[heater.git] / firmware / main.c

/*
 * OVERVIEW
 *
 * Powering up:
 * Immediately after reset, we power down the entire system.
 * We wake up only after the button is pressed for a sufficiently long time.
 *
 * Heater output:
 * The heater output is driven by Timer/Counter 1 in PWM mode.
 * We want to be able to measure the battery voltage both when the
 * output is on, and when the output is off. So we set the T/C1 clock
 * prescaler so that the T/C1 is slow enough, we enable the T/C1 interrupts
 * both on compare match and on overflow. After the interrupt, we trigger
 * the battery voltage measurement with ADC.
 *
 * ADC:
 * To avoid transients, we measure each battery state (when the heater is on
 * and when it is off) separately, and we drop the first few readings.
 * We calculate a running average of the readings to achieve higher accuracy.
 *
 * Buttons:
 * There are two buttons (+ and -). Any button can wake the system up from
 * the power-down state.
 * TODO: When the system is woken up by the "-" button,
 * it starts with the minimum output power, when it is woken up by the "+"
 * button, it start with the maximum output power.
 * When running, the "-" button is used for decreasing the output power,
 * the "+" button is for increasing it.
 * When on the lowest power state, the "-" button switches the system off.
 * Long "-" button press switches the system off, long "+" button
 * press sets the output power to maximum.
 *
 * Status LED:
 * When powering up by a button press, the LED goes on to provide a visual
 * feedback, and is switched off after the button is released.
 * After a button press, the # of blinks of the LED reflects the
 * chosen output power level for some time. Afterwards, it displays
 * the battery level.
 * When the battery is completely exhausted, the output power is switched
 * off, the LED keeps blinking for some time, and then the whole system is
 * switched off to avoid deep discharge of the battery.
 *
 * Timing:
 * The firmware is timed by the Watchdog Timer interrupt. Most of the
 * processing is done from the main loop, IRQs only set various flags
 * or trigger other events.
 */

#include <avr/interrupt.h>
#include <avr/io.h>
#include <avr/power.h>
#include <avr/sleep.h>
#include <avr/wdt.h>
#include <util/delay.h>

#include "logging.h"

/* waking up from the power down state by a button press */
#define WAKEUP_POLL 50  // msec
#define WAKEUP_LIMIT 5  // times WAKEUP_POLL

/* which state (output on or output off) are we measuring now */
static volatile unsigned char adc_type, adc_drop;
#define ADC_RUNAVG_SHIFT 5      // running average shift on batt_on, batt_off
static volatile uint16_t batt_on, batt_off; // measured voltage

/*
 * The voltage divider has 1M5 and 300K resistors (i.e. it measures 1/6th of
 * the real voltage), ADC uses 1.1V internal reference.
 * Macro to calculate upper eight bits of the ADC running-averaged value
 * from the voltage in milivolts.
 */
#define ADC_1100MV_VALUE        1071    // measured, not exactly 1100
#define MV_TO_ADC8(mV)  ((unsigned char)(((uint32_t)(1UL << ADC_RUNAVG_SHIFT) \
                                * (1024UL * (mV)) \
                                / (6UL * ADC_1100MV_VALUE)) >> 8))
static unsigned char batt_levels[] = {
        MV_TO_ADC8(3350),
        MV_TO_ADC8(3700),
        MV_TO_ADC8(3900),
};
#define BATT_N_LEVELS   (sizeof(batt_levels) / sizeof(batt_levels[0]))

/* output power and PWM calculation */
#define PWM_TOP 255
#define PWM_MAX (PWM_TOP - 8)   // to allow for ADC "batt_off" measurements
#define PWM_MIN 8               // to allow for ADC "batt_on" measurements

