Merge pull request #289 from stuartpittaway/stateofhealth

State of health and various other fixes (May 2024)

.github/workflows/main.yml

@@ -10,34 +10,23 @@ jobs:
   job_build_modulecode:
     runs-on: ubuntu-latest
     steps:
-      - uses: actions/checkout@v3
+      - uses: actions/checkout@v4
 
-      - name: Cache pip
-        uses: actions/cache@v3
+      - name: Cache pio
+        uses: actions/cache@v4
         with:
-          path: ~/.cache/pip
-          key: ${{ runner.os }}-pip-${{ hashFiles('**/requirements.txt') }}
-          restore-keys: ${{ runner.os }}-pip-
-
-      - name: Cache PlatformIO
-        uses: actions/cache@v3
-        with:
-          path: ~/.platformio
-          key: ${{ runner.os }}-platformio-2022-${{ hashFiles('**/lockfiles') }}
+          path: |
+            ~/.cache/pip
+            ~/.platformio/.cache
+          key: ${{ runner.os }}-pio
 
       - name: Set up Python
-        uses: actions/setup-python@v4
-
-      - uses: actions/cache@v3
+        uses: actions/setup-python@v5
         with:
-          path: ~/.local/share/virtualenvs
-          key: ${{ runner.os }}-pipenv-${{ hashFiles('Pipfile.lock') }}
-          restore-keys: ${{ runner.os }}-pipenv-
+          python-version: '3.11'
 
       - name: Install PlatformIO
-        run: |
-          python -m pip install --upgrade pip
-          pip install --upgrade platformio
+        run: pip install --upgrade platformio
 
       - name: Create folders
         run: |
@@ -65,13 +54,6 @@ jobs:
         run: |
             cp ./STM32All-In-One/.pio/build/V*/*.bin ~/OUTPUT/Modules/BIN/
   
-      - name: Get latest esptool
-        run: |
-          git clone https://github.com/espressif/esptool.git
-          cd esptool
-          pip install --user -e .
-          cd ~
-          python -m esptool version
 
       - name: Build code for ESP32 controller
         run: pio run --project-dir=/home/runner/work/diyBMSv4ESP32/diyBMSv4ESP32/ESPController --environment esp32-devkitc --project-conf=/home/runner/work/diyBMSv4ESP32/diyBMSv4ESP32/ESPController/platformio.ini
@@ -92,8 +74,12 @@ jobs:
         run: |
           cp ./ESPController/.pio/build/esp32-devkitc/diybms_controller_filesystemimage_espressif32_esp32-devkitc.bin ~/OUTPUT/Controller/
 
-      - name: Build single ESP32 image
+      - name: Get latest esptool / Build single ESP32 image
         run: |
+          git clone https://github.com/espressif/esptool.git
+          cd esptool
+          pip install --user -e .
+          cd ~
           python -m esptool --chip esp32 merge_bin -o ~/OUTPUT/Controller/esp32-controller-firmware-complete.bin --flash_mode=keep --flash_size 4MB 0x1000 ~/OUTPUT/Controller/bootloader.bin 0x8000 ~/OUTPUT/Controller/partitions.bin 0xe000 ~/OUTPUT/Controller/boot_app0.bin 0x10000 ~/OUTPUT/Controller/diybms_controller_firmware_espressif32_esp32-devkitc.bin 0x1C0000 ~/OUTPUT/Controller/diybms_controller_firmware_espressif32_esp32-devkitc.bin 0x370000 ~/OUTPUT/Controller/diybms_controller_filesystemimage_espressif32_esp32-devkitc.bin
 
       - name: Board test code for ESP32 controller
@@ -104,7 +90,7 @@ jobs:
           cp ./ESP32BoardTest/.pio/build/esp32-devkitc/diybms_boardtest_espressif32_esp32-devkitc.bin ~/OUTPUT/ControllerBoardTest/
 
       - name: Publish Artifacts 1
-        uses: actions/upload-artifact@v3
+        uses: actions/upload-artifact@v4
         with:
           name: DIYBMS-Compiled
           path: ~/OUTPUT
@@ -115,7 +101,7 @@ jobs:
     needs: [job_build_modulecode]
     steps:
       - name: Download artifact DIYBMS-Compiled
-        uses: actions/download-artifact@v3
+        uses: actions/download-artifact@v4
         with:
           name: DIYBMS-Compiled
 
