Fixes for MEB battery support (#648)

* Improve MEB support - Add FD CAN overrun checking (incl event) - Process multiple (max 16) CAN RX frames back-to-back to prevent CAN RX overruns - Make MEB extended battery page string handling robust - Add BMS_voltage and BMS_voltage intermediate to extended battery page - Fix temperature calculation - Fix isolation_resistance value - Fix kwh capacity bits - Fix no return value and never reached return statement. - Fix a few bit values - Fix bit position error in 0x1A55555B1 msg. * Change CAN printing format to CANdump format
dalathegreat · Dec 1, 2024 · 7aaaa74 · 7aaaa74
1 parent 5b2320b
commit 7aaaa74
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Showing 7 changed files with 114 additions and 38 deletions.
diff --git a/Software/Software.ino b/Software/Software.ino
@@ -58,6 +58,7 @@ const char* version_number = "7.8.dev";
 // Interval settings
 uint16_t intervalUpdateValues = INTERVAL_1_S;  // Interval at which to update inverter values / Modbus registers
 unsigned long previousMillis10ms = 50;
+unsigned long previousMillis1s = 0;
 unsigned long previousMillisUpdateVal = 0;
 
 // CAN parameters
@@ -257,6 +258,20 @@ void core_loop(void* task_time_us) {
     receive_can_native();  // Receive CAN messages from native CAN port
 #ifdef CAN_FD
     receive_canfd();  // Receive CAN-FD messages.
+    if (millis() - previousMillis1s >= INTERVAL_1_S) {
+      previousMillis10ms = millis();
+      int overflow = canfd.hardwareReceiveBufferOverflowCount();
+      if (overflow > 0){
+        set_event(EVENT_CANFD_RX_OVERRUN, overflow);
+        canfd.resetHardwareReceiveBufferOverflowCount();
+        #ifdef DEBUG_CAN_DATA
+        Serial.print(millis());
+        Serial.print(" RX overrun, lost ");
+        Serial.print(overflow);
+        Serial.println(" messages during 1s.");
+        #endif
+      }
+    }
 #endif
 #ifdef DUAL_CAN
     receive_can_addonMCP2515();  // Receive CAN messages on add-on MCP2515 chip
@@ -592,35 +607,35 @@ enum frameDirection { MSG_RX, MSG_TX };  //RX = 0, TX = 1
 void print_can_frame(CAN_frame frame, frameDirection msgDir);
 void print_can_frame(CAN_frame frame, frameDirection msgDir) {
   uint8_t i = 0;
-  Serial.print(millis());
-  Serial.print(" ");
-  (msgDir == 0) ? Serial.print("RX ") : Serial.print("TX ");
+  Serial.print("(");
+  Serial.print(millis()/1000.0);
+  (msgDir == MSG_RX) ? Serial.print(") RX0 ") : Serial.print(") TX1 ");
   Serial.print(frame.ID, HEX);
-  Serial.print(" ");
+  Serial.print(" [");
   Serial.print(frame.DLC);
-  Serial.print(" ");
+  Serial.print("] ");
   for (i = 0; i < frame.DLC; i++) {
     Serial.print(frame.data.u8[i] < 16 ? "0" : "");
     Serial.print(frame.data.u8[i], HEX);
-    Serial.print(" ");
+    if (i < frame.DLC-1)
+      Serial.print(" ");
   }
-  Serial.println(" ");
+  Serial.println("");
 }
 
 #ifdef CAN_FD
 // Functions
 void receive_canfd() {  // This section checks if we have a complete CAN-FD message incoming
   CANFDMessage frame;
-  if (canfd.available()) {
+  int count = 0;
+  while (canfd.available() && count++ < 16) {
     canfd.receive(frame);
 
     CAN_frame rx_frame;
     rx_frame.ID = frame.id;
     rx_frame.ext_ID = frame.ext;
     rx_frame.DLC = frame.len;
-    for (uint8_t i = 0; i < rx_frame.DLC && i < 64; i++) {
-      rx_frame.data.u8[i] = frame.data[i];
-    }
+    memcpy(rx_frame.data.u8, frame.data, MIN(rx_frame.DLC, 64));
     //message incoming, pass it on to the handler
     receive_can(&rx_frame, CAN_ADDON_FD_MCP2518);
     receive_can(&rx_frame, CANFD_NATIVE);

diff --git a/Software/src/battery/MEB-BATTERY.cpp b/Software/src/battery/MEB-BATTERY.cpp
@@ -533,9 +533,9 @@ void update_values_battery() {  //This function maps all the values fetched via
   datalayer.battery.status.active_power_W =
       ((datalayer.battery.status.voltage_dV * datalayer.battery.status.current_dA) / 100);
 
