Disable feedback current readout on flawed HW Revs

Thermostats v2.2 and below have a noisy and offset feedback current
`tec_i` caused by missing hardware on 2 MAX1968 TEC driver pins:

1. A missing RC filter on the ITEC pin that would have isolated CPU
sampling pulses from the signal; and
2. Some missing buffering on the VREF pin that would have avoided
loading the VREF signal, preventing voltage drops from the nominal 1.5V.

Since the resulting signal `tec_i` derived from these two signals can
have an error of around +/- 100mA, and readback may affect the stability
performance of the Thermostat, disable current readback entirely on
affected hardware revisions for now.

See https://github.com/sinara-hw/Thermostat/issues/117 and
https://github.com/sinara-hw/Thermostat/issues/120.

On hardware revisions v3.x and above, this would be fixed.

README.md

@@ -271,18 +271,19 @@ with the following keys.
 | `tec_u_meas`   | Volts           | Measurement of the voltage across the TEC            |
 | `pid_output`   | Amperes         | PID control output                                   |
 
+Note: With Thermostat v2 and below, the voltage and current readouts `i_tec` and `tec_i` are disabled and null due to faulty hardware that introduces a lot of noise in the signal.
+
 ## PID Tuning
 
 The thermostat implements a PID control loop for each of the TEC channels, more details on setting up the PID control loop can be found [here](./doc/PID%20tuning.md).
 
 ## Fan control
 
-Fan control is available for the thermostat revisions with integrated fan system. For this purpose four commands are available:
+Fan control commands are available for thermostat revisions with an integrated fan system:
 1. `fan` - show fan stats: `fan_pwm`, `abs_max_tec_i`, `auto_mode`, `k_a`, `k_b`, `k_c`.
-2. `fan auto` - enable auto speed controller mode, which correlates with fan curve `fcurve`.
-3. `fan <value>` - set the fan power with the value from `1` to `100` and disable auto mode. There is no way to disable the fan.
+2. `fan auto` - enable auto speed controller mode, where fan speed is controlled by the fan curve `fcurve`.
+3. `fan <value>` - set the fan power with the value from `1` to `100` and disable auto mode. There is no way to completely disable the fan.
 Please note that power doesn't correlate with the actual speed linearly.
-4. `fcurve <a> <b> <c>` - set coefficients of the controlling curve `a*x^2 + b*x + c`, where `x` is `abs_max_tec_i/MAX_TEC_I`, 
-i.e. receives values from 0 to 1 linearly tied to the maximum current. The controlling curve should produce values from 0 to 1,
-as below and beyond values would be substituted by 0 and 1 respectively.
-5. `fcurve default` - restore fan curve settings to defaults: `a = 1.0, b = 0.0, c = 0.0`.
+4. `fcurve <a> <b> <c>` - set coefficients of the controlling curve `a*x^2 + b*x + c`, where `x` is `abs_max_tec_i/MAX_TEC_I`, a normalized value in range [0,1],
+i.e. the (linear) proportion of current output capacity used, on the channel with the largest current flow. The controlling curve is also clamped to [0,1].
+5. `fcurve default` - restore fan curve coefficients to defaults: `a = 1.0, b = 0.0, c = 0.0`.

src/channels.rs

@@ -20,6 +20,7 @@ use crate::{
     command_handler::JsonBuffer,
     pins,
     steinhart_hart,
+    hw_rev,
 };
 
 pub const CHANNELS: usize = 2;
@@ -28,17 +29,18 @@ pub const R_SENSE: f64 = 0.05;
 const DAC_OUT_V_MAX: f64 = 3.0;
 
 // TODO: -pub
-pub struct Channels {
+pub struct Channels<'a> {
     channel0: Channel<Channel0>,
     channel1: Channel<Channel1>,
     pub adc: ad7172::Adc<pins::AdcSpi, pins::AdcNss>,
     /// stm32f4 integrated adc
     pins_adc: pins::PinsAdc,
     pub pwm: pins::PwmPins,
+    hwrev: &'a hw_rev::HWRev,
 }
 
