latcched as BMS_a145 can be active for a while
+  } else if (!BMS_a145_SW_SOC_Change) {
+    clear_event(EVENT_BATTERY_SOC_RECALIBRATION);
+  }
+  // Events: Warning
+  if (BMS_contactorState == 5) {  // BMS has detected welded contactor(s)
+    set_event_latched(EVENT_CONTACTOR_WELDED, 0);
+  } else if (BMS_contactorState != 5) {
+    clear_event(EVENT_CONTACTOR_WELDED);
+  }
 
   if (user_selected_tesla_GTW_chassisType > 1) {  //{{0, "Model S"}, {1, "Model X"}, {2, "Model 3"}, {3, "Model Y"}};
-    // Autodetect algoritm for chemistry on 3/Y packs.
+    // Autodetect algorithm for chemistry on 3/Y packs.
     // NCM/A batteries have 96s, LFP has 102-108s
-    // Drawback with this check is that it takes 3-5minutes before all cells have been counted!
+    // Drawback with this check is that it takes 3-5 minutes before all cells have been counted!
     if (datalayer.battery.info.number_of_cells > 101) {
       datalayer.battery.info.chemistry = battery_chemistry_enum::LFP;
     }
@@ -528,23 +541,28 @@ void TeslaBattery::
       //Start the BMS ECU reset statemachine, only if contactors are OPEN and BMS ECU allows it
       stateMachineBMSReset = 0;
       datalayer.battery.settings.user_requests_tesla_bms_reset = false;
-      logging.println("BMS reset requested");
+      logging.println("INFO: BMS reset requested");
     } else {
       logging.println("ERROR: BMS reset failed due to contactors not being open, or BMS ECU not allowing it");
       stateMachineBMSReset = 0xFF;
       datalayer.battery.settings.user_requests_tesla_bms_reset = false;
+      set_event(EVENT_BMS_RESET_REQ_FAIL, 0);
+      clear_event(EVENT_BMS_RESET_REQ_FAIL);
     }
   }
   if (datalayer.battery.settings.user_requests_tesla_soc_reset) {
-    if (datalayer.battery.status.real_soc < 1500 || datalayer.battery.status.real_soc > 9000) {
-      //Start the SOC reset statemachine, only if SOC < 15% or > 90%
+    if ((datalayer.battery.status.real_soc < 1500 || datalayer.battery.status.real_soc > 9000) &&
+        battery_contactor == 1) {
+      //Start the SOC reset statemachine, only if SOC less than 15% or greater than 90%, and contactors open
       stateMachineSOCReset = 0;
       datalayer.battery.settings.user_requests_tesla_soc_reset = false;
-      logging.println("SOC reset requested");
+      logging.println("INFO: SOC reset requested");
     } else {
-      logging.println("ERROR: SOC reset failed due to SOC not being less than 15 or greater than 90");
+      logging.println("ERROR: SOC reset failed, SOC not < 15 or > 90, or contactors not open");
       stateMachineSOCReset = 0xFF;
       datalayer.battery.settings.user_requests_tesla_soc_reset = false;
+      set_event(EVENT_BATTERY_SOC_RESET_FAIL, 0);
+      clear_event(EVENT_BATTERY_SOC_RESET_FAIL);
     }
   }
 
@@ -779,7 +797,7 @@ void TeslaBattery::
   datalayer_extended.tesla.HVP_shuntBarTempStatus = HVP_shuntBarTempStatus;
   datalayer_extended.tesla.HVP_shuntAsicTempStatus = HVP_shuntAsicTempStatus;
 
