Ts80 Tuned a bit better, Ts100 WiP

2025-02-26 07:53:55 +00:00 · 2019-07-13 22:54:07 +10:00
parent 74b225ceaa
commit c5409f4f1b
8 changed files with 166 additions and 143 deletions
--- a/workspace/TS100/inc/hardware.h
+++ b/workspace/TS100/inc/hardware.h
@@ -16,7 +16,7 @@ extern "C" {
 enum Orientation {
 	ORIENTATION_LEFT_HAND = 0, ORIENTATION_RIGHT_HAND = 1, ORIENTATION_FLAT = 3
 };
-
+#define PID_TIM_HZ (16)
 #if defined(MODEL_TS100) + defined(MODEL_TS80) > 1
 #error "Multiple models defined!"
 #elif defined(MODEL_TS100) + defined(MODEL_TS80) == 0
--- a/workspace/TS100/inc/power.hpp
+++ b/workspace/TS100/inc/power.hpp
@@ -2,23 +2,22 @@
 * Power.hpp
 *
 *  Created on: 28 Oct, 2018
- *     Authors: Ben V. Brown, David Hilton
+ *     Authors: Ben V. Brown, David Hilton (David's Idea)
 */

 #include "stdint.h"
 #include <history.hpp>
-
+#include "hardware.h"
 #ifndef POWER_HPP_
 #define POWER_HPP_

-const uint8_t hz = 32;//PID loop rate
-const uint8_t oscillationPeriod = 3.5 * hz; // dampening look back tuning
+const uint8_t oscillationPeriod = 4 * PID_TIM_HZ; // I term look back value
 extern history<uint32_t, oscillationPeriod> milliWattHistory;
-void setupPower(uint8_t resistance);

-int32_t tempToMilliWatts(int32_t rawTemp, uint16_t mass, uint8_t rawC);
+int32_t tempToMilliWatts(int32_t rawTemp, uint8_t rawC);
 void setTipMilliWatts(int32_t mw);
-uint8_t milliWattsToPWM(int32_t milliWatts, uint8_t divisor,uint8_t sample=0);
-int32_t PWMToMilliWatts(uint8_t pwm, uint8_t divisor);
+uint8_t milliWattsToPWM(int32_t milliWatts, uint8_t divisor,
+		uint8_t sample = 0);
+int32_t PWMToMilliWatts(uint8_t pwm, uint8_t divisor, uint8_t sample = 0);

 #endif /* POWER_HPP_ */
--- a/workspace/TS100/src/Setup.c
+++ b/workspace/TS100/src/Setup.c
@@ -262,9 +262,9 @@ static void MX_TIM3_Init(void) {
 	htim3.Instance = TIM3;
 	htim3.Init.Prescaler = 8;
 	htim3.Init.CounterMode = TIM_COUNTERMODE_UP;
-	htim3.Init.Period = 100;                            // 10 Khz PWM freq
+	htim3.Init.Period = 400;                            // 5 Khz PWM freq
 	htim3.Init.ClockDivision = TIM_CLOCKDIVISION_DIV4;  // 4mhz before div
-	htim3.Init.AutoReloadPreload = TIM_AUTORELOAD_PRELOAD_ENABLE;
+	htim3.Init.AutoReloadPreload = TIM_AUTORELOAD_PRELOAD_ENABLE;//Preload the ARR register (though we dont use this)
 	HAL_TIM_Base_Init(&htim3);

 	sClockSourceConfig.ClockSource = TIM_CLOCKSOURCE_INTERNAL;
@@ -279,7 +279,7 @@ static void MX_TIM3_Init(void) {
 	HAL_TIMEx_MasterConfigSynchronization(&htim3, &sMasterConfig);