-  datalayer.battery.status.temperature_min_dC = ((battery_min_temp / 2) - 350);
+  datalayer.battery.status.temperature_min_dC = (battery_min_temp - 350) / 2;
 
-  datalayer.battery.status.temperature_max_dC = ((battery_max_temp / 2) - 350);
+  datalayer.battery.status.temperature_max_dC = (battery_max_temp - 350) / 2;
 
   //Map all cell voltages to the global array
   memcpy(datalayer.battery.status.cell_voltages_mV, cellvoltages_polled, 108 * sizeof(uint16_t));
@@ -589,7 +589,9 @@ void update_values_battery() {  //This function maps all the values fetched via
   datalayer_extended.meb.BMS_error_lamp_req = BMS_error_lamp_req;
   datalayer_extended.meb.BMS_warning_lamp_req = BMS_warning_lamp_req;
   datalayer_extended.meb.BMS_Kl30c_Status = BMS_Kl30c_Status;
-  datalayer_extended.meb.isolation_resistance == isolation_resistance_kOhm * 5;
+  datalayer_extended.meb.BMS_voltage_intermediate_dV = (BMS_voltage_intermediate - 2000) * 10 / 2 ;
+  datalayer_extended.meb.BMS_voltage_dV = BMS_voltage * 10 / 4;
+  datalayer_extended.meb.isolation_resistance = isolation_resistance_kOhm * 5;
   datalayer_extended.meb.battery_heating = battery_heating_active;
   datalayer_extended.meb.rt_overcurrent = realtime_overcurrent_monitor;
   datalayer_extended.meb.rt_CAN_fault = realtime_CAN_communication_fault;
@@ -890,7 +892,7 @@ void receive_can_battery(CAN_frame rx_frame) {
     case 0x1A5555B1:  // BMS 1000ms cyclic
       // All realtime_ have same enumeration, 0 = no fault, 1 = error level 1, 2 error level 2, 3 error level 3
       realtime_overcurrent_monitor = ((rx_frame.data.u8[3] & 0x01) << 2) | rx_frame.data.u8[2] >> 6;
-      realtime_CAN_communication_fault = (rx_frame.data.u8[3] & 0x0F) >> 1;
+      realtime_CAN_communication_fault = (rx_frame.data.u8[3] & 0x0E) >> 1;
       realtime_overcharge_warning = (rx_frame.data.u8[3] & 0x70) >> 4;
       realtime_SOC_too_high = ((rx_frame.data.u8[4] & 0x03) << 1) | rx_frame.data.u8[3] >> 7;
       realtime_SOC_too_low = (rx_frame.data.u8[4] & 0x1C) >> 2;
@@ -929,7 +931,7 @@ void receive_can_battery(CAN_frame rx_frame) {
       BMS_status_voltage_free = (rx_frame.data.u8[1] & 0xC0) >> 6;
       BMS_OBD_MIL = (rx_frame.data.u8[2] & 0x01);
       BMS_error_status = (rx_frame.data.u8[2] & 0x70) >> 4;
-      BMS_capacity_ah = (rx_frame.data.u8[4] << 9) | (rx_frame.data.u8[3] << 1) | (rx_frame.data.u8[2] >> 7);
+      BMS_capacity_ah = (rx_frame.data.u8[4] & 0x03 << 9) | (rx_frame.data.u8[3] << 1) | (rx_frame.data.u8[2] >> 7);
       BMS_error_lamp_req = (rx_frame.data.u8[4] & 0x04) >> 2;
       BMS_warning_lamp_req = (rx_frame.data.u8[4] & 0x08) >> 3;
       BMS_Kl30c_Status = (rx_frame.data.u8[4] & 0x30) >> 4;

diff --git a/Software/src/datalayer/datalayer_extended.h b/Software/src/datalayer/datalayer_extended.h
@@ -312,6 +312,8 @@ typedef struct {
   bool BMS_OBD_MIL = 0;
   bool BMS_error_lamp_req = 0;
   bool BMS_warning_lamp_req = 0;
+  int32_t BMS_voltage_intermediate_dV = 0;
+  int32_t BMS_voltage_dV = 0;
 } DATALAYER_INFO_MEB;
 
