bms/Application/app/sox/state.c

#include "bsp/gpio.h"
#include "bsp/ml5238.h"
#include "bsp/cs1180.h"
#include "bsp/uart.h"
#include "bsp/mcu_power_sleep.h"
#include "app/sox/measure.h"
#include "app/sox/measure_task.h"
#include "libs/shark_task.h"
#include "libs/logger.h"
#include "app/nv_storage.h"
#include "health.h"
#include "soc.h"
#include "state.h"
#include "iostate.h"

#define ALLOW_DEEP_SLEEP 1
#define SLEEP_IGNORE_UNHEALTH 0
#define ALLOW_POWER_DOWN 1 //disable power down for debug
#define ALLOW_5238_BALANCE 1
#define IGNORE_DISCHARGER_LOW_VOL 0 //忽略放电欠压
static void _current_notify(void);
static void _voltage_notify(void);
static void _temperature_notify(void);
static u32 _bms_main_task_handler(void);
static void _debug_timer_handler(shark_timer_t *t);
static void _process_power_down(void);

static bms_state_t _bms_state;
static int pcb_temp = 100;
static int pcb_temp_count = 0;
static int ml5238_cali_count = 0;
static shark_task_t _bms_main_task = {.handler = _bms_main_task_handler};
static shark_timer_t _debug_timer = {.handler = _debug_timer_handler};
static int open_dfet = 0;
static int open_dfet_failt = 0;
static int close_dfet_reson = 0;
void bms_state_init(void){
	set_log_level(MOD_STATE, L_debug);
	state_debug("BMS System Starting......\n");	
	_bms_state.cell_index_of_max_vol = 0xff;
	_bms_state.bms_addr = 0x30;
	measure_task_init(_current_notify, _voltage_notify, _temperature_notify);
	io_state_init();
	health_init();
	soc_init();
	_bms_state.user_request = USER_REQUEST_PENDING | USER_REQUEST_SMALLCURRENT_ON;
	shark_task_add(&_bms_main_task);
	shark_timer_post(&_debug_timer, 2000);

	pcb_temp = measure_value()->pack_temp[PCB_TEMP_INDEX];
}

bms_state_t *bms_state_get(void){
	return &_bms_state;
}

int bms_work_is_normal(void){
	return _bms_state.work_mode == WORK_MODE_NORMAL;
}

int bms_work_is_aging_test(void){
	return _bms_state.work_mode == WORK_MODE_AGING_TEST;
}

int bms_work_is_pcba_test(void){
	return _bms_state.work_mode == WORK_MODE_PCBA_TEST;
}

int bms_work_is_pack_test(void){
	return _bms_state.work_mode == WORK_MODE_PACK_TEST;
}

int bms_work_is_calibrating(void){
	return _bms_state.work_mode == WORK_MODE_CALIBRATE;
}


int bms_work_mode_set(int mode, int start){
	if (mode < WORK_MODE_AGING_TEST || mode > WORK_MODE_CALIBRATE){
		return 1;
	}
	if (start){
		_bms_state.work_mode = mode;
	}else {
		_bms_state.work_mode = WORK_MODE_NORMAL;
	}
	return 0;
}

void bms_set_ps_charger_in(uint16_t mask, uint16_t in){
	_bms_state.ps_charger_in = in;
	_bms_state.ps_charger_mask = mask;
}

void bms_state_log(void){
	state_debug("Life Time: %d\n", shark_get_seconds());
	state_debug("Sleep Time: %ds\n", get_system_sleep_time());
	state_debug("ml5238 cali: %d\n", ml5238_cali_count);
	state_debug("ps charger mask:in %d, %d\n", _bms_state.ps_charger_mask, _bms_state.ps_charger_in);
	state_debug("open dfet %d - %d - %d\n", open_dfet, open_dfet_failt, close_dfet_reson);
#if 0
	state_debug("Charging: %d\n", _bms_state.charging);
	state_debug("WorkMode %d\n", _bms_state.work_mode);
	state_debug("DMos: %d\n", ml5238_is_discharging());
	state_debug("CMos: %d\n", ml5238_is_charging());
	state_debug("AuxPower: %d\n", AUX_VOL_IS_OPEN());
	state_debug("WorkMode:0x%x\n", _bms_state.work_mode);l
#endif
}

static void _debug_timer_handler(shark_timer_t *t){
#if 0
	static int _log_count = 0;

	int mod = _log_count % 4;
	if (mod == 0){
		bms_state_log();
	}
	if (mod == 1) {
		iostate_log();
	}
	if (mod == 2) {
		soc_log();
	}
	if (mod == 3) {
		measure_log();
	}
	_log_count ++;
#else
	bms_state_log();
	measure_log();
#endif
	shark_timer_post(&_debug_timer, 2000);
}