 	sConfigOC.OCMode = TIM_OCMODE_PWM1;
-	sConfigOC.Pulse = 50;
+	sConfigOC.Pulse = 80;//80% duty cycle, that is AC coupled through the cap
 	sConfigOC.OCPolarity = TIM_OCPOLARITY_HIGH;
 	sConfigOC.OCFastMode = TIM_OCFAST_ENABLE;
 	HAL_TIM_PWM_ConfigChannel(&htim3, &sConfigOC, PWM_Out_CHANNEL);
@@ -291,10 +291,10 @@ static void MX_TIM3_Init(void) {
 	 */
 	GPIO_InitStruct.Pin = PWM_Out_Pin;
 	GPIO_InitStruct.Mode = GPIO_MODE_AF_PP;
-	GPIO_InitStruct.Speed = GPIO_SPEED_FREQ_HIGH;
+	GPIO_InitStruct.Speed = GPIO_SPEED_FREQ_HIGH;//We would like sharp rising edges
 	HAL_GPIO_Init(PWM_Out_GPIO_Port, &GPIO_InitStruct);
 #ifdef MODEL_TS100
-	// Remap TIM3_CH1 to be on pB4
+	// Remap TIM3_CH1 to be on PB4
 	__HAL_AFIO_REMAP_TIM3_PARTIAL();
 #else
 	// No re-map required
@@ -314,14 +314,17 @@ static void MX_TIM2_Init(void) {
 	// Timer 2 is fairly slow as its being used to run the PWM and trigger the ADC
 	// in the PWM off time.
 	htim2.Instance = TIM2;
-	htim2.Init.Prescaler = 785; // pwm out is 10k from tim3, we want to run our PWM at around 10hz or slower on the output stage
+	htim2.Init.Prescaler = 2000; //1mhz tick rate/800 = 1.25 KHz tick rate
+
+	// pwm out is 10k from tim3, we want to run our PWM at around 10hz or slower on the output stage
 	// The input is 1mhz after the div/4, so divide this by 785 to give around 4Hz output change rate
 	//Trade off is the slower the PWM output the slower we can respond and we gain temperature accuracy in settling time,
 	//But it increases the time delay between the heat cycle and the measurement and calculate cycle
 	htim2.Init.CounterMode = TIM_COUNTERMODE_UP;
-	htim2.Init.Period = 255 + 60;
+	htim2.Init.Period = 255 + 20;
 	htim2.Init.ClockDivision = TIM_CLOCKDIVISION_DIV4;  // 4mhz before divide
 	htim2.Init.AutoReloadPreload = TIM_AUTORELOAD_PRELOAD_ENABLE;
+	htim2.Init.RepetitionCounter=0;
 	HAL_TIM_Base_Init(&htim2);

 	sClockSourceConfig.ClockSource = TIM_CLOCKSOURCE_INTERNAL;
@@ -335,7 +338,8 @@ static void MX_TIM2_Init(void) {
 	HAL_TIMEx_MasterConfigSynchronization(&htim2, &sMasterConfig);

 	sConfigOC.OCMode = TIM_OCMODE_PWM1;
-	sConfigOC.Pulse = 255 + 50; //255 is the largest time period of the drive signal, and the 50 offsets this around 5ms afterwards
+	sConfigOC.Pulse = 255 + 10;
+	//255 is the largest time period of the drive signal, and then offset ADC sample to be a bit delayed after this
 	/*
 	 * It takes 4 milliseconds for output to be stable after PWM turns off.
 	 * Assume ADC samples in 0.5ms
@@ -344,11 +348,7 @@ static void MX_TIM2_Init(void) {
 	sConfigOC.OCPolarity = TIM_OCPOLARITY_HIGH;
 	sConfigOC.OCFastMode = TIM_OCFAST_ENABLE;
 	HAL_TIM_PWM_ConfigChannel(&htim2, &sConfigOC, TIM_CHANNEL_1);
-
-	sConfigOC.OCMode = TIM_OCMODE_PWM1;
-	sConfigOC.Pulse = 0;
-	sConfigOC.OCPolarity = TIM_OCPOLARITY_HIGH;
-	sConfigOC.OCFastMode = TIM_OCFAST_ENABLE;
+	sConfigOC.Pulse = 0;//default to entirely off
 	HAL_TIM_OC_ConfigChannel(&htim2, &sConfigOC, TIM_CHANNEL_4);

