Made odometer persist after firmware updates, added hw runtime counter

Author: vedderb

CHANGELOG

@@ -17,6 +17,8 @@
 * Better current controller windup protection.
 * Field weakening support (experimental, be careful and use at your own risk).
 * Use filtered current for axis decoupling.
+* Odometer is now persistent after firmware updates.
+* Added hw runtime counter (see hw_status in terminal)
 
 === FW 5.02 ===
 * IMU calibration improvement.

commands.c

@@ -582,6 +582,7 @@ void commands_process_packet(unsigned char *data, unsigned int len,
 	} break;
 
 	case COMM_REBOOT:
+		conf_general_store_backup_data();
 		// Lock the system and enter an infinite loop. The watchdog will reboot.
 		__disable_irq();
 		for(;;){};

conf_general.c

@@ -48,10 +48,12 @@
 #define EEPROM_BASE_HW			3000
 #define EEPROM_BASE_CUSTOM		4000
 #define EEPROM_BASE_MCCONF_2	5000
+#define EEPROM_BASE_BACKUP		6000
 
 // Global variables
 uint16_t VirtAddVarTab[NB_OF_VAR];
 bool conf_general_permanent_nrf_found = false;
+__attribute__((section(".ram4"))) volatile backup_data g_backup;
 
 // Private functions
 static bool read_eeprom_var(eeprom_var *v, int address, uint16_t base);
@@ -78,11 +80,86 @@ void conf_general_init(void) {
 		VirtAddVarTab[ind++] = EEPROM_BASE_CUSTOM + i;
 	}
 
+	for (unsigned int i = 0;i < (sizeof(backup_data) / 2);i++) {
+		VirtAddVarTab[ind++] = EEPROM_BASE_BACKUP + i;
+	}
+
 	FLASH_Unlock();
 	FLASH_ClearFlag(FLASH_FLAG_OPERR | FLASH_FLAG_WRPERR | FLASH_FLAG_PGAERR |
 			FLASH_FLAG_PGPERR | FLASH_FLAG_PGSERR);
 	EE_Init();
 	FLASH_Lock();
+
+	// Read backup data
+	bool is_ok = true;
+	backup_data backup_tmp;
+	uint8_t *data_addr = (uint8_t*)&backup_tmp;
+	uint16_t var;
+
+	for (unsigned int i = 0;i < (sizeof(backup_data) / 2);i++) {
+		if (EE_ReadVariable(EEPROM_BASE_BACKUP + i, &var) == 0) {
+			data_addr[2 * i] = (var >> 8) & 0xFF;
+			data_addr[2 * i + 1] = var & 0xFF;
+		} else {
+			is_ok = false;
+			break;
+		}
+	}
+
+	if (!is_ok) {
+		memset(data_addr, 0, sizeof(backup_data));
+
+		// If the missing data is a result of programming it might still be in RAM4. Check
+		// and recover the valid values one by one.
+
+		if (g_backup.odometer_init_flag == BACKUP_VAR_INIT_CODE) {
+			backup_tmp.odometer = g_backup.odometer;
+		}
+
+		if (g_backup.runtime_init_flag == BACKUP_VAR_INIT_CODE) {
+			backup_tmp.runtime = g_backup.runtime;
+		}
+	}
+
+	backup_tmp.odometer_init_flag = BACKUP_VAR_INIT_CODE;
+	backup_tmp.runtime_init_flag = BACKUP_VAR_INIT_CODE;
+
+	g_backup = backup_tmp;
+	conf_general_store_backup_data();
+}
+
+/*
+ * Store backup data to emulated eeprom. Currently this is only done from the shutdown function, which
+ * only works if the hardware has a power switch. It would be possible to do this when the input voltage
+ * drops (e.g. on FAULT_CODE_UNDER_VOLTAGE) to not rely on a power switch. The risk with that is that
+ * a page swap might longer than the capacitors have voltage left, which could make cause the motor and
+ * app config to get lost.
+ */
+bool conf_general_store_backup_data(void) {
+	timeout_configure_IWDT_slowest();
+
+	bool is_ok = true;
+	uint8_t *data_addr = (uint8_t*)&g_backup;
+	uint16_t var;
+
+	FLASH_Unlock();
+	FLASH_ClearFlag(FLASH_FLAG_OPERR | FLASH_FLAG_WRPERR | FLASH_FLAG_PGAERR |
+			FLASH_FLAG_PGPERR | FLASH_FLAG_PGSERR);
+
+	for (unsigned int i = 0;i < (sizeof(backup_data) / 2);i++) {
+		var = (data_addr[2 * i] << 8) & 0xFF00;
+		var |= data_addr[2 * i + 1] & 0xFF;
+
+		if (EE_WriteVariable(EEPROM_BASE_BACKUP + i, var) != FLASH_COMPLETE) {
+			is_ok = false;
+			break;
+		}
+	}
+	FLASH_Lock();
+
+	timeout_configure_IWDT();
+
+	return is_ok;
 }
 
