Approx thermal runaway config

source/Core/Inc/Translation.h

@@ -84,6 +84,7 @@ struct TranslationIndexTable {
   uint16_t LockingKeysString;
   uint16_t UnlockingKeysString;
   uint16_t WarningKeysLockedString;
+  uint16_t WarningThermalRunaway;
 
   uint16_t SettingRightChar;
   uint16_t SettingLeftChar;

source/Core/Inc/configuration.h

@@ -94,6 +94,9 @@
 #define DETAILED_SOLDERING 0 // 0: Disable 1: Enable - Default 0
 #define DETAILED_IDLE      0 // 0: Disable 1: Enable - Default 0
 
+#define THERMAL_RUNAWAY_TIME_SEC 20
+#define THERMAL_RUNAWAY_TEMP_C   20
+
 #define CUT_OUT_SETTING          0  // default to no cut-off voltage
 #define RECOM_VOL_CELL           33 // Minimum voltage per cell (Recommended 3.3V (33))
 #define TEMPERATURE_INF          0  // default to 0

source/Core/Threads/GUIThread.cpp

@@ -28,6 +28,7 @@ extern "C" {
 // File local variables
 extern uint32_t   currentTempTargetDegC;
 extern TickType_t lastMovementTime;
+extern bool       heaterThermalRunaway;
 extern osThreadId GUITaskHandle;
 extern osThreadId MOVTaskHandle;
 extern osThreadId PIDTaskHandle;
@@ -62,7 +63,7 @@ void GUIDelay() {
   // This limits the re-draw rate to the LCD and also lets the DMA run
   // As the gui task can very easily fill this bus with transactions, which will
   // prevent the movement detection from running
-  osDelay(50);
+  vTaskDelay(5 * TICKS_10MS);
 }
 void gui_drawTipTemp(bool symbol, const FontStyle font) {
   // Draw tip temp handling unit conversion & tolerance near setpoint
@@ -608,7 +609,6 @@ static void gui_solderingMode(uint8_t jumpToSleep) {
       }
     }
     OLED::refresh();
-
     // Update the setpoints for the temperature
     if (boostModeOn) {
       if (systemSettings.temperatureInF)
@@ -645,6 +645,15 @@ static void gui_solderingMode(uint8_t jumpToSleep) {
     } else {
       setStatusLED(LED_HEATING);
     }
+    // If we have tripped thermal runaway, turn off header and show warning
+    if (heaterThermalRunaway) {
+      currentTempTargetDegC = 0; // heaater control off
+                                 // TODO WARNING
+
+      warnUser(translatedString(Tr->WarningThermalRunaway), 10 * TICKS_SECOND);
+      heaterThermalRunaway = false;
+      return;
+    }
     // slow down ui update rate
     GUIDelay();
   }

source/Core/Threads/PIDThread.cpp

@@ -19,6 +19,7 @@ static TickType_t powerPulseDurationUnit  = (5 * TICKS_100MS) / 2; // 250 ms
 TaskHandle_t      pidTaskNotification     = NULL;
 uint32_t          currentTempTargetDegC   = 0; // Current temperature target in C
 int32_t           powerSupplyWattageLimit = 0;
+bool              heaterThermalRunaway    = false;
 /* StartPIDTask function */
 void startPIDTask(void const *argument __unused) {
   /*
@@ -32,8 +33,10 @@ void startPIDTask(void const *argument __unused) {
   history<int32_t, PID_TIM_HZ> tempError = {{0}, 0, 0};
   currentTempTargetDegC                  = 0; // Force start with no output (off). If in sleep / soldering this will
                                               // be over-ridden rapidly
-  pidTaskNotification    = xTaskGetCurrentTaskHandle();
-  uint32_t PIDTempTarget = 0;
+  pidTaskNotification              = xTaskGetCurrentTaskHandle();
+  uint32_t   PIDTempTarget         = 0;
+  uint16_t   tipTempCRunawayTemp   = 0;
+  TickType_t runawaylastChangeTime = 0;
 #ifdef SLEW_LIMIT
   int32_t x10WattsOutLast = 0;
 #endif
@@ -91,6 +94,33 @@ void startPIDTask(void const *argument __unused) {
         //  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.
+
+        // Check for thermal runaway, where it has been x seconds with negligible (y) temp rise
+        // While trying to actively heat
+        if ((tError > THERMAL_RUNAWAY_TEMP_C)) {
+          // Temp error is high
+          int16_t delta = (int16_t)currentTipTempInC - (int16_t)tipTempCRunawayTemp;
+          if (delta < 0) {
+            delta = -delta;
+          }
+          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
+              heaterThermalRunaway = true;
+            }
+          }
+        } else {
+          tipTempCRunawayTemp   = currentTipTempInC;
+          runawaylastChangeTime = xTaskGetTickCount();
+        }
+
+      } else {
+        tipTempCRunawayTemp   = currentTipTempInC;
+        runawaylastChangeTime = xTaskGetTickCount();
       }
       // If the user turns on the option of using an occasional pulse to keep the power bank on
       if (systemSettings.KeepAwakePulse) {
@@ -111,6 +141,9 @@ void startPIDTask(void const *argument __unused) {
       if (getTipRawTemp(0) > (0x7FFF - 32)) {
         x10WattsOut = 0;
       }
+      if (heaterThermalRunaway) {
+        x10WattsOut = 0;
+      }
       if (systemSettings.powerLimit && x10WattsOut > (systemSettings.powerLimit * 10)) {
         x10WattsOut = systemSettings.powerLimit * 10;
       }