 	HAL_TIM_Base_Start_IT(&htim2);
--- a/workspace/TS100/src/hardware.cpp
+++ b/workspace/TS100/src/hardware.cpp
@@ -10,6 +10,7 @@
 #include "FreeRTOS.h"
 #include "stm32f1xx_hal.h"
 #include "cmsis_os.h"
+#include "history.hpp"
 volatile uint16_t PWMSafetyTimer = 0;
 volatile int16_t CalibrationTempOffset = 0;
 uint16_t tipGainCalValue = 0;
@@ -68,15 +69,31 @@ uint16_t ftoTipMeasurement(uint16_t temp) {
 }

 uint16_t getTipInstantTemperature() {
-	uint16_t sum;
-	sum = hadc1.Instance->JDR1;
-	sum += hadc1.Instance->JDR2;
-	sum += hadc1.Instance->JDR3;
-	sum += hadc1.Instance->JDR4;
-	sum += hadc2.Instance->JDR1;
-	sum += hadc2.Instance->JDR2;
-	sum += hadc2.Instance->JDR3;
-	sum += hadc2.Instance->JDR4;
+	uint16_t sum = 0;	// 12 bit readings * 8 -> 15 bits
+	uint16_t readings[8];
+	//Looking to reject the highest outlier readings.
+	//As on some hardware these samples can run into the op-amp recovery time
+	//Once this time is up the signal stabilises quickly, so no need to reject minimums
+	readings[0] = hadc1.Instance->JDR1;
+	readings[1] = hadc1.Instance->JDR2;
+	readings[2] = hadc1.Instance->JDR3;
+	readings[3] = hadc1.Instance->JDR4;
+	readings[4] = hadc2.Instance->JDR1;
+	readings[5] = hadc2.Instance->JDR2;
+	readings[6] = hadc2.Instance->JDR3;
+	readings[7] = hadc2.Instance->JDR4;
+	uint8_t minID = 0, maxID = 0;
+	for (int i = 0; i < 8; i++) {
+		if (readings[i] < readings[minID])
+			minID = i;
+		else if (readings[i] > readings[maxID])
+			maxID = i;
+	}
+	for (int i = 0; i < 8; i++) {
+		if (i != maxID)
+			sum += readings[i];
+	}
+	sum += readings[minID];	//Duplicate the min to make up for the missing max value
 	return sum;  // 8x over sample
 }
 /*
@@ -117,15 +134,17 @@ uint16_t lookupTipDefaultCalValue(enum TipType tipID) {
 	}
 #endif
 }
+//2 second filter (ADC is PID_TIM_HZ Hz)
+history<uint16_t, PID_TIM_HZ*4> rawTempFilter = { { 0 }, 0, 0 };

 uint16_t getTipRawTemp(uint8_t refresh) {
-	static uint16_t lastSample = 0;
-
 	if (refresh) {
-		lastSample = getTipInstantTemperature();
+		uint16_t lastSample = getTipInstantTemperature();
+		rawTempFilter.update(lastSample);
+		return lastSample;
+	} else {
+		return rawTempFilter.average();
 	}
-
-	return lastSample;
 }