 typedef struct {

diff --git a/Software/src/devboard/utils/events.cpp b/Software/src/devboard/utils/events.cpp
@@ -144,6 +144,7 @@ void init_events(void) {
   events.entries[EVENT_CANMCP_INIT_FAILURE].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_CANFD_BUFFER_FULL].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_CAN_OVERRUN].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_CANFD_RX_OVERRUN].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_CAN_RX_FAILURE].level = EVENT_LEVEL_ERROR;
   events.entries[EVENT_CAN2_RX_FAILURE].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_CANFD_RX_FAILURE].level = EVENT_LEVEL_ERROR;
@@ -270,6 +271,8 @@ const char* get_event_message_string(EVENTS_ENUM_TYPE event) {
       return "CAN-FD buffer overflowed. Some CAN messages were not sent. Contact developers.";
     case EVENT_CAN_OVERRUN:
       return "CAN message failed to send within defined time. Contact developers, CPU load might be too high.";
+    case EVENT_CANFD_RX_OVERRUN:
+      return "CAN-FD failed to receive all messages from CAN bus. Contact developers, CPU load might be too high.";
     case EVENT_CAN_RX_FAILURE:
       return "No CAN communication detected for 60s. Shutting down battery control.";
     case EVENT_CAN2_RX_FAILURE:

diff --git a/Software/src/devboard/utils/events.h b/Software/src/devboard/utils/events.h
@@ -30,6 +30,7 @@
   XX(EVENT_CANMCP_INIT_FAILURE)         \
   XX(EVENT_CANFD_BUFFER_FULL)           \
   XX(EVENT_CAN_OVERRUN)                 \
+  XX(EVENT_CANFD_RX_OVERRUN)            \
   XX(EVENT_CAN_RX_FAILURE)              \
   XX(EVENT_CAN2_RX_FAILURE)             \
   XX(EVENT_CANFD_RX_FAILURE)            \

