Startup behaviour fixes (#1306)

* Reduce PPS max to 20V to avoid instability

Some PSU's cant actually run at 21V

* Creating a rough draft of a "pre start check" concept

* Newer alpine

* Cleaning up MHP detection

* Cleanup comments

* PID: Run prestart based on ADC IRQ rather than times

* MHP30: Far better startup for detecting tip gain

* Newer alpine for github CI

Dockerfile

@@ -14,6 +14,8 @@ RUN apk add --no-cache gcc-riscv-none-elf gcc-arm-none-eabi newlib-riscv-none-el
 # Install Python3 packages
 
 RUN python3 -m pip install bdflib black
+# Git trust
+RUN git config --global --add safe.directory /build/source
 
 COPY . /build/source
 COPY ./ci /build/ci

source/Core/BSP/BSP.h

@@ -86,6 +86,10 @@ enum StatusLED {
 };
 void setStatusLED(const enum StatusLED state);
 
+// preStartChecks are run until they return 0
+// By the PID, after each ADC sample comes in
+// For example, on the MHP30 this is used to figure out the resistance of the hotplate
+uint8_t preStartChecks();
 #ifdef __cplusplus
 }
 #endif

source/Core/BSP/MHP30/BSP.cpp

@@ -13,13 +13,15 @@
 #include <IRQ.h>
 
 WS2812<GPIOA_BASE, WS2812_Pin, 1> ws2812;
-volatile uint16_t                 PWMSafetyTimer = 0;
+volatile uint16_t                 PWMSafetyTimer            = 0;
-volatile uint8_t                  pendingPWM     = 0;
+volatile uint8_t                  pendingPWM                = 0;
-uint16_t                          totalPWM       = 255;
+uint16_t                          totalPWM                  = 255;
-const uint16_t                    powerPWM       = 255;
+const uint16_t                    powerPWM                  = 255;
+uint16_t                          tipSenseResistancex10Ohms = 0;
+volatile bool                     tipMeasurementOccuring    = false;
+history<uint16_t, PID_TIM_HZ>     rawTempFilter             = {{0}, 0, 0};
 
-history<uint16_t, PID_TIM_HZ> rawTempFilter = {{0}, 0, 0};
+void resetWatchdog() { HAL_IWDG_Refresh(&hiwdg); }
-void                          resetWatchdog() { HAL_IWDG_Refresh(&hiwdg); }
 
 #ifdef TEMP_NTC
 // Lookup table for the NTC
@@ -208,7 +210,8 @@ uint16_t getHandleTemperature(uint8_t sample) {
 uint16_t getTipInstantTemperature() { return getADC(2); }
 
 uint16_t getTipRawTemp(uint8_t refresh) {
-  if (refresh) {
+  if (refresh && (tipMeasurementOccuring == false)) {
+
     uint16_t lastSample = getTipInstantTemperature();
     rawTempFilter.update(lastSample);
     return lastSample;
@@ -348,69 +351,82 @@ void setPlatePullup(bool pullingUp) {
   HAL_GPIO_Init(PLATE_SENSOR_PULLUP_GPIO_Port, &GPIO_InitStruct);
 }
 