 uint16_t getInputVoltageX10(uint16_t divisor, uint8_t sample) {
@@ -237,8 +256,6 @@ void startQC(uint16_t divisor) {
 	// Pre check that the input could be >5V already, and if so, dont both
 	// negotiating as someone is feeding in hv
 	uint16_t vin = getInputVoltageX10(divisor, 1);
-	if (vin > 150)
-		return;	// Over voltage
 	if (vin > 100) {
 		QCMode = 1;  // ALready at ~12V
 		return;
--- a/workspace/TS100/src/main.cpp
+++ b/workspace/TS100/src/main.cpp
@@ -271,36 +271,36 @@ static void gui_drawBatteryIcon() {
 		// we need to calculate which of the 10 levels they are on
 		uint8_t cellCount = systemSettings.cutoutSetting + 2;
 		uint32_t cellV = getInputVoltageX10(systemSettings.voltageDiv, 0)
-		/ cellCount;
+				/ cellCount;
 		// Should give us approx cell voltage X10
 		// Range is 42 -> 33 = 9 steps therefore we will use battery 1-10
 		if (cellV < 33)
-		cellV = 33;
-		cellV -= 33;// Should leave us a number of 0-9
+			cellV = 33;
+		cellV -= 33;		// Should leave us a number of 0-9
 		if (cellV > 9)
-		cellV = 9;
+			cellV = 9;
 		OLED::drawBattery(cellV + 1);
 	} else
-	OLED::drawSymbol(15);  // Draw the DC Logo
+		OLED::drawSymbol(15);  // Draw the DC Logo
 #else
-	// On TS80 we replace this symbol with the voltage we are operating on
-	// If <9V then show single digit, if not show duals
-	uint8_t V = getInputVoltageX10(systemSettings.voltageDiv, 0);
-	if (V % 10 >= 5)
-		V = V / 10 + 1;				// round up
-	else
-		V = V / 10;
-	if (V >= 10) {
-		int16_t xPos = OLED::getCursorX();
-		OLED::setFont(1);
-		OLED::printNumber(1, 1);
-		OLED::setCursor(xPos, 8);
-		OLED::printNumber(V % 10, 1);
-		OLED::setFont(0);
-		OLED::setCursor(xPos + 12, 0); // need to reset this as if we drew a wide char
-	} else {
-		OLED::printNumber(V, 1);
-	}
+				// On TS80 we replace this symbol with the voltage we are operating on
+				// If <9V then show single digit, if not show duals
+				uint8_t V = getInputVoltageX10(systemSettings.voltageDiv, 0);
+				if (V % 10 >= 5)
+				V = V / 10 + 1;// round up
+				else
+				V = V / 10;
+				if (V >= 10) {
+					int16_t xPos = OLED::getCursorX();
+					OLED::setFont(1);
+					OLED::printNumber(1, 1);
+					OLED::setCursor(xPos, 8);
+					OLED::printNumber(V % 10, 1);
+					OLED::setFont(0);
+					OLED::setCursor(xPos + 12, 0); // need to reset this as if we drew a wide char
+				} else {
+					OLED::printNumber(V, 1);
+				}
 #endif
 }
 static void gui_solderingTempAdjust() {
@@ -372,7 +372,7 @@ static void gui_solderingTempAdjust() {
 #ifdef MODEL_TS80
 		if (!OLED::getRotation())
 #else
-			if (OLED::getRotation())
+		if (OLED::getRotation())
 #endif
 			OLED::print(SymbolMinus);
 		else
@@ -388,7 +388,7 @@ static void gui_solderingTempAdjust() {
 #ifdef MODEL_TS80
 		if (!OLED::getRotation())
 #else
-			if (OLED::getRotation())
+		if (OLED::getRotation())
 #endif
 			OLED::print(SymbolPlus);
 		else
@@ -415,7 +415,7 @@ static int gui_SolderingSleepingMode() {
 				|| (xTaskGetTickCount() - lastButtonTime < 100))
 			return 0;  // user moved or pressed a button, go back to soldering
 #ifdef MODEL_TS100
-			if (checkVoltageForExit())
+		if (checkVoltageForExit())
 			return 1; // return non-zero on error
 #endif
 		if (systemSettings.temperatureInF) {
@@ -682,9 +682,9 @@ void showVersion(void) {
 		OLED::setCursor(0, 0);  // Position the cursor at the 0,0 (top left)
 		OLED::setFont(1);       // small font
 #ifdef MODEL_TS100
-				OLED::print(SymbolVersionNumber);  // Print version number
-#else
 		OLED::print(SymbolVersionNumber);  // Print version number
+#else
+				OLED::print(SymbolVersionNumber);  // Print version number
 #endif
 		OLED::setCursor(0, 8);  // second line
 		OLED::print(DebugMenu[screen]);
@@ -733,7 +733,7 @@ void showVersion(void) {
 #ifdef MODEL_TS80
 			OLED::printNumber(calculateTipR(), 5);
 #else
-			OLED::printNumber(8500,5));
+			OLED::printNumber(8500, 5);
 #endif
 			break;
 		default:
@@ -871,7 +871,7 @@ void startGUITask(void const *argument __unused) {
 #ifdef MODEL_TS80
 			if (!OLED::getRotation()) {
 #else
-				if (OLED::getRotation()) {
+			if (OLED::getRotation()) {
 #endif
 				OLED::drawArea(12, 0, 84, 16, idleScreenBG);
 				OLED::setCursor(0, 0);
@@ -892,7 +892,7 @@ void startGUITask(void const *argument __unused) {
 #ifdef MODEL_TS80
 				if (!OLED::getRotation()) {
 #else
-					if (OLED::getRotation()) {
+				if (OLED::getRotation()) {
 #endif
 					// in right handed mode we want to draw over the first part
 					OLED::fillArea(55, 0, 41, 16, 0); // clear the area for the temp
@@ -921,19 +921,16 @@ void startPIDTask(void const *argument __unused) {
 	 */
 	setTipMilliWatts(0); // disable the output driver if the output is set to be off
 #ifdef MODEL_TS80
-	idealQCVoltage = calculateMaxVoltage(systemSettings.cutoutSetting);
+			idealQCVoltage = calculateMaxVoltage(systemSettings.cutoutSetting);
 #endif
 	uint8_t rawC = ctoTipMeasurement(101) - ctoTipMeasurement(100); // 1*C change in raw.