-  //Safety checks for CAN message sesnding
+  //Safety checks for CAN message sending
   if ((datalayer.system.status.inverter_allows_contactor_closing == true) &&
       (datalayer.battery.status.bms_status != FAULT) && (!datalayer.system.settings.equipment_stop_active)) {
     // Carry on: 0x221 DRIVE state & reset power down timer
@@ -1667,10 +1685,10 @@ void TeslaBattery::handle_incoming_can_frame(CAN_frame rx_frame) {
       }
       */
       break;
-    case 0x612:  // CAN UDSs for BMS
+    case 0x612:  // CAN UDS responses for BMS
       datalayer.battery.status.CAN_battery_still_alive = CAN_STILL_ALIVE;
       //BMS Query
-      if (stateMachineBMSQuery != 0xFF && stateMachineBMSReset == 0xFF) {
+      if (stateMachineBMSQuery != 0xFF && stateMachineBMSReset == 0xFF && stateMachineSOCReset == 0xFF) {
         if (memcmp(rx_frame.data.u8, "\x02\x50\x03\xAA\xAA\xAA\xAA\xAA", 8) == 0) {
           //Received initial response, proceed to actual query
           logging.println("CAN UDS: Received BMS query initial handshake reply");
@@ -1713,15 +1731,28 @@ void TeslaBattery::handle_incoming_can_frame(CAN_frame rx_frame) {
           break;
         }
       }
-      //BMS Reset
-      if (stateMachineBMSQuery == 0xFF) {  // Make sure this is reset request not query
-        if (memcmp(rx_frame.data.u8, "\x02\x67\x06\xAA\xAA\xAA\xAA\xAA", 8) == 0) {
-          logging.println("CAN UDS: ECU unlocked");
-        } else if (memcmp(rx_frame.data.u8, "\x03\x7F\x11\x78\xAA\xAA\xAA\xAA", 8) == 0) {
-          logging.println("CAN UDS: ECU reset request successful but ECU busy, response pending");
-        } else if (memcmp(rx_frame.data.u8, "\x02\x51\x01\xAA\xAA\xAA\xAA\xAA", 8) == 0) {
-          logging.println("CAN UDS: ECU reset positive response, 1 second downtime");
-        }
+      //BMS ECU responses
+      if (memcmp(rx_frame.data.u8, "\x02\x67\x06\xAA\xAA\xAA\xAA\xAA", 8) == 0) {
+        logging.println("CAN UDS: BMS ECU unlocked");
+      }
+      if (memcmp(rx_frame.data.u8, "\x03\x7F\x11\x78\xAA\xAA\xAA\xAA", 8) == 0) {
+        logging.println("CAN UDS: BMS ECU reset request successful but ECU busy, response pending");
+      }
+      if (memcmp(rx_frame.data.u8, "\x02\x51\x01\xAA\xAA\xAA\xAA\xAA", 8) == 0) {
+        logging.println("CAN UDS: BMS ECU reset positive response, 1 second downtime");
+        set_event(EVENT_BMS_RESET_REQ_SUCCESS, 0);
+        clear_event(EVENT_BMS_RESET_REQ_SUCCESS);
+      }
+      if (memcmp(rx_frame.data.u8, "\x05\x71\x01\x04\x07\x01\xAA\xAA", 8) == 0) {
+        logging.println("CAN UDS: BMS SOC reset accepted, resetting BMS ECU");
+        set_event(EVENT_BATTERY_SOC_RESET_SUCCESS, 0);
+        clear_event(EVENT_BATTERY_SOC_RESET_SUCCESS);
+        stateMachineBMSReset = 6;  // BMS ECU already unlocked etc. so we jump straight to reset
+      }
+      if (memcmp(rx_frame.data.u8, "\x05\x71\x01\x04\x07\x00\xAA\xAA", 8) == 0) {
+        logging.println("CAN UDS: BMS SOC reset failed");
+        set_event(EVENT_BATTERY_SOC_RESET_FAIL, 0);
+        clear_event(EVENT_BATTERY_SOC_RESET_FAIL);
       }
       break;
     default:
@@ -2308,7 +2339,7 @@ void TeslaBattery::printFaultCodesIfActive() {
   printDebugIfActive(BMS_a139_SW_DC_Link_V_Irrational, "ERROR: BMS_a139_SW_DC_Link_V_Irrational");
   printDebugIfActive(BMS_a141_SW_BMB_Status_Warning, "ERROR: BMS_a141_SW_BMB_Status_Warning");
   printDebugIfActive(BMS_a144_Hvp_Config_Mismatch, "ERROR: BMS_a144_Hvp_Config_Mismatch");
-  printDebugIfActive(BMS_a145_SW_SOC_Change, "ERROR: BMS_a145_SW_SOC_Change");
+  printDebugIfActive(BMS_a145_SW_SOC_Change, "INFO: BMS_a145_SW_SOC_Change");
   printDebugIfActive(BMS_a146_SW_Brick_Overdischarged, "ERROR: BMS_a146_SW_Brick_Overdischarged");
   printDebugIfActive(BMS_a149_SW_Missing_Config_Block, "ERROR: BMS_a149_SW_Missing_Config_Block");
   printDebugIfActive(BMS_a151_SW_external_isolation, "ERROR: BMS_a151_SW_external_isolation");

Software/src/devboard/hal/hw_stark.h

@@ -21,6 +21,9 @@ class StarkHal : public Esp32Hal {
  public:
   const char* name() { return "Stark CMR Module"; }
 