-impl Channels {
-    pub fn new(pins: pins::Pins) -> Self {
+impl<'a> Channels<'a> {
+    pub fn new(pins: pins::Pins, hwrev: &'a hw_rev::HWRev) -> Self {
         let mut adc = ad7172::Adc::new(pins.adc_spi, pins.adc_nss).unwrap();
         // Feature not used
         adc.set_sync_enable(false).unwrap();
@@ -56,7 +58,7 @@ impl Channels {
         let channel1 = Channel::new(pins.channel1, adc_calibration1);
         let pins_adc = pins.pins_adc;
         let pwm = pins.pwm;
-        let mut channels = Channels { channel0, channel1, adc, pins_adc, pwm };
+        let mut channels = Channels { channel0, channel1, adc, pins_adc, pwm, hwrev };
         for channel in 0..CHANNELS {
             channels.calibrate_dac_value(channel);
             channels.set_i(channel, ElectricCurrent::new::<ampere>(0.0));
@@ -429,8 +431,8 @@ impl Channels {
 
     fn report(&mut self, channel: usize) -> Report {
         let i_set = self.get_i(channel);
-        let i_tec = self.read_itec(channel);
-        let tec_i = self.get_tec_i(channel);
+        let i_tec = if self.hwrev.major > 2 {Some(self.read_itec(channel))} else {None};
+        let tec_i = if self.hwrev.major > 2 {Some(self.get_tec_i(channel))} else {None};
         let dac_value = self.get_dac(channel);
         let state = self.channel_state(channel);
         let pid_output = ElectricCurrent::new::<ampere>(state.pid.y1);
@@ -524,9 +526,9 @@ impl Channels {
         serde_json_core::to_vec(&summaries)
     }
 
-    pub fn current_abs_max_tec_i(&mut self) -> f64 {
-        max_by(self.get_tec_i(0).abs().get::<ampere>(),
-               self.get_tec_i(1).abs().get::<ampere>(),
+    pub fn current_abs_max_tec_i(&mut self) -> ElectricCurrent {
+        max_by(self.get_tec_i(0).abs(),
+               self.get_tec_i(1).abs(),
                |a, b| a.partial_cmp(b).unwrap_or(core::cmp::Ordering::Equal))
     }
 }
@@ -543,8 +545,8 @@ pub struct Report {
     i_set: ElectricCurrent,
     dac_value: ElectricPotential,
     dac_feedback: ElectricPotential,
-    i_tec: ElectricPotential,
-    tec_i: ElectricCurrent,
+    i_tec: Option<ElectricPotential>,
+    tec_i: Option<ElectricCurrent>,
     tec_u_meas: ElectricPotential,
     pid_output: ElectricCurrent,
 }

src/fan_ctrl.rs

@@ -4,7 +4,10 @@ use stm32f4xx_hal::{
     pwm::{self, PwmChannels},
     pac::TIM8,
 };
-
+use uom::si::{
+    f64::ElectricCurrent,
+    electric_current::ampere,
+};
 use crate::{
     hw_rev::HWSettings,
     command_handler::JsonBuffer,
@@ -50,8 +53,8 @@ impl FanCtrl {
         fan_ctrl
     }
 
-    pub fn cycle(&mut self, abs_max_tec_i: f32) {
-        self.abs_max_tec_i = abs_max_tec_i;
+    pub fn cycle(&mut self, abs_max_tec_i: ElectricCurrent) {
+        self.abs_max_tec_i = abs_max_tec_i.get::<ampere>() as f32;
         if self.fan_auto && self.hw_settings.fan_available {
             let scaled_current = self.abs_max_tec_i / MAX_TEC_I;
             // do not limit upper bound, as it will be limited in the set_pwm()

src/main.rs

@@ -138,7 +138,7 @@ fn main() -> ! {
 
     let mut store = flash_store::store(dp.FLASH);
 
-    let mut channels = Channels::new(pins);
+    let mut channels = Channels::new(pins, &hwrev);
     for c in 0..CHANNELS {
         match store.read_value::<ChannelConfig>(CHANNEL_CONFIG_KEY[c]) {
             Ok(Some(config)) =>
@@ -185,7 +185,7 @@ fn main() -> ! {
                     server.for_each(|_, session| session.set_report_pending(channel.into()));
                 }
 
-                fan_ctrl.cycle(channels.current_abs_max_tec_i() as f32);
+                fan_ctrl.cycle(channels.current_abs_max_tec_i());
 
                 if channels.pid_engaged() {
                     leds.g3.on();