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Merge pull request #619 from dalathegreat/feature/double-automatic-co…
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…ntactor

Feature: Double contactor support + NC support
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@dalathegreat
dalathegreat authored Nov 23, 2024
2 parents 753d33d + 9a7dda5 commit 9e74fcd
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Showing 6 changed files with 120 additions and 90 deletions.
163 changes: 95 additions & 68 deletions Software/Software.ino
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Original file line number Diff line number Diff line change
Expand Up @@ -57,7 +57,7 @@ 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 previousMillis10ms = 0;
unsigned long previousMillisUpdateVal = 0;

// CAN parameters
Expand Down Expand Up @@ -118,27 +118,49 @@ MyTimer check_pause_2s(INTERVAL_2_S);
enum State { DISCONNECTED, PRECHARGE, NEGATIVE, POSITIVE, PRECHARGE_OFF, COMPLETED, SHUTDOWN_REQUESTED };
State contactorStatus = DISCONNECTED;

#define ON 1
#define OFF 0

#ifdef NC_CONTACTORS //Normally closed contactors use inverted logic
#undef ON
#define ON 0
#undef OFF
#define OFF 1
#endif

#define MAX_ALLOWED_FAULT_TICKS 1000
/* NOTE: modify the precharge time constant below to account for the resistance and capacitance of the target system.
* t=3RC at minimum, t=5RC ideally
*/
#define PRECHARGE_TIME_MS 160
#define NEGATIVE_CONTACTOR_TIME_MS 1000
#define POSITIVE_CONTACTOR_TIME_MS 2000
#ifdef PWM_CONTACTOR_CONTROL
#define PWM_Freq 20000 // 20 kHz frequency, beyond audible range
#define PWM_Res 10 // 10 Bit resolution 0 to 1023, maps 'nicely' to 0% 100%
#define PWM_Hold_Duty 250
#define PWM_Off_Duty 0
#define PWM_On_Duty 1023
#define PWM_HOLD_DUTY 250
#define PWM_OFF_DUTY 0
#define PWM_ON_DUTY 1023
#define POSITIVE_PWM_Ch 0
#define NEGATIVE_PWM_Ch 1
#endif
unsigned long prechargeStartTime = 0;
unsigned long negativeStartTime = 0;
unsigned long timeSpentInFaultedMode = 0;
#endif

void set(uint8_t pin, bool direction, uint32_t pwm_freq = 0xFFFFFFFFFF) {
#ifdef PWM_CONTACTOR_CONTROL
if (pwm_freq != 0xFFFFFFFFFF) {
ledcWrite(pin, pwm_freq);
return;
}
#endif
if (direction == 1) {
digitalWrite(pin, HIGH);
} else { // 0
digitalWrite(pin, LOW);
}
}

#ifdef EQUIPMENT_STOP_BUTTON
const unsigned long equipment_button_long_press_duration =
15000; // 15 seconds for long press in case of MOMENTARY_SWITCH
Expand Down Expand Up @@ -280,9 +302,6 @@ void core_loop(void* task_time_us) {
previousMillis10ms = millis();
led_exe();
handle_contactors(); // Take care of startup precharge/contactor closing
#ifdef DOUBLE_BATTERY
check_interconnect_available();
#endif
}
END_TIME_MEASUREMENT_MAX(time_10ms, datalayer.system.status.time_10ms_us);