-uint16_t tipSenseResistancex10Ohms = 0;
+void performTipMeasurementStep(bool start) {
-bool     isTipDisconnected() {
+  static uint16_t   adcReadingPD1Set = 0;
-  static bool       lastTipDisconnectedState = true;
+  static TickType_t lastMeas         = 0;
-  static uint16_t   adcReadingPD1Set         = 0;
+  // Inter state that performs the steps to measure the resistor on the tip
-  static TickType_t lastMeas                 = 0;
+  // Return 1 if a measurement is ongoing
+
+  // We want to perform our startup measurements of the tip resistance until we detect one fitted
+
+  // Step 1; if not setup, we turn on pullup and then wait
+  if (tipMeasurementOccuring == false && (start || tipSenseResistancex10Ohms == 0 || lastMeas == 0)) {
+    tipMeasurementOccuring    = true;
+    tipSenseResistancex10Ohms = 0;
+    lastMeas                  = xTaskGetTickCount();
+    adcReadingPD1Set          = 0;
+    setPlatePullup(true);
+    return;
+  }
+
+  // Wait 100ms for settle time
+  if ((xTaskGetTickCount() - lastMeas) < (TICKS_100MS)) {
+    return;
+  }
+
+  lastMeas = xTaskGetTickCount();
+  // We are sensing the resistance
+  if (adcReadingPD1Set == 0) {
+    // We will record the reading for PD1 being set
+    adcReadingPD1Set = getADC(3);
+    setPlatePullup(false);
+    return;
+  }
+  // Taking reading two
+  uint16_t adcReadingPD1Cleared = getADC(3);
+  uint32_t a                    = ((int)adcReadingPD1Set - (int)adcReadingPD1Cleared);
+  a *= 10000;
+  uint32_t b = ((int)adcReadingPD1Cleared + (32768 - (int)adcReadingPD1Set));
+  if (b) {
+    tipSenseResistancex10Ohms = a / b;
+  } else {
+    tipSenseResistancex10Ohms = adcReadingPD1Set = lastMeas = 0;
+  }
+  if (tipSenseResistancex10Ohms > 1100 || tipSenseResistancex10Ohms < 900) {
+    tipSenseResistancex10Ohms = 0; // out of range
+    adcReadingPD1Set          = 0;
+    lastMeas                  = 0;
+    return;
+  }
+  tipMeasurementOccuring = false;
+}
+bool isTipDisconnected() {
+  static bool lastDisconnectedState = false;
   // For the MHP30 we want to include a little extra logic in here
   // As when the tip is first connected we want to measure the ~100 ohm resistor on the base of the tip
   // And likewise if its removed we want to clear that measurement
   /*
    * plate_sensor_res = ((adc5_value_PD1_set - adc5_value_PD1_cleared) / (adc5_value_PD1_cleared + 4096 - adc5_value_PD1_set)) * 1000.0;
    * */
-
+  if (tipMeasurementOccuring) {
-  bool tipDisconnected = getADC(2) > (4090 * 8);
+    performTipMeasurementStep(false);
-  // We have to handle here that this ^ will trip while measuring the gain resistor
+    return true; // We fake no tip disconnection during the measurement cycle to mask it
-  if (xTaskGetTickCount() - lastMeas < (TICKS_100MS * 2 + (TICKS_100MS / 2))) {
-    tipDisconnected = false;
   }
 
-  if (tipDisconnected != lastTipDisconnectedState) {
+  // If we are too close to the top, most likely disconnected tip
-    if (tipDisconnected) {
+  bool tipDisconnected = getTipInstantTemperature() > (4090 * 8);
-      // Tip is now disconnected
+  if (tipDisconnected == false && lastDisconnectedState == true) {
-      tipSenseResistancex10Ohms = 0; // zero out the resistance
+    // Tip is now disconnected
-      adcReadingPD1Set          = 0;
+    performTipMeasurementStep(true);
-      lastMeas                  = 0;
-    }
-    lastTipDisconnectedState = tipDisconnected;
   }
-  if (!tipDisconnected) {
+  lastDisconnectedState = tipDisconnected;
-    if (tipSenseResistancex10Ohms == 0) {
-      if (lastMeas == 0) {
-        lastMeas = xTaskGetTickCount();
-        setPlatePullup(true);
-      } else if (xTaskGetTickCount() - lastMeas > (TICKS_100MS)) {
-        lastMeas = xTaskGetTickCount();
-        // We are sensing the resistance
-        if (adcReadingPD1Set == 0) {
-          // We will record the reading for PD1 being set
-          adcReadingPD1Set = getADC(3);
-          setPlatePullup(false);
-        } else {
-          // We have taken reading one
-          uint16_t adcReadingPD1Cleared = getADC(3);
-          uint32_t a                    = ((int)adcReadingPD1Set - (int)adcReadingPD1Cleared);
-          a *= 10000;
-          uint32_t b = ((int)adcReadingPD1Cleared + (32768 - (int)adcReadingPD1Set));
-          if (b) {
-            tipSenseResistancex10Ohms = a / b;
-          } else {
-            tipSenseResistancex10Ohms = adcReadingPD1Set = lastMeas = 0;
-          }
-          if (tipSenseResistancex10Ohms > 1100 || tipSenseResistancex10Ohms < 900) {
-            tipSenseResistancex10Ohms = 0; // out of range
-            adcReadingPD1Set          = 0;
-            lastMeas                  = 0;
-          }
-        }
-      }
-      return true; // we fake tip being disconnected until this is measured
-    }
-  }
-
   return tipDisconnected;
 }
+
+uint8_t preStartChecks() {
+  performTipMeasurementStep(false);
+  return tipMeasurementOccuring ? 1 : 0;
+}
 void setBuzzer(bool on) {
   if (on) {
     htim3.Instance->CCR2 = 128;

source/Core/BSP/MHP30/ThermoModel.cpp

@@ -10,7 +10,8 @@
 #include "configuration.h"
 extern uint16_t tipSenseResistancex10Ohms;
 uint32_t        TipThermoModel::convertuVToDegC(uint32_t tipuVDelta) {
-  // For the MHP30, we are mimicing the original code and using the resistor fitted to the base of the heater head, this is measured in the isTipDisconnected() function
+  // For the MHP30, we are mimicing the original code and using the resistor fitted to the base of the heater head,
+  // this is measured at boot in pid task and in the disconnected tip check if tip is removed
   if (tipSenseResistancex10Ohms > 900 && tipSenseResistancex10Ohms <= 1100) {
     int32_t a = ((tipSenseResistancex10Ohms / 10) + 300) * (3300000 - tipuVDelta);
     int32_t b = a / 1000000;

source/Core/BSP/Miniware/BSP.cpp

@@ -282,4 +282,5 @@ bool isTipDisconnected() {
   return tipTemp > tipDisconnectedThres;
 }
 
