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Battery-Emulator/Software/Software.ino
Daniel Öster 5dcaa1c0fd
Update Software.ino
2025-03-28 22:31:30 +02:00

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/* Do not change any code below this line unless you are sure what you are doing */
/* Only change battery specific settings in "USER_SETTINGS.h" */
#include "HardwareSerial.h"
#include "USER_SECRETS.h"
#include "USER_SETTINGS.h"
#include "esp_system.h"
#include "esp_task_wdt.h"
#include "esp_timer.h"
#include "freertos/FreeRTOS.h"
#include "freertos/task.h"
#include "src/communication/can/comm_can.h"
#include "src/communication/contactorcontrol/comm_contactorcontrol.h"
#include "src/communication/equipmentstopbutton/comm_equipmentstopbutton.h"
#include "src/communication/nvm/comm_nvm.h"
#include "src/communication/precharge_control/precharge_control.h"
#include "src/communication/rs485/comm_rs485.h"
#include "src/datalayer/datalayer.h"
#include "src/devboard/sdcard/sdcard.h"
#include "src/devboard/utils/events.h"
#include "src/devboard/utils/led_handler.h"
#include "src/devboard/utils/logging.h"
#include "src/devboard/utils/timer.h"
#include "src/devboard/utils/value_mapping.h"
#include "src/include.h"
#ifndef AP_PASSWORD
#error \
"Initial setup not completed, USER_SECRETS.h is missing. Please rename the file USER_SECRETS.TEMPLATE.h to USER_SECRETS.h and fill in the required credentials. This file is ignored by version control to keep sensitive information private."
#endif
#ifdef WIFI
#include "src/devboard/wifi/wifi.h"
#ifdef WEBSERVER
#include "src/devboard/webserver/webserver.h"
#ifdef MDNSRESPONDER
#include <ESPmDNS.h>
#endif // MDNSRESONDER
#else // WEBSERVER
#ifdef MDNSRESPONDER
#error WEBSERVER needs to be enabled for MDNSRESPONDER!
#endif // MDNSRSPONDER
#endif // WEBSERVER
#ifdef MQTT
#include "src/devboard/mqtt/mqtt.h"
#endif // MQTT
#endif // WIFI
#ifdef PERIODIC_BMS_RESET_AT
#include "src/devboard/utils/ntp_time.h"
#endif
volatile unsigned long long bmsResetTimeOffset = 0;
// The current software version, shown on webserver
const char* version_number = "8.10.dev";
// Interval timers
unsigned long previousMillis10ms = 0;
unsigned long previousMillisUpdateVal = 0;
unsigned long lastMillisOverflowCheck = 0;
// Task time measurement for debugging and for setting CPU load events
MyTimer core_task_timer_10s(INTERVAL_10_S);
int64_t core_task_time_us;
int64_t connectivity_task_time_us;
int64_t logging_task_time_us;
int64_t mqtt_task_time_us;
TaskHandle_t main_loop_task;
TaskHandle_t connectivity_loop_task;
TaskHandle_t logging_loop_task;
TaskHandle_t mqtt_loop_task;
Logging logging;
// Initialization
void setup() {
init_serial();
// We print this after setting up serial, such that is also printed to serial with DEBUG_VIA_USB set.
