Precharge weld check

include/ACU_Constants.h

@@ -24,6 +24,7 @@ namespace ACUSystems
     constexpr const volt VOLTAGE_DIFF_TO_INIT_CB = 0.02;  // differential with lowest cell voltage to enable cell balancing for a cell
     constexpr const celsius BALANCE_TEMP_LIMIT_C = 50.0;
     constexpr const celsius BALANCE_ENABLE_TEMP_THRESH_C = 35.0; // Celsius
+    constexpr const volt TS_ISOLATION_VOLTAGE = 0.2; // Volts
 }
 
 namespace ACUInterfaces {
@@ -32,7 +33,8 @@ namespace ACUInterfaces {
     const size_t SERIAL_BAUDRATE = 115200;
 
     constexpr const size_t TEENSY_OK_PIN = 3; // > Needs to stay HIGH while wd_kick_pin flips to keep BMS_OK high
-    constexpr const size_t WD_KICK_PIN = 4;       // > Needs to flip at 100 Hz to keep BMS_OK high
+    constexpr const size_t WD_KICK_PIN = 4; // > Needs to flip at 100 Hz to keep BMS_OK high
+    constexpr const size_t SW_NOT_OK_PIN = 5;      
     constexpr const size_t N_LATCH_EN_PIN = 6;    // > Input to Safety Light, true when teensy is not in FAULT state
     constexpr const size_t TS_OUT_FILTERED_PIN = 17;
     constexpr const size_t PACK_OUT_FILTERED_PIN = 18;

include/ACU_SystemTasks.h

@@ -30,6 +30,7 @@ extern ::etl::delegate<bool()> has_imd_fault;
 extern ::etl::delegate<bool()> received_valid_shdn_out;
 extern ::etl::delegate<void()> enable_cell_balancing;
 extern ::etl::delegate<void()> disable_cell_balancing;
+extern ::etl::delegate<bool()> contactor_welded;
 extern ::etl::delegate<void()> disable_watchdog;
 extern ::etl::delegate<void()> reinitialize_watchdog;
 extern ::etl::delegate<void()> disable_n_latch_en;
@@ -39,4 +40,6 @@ ::HT_TASK::TaskResponse evaluate_accumulator(const unsigned long &sysMicros, con
 
 ::HT_TASK::TaskResponse tick_state_machine(const unsigned long &sysMicros, const HT_TASK::TaskInfo &taskInfo);
 
+
+
 #endif 

lib/interfaces/include/ADCInterface.h

@@ -25,6 +25,7 @@ struct ADCPinout_s
     pin teensy_pack_out_filtered_pin;
     pin teensy_bspd_current_pin;
     pin teensy_scaled_24V_pin;
+    pin teensy_sw_not_ok_pin;
 };
 
 struct ADCConversions_s
@@ -155,6 +156,10 @@ class ADCInterface
      */
     bool is_in_imd_startup_period() const;
 
+    void set_sw_not_ok_pin_high();
+
+    void set_sw_not_ok_pin_low();
+
 private:
     const ADCInterfaceParams_s _adc_parameters = {};
 

lib/interfaces/src/ACUEthernetInterface.cpp

@@ -45,6 +45,7 @@ hytech_msgs_ACUCoreData ACUEthernetInterface::make_acu_core_data_msg(const ACUCo
     out.min_measured_pack_voltage = shared_state.min_measured_pack_out_voltage;
     out.min_measured_tractive_system_voltage = shared_state.min_measured_ts_out_voltage;
     out.min_measured_shdn_out_voltage = shared_state.min_shdn_out_voltage;
+
 
     return out;
 }

lib/interfaces/src/ADCInterface.cpp

@@ -9,6 +9,7 @@ void ADCInterface::init(uint32_t init_millis) {
     pinMode(_adc_parameters.pinout.teensy_pack_out_filtered_pin, INPUT);
     pinMode(_adc_parameters.pinout.teensy_bspd_current_pin, INPUT);
     pinMode(_adc_parameters.pinout.teensy_scaled_24V_pin, INPUT);
+    pinMode(_adc_parameters.pinout.teensy_sw_not_ok_pin, OUTPUT);
 