-void setStatusLED(const enum StatusLED state) {}
+void    setStatusLED(const enum StatusLED state) {}
+uint8_t preStartChecks() { return 0; }

source/Core/BSP/Pine64/BSP.cpp

@@ -90,3 +90,5 @@ bool isTipDisconnected() {
 }
 
 void setStatusLED(const enum StatusLED state) {}
+
+uint8_t preStartChecks() { return 0; }

source/Core/BSP/Pine64/configuration.h

@@ -124,7 +124,7 @@
 #define POWER_LIMIT_STEPS      5                         //
 #define OP_AMP_GAIN_STAGE      OP_AMP_GAIN_STAGE_PINECIL // Uses TS100 resistors
 #define TEMP_uV_LOOKUP_HAKKO                             // Use Hakko lookup table
-#define USB_PD_VMAX            21                        // Maximum voltage for PD to negotiate
+#define USB_PD_VMAX            20                        // Maximum voltage for PD to negotiate
 #define PID_TIM_HZ             (8)                       // Tick rate of the PID loop
 #define MAX_TEMP_C             450                       // Max soldering temp selectable °C
 #define MAX_TEMP_F             850                       // Max soldering temp selectable °F

source/Core/Threads/GUIThread.cpp

@@ -172,7 +172,7 @@ static void gui_drawBatteryIcon() {
 }
 static void gui_solderingTempAdjust() {
   uint32_t lastChange                = xTaskGetTickCount();
-  currentTempTargetDegC              = 0;
+  currentTempTargetDegC              = 0; // Turn off header while adjusting temp
   uint32_t    autoRepeatTimer        = 0;
   uint8_t     autoRepeatAcceleration = 0;
   bool        waitForRelease         = false;
@@ -511,12 +511,8 @@ static void gui_solderingMode(uint8_t jumpToSleep) {
         boostModeOn = false;
         break;
       case BUTTON_BOTH:
-        // exit
-        return;
-        break;
       case BUTTON_B_LONG:
         return; // exit on back long hold
-        break;
       case BUTTON_F_LONG:
         // if boost mode is enabled turn it on
         if (getSettingValue(SettingsOptions::BoostTemp))
@@ -665,8 +661,6 @@ static void gui_solderingMode(uint8_t jumpToSleep) {
     // If we have tripped thermal runaway, turn off heater and show warning
     if (heaterThermalRunaway) {
       currentTempTargetDegC = 0; // heater control off
-                                 // TODO WARNING
-
       warnUser(translatedString(Tr->WarningThermalRunaway), 10 * TICKS_SECOND);
       heaterThermalRunaway = false;
       return;

source/Core/Threads/PIDThread.cpp

@@ -39,21 +39,26 @@ void startPIDTask(void const *argument __unused) {
   pidTaskNotification    = xTaskGetCurrentTaskHandle();
   uint32_t PIDTempTarget = 0;
   // Pre-seed the adc filters
-  for (int i = 0; i < 128; i++) {
+  for (int i = 0; i < 32; i++) {
-    osDelay(5);
+    ulTaskNotifyTake(pdTRUE, 5);
     TipThermoModel::getTipInC(true);
     getInputVoltageX10(getSettingValue(SettingsOptions::VoltageDiv), 1);
   }
+
+  while (preStartChecks() != 0) {
+    ulTaskNotifyTake(pdTRUE, 2000);
+  }
+
   int32_t x10WattsOut = 0;
 
   for (;;) {
     x10WattsOut = 0;
     // This is a call to block this thread until the ADC does its samples
-    if (ulTaskNotifyTake(pdTRUE, 2000)) {
+    if (ulTaskNotifyTake(pdTRUE, TICKS_SECOND * 2)) {
       // Do the reading here to keep the temp calculations churning along
       uint32_t currentTipTempInC = TipThermoModel::getTipInC(true);
       PIDTempTarget              = currentTempTargetDegC;
-      if (PIDTempTarget) {
+      if (PIDTempTarget > 0) {
         // Cap the max set point to 450C
         if (PIDTempTarget > (450)) {
           // Maximum allowed output