logging.printf("Battery emulator %s build " __DATE__ " " __TIME__ "\n", version_number);
init_events();
init_stored_settings();
#ifdef WIFI
xTaskCreatePinnedToCore((TaskFunction_t)&connectivity_loop, "connectivity_loop", 4096, &connectivity_task_time_us,
TASK_CONNECTIVITY_PRIO, &connectivity_loop_task, WIFI_CORE);
#endif
#if defined(LOG_CAN_TO_SD) || defined(LOG_TO_SD)
xTaskCreatePinnedToCore((TaskFunction_t)&logging_loop, "logging_loop", 4096, &logging_task_time_us,
TASK_CONNECTIVITY_PRIO, &logging_loop_task, WIFI_CORE);
#endif
#ifdef MQTT
xTaskCreatePinnedToCore((TaskFunction_t)&mqtt_loop, "mqtt_loop", 4096, &mqtt_task_time_us, TASK_MQTT_PRIO,
&mqtt_loop_task, WIFI_CORE);
#endif
init_CAN();
init_contactors();
#ifdef PRECHARGE_CONTROL
init_precharge_control();
#endif // PRECHARGE_CONTROL
init_rs485();
#if defined(CAN_INVERTER_SELECTED) || defined(MODBUS_INVERTER_SELECTED) || defined(RS485_INVERTER_SELECTED)
setup_inverter();
#endif
setup_battery();
#ifdef EQUIPMENT_STOP_BUTTON
init_equipment_stop_button();
#endif
#ifdef CAN_SHUNT_SELECTED
setup_can_shunt();
#endif
// BOOT button at runtime is used as an input for various things
pinMode(0, INPUT_PULLUP);
check_reset_reason();
// Initialize Task Watchdog for subscribed tasks
esp_task_wdt_config_t wdt_config = {
.timeout_ms = INTERVAL_5_S, // If task hangs for longer than this, reboot
.idle_core_mask = (1 << CORE_FUNCTION_CORE) | (1 << WIFI_CORE), // Watch both cores
.trigger_panic = true // Enable panic reset on timeout
};
// Start tasks
xTaskCreatePinnedToCore((TaskFunction_t)&core_loop, "core_loop", 4096, &core_task_time_us, TASK_CORE_PRIO,
&main_loop_task, CORE_FUNCTION_CORE);
#ifdef PERIODIC_BMS_RESET_AT
bmsResetTimeOffset = getTimeOffsetfromNowUntil(PERIODIC_BMS_RESET_AT);
if (bmsResetTimeOffset == 0) {
set_event(EVENT_PERIODIC_BMS_RESET_AT_INIT_FAILED, 0);
} else {
set_event(EVENT_PERIODIC_BMS_RESET_AT_INIT_SUCCESS, 0);
}
#endif
}
// Loop empty, all functionality runs in tasks
void loop() {}
#if defined(LOG_CAN_TO_SD) || defined(LOG_TO_SD)
void logging_loop(void* task_time_us) {
init_logging_buffers();
init_sdcard();
while (true) {
#ifdef LOG_TO_SD
write_log_to_sdcard();
#endif
#ifdef LOG_CAN_TO_SD
write_can_frame_to_sdcard();
#endif
}
}
#endif
#ifdef WIFI
void connectivity_loop(void* task_time_us) {
esp_task_wdt_add(NULL); // Register this task with WDT
// Init wifi
init_WiFi();
#ifdef WEBSERVER
// Init webserver
init_webserver();
#endif
#ifdef MDNSRESPONDER
init_mDNS();
#endif
while (true) {
START_TIME_MEASUREMENT(wifi);
wifi_monitor();
#ifdef WEBSERVER
ota_monitor();
#endif
END_TIME_MEASUREMENT_MAX(wifi, datalayer.system.status.wifi_task_10s_max_us);
esp_task_wdt_reset(); // Reset watchdog
delay(1);
}
}
#endif
#ifdef MQTT
void mqtt_loop(void* task_time_us) {
esp_task_wdt_add(NULL); // Register this task with WDT
init_mqtt();
while (true) {
START_TIME_MEASUREMENT(mqtt);
mqtt_loop();
END_TIME_MEASUREMENT_MAX(mqtt, datalayer.system.status.mqtt_task_10s_max_us);
esp_task_wdt_reset(); // Reset watchdog
delay(1);
}
}
#endif
void core_loop(void* task_time_us) {
esp_task_wdt_add(NULL); // Register this task with WDT
TickType_t xLastWakeTime = xTaskGetTickCount();
const TickType_t xFrequency = pdMS_TO_TICKS(1); // Convert 1ms to ticks
led_init();
while (true) {
START_TIME_MEASUREMENT(all);
START_TIME_MEASUREMENT(comm);
#ifdef EQUIPMENT_STOP_BUTTON
monitor_equipment_stop_button();
#endif
// Input, Runs as fast as possible
receive_can(); // Receive CAN messages
#if defined(RS485_INVERTER_SELECTED) || defined(RS485_BATTERY_SELECTED)
receive_RS485(); // Process serial2 RS485 interface
#endif // RS485_INVERTER_SELECTED
END_TIME_MEASUREMENT_MAX(comm, datalayer.system.status.time_comm_us);
#ifdef WEBSERVER
START_TIME_MEASUREMENT(ota);
ElegantOTA.loop();
END_TIME_MEASUREMENT_MAX(ota, datalayer.system.status.time_ota_us);