     _init_millis = init_millis;
     _in_imd_startup_period = true; 
@@ -80,4 +81,12 @@ const ADCInterfaceParams_s& ADCInterface::get_adc_params() const {
 
 bool ADCInterface::is_in_imd_startup_period() const {
     return _in_imd_startup_period;
+}
+
+void ADCInterface::set_sw_not_ok_pin_high() {
+    digitalWrite(_adc_parameters.pinout.teensy_sw_not_ok_pin, HIGH);
+}
+
+void ADCInterface::set_sw_not_ok_pin_low() {
+    digitalWrite(_adc_parameters.pinout.teensy_sw_not_ok_pin, LOW);
 }

lib/interfaces/src/WatchdogInterface.cpp

@@ -5,6 +5,7 @@ void WatchdogInterface::init() {
     pinMode(_watchdog_parameters.pinout.teensy_ok_pin, OUTPUT);
     pinMode(_watchdog_parameters.pinout.teensy_wd_kick_pin, OUTPUT);
     pinMode(_watchdog_parameters.pinout.teensy_n_latch_en_pin, OUTPUT);
+
 
     // Initial Pin States for OUTPUT pins
     digitalWrite(_watchdog_parameters.pinout.teensy_ok_pin, HIGH);

lib/state_machine/include/ACUStateMachine.h

@@ -13,7 +13,9 @@ enum class ACUState_e
     STARTUP = 0, 
     ACTIVE = 1, 
     CHARGING = 2, 
-    FAULTED = 3, 
+    FAULTED = 3,
+    WELDED = 4,
+    WELDPASSED = 5 
 };
 
 class ACUStateMachine
@@ -23,6 +25,9 @@ class ACUStateMachine
         etl::delegate<bool()> charge_state_requested,
         etl::delegate<bool()> has_bms_fault,
         etl::delegate<bool()> has_imd_fault,
+        etl::delegate<bool()> contactor_welded,
+        etl::delegate<void()> set_sw_not_ok_pin_high,
+        etl::delegate<void()> set_sw_not_ok_pin_low,
         etl::delegate<bool()> received_valid_shdn_out,
         etl::delegate<void()> enable_cell_balancing,
         etl::delegate<void()> disable_cell_balancing,
@@ -35,6 +40,9 @@ class ACUStateMachine
     _charge_state_requested(charge_state_requested),
     _has_bms_fault(has_bms_fault),
     _has_imd_fault(has_imd_fault),
+    _contactor_welded(contactor_welded),
+    _set_sw_not_ok_pin_high(set_sw_not_ok_pin_high),
+    _set_sw_not_ok_pin_low(set_sw_not_ok_pin_low),
     _received_valid_shdn_out(received_valid_shdn_out),
     _enable_cell_balancing(enable_cell_balancing),
     _disable_cell_balancing(disable_cell_balancing),
@@ -54,6 +62,8 @@ class ACUStateMachine
     */
     ACUState_e get_state() { return _current_state; } 
 
+
+
 private:
 
     void _set_state(ACUState_e new_state, unsigned long curr_millis);
@@ -72,11 +82,15 @@ class ACUStateMachine
 
     ACUState_e _current_state;
     unsigned long _last_state_changed_time; // time of last state change
-
+
+
     // Lamdas for state machine abstraction, functions defined in main
     etl::delegate<bool()> _charge_state_requested; 
     etl::delegate<bool()> _has_bms_fault;
     etl::delegate<bool()> _has_imd_fault;
+    etl::delegate<bool()> _contactor_welded;
+    etl::delegate<void()> _set_sw_not_ok_pin_high;
+    etl::delegate<void()> _set_sw_not_ok_pin_low;
     etl::delegate<bool()> _received_valid_shdn_out;
     /// @brief setters
     etl::delegate<void()> _enable_cell_balancing;

lib/state_machine/src/ACUStateMachine.cpp

@@ -1,19 +1,37 @@
 #include "ACUStateMachine.h"
+#include <iostream>
+using namespace std;
+
 