/*
 * The values in power_levels[] array are voltages at which the load
 * would give the expected power (we don't have sqrt() function,
 * so we cannot use mW values directly. They can be calculated as
 * voltage[V] = sqrt(load_resistance[Ohm] * expected_power[W])
 * or
 * voltage[mV] = sqrt(load_resistance[mOhm] * expected_power[mW])
 *
 * I use 1.25 W as minimum power, each step is sqrt(2)*previous_step,
 * so the 5th step is 5 W.
 */
static unsigned char power_levels[] = {
        MV_TO_ADC8(1581),       // 1250 mW for 2 Ohm load
        MV_TO_ADC8(1880),       // 1768 mW for 2 Ohm load
        MV_TO_ADC8(2236),       // 2500 mW for 2 Ohm load
        MV_TO_ADC8(2659),       // 3536 mW for 2 Ohm load
        MV_TO_ADC8(3162),       // 5000 mW for 2 Ohm load
};
#define N_POWER_LEVELS  (sizeof(power_levels) / sizeof(power_levels[0]))

static unsigned char power_level = 0; // selected power level
static unsigned char power_level_changed; // for visual feedback

#define LED_PWRCHANGE_COUNT     5
#define LED_BATTEMPTY_COUNT     60

/* timing by WDT */
static volatile unsigned char jiffies, next_clock_tick;

/* button press duration (in jiffies) */
#define BUTTON_SHORT_MIN        1
#define BUTTON_LONG_MIN         10


/* ========= Analog to Digital Converter (battery voltage) ========== */
static void adc_init()
{
        power_adc_enable();

        ADCSRA = _BV(ADEN)                      // enable
                | _BV(ADPS1) | _BV(ADPS0);      // clk/8 = 125 kHz
        ADMUX = _BV(REFS1) | _BV(MUX1) | _BV(MUX0);
                // 1.1V reference, PB3 pin, single-ended
        DIDR0 |= _BV(ADC3D);    // PB3 pin as analog input
}

static void adc_susp()
{
        ADCSRA = 0;             // disable ADC
        DIDR0 &= ~_BV(ADC3D);   // disable analog input on PB3

        power_adc_disable();
}

static void adc_start_measurement(unsigned char on)
{
        adc_drop = 1;
        adc_type = on;
        ADCSRA |= _BV(ADSC) | _BV(ADIE);
}

ISR(ADC_vect)
{
        uint16_t adcw = ADCW;

        if (adc_drop) {
                adc_drop--;
                ADCSRA |= _BV(ADSC);
                return;
        }

        // TODO: We may want to disable ADC after here to save power,
        // but compared to the heater power it would be negligible,
        // so don't bother with it.
        if (adc_type == 0) {
                if (batt_off) {
                        batt_off += adcw - (batt_off >> ADC_RUNAVG_SHIFT);
                } else {
                        batt_off = adcw << ADC_RUNAVG_SHIFT;
                }
        } else {
                if (batt_on) {
                        batt_on += adcw - (batt_on >> ADC_RUNAVG_SHIFT);
                } else {
                        batt_on = adcw << ADC_RUNAVG_SHIFT;
                }
        }
        ADCSRA &= ~_BV(ADIE);
}

/* ===================== Timer/Counter1 for PWM ===================== */
static void pwm_init()
{
        power_timer1_enable();

        DDRB |= _BV(PB4);
        PORTB &= ~_BV(PB4);

        // TCCR1 = _BV(CS10); // clk/1 = 1 MHz
        // TCCR1 = _BV(CS11) | _BV(CS13); // clk/512 = 2 kHz
        /*
         * clk/64 = 16 kHz. We use PWM_MIN and PWM_MAX, so we have at least
         * 8 full T/C1 cycles to do two ADC measurements. The ADC with 125 kHz
         * clock can do about 7000-9000 measurement per second, so we should
         * be safe both on low and high OCR1B values with this clock
         */
        TCCR1 = _BV(CS12) | _BV(CS11) | _BV(CS10);

        GTCCR = _BV(COM1B1) | _BV(PWM1B);
        OCR1C = PWM_TOP;
        // OCR1B = steps[0];
        OCR1B = 0;
        TIMSK = _BV(OCIE1B) | _BV(TOIE1);
}

static void pwm_susp()
{
        TCCR1 = 0;
        TIMSK = 0;
        GTCCR = 0;
        PORTB &= ~_BV(PB4);
}