/*
 放电mos和充电mos的开关要小心:
 1. 大部分的情况下，尽量能做到同时开关，主要是用来保护被关闭那路mos的体二极管(不能过大电流)
 2. 充电过压的情况下，必须要关闭充电mos，但是这个时候放电mos可能是打开的，这样的情况下，
    需要检测放电电流，超过10A必须强制打开充电mos,防止烧充电mos的体二极管
 3. 收到打开大电的指令后，必须两个mos都要打开,然后再经过2的判断
    。。。。。
*/
void discharger_open(int open){
	/* 打开大电前，先打开短路保护*/
	if (open) {
		int mode = SHORT_CURRENT_MODE_100A_200A;
		int try_count = 3;
		/* 确保短路保护设置成功后才能开大电 */
		do {
			ml5238_short_current_detect(mode);//SP600:100A, SP700:200A
		}while(!ml5238_is_short_current_enabled(mode) && (try_count-- >= 0));
		if ((try_count < 0) && !ml5238_is_short_current_enabled(mode)){
			state_error("set short current error\n");
			return;
		}
	}else {
		ml5238_short_current_detect(SHORT_CURRENT_MODE_DISABLE);
	}
	ml5238_enable_discharger_mosfet(open);
}


void charger_open(int open) {
	ml5238_enable_charger_mosfet(open);
}


void start_aux_power(int start){
	if (start){
		AUX_VOL_OPEN(1);
	}else {
		AUX_VOL_OPEN(0);
		health_stop_aux_detect();
	}
}

void system_power_down(void){
	bms_health()->powerdown_lower_voltage = 1;
	_process_power_down();
}

#define Health_Success 0
#define Health_Discharger_Failt 1
#define Health_charger_Fault 2
#define Health_aux_Fault 4
#define Health_Fault_Can_Sleep 8
static s32 _process_unheath(void){
	u32 unhealth = Health_Success;
	if (bms_health()->load_current_short) {//短路检测后，关闭充放电mos
		discharger_open(0);
		charger_open(0); //disable charger mosfet
		start_aux_power(0);
		_bms_state.charging = 0;
		close_dfet_reson = 2;
		unhealth = (Health_Discharger_Failt | Health_charger_Fault);
	}
	if (!bms_work_is_normal()){
		return unhealth; //测试模式只关注短路保护
	}
	if (bms_health()->charger_over_current || bms_health()->charger_over_temp || bms_health()->charger_lower_temp ||
				bms_health()->charger_over_voltage || bms_health()->sigle_cell_over_voltage){
		if (_bms_state.ps_charger_mask && !_bms_state.ps_charger_in){

		}else {
			charger_open(0); //disable charger mosfet
			unhealth |= Health_charger_Fault;
		}
	}
	if (bms_health()->over_temp_deny_charger|| bms_health()->lower_temp_deny_charger) {
		if (_bms_state.ps_charger_mask && !_bms_state.ps_charger_in){

		}else if (_bms_state.charging) {
			charger_open(0); //disable charger mosfet
			unhealth |= Health_charger_Fault;
		}
	}
	if (bms_health()->discharger_over_temp || bms_health()->discharger_lower_temp){
		if (bms_health()->discharger_over_temp){ //放电过高温后，小电流也必须关闭
			start_aux_power(0);
			unhealth |= Health_aux_Fault;
		}
		discharger_open(0); //disable charger mosfet
		close_dfet_reson = 3;
		unhealth |= Health_Discharger_Failt;
	}

	if (bms_health()->sigle_cell_lower_voltage || bms_health()->discharger_lower_voltage) {
		unhealth |= Health_Fault_Can_Sleep;
#if IGNORE_DISCHARGER_LOW_VOL==0
		if (!(_bms_state.ps_charger_mask && _bms_state.ps_charger_in)) {//PSxxx 告知有充电器插入，忽略欠压
			unhealth |= Health_Discharger_Failt | Health_aux_Fault;
			start_aux_power(0);
			if (ml5238_is_discharging()) {
				close_dfet_reson = 4;
				discharger_open(0);
			}
		}
#endif
	}
	if (bms_health()->over_temp_deny_discharger|| bms_health()->lower_temp_deny_discharger) {
		if (!_bms_state.charging) {
			close_dfet_reson = 5;
			discharger_open(0); //disable discharger mosfet
		}
		unhealth |= (Health_Discharger_Failt | Health_Fault_Can_Sleep);		
	}
	if (io_state()->aux_lock_detect || bms_health()->small_current_short) {
		unhealth |= Health_aux_Fault;
		if (bms_health()->small_current_real_short) {
			unhealth |= Health_Discharger_Failt;
		}
	}
	