#endif // WEBSERVER
// Process
if (millis() - previousMillis10ms >= INTERVAL_10_MS) {
previousMillis10ms = millis();
START_TIME_MEASUREMENT(time_10ms);
led_exe();
handle_contactors(); // Take care of startup precharge/contactor closing
#ifdef PRECHARGE_CONTROL
handle_precharge_control();
#endif // PRECHARGE_CONTROL
END_TIME_MEASUREMENT_MAX(time_10ms, datalayer.system.status.time_10ms_us);
}
if (millis() - previousMillisUpdateVal >= INTERVAL_1_S) {
previousMillisUpdateVal = millis(); // Order matters on the update_loop!
START_TIME_MEASUREMENT(time_values);
update_pause_state(); // Check if we are OK to send CAN or need to pause
update_values_battery(); // Fetch battery values
#ifdef DOUBLE_BATTERY
update_values_battery2();
check_interconnect_available();
#endif // DOUBLE_BATTERY
update_calculated_values();
update_machineryprotection(); // Check safeties
update_values_inverter(); // Update values heading towards inverter
END_TIME_MEASUREMENT_MAX(time_values, datalayer.system.status.time_values_us);
}
START_TIME_MEASUREMENT(cantx);
// Output
transmit_can(); // Send CAN messages to all components
#ifdef RS485_BATTERY_SELECTED
transmit_rs485();
#endif // RS485_BATTERY_SELECTED
END_TIME_MEASUREMENT_MAX(cantx, datalayer.system.status.time_cantx_us);
END_TIME_MEASUREMENT_MAX(all, datalayer.system.status.core_task_10s_max_us);
#ifdef FUNCTION_TIME_MEASUREMENT
if (datalayer.system.status.core_task_10s_max_us > datalayer.system.status.core_task_max_us) {
// Update worst case total time
datalayer.system.status.core_task_max_us = datalayer.system.status.core_task_10s_max_us;
// Record snapshots of task times
datalayer.system.status.time_snap_comm_us = datalayer.system.status.time_comm_us;
datalayer.system.status.time_snap_10ms_us = datalayer.system.status.time_10ms_us;
datalayer.system.status.time_snap_values_us = datalayer.system.status.time_values_us;
datalayer.system.status.time_snap_cantx_us = datalayer.system.status.time_cantx_us;
datalayer.system.status.time_snap_ota_us = datalayer.system.status.time_ota_us;
}
datalayer.system.status.core_task_max_us =
MAX(datalayer.system.status.core_task_10s_max_us, datalayer.system.status.core_task_max_us);
if (core_task_timer_10s.elapsed()) {
datalayer.system.status.time_ota_us = 0;
datalayer.system.status.time_comm_us = 0;
datalayer.system.status.time_10ms_us = 0;
datalayer.system.status.time_values_us = 0;
datalayer.system.status.time_cantx_us = 0;
datalayer.system.status.core_task_10s_max_us = 0;
datalayer.system.status.wifi_task_10s_max_us = 0;
datalayer.system.status.mqtt_task_10s_max_us = 0;
}
#endif // FUNCTION_TIME_MEASUREMENT
#ifdef DEBUG_LOG
logging.log_bms_status(datalayer.battery.status.real_bms_status);
#endif
esp_task_wdt_reset(); // Reset watchdog to prevent reset
vTaskDelayUntil(&xLastWakeTime, xFrequency);
}
}
// Initialization functions
void init_serial() {
// Init Serial monitor
Serial.begin(115200);
while (!Serial) {}
#ifdef DEBUG_VIA_USB
Serial.println("__ OK __");
#endif // DEBUG_VIA_USB
}
#ifdef DOUBLE_BATTERY
void check_interconnect_available() {
if (datalayer.battery.status.voltage_dV == 0 || datalayer.battery2.status.voltage_dV == 0) {
return; // Both voltage values need to be available to start check
}
uint16_t voltage_diff = abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV);
if (voltage_diff <= 30) { // If we are within 3.0V between the batteries
clear_event(EVENT_VOLTAGE_DIFFERENCE);
if (datalayer.battery.status.bms_status == FAULT) {
// If main battery is in fault state, disengage the second battery
datalayer.system.status.battery2_allows_contactor_closing = false;
} else { // If main battery is OK, allow second battery to join
datalayer.system.status.battery2_allows_contactor_closing = true;
}
} else { //Voltage between the two packs is too large
set_event(EVENT_VOLTAGE_DIFFERENCE, (uint8_t)(voltage_diff / 10));