 #ifdef MODEL_TS80
-	//Set power management code to the tip resistance in ohms * 10
-	setupPower(calculateTipR() / 100);
-	TickType_t lastPowerPulse = 0;
-#else
-	setupPower(85);
-
+			//Set power management code to the tip resistance in ohms * 10
+			TickType_t lastPowerPulse = 0;
 #endif
-	history<int32_t> tempError = { { 0 }, 0, 0 };
+	// Tip temp reading filter
+	history<int32_t, PID_TIM_HZ / 4> tempError = { { 0 }, 0, 0 };
 	currentlyActiveTemperatureTarget = 0; // Force start with no output (off). If in sleep / soldering this will
 										  // be over-ridden rapidly
 	pidTaskNotification = xTaskGetCurrentTaskHandle();
@@ -947,9 +944,9 @@ void startPIDTask(void const *argument __unused) {
 				if (currentlyActiveTemperatureTarget > ctoTipMeasurement(450)) {
 					//Maximum allowed output
 					currentlyActiveTemperatureTarget = ctoTipMeasurement(450);
-				} else if (currentlyActiveTemperatureTarget > 32400) {
-					//Cap to max adc reading
-					currentlyActiveTemperatureTarget = 32400;
+				} else if (currentlyActiveTemperatureTarget > 32700) {
+					//Cap to max adc reading (32768)
+					currentlyActiveTemperatureTarget = 32700;
 				}

 				// As we get close to our target, temp noise causes the system
@@ -963,27 +960,15 @@ void startPIDTask(void const *argument __unused) {
 				tempError.update(tError);

 				// Now for the PID!
-				int32_t milliWattsOut = 0;

 				// P term - total power needed to hit target temp next cycle.
 				// thermal mass = 1690 milliJ/*C for my tip.
 				//  = Watts*Seconds to raise Temp from room temp to +100*C, divided by 100*C.
-				// we divide milliWattsNeeded by 20 to let the I term dominate near the set point.
-				//  This is necessary because of the temp noise and thermal lag in the system.
-				// Once we have feed-forward temp estimation we should be able to better tune this.

-#ifdef MODEL_TS100
-				const uint16_t mass = 2020 / 20; // divide here so division is compile-time.
-#endif
-#ifdef MODEL_TS80
-				const uint16_t mass = 2020 / 50;
-#endif
-
-				int32_t milliWattsNeeded = tempToMilliWatts(tempError.average(),
-						mass, rawC);
+				int32_t milliWattsOut = tempToMilliWatts(tempError.average(),
+						rawC);
 				// note that milliWattsNeeded is sometimes negative, this counters overshoot
 				//  from I term's inertia.
-				milliWattsOut += milliWattsNeeded;

 				// I term - energy needed to compensate for heat loss.
 				// We track energy put into the system over some window.
@@ -991,11 +976,12 @@ void startPIDTask(void const *argument __unused) {
 				//  (If it isn't, P will dominate).
 				milliWattsOut += milliWattHistory.average();