	return unhealth;
}


//处理PS100/310/320/360，充电底座，充电柜的指令或者bms自己发给自己的指令
static void _process_user_request(s32 health){
	if (_bms_state.user_request & USER_REQUEST_PENDING){
		//开关小电
		if (_bms_state.user_request & USER_REQUEST_SMALLCURRENT_OFF){
			start_aux_power(0);
		}
		if (_bms_state.user_request & USER_REQUEST_DISCHARGER_OFF){
			discharger_open(0);
		}
		if (_bms_state.user_request & USER_REQUEST_CHARGER_OFF){
			charger_open(0);
		}

		if (_bms_state.user_request & USER_REQUEST_SMALLCURRENT_ON){ 
			if (!(health & Health_aux_Fault)){
				start_aux_power(1);
			}
		}
		if (_bms_state.user_request & USER_REQUEST_CHARGER_ON){
			if (!(health & Health_charger_Fault)){
				charger_open(1);
			}
		}
		if (_bms_state.user_request & USER_REQUEST_DISCHARGER_ON) {
			open_dfet ++;
			if (!(health & Health_Discharger_Failt)){
				discharger_open(1);
			}else {
				open_dfet_failt ++;
			}
		}
		_bms_state.user_request &= ~USER_REQUEST_PENDING;//clear user request pending
	}
}

static void _process_power_down(void){
#if (ALLOW_POWER_DOWN==1)	
	if (bms_health()->powerdown_lower_voltage){
		state_debug("BMS System PowerDown!!\n");

		if (bms_work_is_normal() && soc_update_by_ocv()) {
			nv_save_all_soc();
		}
		
		shark_uart_flush();
		if (bms_work_is_normal()) {
			if (io_state()->charger_detect_irq || io_state()->charger_detect){//have charger, do'nt power down
				bms_health()->powerdown_lower_voltage = 0;
				return;
			}
		}
		start_aux_power(0);
		discharger_open(0);
		charger_open(0);
		
		/*需要等待B-和P-之间的电容放电掉后，才能设置5238 power down，
		否则5238会触发充电器插入检测，导致重新开机，进入powerdown <->开机的无限循环*/
		/* 需要先关闭负载检测，否则充电器检测会分压掉一部分 */
		ml5238_enable_load_detect(0);
		ml5238_enable_charger_detect(AUX_VOL_IS_OPEN(), 1);
		delay_us(2* 1000);
		u64 wait_start = shark_get_mseconds();
		while(!ml5238_charger_is_disconnect(AUX_VOL_IS_OPEN())){
			shark_uart_flush();
			wdog_reload();
			if (shark_get_mseconds() - wait_start >= 2000){
				bms_health()->powerdown_lower_voltage = 0;
				ml5238_enable_charger_detect(AUX_VOL_IS_OPEN(), 0);
				return;
			}
		}
		LED_ALL_ON(0);
		CS1180_PWR_ENABLE(0);
		DCDC_VOL_OPEN(0);
		ml5238_power_down();
	}
#endif
}


static void _process_deepsleep(s32 health){
#if (ALLOW_DEEP_SLEEP==1)
	static u64 _sleep_time = 0;
#if (SLEEP_IGNORE_UNHEALTH==0)
	if ((health != Health_Success) && ((health & Health_Fault_Can_Sleep) != Health_Fault_Can_Sleep)){
		return;
	}
#endif
	if (!bms_work_is_normal()){
		return; //测试模式下不休眠
	}
	if (ml5238_is_charging() || ml5238_is_discharging() || io_state()->charger_detect_irq || _bms_state.charging){
		return;
	}

	if(io_state()->hall_detect){
		return;
	}

	if (!shark_uart_timeout()){
		return;
	}

	if (io_state()->aux_lock_detect){
		return;
	}
	if (shark_get_mseconds() < (_sleep_time + 3 * 1000)){
		return;
	}
	
	nv_save_all_soc();
	mcu_enter_deepsleep();
	soc_update_for_deepsleep(mcu_get_sleeptime());//补偿休眠的功耗
	_sleep_time = shark_get_mseconds();
#endif	
}