 /**

conf_general.h

@@ -24,7 +24,7 @@
 #define FW_VERSION_MAJOR			5
 #define FW_VERSION_MINOR			03
 // Set to 0 for building a release and iterate during beta test builds
-#define FW_TEST_VERSION_NUMBER		20
+#define FW_TEST_VERSION_NUMBER		21
 
 #include "datatypes.h"
 
@@ -315,9 +315,11 @@
 
 // Global configuration variables
 extern bool conf_general_permanent_nrf_found;
+extern volatile backup_data g_backup;
 
 // Functions
 void conf_general_init(void);
+bool conf_general_store_backup_data(void);
 bool conf_general_read_eeprom_var_hw(eeprom_var *v, int address);
 bool conf_general_read_eeprom_var_custom(eeprom_var *v, int address);
 bool conf_general_store_eeprom_var_hw(eeprom_var *v, int address);

datatypes.h

@@ -1221,4 +1221,14 @@ typedef struct {
 	uint8_t num_vescs;
 } setup_values;
 
+#define BACKUP_VAR_INIT_CODE				92891934
+
+typedef struct __attribute__((packed)) {
+	uint32_t odometer_init_flag;
+	uint64_t odometer; // Meters
+
+	uint32_t runtime_init_flag;
+	uint64_t runtime; // Seconds
+} backup_data;
+
 #endif /* DATATYPES_H_ */

eeprom.h

@@ -71,7 +71,7 @@
 
 /* Variables' number */
 #define NB_OF_VAR             ((uint16_t)((2 * sizeof(mc_configuration) + sizeof(app_configuration) + 1) / 2) + \
-                              EEPROM_VARS_HW * 2 + EEPROM_VARS_CUSTOM * 2)
+                              EEPROM_VARS_HW * 2 + EEPROM_VARS_CUSTOM * 2 + sizeof(backup_data) * 2)
 
 /* Exported types ------------------------------------------------------------*/
 /* Exported macro ------------------------------------------------------------*/

mc_interface.c

@@ -83,6 +83,10 @@ typedef struct {
 	float m_motor_current_unbalance;
 	float m_motor_current_unbalance_error_rate;
 	float m_f_samp_now;
+
+	// Backup data counters
+	uint64_t m_odometer_last;
+	uint64_t m_runtime_last;
 } motor_if_state_t;
 
 // Private variables
@@ -115,8 +119,6 @@ static volatile bool m_sample_is_second_motor;
 static volatile mc_fault_code m_fault_stop_fault;
 static volatile bool m_fault_stop_is_second_motor;
 
-static volatile uint32_t m_odometer_meters;
-
 // Private functions
 static void update_override_limits(volatile motor_if_state_t *motor, volatile mc_configuration *conf);
 static void run_timer_tasks(volatile motor_if_state_t *motor);
@@ -159,12 +161,6 @@ void mc_interface_init(void) {
 	m_sample_mode = DEBUG_SAMPLING_OFF;
 	m_sample_mode_last = DEBUG_SAMPLING_OFF;
 	m_sample_is_second_motor = false;
-	//initialize odometer to EEPROM value
-	m_odometer_meters = 0;
-	eeprom_var v;
-	if(conf_general_read_eeprom_var_custom(&v, EEPROM_ADDR_ODOMETER)) {
-		m_odometer_meters = v.as_u32;
-	}
 
 	// Start threads
 	chThdCreateStatic(timer_thread_wa, sizeof(timer_thread_wa), NORMALPRIO, timer_thread, NULL);
@@ -2122,6 +2118,23 @@ static void run_timer_tasks(volatile motor_if_state_t *motor) {
 	bool is_motor_1 = motor == &m_motor_1;
 	mc_interface_select_motor_thread(is_motor_1 ? 1 : 2);
 