-				// D term - use sudden temp change to counter fast cooling/heating.
-				//  In practice, this provides an early boost if temp is dropping
-				//  and counters extra power if the iron is no longer losing temp.
-				// basically: temp - lastTemp
-				//  Unfortunately, our temp signal is too noisy to really help.
+				// Not Used:
+				// 	D term - use sudden temp change to counter fast cooling/heating.
+				//  	In practice, this provides an early boost if temp is dropping
+				//  		and counters extra power if the iron is no longer losing temp.
+				// 		basically: temp - lastTemp
+				//  	Unfortunately, our temp signal is too noisy to really help.

 				setTipMilliWatts(milliWattsOut);
 			} else {
@@ -1005,9 +991,10 @@ void startPIDTask(void const *argument __unused) {
 				// This is purely guesswork :'( as everyone implements stuff differently
 				if (xTaskGetTickCount() - lastPowerPulse < 10) {
 					// for the first 100mS turn on for a bit
-					setTipMilliWatts(5000);	// typically its around 5W to hold the current temp, so this wont raise temp much
-				} else
+					setTipMilliWatts(2000);// typically its around 5W to hold the current temp, so this wont raise temp much
+				} else {
 					setTipMilliWatts(0);
+				}
 				//Then wait until the next 0.5 seconds
 				if (xTaskGetTickCount() - lastPowerPulse > 50) {
 					lastPowerPulse = xTaskGetTickCount();
@@ -1019,7 +1006,6 @@ void startPIDTask(void const *argument __unused) {

 			HAL_IWDG_Refresh(&hiwdg);
 		} else {
-			asm("bkpt");

 //ADC interrupt timeout
 			setTipMilliWatts(0);
@@ -1035,9 +1021,9 @@ void startMOVTask(void const *argument __unused) {
 #ifdef MODEL_TS80
 	startQC(systemSettings.voltageDiv);
 	while (pidTaskNotification == 0)
-		osDelay(30);  // To ensure we return after idealQCVoltage/tip resistance
+	osDelay(30);  // To ensure we return after idealQCVoltage/tip resistance

-	seekQC(idealQCVoltage, systemSettings.voltageDiv); // this will move the QC output to the preferred voltage to start with
+	seekQC(idealQCVoltage, systemSettings.voltageDiv);// this will move the QC output to the preferred voltage to start with

 #else
 	osDelay(250);  // wait for accelerometer to stabilize
@@ -1096,16 +1082,11 @@ void startMOVTask(void const *argument __unused) {
 bool showBootLogoIfavailable() {
 	// check if the header is there (0xAA,0x55,0xF0,0x0D)
 	// If so display logo
-	// TODO REDUCE STACK ON THIS ONE, USE DRAWING IN THE READ LOOP
-	uint16_t temp[98];
-
-	for (uint8_t i = 0; i < (98); i++) {
-		temp[i] = *(uint16_t *) (FLASH_LOGOADDR + (i * 2));
-	}
 	uint8_t temp8[98 * 2];
 	for (uint8_t i = 0; i < 98; i++) {
-		temp8[i * 2] = temp[i] >> 8;
-		temp8[i * 2 + 1] = temp[i] & 0xFF;
+		uint16_t temp = *(uint16_t *) (FLASH_LOGOADDR + (i * 2));
+		temp8[i * 2] = temp >> 8;
+		temp8[i * 2 + 1] = temp & 0xFF;
 	}

 	if (temp8[0] != 0xAA)
--- a/workspace/TS100/src/power.cpp
+++ b/workspace/TS100/src/power.cpp
@@ -9,58 +9,84 @@
 #include <Settings.h>
 #include <hardware.h>

-uint8_t tipResistance = 85; //x10 ohms, 8.5 typical for ts100, 4.5 typical for ts80
 const uint16_t powerPWM = 255;
-const uint16_t totalPWM = 255 + 60; //htim2.Init.Period, the full PWM cycle
+const uint16_t totalPWM = 255 + 30; //htim2.Init.Period, the full PWM cycle