}
}
#endif // DOUBLE_BATTERY
void update_calculated_values() {
/* Calculate allowed charge/discharge currents*/
if (datalayer.battery.status.voltage_dV > 10) {
// Only update value when we have voltage available to avoid div0. TODO: This should be based on nominal voltage
datalayer.battery.status.max_charge_current_dA =
((datalayer.battery.status.max_charge_power_W * 100) / datalayer.battery.status.voltage_dV);
datalayer.battery.status.max_discharge_current_dA =
((datalayer.battery.status.max_discharge_power_W * 100) / datalayer.battery.status.voltage_dV);
}
/* Restrict values from user settings if needed*/
if (datalayer.battery.status.max_charge_current_dA > datalayer.battery.settings.max_user_set_charge_dA) {
datalayer.battery.status.max_charge_current_dA = datalayer.battery.settings.max_user_set_charge_dA;
datalayer.battery.settings.user_settings_limit_charge = true;
} else {
datalayer.battery.settings.user_settings_limit_charge = false;
}
if (datalayer.battery.status.max_discharge_current_dA > datalayer.battery.settings.max_user_set_discharge_dA) {
datalayer.battery.status.max_discharge_current_dA = datalayer.battery.settings.max_user_set_discharge_dA;
datalayer.battery.settings.user_settings_limit_discharge = true;
} else {
datalayer.battery.settings.user_settings_limit_discharge = false;
}
/* Calculate active power based on voltage and current*/
datalayer.battery.status.active_power_W =
(datalayer.battery.status.current_dA * (datalayer.battery.status.voltage_dV / 100));
/* Calculate if battery or inverter is limiting factor*/
if (datalayer.battery.status.current_dA == 0) { //Battery idle
if (datalayer.battery.status.max_discharge_current_dA > 0) {
//We allow discharge, but inverter does nothing. Inverter is limiting
datalayer.battery.settings.inverter_limits_discharge = true;
} else {
datalayer.battery.settings.inverter_limits_discharge = false;
}
if (datalayer.battery.status.max_charge_current_dA > 0) {
//We allow charge, but inverter does nothing. Inverter is limiting
datalayer.battery.settings.inverter_limits_charge = true;
} else {
datalayer.battery.settings.inverter_limits_charge = false;
}
} else if (datalayer.battery.status.current_dA < 0) { //Battery discharging
if (-datalayer.battery.status.current_dA < datalayer.battery.status.max_discharge_current_dA) {
datalayer.battery.settings.inverter_limits_discharge = true;
} else {
datalayer.battery.settings.inverter_limits_discharge = false;
}
} else { // > 0 Battery charging
//If actual current is smaller than max we allow, inverter is limiting factor
if (datalayer.battery.status.current_dA < datalayer.battery.status.max_charge_current_dA) {
datalayer.battery.settings.inverter_limits_charge = true;
} else {
datalayer.battery.settings.inverter_limits_charge = false;
}
}
#ifdef DOUBLE_BATTERY
/* Calculate active power based on voltage and current for battery 2*/
datalayer.battery2.status.active_power_W =
(datalayer.battery2.status.current_dA * (datalayer.battery2.status.voltage_dV / 100));
#endif // DOUBLE_BATTERY
if (datalayer.battery.settings.soc_scaling_active) {
/** SOC Scaling
*
* This is essentially a more static version of a stochastic oscillator (https://en.wikipedia.org/wiki/Stochastic_oscillator)
*
* The idea is this:
*
* real_soc - min_percent 3000 - 1000
* ------------------------- = scaled_soc, or ----------- = 0.25
* max_percent - min-percent 8000 - 1000
*
* Because we use integers, we want to account for the scaling:
*
* 10000 * (real_soc - min_percent) 10000 * (3000 - 1000)
* -------------------------------- = scaled_soc, or --------------------- = 2500
* max_percent - min_percent 8000 - 1000
*
* Or as a one-liner: (10000 * (real_soc - min_percentage)) / (max_percentage - min_percentage)
*
* Before we use real_soc, we must make sure that it's within the range of min_percentage and max_percentage.