@@ -142,7 +128,7 @@ jobs:
         run: mv release.zip release_${{ env.dt }}.zip
 
       - name: Publish Artifact
-        uses: actions/upload-artifact@v3
+        uses: actions/upload-artifact@v4
         with:
           name: DIYBMS-Release-Artifact-${{ env.dt }}
           path: |

ESP32BoardTest/platformio.ini

@@ -36,25 +36,22 @@ build_flags =
 [env]
 framework = arduino
 ; 4MB FLASH DEVKITC
-platform = espressif32
-;platform  = https://github.com/platformio/platform-espressif32.git#feature/arduino-upstream
+platform = espressif32@~6.4.0
 
 board = esp32dev
 monitor_speed = 115200
-monitor_port=COM4
+monitor_port=COM3
 monitor_filters = log2file, esp32_exception_decoder
 board_build.flash_mode = dout
 board_build.filesystem = littlefs
 extra_scripts =
         pre:buildscript_versioning.py
 
-
-
 upload_speed=921600
-upload_port=COM4
+upload_port=COM3
 
 platform_packages =
-   framework-arduinoespressif32 @ https://github.com/espressif/arduino-esp32.git#2.0.6
+   framework-arduinoespressif32 @ https://github.com/espressif/arduino-esp32.git#2.0.14
 
 board_build.partitions = diybms_partitions.csv
 

ESP32BoardTest/src/main.cpp

@@ -87,6 +87,9 @@ static constexpr const char *const TAG = "diybms";
 #define RS485_TX GPIO_NUM_22
 #define RS485_ENABLE GPIO_NUM_25
 
+#define INA229_CHIPSELECT GPIO_NUM_33
+#define INA229_INTERRUPT_PIN GPIO_NUM_35
+
 enum RGBLED : uint8_t
 {
     OFF = 0,
@@ -605,7 +608,7 @@ void testSerial()
     delay(10);
 
     ESP_LOGI(TAG, "Test serial TX1/RX1");
-    for (size_t i = 0; i < 50; i++)
+    for (size_t i = 0; i < 20; i++)
     {
         SERIAL_DATA.println("test!");
 
@@ -623,6 +626,65 @@ void testSerial()
     }
 }
 
+    enum INA_REGISTER : uint8_t
+    {
+        CONFIG = 0,
+        ADC_CONFIG = 1,
+        // Shunt Calibration
+        SHUNT_CAL = 2,
+        // Shunt Temperature Coefficient
+        SHUNT_TEMPCO = 3,
+        // Shunt Voltage Measurement 24bit
+        VSHUNT = 4,
+        // Bus Voltage Measurement 24bit
+        VBUS = 5,
+        DIETEMP = 6,
+        // Current Result 24bit
+        CURRENT = 7,
+        // Power Result 24bit
+        POWER = 8,
+        // Energy Result 40bit
+        ENERGY = 9,
+        // Charge Result 40bit
+        CHARGE = 0x0A,
+        // Alert triggers
+        DIAG_ALRT = 0x0b,
+        // Shunt Overvoltage Threshold
+        // overcurrent protection
+        SOVL = 0x0c,
+        // Shunt Undervoltage Threshold
+        // undercurrent protection
+        SUVL = 0x0d,
+        // Bus Overvoltage Threshold
+        BOVL = 0x0e,
+        // Bus Undervoltage Threshold
+        BUVL = 0x0f,
+        // Temperature Over-Limit Threshold
+        TEMP_LIMIT = 0x10,
+        // Power Over-Limit Threshold
+        PWR_LIMIT = 0x11,
+        // Manufacturer ID
+        MANUFACTURER_ID = 0x3E,
+        // Device ID
+        DEVICE_ID = 0x3F
+
+    };
+
+uint16_t read16bits(INA_REGISTER r)
+{
+    SPISettings _spisettings = SPISettings(10000000, MSBFIRST, SPI_MODE1);
+    vspi.beginTransaction(_spisettings);
+    digitalWrite(INA229_CHIPSELECT, LOW);
+    // The transfers are always a step behind, so the transfer reads the previous value/command
+    vspi.write((uint8_t)((r << 2U) | B00000001));
+    uint16_t value = vspi.transfer16(0);
+    digitalWrite(INA229_CHIPSELECT, HIGH);
+    vspi.endTransaction();
+
+    ESP_LOGD(TAG, "Read register 0x%02x = 0x%04x", r, value);
+    return value;
+}
+
 void setup()
 {
     // We are not testing ESP32, so switch off WIFI + BT
@@ -638,6 +700,18 @@ void setup()
     ConfigureI2C();
     ConfigureVSPI();
 