+  //Always enable BMS power on Stark CMR, it does not collide with any pin definitions
+  virtual bool always_enable_bms_power() { return true; }
+
   // Not needed, GPIO 16 has hardware pullup for PSRAM compatibility
   virtual gpio_num_t PIN_5V_EN() { return GPIO_NUM_NC; }
 

Software/src/devboard/utils/events.cpp

@@ -67,6 +67,9 @@ void init_events(void) {
   events.entries[EVENT_BATTERY_UNDERVOLTAGE].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_BATTERY_VALUE_UNAVAILABLE].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_BATTERY_ISOLATION].level = EVENT_LEVEL_WARNING;
+  events.entries[EVENT_BATTERY_SOC_RECALIBRATION].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_BATTERY_SOC_RESET_SUCCESS].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_BATTERY_SOC_RESET_FAIL].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_VOLTAGE_DIFFERENCE].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_SOH_DIFFERENCE].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_SOH_LOW].level = EVENT_LEVEL_ERROR;
@@ -124,6 +127,8 @@ void init_events(void) {
   events.entries[EVENT_EQUIPMENT_STOP].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_SD_INIT_FAILED].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_PERIODIC_BMS_RESET].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_BMS_RESET_REQ_SUCCESS].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_BMS_RESET_REQ_FAIL].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_BATTERY_TEMP_DEVIATION_HIGH].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_GPIO_CONFLICT].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_GPIO_NOT_DEFINED].level = EVENT_LEVEL_ERROR;
@@ -244,6 +249,12 @@ String get_event_message_string(EVENTS_ENUM_TYPE event) {
       return "Battery measurement unavailable. Check 12V power supply and battery wiring!";
     case EVENT_BATTERY_ISOLATION:
       return "Battery reports isolation error. High voltage might be leaking to ground. Check battery!";
+    case EVENT_BATTERY_SOC_RECALIBRATION:
+      return "The BMS updated the HV battery State of Charge (SOC) by more than 3pct based on SocByOcv.";
+    case EVENT_BATTERY_SOC_RESET_SUCCESS:
+      return "SOC reset routine was successful.";
+    case EVENT_BATTERY_SOC_RESET_FAIL:
+      return "SOC reset routine failed - check SOC is < 15 or > 90, and contactors are open.";
     case EVENT_VOLTAGE_DIFFERENCE:
       return "Too large voltage diff between the batteries. Second battery cannot join the DC-link";
     case EVENT_SOH_DIFFERENCE:
@@ -361,7 +372,11 @@ String get_event_message_string(EVENTS_ENUM_TYPE event) {
     case EVENT_SD_INIT_FAILED:
       return "SD card initialization failed, check hardware. Power must be removed to reset the SD card.";
     case EVENT_PERIODIC_BMS_RESET:
-      return "BMS Reset Event Completed.";
+      return "BMS reset event completed.";
+    case EVENT_BMS_RESET_REQ_SUCCESS:
+      return "BMS reset request completed successfully.";
+    case EVENT_BMS_RESET_REQ_FAIL:
+      return "BMS reset request failed - check contactors are open.";
     case EVENT_GPIO_CONFLICT:
       return "GPIO Pin Conflict: The pin used by '" + esp32hal->failed_allocator() + "' is already allocated by '" +
              esp32hal->conflicting_allocator() + "'. Please check your configuration and assign different pins.";

Software/src/devboard/utils/events.h

@@ -49,6 +49,9 @@
   XX(EVENT_BATTERY_ISOLATION)           \
   XX(EVENT_BATTERY_REQUESTS_HEAT)       \
   XX(EVENT_BATTERY_WARMED_UP)           \
+  XX(EVENT_BATTERY_SOC_RECALIBRATION)   \
+  XX(EVENT_BATTERY_SOC_RESET_SUCCESS)   \
+  XX(EVENT_BATTERY_SOC_RESET_FAIL)      \
   XX(EVENT_VOLTAGE_DIFFERENCE)          \
   XX(EVENT_SOH_DIFFERENCE)              \
   XX(EVENT_SOH_LOW)                     \
@@ -107,6 +110,8 @@
   XX(EVENT_AUTOMATIC_PRECHARGE_FAILURE) \
   XX(EVENT_SD_INIT_FAILED)              \
   XX(EVENT_PERIODIC_BMS_RESET)          \
+  XX(EVENT_BMS_RESET_REQ_SUCCESS)       \
+  XX(EVENT_BMS_RESET_REQ_FAIL)          \
   XX(EVENT_BATTERY_TEMP_DEVIATION_HIGH) \
   XX(EVENT_GPIO_NOT_DEFINED)            \
   XX(EVENT_GPIO_CONFLICT)               \