diff --git a/Software/src/devboard/webserver/advanced_battery_html.cpp b/Software/src/devboard/webserver/advanced_battery_html.cpp
@@ -348,27 +348,80 @@ String advanced_battery_processor(const String& var) {
     content += datalayer_extended.meb.shutdown_active ? "<h4>Shutdown: Active!</h4>" : "<h4>Shutdown: No</h4>";
     content += datalayer_extended.meb.componentprotection ? "<h4>Component protection: Active!</h4>"
                                                           : "<h4>Component protection: No</h4>";
-    const char* HVIL_status[] = {"Init", "Closed", "Open!", "Fault"};
-    content += "<h4>HVIL status: " + String(HVIL_status[datalayer_extended.meb.HVIL]) + "</h4>";
-    content += "<h4>KL30C status: " + String(HVIL_status[datalayer_extended.meb.BMS_Kl30c_Status]) + "</h4>";
-    const char* BMS_modes[] = {"HV inactive", "HV active",     "Balancing",   "Extern charging",
-                               "AC charging", "Battery error", "DC charging", "Init"};
-    content += "<h4>BMS mode: " + String(BMS_modes[datalayer_extended.meb.BMS_mode]) + "</h4>";
-    const char* diagnostic_modes[] = {"Init", "Battery display",       "",     "", "Battery display OK",
-                                      "",     "Display battery check", "Fault"};
-    content += "<h4>Diagnostic: " + String(diagnostic_modes[datalayer_extended.meb.battery_diagnostic]) + "</h4>";
-    const char* HV_line_status[] = {"Init", "No open HV line detected", "Open HV line", "Fault"};
-    content += "<h4>HV line status: " + String(HV_line_status[datalayer_extended.meb.status_HV_line]) + "</h4>";
-    const char* warning_support_status[] = {"OK", "Not OK", "", "", "", "", "Init", "Fault"};
-    content +=
-        "<h4>Warning support: " + String(warning_support_status[datalayer_extended.meb.warning_support]) + "</h4>";
-    const char* voltage_free_status[] = {"Init", "BMS interm circuit voltage free (U<20V)",
-                                         "BMS interm circuit not voltage free (U >= 25V)", "Error"};
-    content +=
-        "<h4>Voltage status: " + String(voltage_free_status[datalayer_extended.meb.BMS_status_voltage_free]) + "</h4>";
-    const char* bms_error_status[] = {"Component IO", "Iso Error 1",     "Iso Error 2",           "Interlock",
-                                      "SD",           "Performance red", "No component function", "Init"};
-    content += "<h4>BMS error status: " + String(bms_error_status[datalayer_extended.meb.BMS_error_status]) + "</h4>";
+    content += "<h4>HVIL status: ";
+    switch (datalayer_extended.meb.HVIL){
+      case 0: content+= String("Init"); break;
+      case 1: content+= String("Closed"); break;
+      case 2: content+= String("Open!"); break;
+      case 3: content+= String("Fault"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>KL30C status: ";
+    switch (datalayer_extended.meb.BMS_Kl30c_Status){
+      case 0: content+= String("Init"); break;
+      case 1: content+= String("Closed"); break;
+      case 2: content+= String("Open!"); break;
+      case 3: content+= String("Fault"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>BMS mode: ";
+    switch (datalayer_extended.meb.BMS_mode){
+      case 0: content+= String("HV inactive"); break;
+      case 1: content+= String("HV active"); break;
+      case 2: content+= String("Balancing"); break;
+      case 3: content+= String("Extern charging"); break;
+      case 4: content+= String("AC charging"); break;
+      case 5: content+= String("Battery error"); break;
+      case 6: content+= String("DC charging"); break;
+      case 7: content+= String("Init"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>Diagnostic: ";
+    switch (datalayer_extended.meb.battery_diagnostic){
+      case 0: content+= String("Init"); break;
+      case 1: content+= String("Battery display"); break;
+      case 4: content+= String("Battery display OK"); break;
+      case 6: content+= String("Battery display check"); break;
+      case 7: content+= String("Fault"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>HV line status: ";
+    switch (datalayer_extended.meb.status_HV_line){
+      case 0: content+= String("Init"); break;
+      case 1: content+= String("No open HV line detected"); break;
+      case 2: content+= String("Open HV line"); break;
+      case 3: content+= String("Fault"); break;
+      default: content += String("? ") + String(datalayer_extended.meb.status_HV_line);
+    }
+    content += "</h4><h4>Warning support: ";
+    switch (datalayer_extended.meb.warning_support){
+      case 0: content+= String("OK"); break;
+      case 1: content+= String("Not OK"); break;
+      case 6: content+= String("Init"); break;
+      case 7: content+= String("Fault"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>Interm. Voltage ("+ String(datalayer_extended.meb.BMS_voltage_intermediate_dV/10.0, 1)+"V) status: ";
+    switch (datalayer_extended.meb.BMS_status_voltage_free){
+      case 0: content+= String("Init"); break;
+      case 1: content+= String("BMS interm circuit voltage free (U<20V)"); break;
+      case 2: content+= String("BMS interm circuit not voltage free (U >= 25V)"); break;
+      case 3: content+= String("Error"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>BMS error status: ";
+    switch (datalayer_extended.meb.BMS_error_status){
+      case 0: content+= String("Component IO"); break;
+      case 1: content+= String("Iso Error 1"); break;
+      case 2: content+= String("Iso Error 2"); break;
+      case 3: content+= String("Interlock"); break;
+      case 4: content+= String("SD"); break;
+      case 5: content+= String("Performance red"); break;
+      case 6: content+= String("No component function"); break;
+      case 7: content+= String("Init"); break;
+      default: content += String("?");
+    }
+    content += "</h4><h4>BMS voltage: " + String(datalayer_extended.meb.BMS_voltage_dV/10.0, 1) + "</h4>";
     content += datalayer_extended.meb.BMS_OBD_MIL ? "<h4>OBD MIL: ON!</h4>" : "<h4>OBD MIL: Off</h4>";
     content +=
         datalayer_extended.meb.BMS_error_lamp_req ? "<h4>Red error lamp: ON!</h4>" : "<h4>Red error lamp: Off</h4>";

diff --git a/Software/src/devboard/webserver/events_html.cpp b/Software/src/devboard/webserver/events_html.cpp
@@ -58,8 +58,8 @@ String events_processor(const String& var) {
     order_events.clear();
     content.concat(FPSTR(EVENTS_HTML_END));
     return content;
-    return String();
   }
+  return String();
 }
 
 /* Script for displaying event log before it gets minified