Expand All @@ -292,6 +311,7 @@ void core_loop(void* task_time_us) {
update_values_battery(); // Fetch battery values
#ifdef DOUBLE_BATTERY
update_values_battery2();
check_interconnect_available();
#endif
update_calculated_values();
#ifndef SERIAL_LINK_RECEIVER
Expand Down Expand Up @@ -497,27 +517,34 @@ void init_CAN() {
void init_contactors() {
// Init contactor pins
#ifdef CONTACTOR_CONTROL
#ifndef PWM_CONTACTOR_CONTROL
pinMode(POSITIVE_CONTACTOR_PIN, OUTPUT);
digitalWrite(POSITIVE_CONTACTOR_PIN, LOW);
pinMode(NEGATIVE_CONTACTOR_PIN, OUTPUT);
digitalWrite(NEGATIVE_CONTACTOR_PIN, LOW);
#else
#ifdef PWM_CONTACTOR_CONTROL
ledcAttachChannel(POSITIVE_CONTACTOR_PIN, PWM_Freq, PWM_Res,
POSITIVE_PWM_Ch); // Setup PWM Channel Frequency and Resolution
ledcAttachChannel(NEGATIVE_CONTACTOR_PIN, PWM_Freq, PWM_Res,
NEGATIVE_PWM_Ch); // Setup PWM Channel Frequency and Resolution
ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Off_Duty); // Set Positive PWM to 0%
ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Off_Duty); // Set Negative PWM to 0%
ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_OFF_DUTY); // Set Positive PWM to 0%
ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_OFF_DUTY); // Set Negative PWM to 0%
#else //Normal CONTACTOR_CONTROL
pinMode(POSITIVE_CONTACTOR_PIN, OUTPUT);
set(POSITIVE_CONTACTOR_PIN, OFF);
pinMode(NEGATIVE_CONTACTOR_PIN, OUTPUT);
set(NEGATIVE_CONTACTOR_PIN, OFF);
#endif
pinMode(PRECHARGE_PIN, OUTPUT);
digitalWrite(PRECHARGE_PIN, LOW);
#endif
set(PRECHARGE_PIN, OFF);
#endif //CONTACTOR_CONTROL
#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY

pinMode(SECOND_POSITIVE_CONTACTOR_PIN, OUTPUT);
set(SECOND_POSITIVE_CONTACTOR_PIN, OFF);
pinMode(SECOND_NEGATIVE_CONTACTOR_PIN, OUTPUT);
set(SECOND_NEGATIVE_CONTACTOR_PIN, OFF);
#endif //CONTACTOR_CONTROL_DOUBLE_BATTERY
// Init BMS contactor
#ifdef HW_STARK // TODO: Rewrite this so LilyGo can also handle this BMS contactor
pinMode(BMS_POWER, OUTPUT);
digitalWrite(BMS_POWER, HIGH);
#endif
#endif //HW_STARK
}

void init_rs485() {
Expand Down Expand Up @@ -695,14 +722,18 @@ void check_interconnect_available() {
return; // Both voltage values need to be available to start check
}

if (abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) < 30) { // If we are within 3.0V
uint16_t voltage_diff = abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV);

if (voltage_diff <= 30) { // If we are within 3.0V between the batteries
clear_event(EVENT_VOLTAGE_DIFFERENCE);
if (datalayer.battery.status.bms_status != FAULT) { // Only proceed if we are not in faulted state
if (datalayer.battery.status.bms_status == FAULT) {
// If main battery is in fault state, disengage the second battery
datalayer.system.status.battery2_allows_contactor_closing = false;
} else { // If main battery is OK, allow second battery to join
datalayer.system.status.battery2_allows_contactor_closing = true;
}
} else { //We are over 3.0V diff
set_event(EVENT_VOLTAGE_DIFFERENCE,
(uint8_t)(abs(datalayer.battery.status.voltage_dV - datalayer.battery2.status.voltage_dV) / 10));
} else { //Voltage between the two packs is too large
set_event(EVENT_VOLTAGE_DIFFERENCE, (uint8_t)(voltage_diff / 10));
}
}
#endif //DOUBLE_BATTERY
Expand All @@ -712,6 +743,10 @@ void handle_contactors() {
datalayer.system.status.inverter_allows_contactor_closing = digitalRead(INVERTER_CONTACTOR_ENABLE_PIN);
#endif

#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY
handle_contactors_battery2();
#endif

#ifdef CONTACTOR_CONTROL
// First check if we have any active errors, incase we do, turn off the battery
if (datalayer.battery.status.bms_status == FAULT) {
Expand All @@ -720,50 +755,38 @@ void handle_contactors() {
timeSpentInFaultedMode = 0;
}