Software/src/devboard/webserver/settings_html.cpp

@@ -1058,19 +1058,19 @@ const char* getCANInterfaceName(CAN_Interface interface) {
 
         <div class="if-cbms">
         <label>Battery max design voltage (V): </label>
-        <input name='BATTPVMAX' pattern="^[0-9]+(\.[0-9]+)?$" type='text' value='%BATTPVMAX%'   
+        <input name='BATTPVMAX' pattern="[0-9]+(\.[0-9]+)?" type='text' value='%BATTPVMAX%'   
         title="Maximum safe voltage for the entire battery pack in volts. Used as charge target and protection limits." />
 
         <label>Battery min design voltage (V): </label>
-        <input name='BATTPVMIN' pattern="^[0-9]+(\.[0-9]+)?$" type='text' value='%BATTPVMIN%' 
+        <input name='BATTPVMIN' pattern="[0-9]+(\.[0-9]+)?" type='text' value='%BATTPVMIN%' 
         title="Minimum safe voltage for the entire battery pack in volts. Further discharge not possible below this limit." />
 
         <label>Cell max design voltage (mV): </label>
-        <input name='BATTCVMAX' pattern="^[0-9]+$" type='text' value='%BATTCVMAX%' 
+        <input name='BATTCVMAX' pattern="[0-9]+" type='text' value='%BATTCVMAX%' 
         title="Maximum voltage per individual cell in millivolts. Charging stops if one cell reaches this voltage." />
 
         <label>Cell min design voltage (mV): </label>
-        <input name='BATTCVMIN' pattern="^[0-9]+$" type='text' value='%BATTCVMIN%' 
+        <input name='BATTCVMIN' pattern="[0-9]+$" type='text' value='%BATTCVMIN%' 
         title="Minimum voltage per individual cell in millivolts. Discharge stops if one cell drops to this voltage." />
         </div>
 
@@ -1104,33 +1104,33 @@ const char* getCANInterfaceName(CAN_Interface interface) {
 
         <div class="if-sofar">
         <label>Sofar Battery ID (0-15): </label>
-        <input name='SOFAR_ID' type='text' value="%SOFAR_ID%" pattern="^[0-9]{1,2}$" />
+        <input name='SOFAR_ID' type='text' value="%SOFAR_ID%" pattern="[0-9]{1,2}" />
         </div>
 
         <div class="if-pylonish">
         <label>Reported cell count (0 for default): </label>
-        <input name='INVCELLS' type='text' value="%INVCELLS%" pattern="^[0-9]+$" />
+        <input name='INVCELLS' type='text' value="%INVCELLS%" pattern="[0-9]+" />
         </div>
 
         <div class="if-pylonish if-solax">
         <label>Reported module count (0 for default): </label>
-        <input name='INVMODULES' type='text' value="%INVMODULES%" pattern="^[0-9]+$" />
+        <input name='INVMODULES' type='text' value="%INVMODULES%" pattern="[0-9]+" />
         </div>
 
         <div class="if-pylonish">
         <label>Reported cells per module (0 for default): </label>
-        <input name='INVCELLSPER' type='text' value="%INVCELLSPER%" pattern="^[0-9]+$" />
+        <input name='INVCELLSPER' type='text' value="%INVCELLSPER%" pattern="[0-9]+" />
 
         <label>Reported voltage level (0 for default): </label>
-        <input name='INVVLEVEL' type='text' value="%INVVLEVEL%" pattern="^[0-9]+$" />
+        <input name='INVVLEVEL' type='text' value="%INVVLEVEL%" pattern="[0-9]+" />
 
         <label>Reported Ah capacity (0 for default): </label>
-        <input name='INVCAPACITY' type='text' value="%INVCAPACITY%" pattern="^[0-9]+$" />
+        <input name='INVCAPACITY' type='text' value="%INVCAPACITY%" pattern="[0-9]+" />
         </div>
 
         <div class="if-solax">
         <label>Reported battery type (in decimal): </label>
-        <input name='INVBTYPE' type='text' value="%INVBTYPE%" pattern="^[0-9]+$" />
+        <input name='INVBTYPE' type='text' value="%INVBTYPE%" pattern="[0-9]+" />
 