ISR(TIM1_OVF_vect)
{
        adc_start_measurement(1);
}

ISR(TIM1_COMPB_vect)
{
        adc_start_measurement(0);
}

static void pwm_set(unsigned char pwm)
{
        OCR1B = pwm;
}

/* ===================== Status LED on pin PB2 ======================= */
static void status_led_init()
{
        DDRB |= _BV(PB2);
        PORTB &= ~_BV(PB2);
}

static void status_led_on()
{
        PORTB |= _BV(PB2);
}

static void status_led_off()
{
        PORTB &= ~_BV(PB2);
}

static unsigned char status_led_is_on()
{
        return PORTB & _BV(PB2) ? 1 : 0;
}

/* ================== Buttons on pin PB0 and PB1 ===================== */
static void buttons_init()
{
        DDRB &= ~(_BV(PB0) | _BV(PB1)); // set as input
        PORTB |= _BV(PB0) | _BV(PB1);   // internal pull-up

        GIMSK &= ~_BV(PCIE); // disable pin-change IRQs
        PCMSK = 0; // disable pin-change IRQs on all pins of port B
}

static void buttons_susp()
{
        buttons_init();

        GIMSK |= _BV(PCIE);
        PCMSK |= _BV(PCINT0) | _BV(PCINT1);
}

static unsigned char buttons_pressed()
{
        return (
                (PINB & _BV(PB0) ? 0 : 1)
                |
                (PINB & _BV(PB1) ? 0 : 2)
        );
}

static unsigned char buttons_wait_for_release()
{
        uint16_t wake_count = 0;

        do {
                if (++wake_count > WAKEUP_LIMIT)
                        status_led_on(); // inform the user

                _delay_ms(WAKEUP_POLL);
        } while (buttons_pressed());

        status_led_off();

        return wake_count > WAKEUP_LIMIT;
}

ISR(PCINT0_vect)
{
        // empty - let it wake us from sleep, but do nothing else
}

/* ==== Watchdog Timer for timing blinks and other periodic tasks ==== */
static void wdt_init()
{
        next_clock_tick = 0;
        jiffies = 0;
        WDTCR = _BV(WDIE) | _BV(WDP1); // interrupt mode, 64 ms
}

static void wdt_susp()
{
        wdt_disable();
}

ISR(WDT_vect) {
        next_clock_tick = 1;
        jiffies++;
}

/* ====== Hardware init, teardown, powering down and waking up ====== */
static void hw_setup()
{
        power_all_disable();

        pwm_init();
        adc_init();
        status_led_init();
        wdt_init();
}

static void hw_suspend()
{
        adc_susp();
        pwm_susp();
        status_led_init(); // we don't have a separate _susp() here
        buttons_susp();
        wdt_susp();

        power_all_disable();
}

static void power_down()
{
        hw_suspend();

        do {
                // G'night
                set_sleep_mode(SLEEP_MODE_PWR_DOWN);
                sleep_enable();
                sleep_bod_disable();
                sei();
                sleep_cpu();

                // G'morning
                cli();
                sleep_disable();

                // allow wakeup by long button-press only
        } while (!buttons_wait_for_release());

        // OK, wake up now
        hw_setup();
}

/* ============ Status LED blinking =================================== */
static unsigned char blink_on_time, blink_off_time, n_blinks;
static unsigned char blink_counter;

static unsigned char battery_level()
{
        unsigned char i, adc8;

        // NOTE: we use 8-bit value only, so we don't need lock to protect
        // us against concurrently running ADC IRQ handler:
        adc8 = batt_off >> 8;

        for (i = 0; i < BATT_N_LEVELS; i++)
                if (batt_levels[i] > adc8)
                        break;

        return i;
}

static void status_led_next_pattern()
{
        static unsigned char battery_exhausted;

        if (power_level_changed) {
                power_level_changed--;
                n_blinks = power_level + 1;
        } else {
                unsigned char b_level = battery_level();
                if (b_level) {
                        battery_exhausted = 0;
                } else if (battery_exhausted) {
                        if (!--battery_exhausted)
                                power_down();
                } else {
                        battery_exhausted = LED_BATTEMPTY_COUNT;
                }

                n_blinks = b_level + 1;
        }

        blink_on_time = 2;
        blink_off_time = 1;
        blink_counter = 10;
}

static void timer_blink()
{
        if (blink_counter) {
                blink_counter--;
        } else if (!status_led_is_on()) {
                status_led_on();
                blink_counter = blink_on_time;
        } else if (n_blinks) {
                --n_blinks;
                status_led_off();
                blink_counter = blink_off_time;
        } else {
                status_led_next_pattern();
        }
}