//handle contactor control SHUTDOWN_REQUESTED vs DISCONNECTED
if (timeSpentInFaultedMode > MAX_ALLOWED_FAULT_TICKS ||
(datalayer.system.settings.equipment_stop_active && contactorStatus != SHUTDOWN_REQUESTED)) {
//handle contactor control SHUTDOWN_REQUESTED
if (timeSpentInFaultedMode > MAX_ALLOWED_FAULT_TICKS) {
contactorStatus = SHUTDOWN_REQUESTED;
datalayer.system.settings.equipment_stop_active = true;
}
if (contactorStatus == SHUTDOWN_REQUESTED && !datalayer.system.settings.equipment_stop_active) {
contactorStatus = DISCONNECTED;
}

if (contactorStatus == SHUTDOWN_REQUESTED) {
digitalWrite(PRECHARGE_PIN, LOW);
#ifndef PWM_CONTACTOR_CONTROL
digitalWrite(NEGATIVE_CONTACTOR_PIN, LOW);
digitalWrite(POSITIVE_CONTACTOR_PIN, LOW);
#else
ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Off_Duty);
ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Off_Duty);
#endif
set(PRECHARGE_PIN, OFF);
set(NEGATIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
set(POSITIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
set_event(EVENT_ERROR_OPEN_CONTACTOR, 0);
datalayer.system.status.contactor_control_closed = false;
datalayer.system.status.contactors_engaged = false;
return; // A fault scenario latches the contactor control. It is not possible to recover without a powercycle (and investigation why fault occured)
}

// After that, check if we are OK to start turning on the battery
if (contactorStatus == DISCONNECTED) {
digitalWrite(PRECHARGE_PIN, LOW);
#ifndef PWM_CONTACTOR_CONTROL
digitalWrite(NEGATIVE_CONTACTOR_PIN, LOW);
digitalWrite(POSITIVE_CONTACTOR_PIN, LOW);
#else
ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Off_Duty);
ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Off_Duty);
#endif
set(PRECHARGE_PIN, OFF);
set(NEGATIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);
set(POSITIVE_CONTACTOR_PIN, OFF, PWM_OFF_DUTY);

if (datalayer.system.status.battery_allows_contactor_closing &&
datalayer.system.status.inverter_allows_contactor_closing) {
datalayer.system.status.inverter_allows_contactor_closing && !datalayer.system.settings.equipment_stop_active) {
contactorStatus = PRECHARGE;
}
}

// In case the inverter requests contactors to open, set the state accordingly
if (contactorStatus == COMPLETED) {
if (!datalayer.system.status.inverter_allows_contactor_closing)
//Incase inverter (or estop) requests contactors to open, make state machine jump to Disconnected state (recoverable)
if (!datalayer.system.status.inverter_allows_contactor_closing || datalayer.system.settings.equipment_stop_active) {
contactorStatus = DISCONNECTED;
}
// Skip running the state machine below if it has already completed
return;
}
Expand All @@ -772,43 +795,33 @@ void handle_contactors() {
// Handle actual state machine. This first turns on Precharge, then Negative, then Positive, and finally turns OFF precharge
switch (contactorStatus) {
case PRECHARGE:
digitalWrite(PRECHARGE_PIN, HIGH);
set(PRECHARGE_PIN, ON);
prechargeStartTime = currentTime;
contactorStatus = NEGATIVE;
break;

case NEGATIVE:
if (currentTime - prechargeStartTime >= PRECHARGE_TIME_MS) {
#ifndef PWM_CONTACTOR_CONTROL
digitalWrite(NEGATIVE_CONTACTOR_PIN, HIGH);
#else
ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_On_Duty);
#endif
set(NEGATIVE_CONTACTOR_PIN, ON, PWM_ON_DUTY);
negativeStartTime = currentTime;
contactorStatus = POSITIVE;
}
break;

case POSITIVE:
if (currentTime - negativeStartTime >= NEGATIVE_CONTACTOR_TIME_MS) {
#ifndef PWM_CONTACTOR_CONTROL
digitalWrite(POSITIVE_CONTACTOR_PIN, HIGH);
#else
ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_On_Duty);
#endif
set(POSITIVE_CONTACTOR_PIN, ON, PWM_ON_DUTY);
contactorStatus = PRECHARGE_OFF;
}
break;