+// thermal mass = 1690 milliJ/*C for my tip.
+//  ->  Wattsx10*Seconds to raise Temp from room temp to +100*C, divided by 100*C.
+// we divide mass by 20 to let the I term dominate near the set point.
+//  This is necessary because of the temp noise and thermal lag in the system.
+// Once we have feed-forward temp estimation we should be able to better tune this.
+
+#ifdef MODEL_TS100
+const uint16_t tipMass = 2020 ; // divide here so division is compile-time.
+const uint8_t tipResistance = 85;//x10 ohms, 8.5 typical for ts100, 4.5 typical for ts80
+
+#endif
+#ifdef MODEL_TS80
+const uint16_t tipMass = 1000/4;
+const uint8_t tipResistance = 46; //x10 ohms, 8.5 typical for ts100, 4.5 typical for ts80
+
+#endif
 history<uint32_t, oscillationPeriod> milliWattHistory = { { 0 }, 0, 0 };

-void setupPower(uint8_t res) {
-	tipResistance = res;
-}
-
-int32_t tempToMilliWatts(int32_t rawTemp, uint16_t mass, uint8_t rawC) {
+int32_t tempToMilliWatts(int32_t rawTemp, uint8_t rawC) {
 	// mass is in milliJ/*C, rawC is raw per degree C
 	// returns milliWatts needed to raise/lower a mass by rawTemp
 	//  degrees in one cycle.
-	int32_t milliJoules = mass * rawTemp / rawC;
-	return milliJoules * hz;
+	int32_t milliJoules = tipMass * (rawTemp / rawC);
+	return milliJoules;
 }

 void setTipMilliWatts(int32_t mw) {
 	//Enforce Max Watts Limiter # TODO

-	int32_t output = milliWattsToPWM(mw, systemSettings.voltageDiv / 10,1);
+	int32_t output = milliWattsToPWM(mw, systemSettings.voltageDiv / 10, 1);
 	setTipPWM(output);
-	uint16_t actualMilliWatts = PWMToMilliWatts(output,
-			systemSettings.voltageDiv / 10);
+	uint32_t actualMilliWatts = PWMToMilliWatts(output,
+			systemSettings.voltageDiv / 10, 0);

 	milliWattHistory.update(actualMilliWatts);
 }

-uint8_t milliWattsToPWM(int32_t milliWatts, uint8_t divisor, uint8_t sample) {
+int32_t availableW10(uint8_t divisor, uint8_t sample) {
 	//P = V^2 / R, v*v = v^2 * 100
 	//				R = R*10
-	// P therefore is in V^2*10/R = W*10.
-	// Scale input milliWatts to the pwm rate
-	if (milliWatts == 0)
-		return 0;
+	// P therefore is in V^2*100/R*10 = W*10.
 	int32_t v = getInputVoltageX10(divisor, sample);	// 100 = 10v
-	int32_t availableMilliWatts = v * v / tipResistance;
+	int32_t availableWattsX10 = (v * v) / tipResistance;
+	//However, 100% duty cycle is not possible as there is a dead time while the ADC takes a reading
+	//Therefore need to scale available milliwats by this

-	//int32_t pwm = ((powerPWM * totalPWM / powerPWM) * milliWatts)	/ availableMilliWatts;
-	int32_t pwm = (totalPWM * milliWatts) / availableMilliWatts;
+	// avMw=(AvMw*powerPWM)/totalPWM.
+	availableWattsX10 = availableWattsX10 * powerPWM;
+	availableWattsX10 /= totalPWM;
+
+	//availableMilliWattsX10 is now an accurate representation
+	return availableWattsX10;
+}
+
+uint8_t milliWattsToPWM(int32_t milliWatts, uint8_t divisor, uint8_t sample) {
+
+	// Scale input milliWatts to the pwm rate
+	if (milliWatts < 10) // no pint driving tip
+		return 0;
+
+	//Calculate desired milliwatts as a percentage of availableW10
+	int32_t pwm = (powerPWM * milliWatts) / availableW10(divisor, sample);
 	if (pwm > powerPWM) {
-		pwm = powerPWM;
-	} else if (pwm < 0) {
+		pwm = powerPWM;	//constrain to max PWM counter, shouldnt be possible, but small cost for safety to avoid wraps
+	} else if (pwm < 0) {	//cannot go negative
 		pwm = 0;
 	}
-
-
 	return pwm;
 }