/*when work as test mode, we do'n need close the discharger */
static int _can_close_mos_no_hall(void){
	if (bms_work_is_normal()){
		return 1;
	}
	return 0;
}

static void _process_iostate_changed(s32 unhealth){
	if (!(io_state()->hall_detect)&& _can_close_mos_no_hall()){
		bms_set_ps_charger_in(0, 0);
		if (ml5238_is_discharging() && (!_bms_state.charging)){
			discharger_open(0);
			close_dfet_reson = 1;
			open_dfet = open_dfet_failt = 0; //clear open dfet count
		}
		if (!AUX_VOL_IS_OPEN()){
			start_aux_power(1);
		}
		if (!io_state()->charger_detect_irq && ml5238_is_charging() && (!_bms_state.charging)){
			charger_open(0);
		}
	}
	if (io_state()->charger_detect_irq && ((unhealth & Health_charger_Fault) == 0) && (_bms_state.cell_max_vol < SIGLE_CELL_MAX_CHARGER_VOLTAGE)) {
		if (!ml5238_is_charging() && shark_uart_timeout()){//不在车上，底座上，充电柜上，检测到充电器插入，自动打开充电，否则的话，只能通过指令来打开充电mos
			if (!(bms_health()->over_temp_deny_charger|| bms_health()->lower_temp_deny_charger)) {
				charger_open(1);
			}
		}
	}
	if (io_state()->hall_detect){
		_bms_state.bms_addr = 0x30 + 1;
		bms_health()->hall_is_detected = 1;
	}else {
		_bms_state.bms_addr = 0x30;
		bms_health()->hall_is_detected = 0;
	}
}

static u32 _bms_main_task_handler(void){
	s32 unhealth = _process_unheath();
	_process_user_request(unhealth);
	_process_deepsleep(unhealth);
	_process_power_down();
	_process_iostate_changed(unhealth);
	return 0;
}

extern void show_leds_for_charging(uint8_t charging);
static debounce_t _charging_detect = {.count = 0, .max_count = 10, .init_count = 0};
static int cs1180_may_error_count = 0;
static void check_charging(){
	/* 解决cs1180可能出错，导致误判充电，离仓后无法休眠 */
	int may_error = 0;
	if (measure_value()->load_current >= MIN_START_CHARGER_CURRENT) {
		if (measure_value()->load_current != measure_value()->current_5238) {
			if (measure_value()->current_5238 <= 0) { //cs1180检测到充电电流，5238检测到负电流
				if (++cs1180_may_error_count >= _charging_detect.max_count/2) {
					measure_value()->load_current = measure_value()->current_5238;
					cs1180_adc_shutdown();
					cs1180_may_error_count = 0;
				}
				may_error = 1;
			}
		}
	}
	if (may_error == 0) {
		cs1180_may_error_count = 0;
	}
	if ((measure_value()->load_current >= MIN_START_CHARGER_CURRENT)) {
		if (!_bms_state.charging) {
			debounce_inc(_charging_detect);
			if (debounce_reach_max(_charging_detect)){
				_bms_state.charging = 1;
				show_leds_for_charging(1);
				debounce_reset(_charging_detect);
			}
		}else {
			debounce_reset(_charging_detect);
		}
	}else/* if ((measure_value()->load_current < MIN_START_LOADING_CURRENT))*/{
		if (_bms_state.charging) {
			debounce_inc(_charging_detect);
			if (debounce_reach_max(_charging_detect)){
				_bms_state.charging = 0;
				show_leds_for_charging(0);
				debounce_reset(_charging_detect);
			}
		}else {
			debounce_reset(_charging_detect);
		}
	}
}

/* if discharger mos and charger mos, one is open but other is closed.
   we must judage the current: if current is large than 10A(-10A), 
   we must open the closed mos to avoid the closed mos to be destroyed
*/
#define MIN_CURRENT_FOR_BOTH_MOS_OPEN (1000)
static int _min_current_for_both_mos_count = 0;
static u32 _check_mos_time = 0;
static __INLINE u32 _open_all_mos_time(void){
	if (abs(measure_value()->load_current) >= MIN_CURRENT_FOR_BOTH_MOS_OPEN * 2){
		return 0;
	}
	if (abs(measure_value()->load_current) >= MIN_CURRENT_FOR_BOTH_MOS_OPEN) {
		return 10;
	}
	return 30;
}
static void _check_mos_stat(void){
	if (abs(measure_value()->load_current) >= MIN_CURRENT_FOR_BOTH_MOS_OPEN){
		_min_current_for_both_mos_count ++;
		if (_min_current_for_both_mos_count >= 2){
			int dmos = ml5238_is_discharging();
			int cmos = ml5238_is_charging();
			if (dmos + cmos == 0){
				//state_error("current = %d, but all mos is closed\n", measure_value()->load_current);
				return;
			}
			if (dmos == 1 && cmos == 1){
				return;
			}
			if (shark_get_seconds() >= (_check_mos_time + _open_all_mos_time())) {
				uint32_t request = USER_REQUEST_PENDING;
				if (!dmos) {
					request |= USER_REQUEST_DISCHARGER_ON;
				}else {
					request |= USER_REQUEST_CHARGER_ON;
				}
				_bms_state.user_request = request;
				_check_mos_time = shark_get_seconds();
			}
		}
	}else {
		_min_current_for_both_mos_count = 0;
	}
}