+
+    uint16_t value = read16bits(INA_REGISTER::DEVICE_ID);
+    if ((value >> 4) == 0x229)
+    {
+        ESP_LOGI(TAG, "FOUND CURRENT SHUNT CHIP INA%02x, Revision=%u", value >> 4, value & B1111);        
+    }
+    else
+    {
+        // Stop here - no chip found
+        ESP_LOGW(TAG, "** CURRENT SHUNT CHIP INA229 CHIP ABSENT **");
+    }
+
     mountSDCard();
 
     // Create a test file
@@ -681,7 +755,7 @@ void setup()
     Led(RGBLED::OFF);
 
     // Test SERIAL
-    SERIAL_DATA.begin(2400, SERIAL_8N1, 2, 32); // Serial for comms to modules
+    SERIAL_DATA.begin(5000, SERIAL_8N1, 2, 32); // Serial for comms to modules
     testSerial();
 
     init_tft_display();

ESPController/data/cfg_lifepo4_16cells.json

@@ -1 +1 @@
-{"diybms_settings":{"totalNumberOfBanks":1,"totalNumberOfSeriesModules":16,"baudRate":10000,"interpacketgap":3000,"graph_voltagehigh":3650,"graph_voltagelow":3000,"BypassOverTempShutdown":65,"BypassThresholdmV":3450,"timeZone":0,"minutesTimeZone":0,"daylight":false,"ntpServer":"time.google.com","loggingEnabled":false,"loggingFrequencySeconds":15,"currentMonitoringEnabled":true,"currentMonitoringModBusAddress":90,"rs485baudrate":19200,"rs485databits":3,"rs485parity":0,"rs485stopbits":1,"language":"en","mqtt":{"enabled":true,"uri":"mqtt://192.168.0.26:1883","topic":"emon/diybms","username":"emonpi","password":"emonpimqtt2016"},"influxdb":{"enabled":false,"apitoken":"","bucket":"bucketname","org":"organisation","url":"http://192.168.0.49:8086/api/v2/write","logfreq":15},"outputs":{"default":[153,153,153,153],"type":[0,0,0,0]},"rules":{"EmergencyStop":{"value":0,"hysteresis":0,"state":[0,0,0,0]},"BMSError":{"value":0,"hysteresis":0,"state":[0,0,0,0]},"CurrentMonitorOverCurrentAmps":{"value":100,"hysteresis":100,"state":[0,0,0,0]},"ModuleOverVoltage":{"value":3650,"hysteresis":3500,"state":[255,0,0,0]},"ModuleUnderVoltage":{"value":2900,"hysteresis":3050,"state":[255,0,0,0]},"ModuleOverTemperatureInternal":{"value":75,"hysteresis":75,"state":[0,0,0,0]},"ModuleUnderTemperatureInternal":{"value":5,"hysteresis":5,"state":[0,0,0,0]},"ModuleOverTemperatureExternal":{"value":50,"hysteresis":50,"state":[0,0,0,0]},"ModuleUnderTemperatureExternal":{"value":2,"hysteresis":2,"state":[0,0,0,0]},"CurrentMonitorOverVoltage":{"value":57600,"hysteresis":57000,"state":[0,0,0,0]},"CurrentMonitorUnderVoltage":{"value":48000,"hysteresis":49000,"state":[0,0,0,0]},"BankOverVoltage":{"value":57600,"hysteresis":57000,"state":[0,0,0,0]},"BankUnderVoltage":{"value":48000,"hysteresis":49000,"state":[0,0,0,0]},"Timer2":{"value":1020,"hysteresis":1020,"state":[0,0,0,0]},"Timer1":{"value":480,"hysteresis":480,"state":[0,0,0,0]}},"canbusprotocol":2,"nominalbatcap":280,"chargevolt":568,"chargecurrent":650,"dischargecurrent":650,"dischargevolt":488,"chargetemplow":0,"chargetemphigh":50,"dischargetemplow":-30,"dischargetemphigh":55,"stopchargebalance":false,"socoverride":false,"socforcelow":false,"dynamiccharge":true,"preventdischarge":false,"preventcharging":false,"cellminmv":3050,"cellmaxmv":3460,"kneemv":3320,"cellmaxspikemv":3550,"sensitivity":27,"cur_val1":36,"cur_val2":7,"tilevisibility":[49152,0,62209,0,0]}}
+{"diybms_settings":{"totalNumberOfBanks":1,"totalNumberOfSeriesModules":16,"baudRate":10000,"interpacketgap":3000,"graph_voltagehigh":3650,"graph_voltagelow":3000,"BypassOverTempShutdown":65,"BypassThresholdmV":3450,"timeZone":0,"minutesTimeZone":0,"daylight":false,"ntpServer":"time.google.com","loggingEnabled":false,"loggingFrequencySeconds":15,"currentMonitoringEnabled":true,"currentMonitoringModBusAddress":90,"rs485baudrate":19200,"rs485databits":3,"rs485parity":0,"rs485stopbits":1,"language":"en","mqtt":{"enabled":true,"uri":"mqtt://192.168.0.26:1883","topic":"emon/diybms","username":"emonpi","password":"emonpimqtt2016"},"influxdb":{"enabled":false,"apitoken":"","bucket":"bucketname","org":"organisation","url":"http://192.168.0.49:8086/api/v2/write","logfreq":15},"outputs":{"default":[153,153,153,153],"type":[0,0,0,0]},"rules":{"EmergencyStop":{"value":0,"hysteresis":0,"state":[0,0,0,0]},"BMSError":{"value":0,"hysteresis":0,"state":[0,0,0,0]},"CurrentMonitorOverCurrentAmps":{"value":100,"hysteresis":100,"state":[0,0,0,0]},"ModuleOverVoltage":{"value":3650,"hysteresis":3500,"state":[255,0,0,0]},"ModuleUnderVoltage":{"value":2900,"hysteresis":3050,"state":[255,0,0,0]},"ModuleOverTemperatureInternal":{"value":75,"hysteresis":75,"state":[0,0,0,0]},"ModuleUnderTemperatureInternal":{"value":5,"hysteresis":5,"state":[0,0,0,0]},"ModuleOverTemperatureExternal":{"value":50,"hysteresis":50,"state":[0,0,0,0]},"ModuleUnderTemperatureExternal":{"value":2,"hysteresis":2,"state":[0,0,0,0]},"CurrentMonitorOverVoltage":{"value":57600,"hysteresis":57000,"state":[0,0,0,0]},"CurrentMonitorUnderVoltage":{"value":48000,"hysteresis":49000,"state":[0,0,0,0]},"BankOverVoltage":{"value":57600,"hysteresis":57000,"state":[0,0,0,0]},"BankUnderVoltage":{"value":48000,"hysteresis":49000,"state":[0,0,0,0]},"Timer2":{"value":1020,"hysteresis":1020,"state":[0,0,0,0]},"Timer1":{"value":480,"hysteresis":480,"state":[0,0,0,0]}},"protocol":2,"nominalbatcap":280,"chargevolt":568,"chargecurrent":650,"dischargecurrent":650,"dischargevolt":488,"chargetemplow":0,"chargetemphigh":50,"dischargetemplow":-30,"dischargetemphigh":55,"stopchargebalance":false,"socoverride":false,"socforcelow":false,"dynamiccharge":true,"preventdischarge":false,"preventcharging":false,"cellminmv":3050,"cellmaxmv":3460,"kneemv":3320,"cellmaxspikemv":3550,"sensitivity":27,"cur_val1":36,"cur_val2":7,"tilevisibility":[49152,0,62209,0,0]}}