 void ACUStateMachine::tick_state_machine(unsigned long current_millis) {
     switch(_current_state) {
         case ACUState_e::STARTUP: 
         {   
-            if (_received_valid_shdn_out()) {
-                _set_state(ACUState_e::ACTIVE, current_millis);
-                break;
+            if (current_millis - _last_state_changed_time >= 1000) {
+                if (_contactor_welded()) {
+                    _set_state(ACUState_e::WELDED, current_millis);
+                    break;
+                }
+                else {
+                    _set_state(ACUState_e::WELDPASSED, current_millis);
+                    break;
+                }
             }
-            if ((current_millis - _last_state_changed_time > 2000) && (_has_bms_fault() || _has_imd_fault())) {
-                _set_state(ACUState_e::FAULTED, current_millis);
+
+            break;
+        }
+        case ACUState_e::WELDPASSED:
+        {
+            if (_received_valid_shdn_out()) { 
+                _set_state(ACUState_e::ACTIVE, current_millis);
                 break;
             }
-            break;
         }
+        case ACUState_e::WELDED:
+        {
+
+        }
+
         case ACUState_e::ACTIVE: 
         {
             if (_charge_state_requested()) {
@@ -84,6 +102,8 @@ void ACUStateMachine::_handle_exit_logic(ACUState_e prev_state, unsigned long cu
         }
         case ACUState_e::STARTUP:
         case ACUState_e::ACTIVE:
+        case ACUState_e::WELDPASSED:
+        case ACUState_e::WELDED:
         default:
             break;
     }
@@ -94,9 +114,20 @@ void ACUStateMachine::_handle_entry_logic(ACUState_e new_state, unsigned long cu
     switch(new_state) {
         case ACUState_e::STARTUP: 
         {
+            _last_state_changed_time = curr_millis;
             _reinitialize_watchdog();
             break;
         }
+        case ACUState_e::WELDPASSED:
+        {
+            _set_sw_not_ok_pin_low();
+            break;
+        }
+        case ACUState_e::WELDED:
+        {
+            _set_sw_not_ok_pin_high();
+            break;
+        }
         case ACUState_e::CHARGING: 
         {   
             _enable_cell_balancing();
@@ -113,4 +144,5 @@ void ACUStateMachine::_handle_entry_logic(ACUState_e new_state, unsigned long cu
         default:
             break;
     }
-}
+}
+

lib/systems/include/ACUController.h

@@ -1,6 +1,7 @@
 #ifndef ACUCONTROLLER_H
 #define ACUCONTROLLER_H
 
+#include <Arduino.h>
 #include <array>
 #include <stddef.h>
 #include <stdio.h>
@@ -20,6 +21,8 @@ namespace acu_controller_default_parameters
     constexpr const float PACK_MAX_VOLTAGE = 529.2;         // from data sheet https://wiki.hytechracing.org/books/ht09-design/page/molicel-pack-investigation
     constexpr const float PACK_MIN_VOLTAGE = 378.0;         // from data sheet^ but just assume 126 * 3.0V
     constexpr const float PACK_INTERNAL_RESISTANCE = 0.246; // Ohms (measured)
+
+
 }
 struct ACUControllerData_s
 {
@@ -37,6 +40,9 @@ struct ACUControllerData_s
     uint32_t last_bms_not_ok_eval;
     bool charging_enabled;
     bool balancing_enabled;
+    bool high_side_contactor_welded;
+    bool low_side_contactor_welded;
+
 };
 
 struct ACUControllerThresholds_s
@@ -50,6 +56,7 @@ struct ACUControllerThresholds_s
     volt v_diff_to_init_cb = 0;
     celsius balance_temp_limit_c = 0;
     celsius balance_enable_temp_c = 0;
+    volt ts_isolation_voltage = 0;
 };
 
 struct ACUControllerFaultDurations_s
@@ -99,8 +106,10 @@ class ACUController
                     .pack_nominal_capacity = acu_controller_default_parameters::PACK_NOMINAL_CAPACITY_AH,
                     .pack_max_voltage = acu_controller_default_parameters::PACK_MAX_VOLTAGE,
                     .pack_min_voltage = acu_controller_default_parameters::PACK_MIN_VOLTAGE,
-                    .pack_internal_resistance = acu_controller_default_parameters::PACK_INTERNAL_RESISTANCE
-                }) : _acu_parameters{thresholds, invalid_packet_count_thresh, fault_durations, pack_specs} {};
+                    .pack_internal_resistance = acu_controller_default_parameters::PACK_INTERNAL_RESISTANCE}
+
+
+            ) : _acu_parameters{thresholds, invalid_packet_count_thresh, fault_durations, pack_specs} {};
 
     /**
      * @brief Initialize the status time stamps because we don't want accidental sudden faults
@@ -118,6 +127,7 @@ class ACUController
      * Calculate Cell Balancing values
      * @pre cell charging is enabled
      * @post output will have the new values
+     * check TS isolation
      */
     void calculate_cell_balance_statuses(bool* output, const volt* voltages, size_t num_of_voltage_cells, volt min_voltage);
 