static void _current_notify(void){
	check_charging();
	check_current_state(); //check health of current
	_check_mos_stat();
	soc_update(); //计算soc
}

#if (ALLOW_5238_BALANCE==1)

/* 需要检查电芯的电压，如果发现有电芯电压过高，需要开启被动均衡 
 * 充电过程中考虑balance,主要是希望cell 电压扩散后，保证1. 单电芯不能过压， 2. 单电芯不能比平均电压过低,导致
 * 木桶效应,目标是电压最高的那个cell，尽量压制，不让电压再升高，或者升高的尽量慢一些
*/
static void _balance_timer_handler(shark_timer_t *t);

static shark_timer_t _balance_timer = {.handler = _balance_timer_handler};

static debounce_t _cell_balance = {.count = 0, .max_count = 10, .init_count = 0};

static void _balance_timer_handler(shark_timer_t *t){
	ml5238_cell_start_balance(0);
	_bms_state.pack_balancing = 0;
}

static uint32_t get_balance_mask(uint8_t current_max_index){
	return BIT(current_max_index);
}

static void check_cell_balance(uint8_t current_max_index){
	if (!_bms_state.charging){ //not charging, need not do balance
		if (_bms_state.pack_balancing){
			_bms_state.pack_balancing = 0;
			_cell_balance.count = 10;
			ml5238_cell_start_balance(0);
			shark_timer_cancel(&_balance_timer);
		}
		return;
	}
	if ((!_bms_state.pack_balancing && _bms_state.cell_max_vol < MAX_CELL_VOLTAGE_FOR_BALACNE) || _bms_state.pack_balancing){
		return;
	}
	if (_bms_state.cell_max_vol >= MAX_CELL_VOLTAGE_FOR_BALACNE){
		debounce_inc(_cell_balance);
	}else {
		debounce_reset(_cell_balance);
	}
	if (!_bms_state.pack_balancing && debounce_reach_max(_cell_balance)){
		_bms_state.pack_balancing = 1;
		ml5238_cell_start_balance(get_balance_mask(current_max_index));
		shark_timer_post(&_balance_timer, 30 * 1000); //stop balance after 30s
		debounce_reset(_cell_balance);
	}
	_bms_state.cell_index_of_max_vol = current_max_index;	
}
#endif
static uint8_t calc_cell_voltage(void){
	uint16_t voltage = 0;
	uint16_t max_cell = 0;
	uint16_t min_cell = 0xf000;
	uint8_t max_index = 0;
	for (int i = 0; i < CELLS_NUM; i++){
		voltage += measure_value()->cell_vol[i];
		if (max_cell < measure_value()->cell_vol[i]){
			max_cell = measure_value()->cell_vol[i];
			max_index = i;
		}
		if (min_cell > measure_value()->cell_vol[i]){
			min_cell = measure_value()->cell_vol[i];
		}		
	}
	_bms_state.pack_voltage = voltage;
	_bms_state.cell_max_vol = max_cell;
	_bms_state.cell_min_vol = min_cell;	
	return max_index;
}

static void _voltage_notify(void){
	uint8_t max_index = calc_cell_voltage();
	check_voltage_state(); //check health of cell voltage
#if (ALLOW_5238_BALANCE==1)
	check_cell_balance(max_index);
#endif
}

static void _temperature_notify(void){
	int pcb_current_temp = measure_value()->pack_temp[PCB_TEMP_INDEX];
	if (abs(pcb_temp - pcb_current_temp) >= 5){//pcb温度变化超过5度，需要重新校准ML5238
		if (pcb_temp_count ++ >= 5) {
			current_calibrate();
			state_warning("ML5238 calibrate, %d -> %d!!\n", pcb_temp, pcb_current_temp);
			pcb_temp = pcb_current_temp;
			pcb_temp_count = 0;
			ml5238_cali_count ++;
		}
	}else {
		pcb_temp_count = 0;
	}
	check_temp_state(); //check health of cell/pcb temperature
}