         <label>Inverter should ignore contactors: </label>
         <input type='checkbox' name='INVICNT' value='on' %INVICNT% />
@@ -1227,7 +1227,7 @@ const char* getCANInterfaceName(CAN_Interface interface) {
 
         <div class="if-extprecharge">
             <label>Precharge, maximum ms before fault: </label>
-            <input name='MAXPRETIME' type='text' value="%MAXPRETIME%" pattern="^[0-9]+$" />
+            <input name='MAXPRETIME' type='text' value="%MAXPRETIME%" pattern="[0-9]+" />
 
           <label>Normally Open (NO) inverter disconnect contactor: </label>
           <input type='checkbox' name='NOINVDISC' value='on' %NOINVDISC% />
@@ -1249,14 +1249,14 @@ const char* getCANInterfaceName(CAN_Interface interface) {
 
         <label>Access point name: </label>
         <input type='text' name='APNAME' value="%APNAME%" 
-        pattern="[A-Za-z0-9!#*]{8,63}" 
-        title="Name must be 8-63 characters long and may only contain letters, numbers and some special characters: !#*"
+        pattern="[A-Za-z0-9!#*-]{8,63}" 
+        title="Name must be 8-63 characters long and may only contain letters, numbers and some special characters: !#*-"
         required />
 
         <label>Access point password: </label>
         <input type='text' name='APPASSWORD' value="%APPASSWORD%" 
-        pattern="[A-Za-z0-9!#*]{8,63}" 
-        title="Password must be 8-63 characters long and may only contain letters, numbers and some special characters: !#*"
+        pattern="[A-Za-z0-9!#*-]{8,63}" 
+        title="Password must be 8-63 characters long and may only contain letters, numbers and some special characters: !#*-"
         required />
 
         <label>Wifi channel 0-14: </label>
@@ -1266,8 +1266,8 @@ const char* getCANInterfaceName(CAN_Interface interface) {
 
         <label>Custom Wifi hostname: </label>
         <input type='text' name='HOSTNAME' value="%HOSTNAME%" 
-        pattern="[A-Za-z0-9!*]" 
-        title="Optional: Hostname may only contain only letters, numbers, ! and *" />
+        pattern="[A-Za-z0-9!#*-]+"
+        title="Optional: Hostname may only contain letters, numbers and some special characters: !#*-" />
 
         <label>Use static IP address: </label>
         <input type='checkbox' name='STATICIP' value='on' %STATICIP% />
@@ -1305,18 +1305,18 @@ const char* getCANInterfaceName(CAN_Interface interface) {
         <div class='if-mqtt'>
         <label>MQTT server: </label>
         <input type='text' name='MQTTSERVER' value="%MQTTSERVER%" 
-        pattern="^([A-Za-z0-9.-]+|)/$"
+        pattern="[A-Za-z0-9.-]+"
         title="Hostname (letters, numbers, dots, hyphens)" />
         <label>MQTT port: </label>
         <input type='number' name='MQTTPORT' value="%MQTTPORT%" 
         min="1" max="65535" step="1"
         title="Port number (1-65535)" />
         <label>MQTT user: </label><input type='text' name='MQTTUSER' value="%MQTTUSER%"         
-        pattern="[A-Za-z0-9!#*]" 
-        title="MQTT username can only contain letters, numbers and some special characters: !#*" />
+        pattern="[A-Za-z0-9!#*-]+"
+        title="MQTT username can only contain letters, numbers and some special characters: !#*-" />
         <label>MQTT password: </label><input type='password' name='MQTTPASSWORD' value="%MQTTPASSWORD%" 
-        pattern="[A-Za-z0-9!#*]" 
-        title="MQTT password can only contain letters, numbers and some special characters: !#*" />
+        pattern="[A-Za-z0-9!#*-]+"
+        title="MQTT password can only contain letters, numbers and some special characters: !#*-" />
         <label>MQTT timeout ms: </label>
         <input name='MQTTTIMEOUT' type='number' value="%MQTTTIMEOUT%" 
         min="1" max="60000" step="1"

Software/src/devboard/wifi/wifi.cpp

@@ -240,7 +240,6 @@ void init_mDNS() {
 }
 
 void init_WiFi_AP() {
-  ssidAP = std::string("BatteryEmulator") + WiFi.macAddress().c_str();
 
   DEBUG_PRINTF("Creating Access Point: %s\n", ssidAP.c_str());
   DEBUG_PRINTF("With password: %s\n", passwordAP.c_str());