@@ -136,6 +146,9 @@ class ACUController
     {
         _acu_state.charging_enabled = false;
     }
+
+    bool check_ts_isolation(volt pack_voltage_adc, volt ts_voltage_adc);
+
 private:
 
 

lib/systems/src/ACUController.cpp

@@ -1,6 +1,7 @@
 #include "ACUController.h"
 
 
+
 void ACUController::init(time_ms system_start_time, volt pack_voltage)
 {
     _acu_state.last_time_ov_fault_not_present = system_start_time;
@@ -12,6 +13,8 @@ void ACUController::init(time_ms system_start_time, volt pack_voltage)
     _acu_state.prev_bms_time_stamp = system_start_time;
     _acu_state.SoC = (pack_voltage <= _acu_parameters.pack_specs.pack_min_voltage) ? 0.0f : ((pack_voltage - _acu_parameters.pack_specs.pack_min_voltage) / (_acu_parameters.pack_specs.pack_max_voltage - _acu_parameters.pack_specs.pack_min_voltage));
     _acu_state.balancing_enabled = false;
+    _acu_state.high_side_contactor_welded = false;
+    _acu_state.low_side_contactor_welded = false;
 }
 
 
@@ -100,7 +103,6 @@ ACUControllerData_s ACUController::evaluate_accumulator(time_ms current_millis,
     // Determine if bms is ok
     _acu_state.bms_ok = _check_bms_ok(current_millis);
 
-
     return _acu_state;
 }
 
@@ -173,4 +175,15 @@ bool ACUController::_check_invalid_packet_faults(time_ms current_millis)
 {
     bool invalid_packet_fault = (current_millis - _acu_state.last_time_invalid_packet_present) > _acu_parameters.fault_durations.max_allowed_invalid_packet_fault_dur;
     return invalid_packet_fault;
+}
+
+bool ACUController::check_ts_isolation(volt pack_voltage_adc, volt ts_voltage_adc) 
+{
+
+
+    _acu_state.low_side_contactor_welded = !(pack_voltage_adc < _acu_parameters.thresholds.ts_isolation_voltage);
+    _acu_state.high_side_contactor_welded = !(ts_voltage_adc < _acu_parameters.thresholds.ts_isolation_voltage);
+
+    bool sw_not_ok = _acu_state.low_side_contactor_welded || _acu_state.high_side_contactor_welded;
+    return sw_not_ok;
 }

platformio.ini

@@ -1,7 +1,7 @@
 [common]
 lib_deps_shared = 
   https://github.com/hytech-racing/shared_firmware_systems.git
-  https://github.com/hytech-racing/shared_firmware_types.git#9525cc8b5778567afee9d9121f8f8933367e13b3
+  https://github.com/hytech-racing/shared_firmware_types.git#7a3684f9501d672b8229476644b8ee5556f0adb5
   Embedded Template Library@^20.39.4
 
 ; Teensy41 Environment. This environment is the primary environment for uploading code to the car.

src/ACU_InterfaceTasks.cpp

@@ -44,7 +44,11 @@ static ACUAllDataType_s make_acu_all_data()
     out.core_data.min_measured_ts_out_voltage = watchdog.min_measured_ts_out_voltage;
     out.core_data.min_shdn_out_voltage = watchdog.min_shdn_out_voltage; 
     // SoC/SoH placeholders (leave unchanged here)
-    out.SoC = ACUControllerInstance::instance().get_status().SoC;
+    auto ACUStatus = ACUControllerInstance::instance().get_status();
+
+    out.SoC = ACUStatus.SoC;
+    out.core_data.high_side_contactor_welded = ACUStatus.high_side_contactor_welded;
+    out.core_data.low_side_contactor_welded = ACUStatus.low_side_contactor_welded;
 
     return out;
 }
@@ -94,7 +98,8 @@ void initialize_all_interfaces()
                                 ACUInterfaces::TS_OUT_FILTERED_PIN,
                                 ACUInterfaces::PACK_OUT_FILTERED_PIN,
                                 ACUInterfaces::BSPD_CURRENT_PIN,
-                                ACUInterfaces::SCALED_24V_PIN},
+                                ACUInterfaces::SCALED_24V_PIN, 
+                                ACUInterfaces::SW_NOT_OK_PIN},
                                 ADCConversions_s {ACUInterfaces::SHUTDOWN_CONV_FACTOR,
                                 ACUInterfaces::PRECHARGE_CONV_FACTOR,
                                 ACUInterfaces::PACK_AND_TS_OUT_CONV_FACTOR,