case PRECHARGE_OFF:
if (currentTime - negativeStartTime >= POSITIVE_CONTACTOR_TIME_MS) {
digitalWrite(PRECHARGE_PIN, LOW);
#ifdef PWM_CONTACTOR_CONTROL
ledcWrite(NEGATIVE_CONTACTOR_PIN, PWM_Hold_Duty);
ledcWrite(POSITIVE_CONTACTOR_PIN, PWM_Hold_Duty);
#endif
set(PRECHARGE_PIN, OFF);
set(NEGATIVE_CONTACTOR_PIN, ON, PWM_HOLD_DUTY);
set(POSITIVE_CONTACTOR_PIN, ON, PWM_HOLD_DUTY);
contactorStatus = COMPLETED;
datalayer.system.status.contactor_control_closed = true;
datalayer.system.status.contactors_engaged = true;
}
break;
default:
Expand All @@ -817,6 +830,20 @@ void handle_contactors() {
#endif // CONTACTOR_CONTROL
}

#ifdef CONTACTOR_CONTROL_DOUBLE_BATTERY
void handle_contactors_battery2() {
if ((contactorStatus == COMPLETED) && datalayer.system.status.battery2_allows_contactor_closing) {
set(SECOND_NEGATIVE_CONTACTOR_PIN, ON);
set(SECOND_POSITIVE_CONTACTOR_PIN, ON);
datalayer.system.status.contactors_battery2_engaged = true;
} else { // Closing contactors on secondary battery not allowed
set(SECOND_NEGATIVE_CONTACTOR_PIN, OFF);
set(SECOND_POSITIVE_CONTACTOR_PIN, OFF);
datalayer.system.status.contactors_battery2_engaged = false;
}
}
#endif //CONTACTOR_CONTROL_DOUBLE_BATTERY

void update_calculated_values() {
/* Calculate allowed charge/discharge currents*/
if (datalayer.battery.status.voltage_dV > 10) {
Expand Down
8 changes: 6 additions & 2 deletions Software/USER_SETTINGS.h
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Original file line number Diff line number Diff line change
Expand Up @@ -55,12 +55,16 @@
//#define HW_STARK
//#define HW_3LB

/* Contactor settings. If you have a battery that does not activate contactors via CAN, configure this section */
//#define CONTACTOR_CONTROL //Enable this line to have the emulator handle automatic precharge/contactor+/contactor- closing sequence (See wiki for pins)
//#define CONTACTOR_CONTROL_DOUBLE_BATTERY //Enable this line to have the emulator hardware control secondary set of contactors for double battery setups (See wiki for pins)
//#define PWM_CONTACTOR_CONTROL //Enable this line to use PWM for CONTACTOR_CONTROL, which lowers power consumption and heat generation. CONTACTOR_CONTROL must be enabled.
//#define NC_CONTACTORS //Enable this line to control normally closed contactors. CONTACTOR_CONTROL must be enabled for this option. Extremely rare setting!