*/
uint32_t calc_soc;
uint32_t calc_max_capacity;
uint32_t calc_reserved_capacity;
// Make sure that the SOC starts out between min and max percentages
calc_soc = CONSTRAIN(datalayer.battery.status.real_soc, datalayer.battery.settings.min_percentage,
datalayer.battery.settings.max_percentage);
// Perform scaling
calc_soc = 10000 * (calc_soc - datalayer.battery.settings.min_percentage);
calc_soc = calc_soc / (datalayer.battery.settings.max_percentage - datalayer.battery.settings.min_percentage);
datalayer.battery.status.reported_soc = calc_soc;
// Calculate the scaled remaining capacity in Wh
if (datalayer.battery.info.total_capacity_Wh > 0 && datalayer.battery.status.real_soc > 0) {
calc_max_capacity = (datalayer.battery.status.remaining_capacity_Wh * 10000 / datalayer.battery.status.real_soc);
calc_reserved_capacity = calc_max_capacity * datalayer.battery.settings.min_percentage / 10000;
// remove % capacity reserved in min_percentage to total_capacity_Wh
if (datalayer.battery.status.remaining_capacity_Wh > calc_reserved_capacity) {
datalayer.battery.status.reported_remaining_capacity_Wh =
datalayer.battery.status.remaining_capacity_Wh - calc_reserved_capacity;
} else {
datalayer.battery.status.reported_remaining_capacity_Wh = 0;
}
datalayer.battery.info.reported_total_capacity_Wh =
(datalayer.battery.info.total_capacity_Wh *
(datalayer.battery.settings.max_percentage - datalayer.battery.settings.min_percentage)) /
10000;
} else {
datalayer.battery.status.reported_remaining_capacity_Wh = datalayer.battery.status.remaining_capacity_Wh;
}
#ifdef DOUBLE_BATTERY
// Calculate the scaled remaining capacity in Wh
if (datalayer.battery2.info.total_capacity_Wh > 0 && datalayer.battery2.status.real_soc > 0) {
calc_max_capacity =
(datalayer.battery2.status.remaining_capacity_Wh * 10000 / datalayer.battery2.status.real_soc);
calc_reserved_capacity = calc_max_capacity * datalayer.battery2.settings.min_percentage / 10000;
// remove % capacity reserved in min_percentage to total_capacity_Wh
if (datalayer.battery2.status.remaining_capacity_Wh > calc_reserved_capacity) {
datalayer.battery2.status.reported_remaining_capacity_Wh =
datalayer.battery2.status.remaining_capacity_Wh - calc_reserved_capacity;
} else {
datalayer.battery2.status.reported_remaining_capacity_Wh = 0;
}
} else {
datalayer.battery2.status.reported_remaining_capacity_Wh = datalayer.battery2.status.remaining_capacity_Wh;
}
#endif // DOUBLE_BATTERY
} else { // soc_scaling_active == false. No SOC window wanted. Set scaled to same as real.
