Merge branch 'dev' into dev

source/Core/Threads/PIDThread.cpp

@@ -30,7 +30,7 @@ int32_t                    powerSupplyWattageLimit = 0;
 bool                       heaterThermalRunaway    = false;
 
 static int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t current_value);
-static void    detectThermalRunaway(const TemperatureType_t currentTipTempInC, const TemperatureType_t tError);
+static void    detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut);
 static void    setOutputx10WattsViaFilters(int32_t x10Watts);
 static int32_t getX10WattageLimits();
 
@@ -92,8 +92,8 @@ void startPIDTask(void const *argument __unused) {
           PIDTempTarget = TipThermoModel::getTipMaxInC();
         }
 
-        detectThermalRunaway(currentTipTempInC, PIDTempTarget - currentTipTempInC);
         x10WattsOut = getPIDResultX10Watts(PIDTempTarget, currentTipTempInC);
+        detectThermalRunaway(currentTipTempInC, x10WattsOut);
       } else {
         detectThermalRunaway(currentTipTempInC, 0);
       }
@@ -228,31 +228,59 @@ int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t curr
 #endif
 }
 
-void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const TemperatureType_t tError) {
-  static TemperatureType_t tipTempCRunawayTemp   = 0;
-  static TickType_t        runawaylastChangeTime = 0;
+/*
+ * Detection of thermal runaway
+ * The goal of this is to handle cases where something has gone wrong
+ * 1. The tip MOSFET is broken, so power is being constantly applied to the tip
+ * a. This can show as temp being stuck at max
+ * b. Or temp rising when the heater is off
+ * 2. Broken temperature sense
+ * a. Temp is stuck at a value
+ * These boil down to either a constantly rising temperature or a temperature that is stuck at a value
+ * These are both covered; but looking at the eye/delta between min and max temp seen
+ */
+void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut) {
 
-  // Check for thermal runaway, where it has been x seconds with negligible (y) temp rise
-  // While trying to actively heat
+  static TemperatureType_t tiptempMin         = 0xFFFF; // Min tip temp seen
+  static TemperatureType_t tipTempMax         = 0;      // Max tip temp seen while heater is on
+  bool                     thisCycleIsHeating = x10WattsOut > 0;
+  static TickType_t        heatCycleStart     = 0;
 
-  // If we are more than 20C below the setpoint
-  if ((tError > THERMAL_RUNAWAY_TEMP_C)) {
+  static bool haveSeenDelta = false;
 
-    // If we have heated up by more than 20C since last sample point, snapshot time and tip temp
-    TemperatureType_t delta = currentTipTempInC - tipTempCRunawayTemp;
-    if (delta > THERMAL_RUNAWAY_TEMP_C) {
-      // We have heated up more than the threshold, reset the timer
-      tipTempCRunawayTemp   = currentTipTempInC;
-      runawaylastChangeTime = xTaskGetTickCount();
-    } else {
-      if ((xTaskGetTickCount() - runawaylastChangeTime) > (THERMAL_RUNAWAY_TIME_SEC * TICKS_SECOND)) {
-        // It has taken too long to rise
+  // Check for readings being pegged at the top of the ADC while the heater is off
+  if (!thisCycleIsHeating && (getTipRawTemp(0) > (0x7FFF - 16))) {
+    heaterThermalRunaway = true;
+  }
+
+  if (haveSeenDelta) {
+    return;
+  }
+
+  if (currentTipTempInC < tiptempMin) {
+    tiptempMin = currentTipTempInC;
+  }
+  if (thisCycleIsHeating && currentTipTempInC > tipTempMax) {
+    tipTempMax = currentTipTempInC;
+  }
+  if (thisCycleIsHeating) {
+    if (heatCycleStart == 0) {
+      heatCycleStart = xTaskGetTickCount();
+    }
+  } else {
+    heatCycleStart = 0;
+  }
+
+  if ((xTaskGetTickCount() - heatCycleStart) > (THERMAL_RUNAWAY_TIME_SEC * TICKS_SECOND)) {
+    if (tipTempMax > tiptempMin) {
+      // Have been heating for min seconds, check if the delta is large enough
+      TemperatureType_t delta = tipTempMax - tiptempMin;
+      haveSeenDelta           = true;
+
+      if (delta < THERMAL_RUNAWAY_TEMP_C) {
         heaterThermalRunaway = true;
       }
     }
-  } else {
-    tipTempCRunawayTemp   = currentTipTempInC;
-    runawaylastChangeTime = xTaskGetTickCount();
   }
 }
 
@@ -308,4 +336,4 @@ void setOutputx10WattsViaFilters(int32_t x10WattsOut) {
 #endif
   setTipX10Watts(x10WattsOut);
   resetWatchdog();
-}
+}

source/Core/Threads/UI/logic/OperatingModes.h

@@ -29,20 +29,20 @@ extern "C" {
 #endif
 
 enum class OperatingMode {
-  StartupLogo = 0,    // Showing the startup logo
-  CJCCalibration,     // Cold Junction Calibration
-  StartupWarnings,    // Startup checks and warnings
-  InitialisationDone, // Special state we use just before we to home screen at first startup. Allows jumping to extra startup states
-  HomeScreen,         // Home/Idle screen that is the main launchpad to other modes
-  Soldering,          // Main soldering operating mode
-  SolderingProfile,   // Soldering by following a profile, used for reflow for example
-  Sleeping,           // Sleep state holds iron at lower sleep temp
-  Hibernating,        // Like sleeping but keeps heater fully off until woken
-  SettingsMenu,       // Settings Menu
-  DebugMenuReadout,   // Debug metrics
-  TemperatureAdjust,  // Set point temperature adjustment
-  UsbPDDebug,         // USB PD debugging information
-  ThermalRunaway,     // Thermal Runaway warning state.
+  StartupLogo=10,        // Showing the startup logo
+  CJCCalibration=11,     // Cold Junction Calibration
+  StartupWarnings=12,    // Startup checks and warnings
+  InitialisationDone=13, // Special state we use just before we to home screen at first startup. Allows jumping to extra startup states
+  HomeScreen=0,         // Home/Idle screen that is the main launchpad to other modes
+  Soldering=1,          // Main soldering operating mode
+  SolderingProfile=6,   // Soldering by following a profile, used for reflow for example
+  Sleeping=3,           // Sleep state holds iron at lower sleep temp
+  Hibernating=14,       // Like sleeping but keeps heater fully off until woken
+  SettingsMenu=4,       // Settings Menu
+  DebugMenuReadout=5,   // Debug metrics
+  TemperatureAdjust=7,  // Set point temperature adjustment
+  UsbPDDebug=8,         // USB PD debugging information
+  ThermalRunaway=9,     // Thermal Runaway warning state.
 };
 
 enum class TransitionAnimation {

source/Core/Threads/UI/logic/Soldering.cpp

@@ -138,9 +138,7 @@ OperatingMode gui_solderingMode(const ButtonState buttons, guiContext *cxt) {
 
   // Draw in the screen details
   if (getSettingValue(SettingsOptions::DetailedSoldering)) {
-
     ui_draw_soldering_power_status(cxt->scratch_state.state2);
-
   } else {
     ui_draw_soldering_basic_status(cxt->scratch_state.state2);
   }