From 1b0c3bcb67dd56f8aa574fdeac7a9244c8eba0d2 Mon Sep 17 00:00:00 2001
From: "Ben V. Brown" <ralim@ralimtek.com>
Date: Tue, 14 Sep 2021 21:48:58 +1000
Subject: [PATCH] Cleaning up fast/slow PWM change

---
 source/Core/Inc/configuration.h | 25 +++++++++++--------
 source/Core/Src/power.cpp       | 43 ++++++++++++++++++++-------------
 2 files changed, 41 insertions(+), 27 deletions(-)

diff --git a/source/Core/Inc/configuration.h b/source/Core/Inc/configuration.h
index 0f85e170..d4864556 100644
--- a/source/Core/Inc/configuration.h
+++ b/source/Core/Inc/configuration.h
@@ -227,28 +227,33 @@
 #endif
 
 #ifdef MODEL_TS100
-const int32_t tipMass       = 65; // X10 watts to raise 1 deg C in 1 second
-const uint8_t tipResistance = 75; // x10 ohms, 7.5 typical for ts100 tips
+const int32_t HARDWARE_MAX_WATTAGE_X10 = 750;
+const int32_t TIP_THERMAL_MASS         = 65; // X10 watts to raise 1 deg C in 1 second
+const uint8_t tipResistance            = 75; // x10 ohms, 7.5 typical for ts100 tips
 #endif
 
 #ifdef MODEL_Pinecil
-const int32_t tipMass       = 45; // X10 watts to raise 1 deg C in 1 second
-const uint8_t tipResistance = 75; // x10 ohms, 7.5 typical for ts100 tips
+const int32_t HARDWARE_MAX_WATTAGE_X10 = 750;
+const int32_t TIP_THERMAL_MASS         = 65; // X10 watts to raise 1 deg C in 1 second
+const uint8_t tipResistance            = 75; // x10 ohms, 7.5 typical for ts100 tips
 #endif
 
 #ifdef MODEL_TS80
-const uint32_t tipMass       = 40;
-const uint8_t  tipResistance = 45; // x10 ohms, 4.5 typical for ts80 tips
+const int32_t  HARDWARE_MAX_WATTAGE_X10 = 180;
+const uint32_t TIP_THERMAL_MASS         = 40;
+const uint8_t  tipResistance            = 45; // x10 ohms, 4.5 typical for ts80 tips
 #endif
 
 #ifdef MODEL_TS80P
-const uint32_t tipMass       = 40;
-const uint8_t  tipResistance = 45; // x10 ohms, 4.5 typical for ts80 tips
+const int32_t  HARDWARE_MAX_WATTAGE_X10 = 300;
+const uint32_t TIP_THERMAL_MASS         = 40;
+const uint8_t  tipResistance            = 45; // x10 ohms, 4.5 typical for ts80 tips
 #endif
 
 #ifdef MODEL_MHP30
-const uint32_t tipMass       = 45; // TODO
-const uint8_t  tipResistance = 60; // x10 ohms, ~6 typical
+const int32_t  HARDWARE_MAX_WATTAGE_X10 = 650;
+const uint32_t TIP_THERMAL_MASS         = 65; // TODO, needs refinement
+const uint8_t  tipResistance            = 60; // x10 ohms, ~6 typical
 #endif
 
 #ifdef POW_QC_20V
diff --git a/source/Core/Src/power.cpp b/source/Core/Src/power.cpp
index 97e4472a..dec27147 100644
--- a/source/Core/Src/power.cpp
+++ b/source/Core/Src/power.cpp
@@ -13,18 +13,31 @@ static int32_t PWMToX10Watts(uint8_t pwm, uint8_t sample);
 
 expMovingAverage<uint32_t, wattHistoryFilter> x10WattHistory = {0};
 
+bool shouldBeUsingFastPWMMode(const uint8_t pwmTicks) {
+  // Determine if we should use slow or fast PWM mode
+  // Crossover between modes set around the midpoint of the PWM control point
+  static bool lastPWMWasFast = true;
+  if (pwmTicks > (128 + 8) && lastPWMWasFast) {
+    lastPWMWasFast = false;
+  } else if (pwmTicks < (128 - 8) && !lastPWMWasFast) {
+    lastPWMWasFast = true;
+  }
+  return lastPWMWasFast;
+}
+
 int32_t tempToX10Watts(int32_t rawTemp) {
-  // mass is in milliJ/*C, rawC is raw per degree C
-  // returns milliWatts needed to raise/lower a mass by rawTemp
+  // mass is in x10J/*C, rawC is raw per degree C
+  // returns x10Watts needed to raise/lower a mass by rawTemp
   //  degrees in one cycle.
-  int32_t milliJoules = tipMass * rawTemp;
-  return milliJoules;
+  int32_t x10Watts = TIP_THERMAL_MASS * rawTemp;
+  return x10Watts;
 }
 
 void setTipX10Watts(int32_t mw) {
-  int32_t output = X10WattsToPWM(mw, 1);
-  setTipPWM(output);
-  uint32_t actualMilliWatts = PWMToX10Watts(output, 0);
+  int32_t    outputPWMLevel   = X10WattsToPWM(mw, 1);
+  const bool shouldUseFastPWM = shouldBeUsingFastPWMMode(outputPWMLevel);
+  setTipPWM(outputPWMLevel, shouldUseFastPWM);
+  uint32_t actualMilliWatts = PWMToX10Watts(outputPWMLevel, 0);
 
   x10WattHistory.update(actualMilliWatts);
 }
@@ -45,7 +58,6 @@ static uint32_t availableW10(uint8_t sample) {
   // availableMilliWattsX10 is now an accurate representation
   return availableWattsX10;
 }
-
 uint8_t X10WattsToPWM(int32_t milliWatts, uint8_t sample) {
   // Scale input milliWatts to the pwm range available
   if (milliWatts < 1) {
@@ -56,15 +68,12 @@ uint8_t X10WattsToPWM(int32_t milliWatts, uint8_t sample) {
 
   // Calculate desired milliwatts as a percentage of availableW10
   uint32_t pwm;
-  do {
-    pwm = (powerPWM * milliWatts) / availableW10(sample);
-    if (pwm > powerPWM) {
-      // constrain to max PWM counter, shouldn't be possible,
-      // but small cost for safety to avoid wraps
-      pwm = powerPWM;
-    }
-  } while (tryBetterPWM(pwm));
-
+  pwm = (powerPWM * milliWatts) / availableW10(sample);
+  if (pwm > powerPWM) {
+    // constrain to max PWM counter, shouldn't be possible,
+    // but small cost for safety to avoid wraps
+    pwm = powerPWM;
+  }
   return pwm;
 }