datalayer.battery.status.reported_soc = datalayer.battery.status.real_soc;
datalayer.battery.status.reported_remaining_capacity_Wh = datalayer.battery.status.remaining_capacity_Wh;
#ifdef DOUBLE_BATTERY
datalayer.battery2.status.reported_soc = datalayer.battery2.status.real_soc;
datalayer.battery2.status.reported_remaining_capacity_Wh = datalayer.battery2.status.remaining_capacity_Wh;
#endif
}
#ifdef DOUBLE_BATTERY
// Perform extra SOC sanity checks on double battery setups
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;
datalayer.battery.status.reported_remaining_capacity_Wh = datalayer.battery.status.remaining_capacity_Wh;
}
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;
datalayer.battery.status.reported_remaining_capacity_Wh = datalayer.battery2.status.remaining_capacity_Wh;
}
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;
datalayer.battery.status.reported_remaining_capacity_Wh = datalayer.battery.status.remaining_capacity_Wh;
}
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;
datalayer.battery.status.reported_remaining_capacity_Wh = datalayer.battery2.status.remaining_capacity_Wh;
}
#endif // DOUBLE_BATTERY
// Check if millis() has overflowed. Used in events to keep better track of time
if (millis() < lastMillisOverflowCheck) { // Overflow detected
datalayer.system.status.millisrolloverCount++;
}
lastMillisOverflowCheck = millis();
}
void update_values_inverter() {
#ifdef CAN_INVERTER_SELECTED
update_values_can_inverter();
#endif // CAN_INVERTER_SELECTED
#ifdef MODBUS_INVERTER_SELECTED
update_modbus_registers_inverter();
#endif // CAN_INVERTER_SELECTED
#ifdef RS485_INVERTER_SELECTED
update_RS485_registers_inverter();
#endif // CAN_INVERTER_SELECTED
}
void check_reset_reason() {
esp_reset_reason_t reason = esp_reset_reason();
switch (reason) {
case ESP_RST_UNKNOWN: //Reset reason can not be determined
set_event(EVENT_RESET_UNKNOWN, reason);
break;
case ESP_RST_POWERON: //OK Reset due to power-on event
set_event(EVENT_RESET_POWERON, reason);
break;
case ESP_RST_EXT: //Reset by external pin (not applicable for ESP32)
set_event(EVENT_RESET_EXT, reason);
break;
case ESP_RST_SW: //OK Software reset via esp_restart
set_event(EVENT_RESET_SW, reason);
break;
case ESP_RST_PANIC: //Software reset due to exception/panic
set_event(EVENT_RESET_PANIC, reason);
break;
case ESP_RST_INT_WDT: //Reset (software or hardware) due to interrupt watchdog
set_event(EVENT_RESET_INT_WDT, reason);
break;
case ESP_RST_TASK_WDT: //Reset due to task watchdog
set_event(EVENT_RESET_TASK_WDT, reason);
break;
case ESP_RST_WDT: //Reset due to other watchdogs
set_event(EVENT_RESET_WDT, reason);
break;
case ESP_RST_DEEPSLEEP: //Reset after exiting deep sleep mode
set_event(EVENT_RESET_DEEPSLEEP, reason);
break;
case ESP_RST_BROWNOUT: //Brownout reset (software or hardware)
set_event(EVENT_RESET_BROWNOUT, reason);
break;
case ESP_RST_SDIO: //Reset over SDIO
set_event(EVENT_RESET_SDIO, reason);
break;
case ESP_RST_USB: //Reset by USB peripheral
set_event(EVENT_RESET_USB, reason);
break;
case ESP_RST_JTAG: //Reset by JTAG
set_event(EVENT_RESET_JTAG, reason);
break;
case ESP_RST_EFUSE: //Reset due to efuse error
set_event(EVENT_RESET_EFUSE, reason);
break;
case ESP_RST_PWR_GLITCH: //Reset due to power glitch detected
set_event(EVENT_RESET_PWR_GLITCH, reason);
break;
case ESP_RST_CPU_LOCKUP: //Reset due to CPU lock up
set_event(EVENT_RESET_CPU_LOCKUP, reason);
break;
default:
break;
}
}
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