-int32_t PWMToMilliWatts(uint8_t pwm, uint8_t divisor) {
-	int32_t v = getInputVoltageX10(divisor, 0);
-	return pwm * (v * v / tipResistance) / (powerPWM * totalPWM / powerPWM);
+int32_t PWMToMilliWatts(uint8_t pwm, uint8_t divisor, uint8_t sample) {
+	int32_t maxMW = availableW10(divisor, sample); //Get the milliwatts for the max pwm period
+	//Then convert pwm into percentage of powerPWM to get the percentage of the max mw
+	int32_t res = (pwm * maxMW) / powerPWM;
+	if (res < 0)
+		res = 0;
+	return res;
 }
--- a/workspace/TS100A/.cproject
+++ b/workspace/TS100A/.cproject
@@ -52,7 +52,7 @@
 							<tool command="arm-atollic-eabi-gcc -c" commandLinePattern="${COMMAND} ${INPUTS} ${FLAGS} ${OUTPUT_FLAG} ${OUTPUT_PREFIX}${OUTPUT}" errorParsers="org.eclipse.cdt.core.GCCErrorParser" id="com.atollic.truestudio.exe.release.toolchain.gcc.45651038" name="C Compiler" superClass="com.atollic.truestudio.exe.release.toolchain.gcc">
 								<option id="com.atollic.truestudio.gcc.symbols.defined.1383071182" name="Defined symbols" superClass="com.atollic.truestudio.gcc.symbols.defined" useByScannerDiscovery="false" valueType="definedSymbols">
 									<listOptionValue builtIn="false" value="STM32F103T8Ux"/>
-									<listOptionValue builtIn="false" value="MODEL_TS80"/>
+									<listOptionValue builtIn="false" value="MODEL_TS100"/>
 									<listOptionValue builtIn="false" value="STM32F1"/>
 									<listOptionValue builtIn="false" value="STM32"/>
 									<listOptionValue builtIn="false" value="USE_HAL_DRIVER"/>
@@ -96,7 +96,7 @@
 							<tool command="arm-atollic-eabi-g++ -c" commandLinePattern="${COMMAND} ${INPUTS} ${FLAGS} ${OUTPUT_FLAG} ${OUTPUT_PREFIX}${OUTPUT}" errorParsers="org.eclipse.cdt.core.GCCErrorParser" id="com.atollic.truestudio.exe.release.toolchain.gpp.93636755" name="C++ Compiler" superClass="com.atollic.truestudio.exe.release.toolchain.gpp">
 								<option id="com.atollic.truestudio.gpp.symbols.defined.552082963" name="Defined symbols" superClass="com.atollic.truestudio.gpp.symbols.defined" useByScannerDiscovery="false" valueType="definedSymbols">
 									<listOptionValue builtIn="false" value="STM32F103T8Ux"/>
-									<listOptionValue builtIn="false" value="MODEL_TS80"/>
+									<listOptionValue builtIn="false" value="MODEL_TS100"/>
 									<listOptionValue builtIn="false" value="STM32F1"/>
 									<listOptionValue builtIn="false" value="STM32"/>
 									<listOptionValue builtIn="false" value="USE_HAL_DRIVER"/>
--- a/workspace/TS100A/.project
+++ b/workspace/TS100A/.project
@@ -221,9 +221,9 @@
 			<locationURI>PARENT-1-PROJECT_LOC/TS100/src/gui.cpp</locationURI>
 		</link>
 		<link>
-			<name>src/hardware.c</name>
+			<name>src/hardware.cpp</name>
 			<type>1</type>
-			<locationURI>PARENT-1-PROJECT_LOC/TS100/src/hardware.c</locationURI>
+			<locationURI>PARENT-1-PROJECT_LOC/TS100/src/hardware.cpp</locationURI>
 		</link>
 		<link>
 			<name>src/main.cpp</name>