/* Other options */
//#define DEBUG_VIA_USB //Enable this line to have the USB port output serial diagnostic data while program runs (WARNING, raises CPU load, do not use for production)
//#define DEBUG_CAN_DATA //Enable this line to print incoming/outgoing CAN & CAN-FD messages to USB serial (WARNING, raises CPU load, do not use for production)
//#define INTERLOCK_REQUIRED //Nissan LEAF specific setting, if enabled requires both high voltage conenctors to be seated before starting
//#define CONTACTOR_CONTROL //Enable this line to have pins 25,32,33 handle automatic precharge/contactor+/contactor- closing sequence
//#define PWM_CONTACTOR_CONTROL //Enable this line to use PWM for CONTACTOR_CONTROL, which lowers power consumption and heat generation. CONTACTOR_CONTROL must be enabled.
//#define DUAL_CAN //Enable this line to activate an isolated secondary CAN Bus using add-on MCP2515 chip (Needed for some inverters / double battery)
#define CRYSTAL_FREQUENCY_MHZ 8 //DUAL_CAN option, what is your MCP2515 add-on boards crystal frequency?
//#define CAN_FD //Enable this line to activate an isolated secondary CAN-FD bus using add-on MCP2518FD chip / Native CANFD on Stark board
Expand Down
14 changes: 5 additions & 9 deletions Software/src/battery/NISSAN-LEAF-BATTERY.cpp
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Original file line number Diff line number Diff line change
Expand Up @@ -136,10 +136,10 @@ static uint16_t battery2_TEMP = 0; //Temporary value used in s
static uint16_t battery2_Wh_Remaining = 0; //Amount of energy in battery, in Wh
static uint16_t battery2_GIDS = 273; //Startup in 24kWh mode
static uint16_t battery2_MAX = 0;
static uint16_t battery2_Max_GIDS = 273; //Startup in 24kWh mode
static uint16_t battery2_StateOfHealth = 99; //State of health %
static uint16_t battery2_Total_Voltage2 = 740; //Battery voltage (0-450V) [0.5V/bit, so actual range 0-800]
static int16_t battery2_Current2 = 0; //Battery current (-400-200A) [0.5A/bit, so actual range -800-400]
static uint16_t battery2_Max_GIDS = 273; //Startup in 24kWh mode
static uint16_t battery2_StateOfHealth = 99; //State of health %
static uint16_t battery2_Total_Voltage2 = 0; //Battery voltage (0-450V) [0.5V/bit, so actual range 0-800]
static int16_t battery2_Current2 = 0; //Battery current (-400-200A) [0.5A/bit, so actual range -800-400]
static int16_t battery2_HistData_Temperature_MAX = 6; //-40 to 86*C
static int16_t battery2_HistData_Temperature_MIN = 5; //-40 to 86*C
static int16_t battery2_AverageTemperature = 6; //Only available on ZE0, in celcius, -40 to +55
Expand Down Expand Up @@ -514,11 +514,7 @@ void receive_can_battery2(CAN_frame rx_frame) {
battery2_Relay_Cut_Request = ((rx_frame.data.u8[1] & 0x18) >> 3);
battery2_Failsafe_Status = (rx_frame.data.u8[1] & 0x07);
battery2_MainRelayOn_flag = (bool)((rx_frame.data.u8[3] & 0x20) >> 5);
if (battery2_MainRelayOn_flag) {
datalayer.system.status.battery2_allows_contactor_closing = true;
} else {
datalayer.system.status.battery2_allows_contactor_closing = false;
}
//battery2_allows_contactor_closing written by check_interconnect_available();
battery2_Full_CHARGE_flag = (bool)((rx_frame.data.u8[3] & 0x10) >> 4);
battery2_Interlock = (bool)((rx_frame.data.u8[3] & 0x08) >> 3);
break;
Expand Down
4 changes: 3 additions & 1 deletion Software/src/datalayer/datalayer.h
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Original file line number Diff line number Diff line change
Expand Up @@ -192,7 +192,9 @@ typedef struct {
bool inverter_allows_contactor_closing = true;
#ifdef CONTACTOR_CONTROL
/** True if the contactor controlled by battery-emulator is closed */
bool contactor_control_closed = false;
bool contactors_engaged = false;
/** True if the contactor controlled by battery-emulator is closed. Determined by check_interconnect_available(); if voltage is OK */
bool contactors_battery2_engaged = false;
#endif
} DATALAYER_SYSTEM_STATUS_TYPE;

Expand Down
6 changes: 3 additions & 3 deletions Software/src/devboard/hal/hw_3LB.h
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Original file line number Diff line number Diff line change
Expand Up @@ -52,9 +52,9 @@
#define NEGATIVE_CONTACTOR_PIN 33
#define PRECHARGE_PIN 25

#define 2ND_POSITIVE_CONTACTOR_PIN 13
#define 2ND_NEGATIVE_CONTACTOR_PIN 16
#define 2ND_PRECHARGE_PIN 18
#define SECOND_POSITIVE_CONTACTOR_PIN 13
#define SECOND_NEGATIVE_CONTACTOR_PIN 16
#define SECOND_PRECHARGE_PIN 18

// SMA CAN contactor pins
#define INVERTER_CONTACTOR_ENABLE_PIN 36
Expand Down
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