ESPController/include/CurrentMonitorINA229.h

@@ -217,9 +217,12 @@ class CurrentMonitorINA229
                    uint16_t shunttempcoefficient,
                    bool TemperatureCompEnabled);
 
-    void GuessSOC();
+    void DefaultSOC();
     void TakeReadings();
 
+    uint32_t raw_milliamphour_out()  const{ return milliamphour_out; }
+    uint32_t raw_milliamphour_in()  const{ return milliamphour_in; }
+
     uint32_t calc_milliamphour_out()  const{ return milliamphour_out - milliamphour_out_offset; }
     uint32_t calc_milliamphour_in()  const{ return milliamphour_in - milliamphour_in_offset; }
     uint32_t calc_daily_milliamphour_out()  const{ return daily_milliamphour_out; }
@@ -264,12 +267,15 @@ class CurrentMonitorINA229
         return registers.R_DIAG_ALRT & ALL_ALERT_BITS;
     }
     void SetSOC(uint16_t value);
+    void SetSOCByMilliAmpCounter(uint32_t in,uint32_t out);
 
     void ResetDailyAmpHourCounters() {
         daily_milliamphour_out=0;
         daily_milliamphour_in=0;
     }
 
+    uint16_t raw_stateofcharge() const { return SOC; }
+
 private:
     uint16_t SOC = 0;
     float voltage = 0;