/* ======== Button press detection and  handling ===================== */
static void button_pressed(unsigned char button, unsigned char long_press)
{
        // ignore simlultaneous button 1 and 2 press
        // Note: we set power_level_changed after each button press,
        // even when the power is at maximum, to provide visual feedback
        // with status LED.
        if (long_press) {
                if (button == 1) {
                        power_down();
                        return;
                } else if (button == 2) {
                        power_level = N_POWER_LEVELS-1;
                }
        } else { // short press
                if (button == 1) {
                        if (power_level > 0) {
                                --power_level;
                        } else {
                                power_down();
                                return;
                        }
                } else if (button == 2) {
                        if (power_level < N_POWER_LEVELS-1) {
                                ++power_level;
                        }
                }
        }
        power_level_changed = LED_PWRCHANGE_COUNT;
        status_led_next_pattern();
}

static unsigned char button_state, button_state_time;

static void timer_check_buttons()
{
        unsigned char newstate = buttons_pressed();

        if (newstate == button_state) {
                if (newstate && button_state_time < BUTTON_LONG_MIN)
                        ++button_state_time;

                if (newstate && button_state_time >= BUTTON_LONG_MIN) {
                        status_led_on();
                }
                return;
        }

        if (newstate) {
                button_state = newstate;
                button_state_time = 0;
                return;
        }

        // just released
        if (button_state_time >= BUTTON_SHORT_MIN)
                button_pressed(button_state,
                        button_state_time >= BUTTON_LONG_MIN ? 1 : 0);

        button_state = newstate;
        button_state_time = 0;
}

/* ===================== Output power control ======================== */
static void calculate_power_level()
{
        uint32_t pwm;
        unsigned char batt_on8;

        if (battery_level() == 0) {
                pwm_set(0);
                // TODO power_down() after some time
                return;
        }

        if (!batt_on) {
                batt_on = batt_off;
        };

        batt_on8 = batt_on >> 8;

        pwm = (uint32_t)PWM_TOP * power_levels[power_level]
                * power_levels[power_level];
        pwm /= (uint32_t)batt_on8 * batt_on8;

        if (pwm > PWM_MAX)
                pwm = PWM_MAX;

        if (pwm < PWM_MIN)
                pwm = PWM_MIN;

#if 0
        log_byte(0x10 + power_level);
        log_byte(batt_on8);
        log_byte(pwm & 0xFF);
#endif

        pwm_set(pwm);
}

int main()
{
        log_init();

#if 0
        log_word(batt_levels[0]);
        log_word(batt_levels[1]);
        log_word(batt_levels[2]);
        log_flush();
#endif
        log_byte(power_levels[0]);
        log_byte(power_levels[4]);
        log_flush();

        power_down();

        sei();

        // we try to be completely IRQ-driven, so just wait for IRQs here
        while(1) {
                cli();
                set_sleep_mode(SLEEP_MODE_IDLE);
                sleep_enable();
                // keep BOD active, no sleep_bod_disable();
                sei();
                sleep_cpu();
                sleep_disable();

                // FIXME: Maybe handle new ADC readings as well?
                if (next_clock_tick) {
                        next_clock_tick = 0;
                        timer_blink();
                        // this has to be after the timer_blink() call
                        // to override the status LED during long button press
                        timer_check_buttons();

                        if ((jiffies & 0x0F) == 0) {
                                calculate_power_level();
#if 0
                                log_byte(0xcc);
                                log_byte(i);
                                log_byte(batt_off >> 8);
                                log_byte(batt_on >> 8);
#endif
                        }
                        log_flush();
                }
        }
}