+	// Update backup data (for motor 1 only)
+	if (is_motor_1) {
+		uint64_t odometer = mc_interface_get_distance_abs();
+		g_backup.odometer += odometer - m_motor_1.m_odometer_last;
+		m_motor_1.m_odometer_last = odometer;
+
+		uint64_t runtime = chVTGetSystemTimeX() / CH_CFG_ST_FREQUENCY;
+
+		// Handle wrap around
+		if (runtime < m_motor_1.m_runtime_last) {
+			m_motor_1.m_runtime_last = 0;
+		}
+
+		g_backup.runtime += runtime - m_motor_1.m_runtime_last;
+		m_motor_1.m_runtime_last = runtime;
+	}
+
 	motor->m_f_samp_now = mc_interface_get_sampling_frequency_now();
 
 	// Decrease fault iterations
@@ -2453,8 +2466,8 @@ unsigned mc_interface_calc_crc(mc_configuration* conf_in, bool is_motor_2) {
  * @param new_odometer_meters
  * new odometer value in meters
  */
-void mc_interface_set_odometer(uint32_t new_odometer_meters) {
-	m_odometer_meters = new_odometer_meters - roundf(mc_interface_get_distance_abs());
+void mc_interface_set_odometer(uint64_t new_odometer_meters) {
+	g_backup.odometer = new_odometer_meters;
 }
 
 /**
@@ -2463,18 +2476,6 @@ void mc_interface_set_odometer(uint32_t new_odometer_meters) {
  * @return
  * Odometer value in meters, including current trip
  */
-uint32_t mc_interface_get_odometer(void) {
-	return m_odometer_meters + roundf(mc_interface_get_distance_abs());
-}
-
-/**
- * Save current odometer value to persistent memory
- *
- * @return
- * success
- */
-bool mc_interface_save_odometer(void) {
-	eeprom_var v;
-	v.as_u32 = mc_interface_get_odometer();
-	return conf_general_store_eeprom_var_custom(&v, EEPROM_ADDR_ODOMETER);
+uint64_t mc_interface_get_odometer(void) {
+	return g_backup.odometer;
 }

mc_interface.h

@@ -86,9 +86,8 @@ float mc_interface_get_distance(void);
 float mc_interface_get_distance_abs(void);
 
 // odometer
-uint32_t mc_interface_get_odometer(void);
-void mc_interface_set_odometer(uint32_t new_odometer_meters);
-bool mc_interface_save_odometer(void);
+uint64_t mc_interface_get_odometer(void);
+void mc_interface_set_odometer(uint64_t new_odometer_meters);
 
 setup_values mc_interface_get_setup_values(void);
 

shutdown.c

@@ -19,7 +19,7 @@
 
 #include "shutdown.h"
 #include "app.h"
-#include "mc_interface.h"
+#include "conf_general.h"
 
 #ifdef HW_SHUTDOWN_HOLD_ON
 
@@ -63,7 +63,7 @@ void shutdown_set_sampling_disabled(bool disabled) {
 }
 
 bool do_shutdown(void) {
-	mc_interface_save_odometer();
+	conf_general_store_backup_data();
 	DISABLE_GATE();
 	HW_SHUTDOWN_HOLD_OFF();
 	return true;

terminal.c

@@ -165,7 +165,7 @@ void terminal_process_string(char *str) {
 	} else if (strcmp(argv[0], "dist") == 0) {
 		commands_printf("Trip dist.      : %.2f m", (double)mc_interface_get_distance());
 		commands_printf("Trip dist. (ABS): %.2f m", (double)mc_interface_get_distance_abs());
-		commands_printf("Odometer        : %u   m\n", mc_interface_get_odometer());
+		commands_printf("Odometer        : %llu m\n", mc_interface_get_odometer());
 	} else if (strcmp(argv[0], "tim") == 0) {
 		chSysLock();
 		volatile int t1_cnt = TIM1->CNT;
@@ -548,6 +548,9 @@ void terminal_process_string(char *str) {
 				STM32_UUID_8[8], STM32_UUID_8[9], STM32_UUID_8[10], STM32_UUID_8[11]);
 		commands_printf("Permanent NRF found: %s", conf_general_permanent_nrf_found ? "Yes" : "No");
 
+		commands_printf("Odometer : %llu m", mc_interface_get_odometer());
+		commands_printf("Runtime  : %llu s", g_backup.runtime);
+
 		float curr0_offset;
 		float curr1_offset;
 		float curr2_offset;