Cold Boot Proof of Concept (#58)

Graceful Cold Boot PoC

Electronics/PCB (KiCAD)/Motherboard/RevD/CARs/CAR066 - 16U2 toggles reset ~2.5 seconds after powerup/CAR066 - 16U2 toggles reset pin ~2.5 seconds after powerup.txt

@@ -0,0 +1,3 @@
+16U2 toggle PD7 ~2.5 seconds after powerup.  This causes pulse on MEGA2560's reset pin, which briefly disables Mega's output pins... but for some reason doesn't actually reset program execution.
+
+This only occurs when USB cable is connected during powerup.  Given that a USB cable typically powers the 5V rail, this won't actually ever occur; in my testing that lead to this CAR, my USB cable's 5V wire was cut.

Firmware/firmwareLiBCM/config.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //config.h - compile time configuration parameters
@@ -7,8 +7,8 @@
     #define config_h
     #include "src/libcm.h"
 
-    #define FW_VERSION "0.9.4b"
-    #define BUILD_DATE "2024JUL09"
+    #define FW_VERSION "0.9.4d"
+    #define BUILD_DATE "2024JUL23"
 
     //////////////////////////////////////////////////////////////////
 
@@ -46,6 +46,8 @@
         #define LCD_4X20_CONNECTED  //display included with all LiBCM Kits
         //#define LIDISPLAY_CONNECTED //optional color touch screen display //JTS2doLater: mudder has not yet tested this code. Use at your own risk.
 
+    //you don't need to change any settings below this line (but you can if you know what you're doing):
+    //__________________________________________________________________________________________________
 
     //////////////////////////////////////////////////////////////////
 

Firmware/firmwareLiBCM/firmwareLiBCM.ino

@@ -1,31 +1,30 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 //Lithium battery BMS for G1 Honda Insight.  Replaces OEM BCM module.
 
 #include "src/libcm.h"
 
-void setup() //~t=2 milliseconds, BUT NOTE this doesn't include CPU_CLOCK warmup or bootloader delay
+void setup() 
 {
+    //getting here takes ~02 milliseconds after poweron reset
+    //getting here takes ~16 milliseconds after IMA switch on
     gpio_begin();
     wdt_disable();
+    LiControl_begin(); //SPI errors until initialized
+    LTC68042configure_initialize();
     Serial.begin(115200); //USB
     METSCI_begin();
     BATTSCI_begin();
     heater_begin();
-    LiDisplay_begin();
-    LiControl_begin();
-    LTC68042configure_initialize();
     eeprom_begin();
+    LiDisplay_begin();
+
+    if (gpio_keyStateNow() == GPIO_KEY_ON) { keyOn_coldBootTasks();          }
+    else                                   { debugUSB_printWelcomeMessage(); }
 
     bringupTester_gridcharger(); 
     bringupTester_motherboard();
 
-    if (gpio_keyStateNow() == GPIO_KEY_ON){ LED(3,ON); } //turn LED3 on if LiBCM (re)boots while driving
-
-    Serial.print(F("\n\nLiBCM v" FW_VERSION ", " BUILD_DATE "\n'$HELP' for info\n"));
-    debugUSB_printHardwareRevision();
-    debugUSB_printConfigParameters();
-
     wdt_enable(WDTO_2S); //set watchdog reset vector to 2 seconds
 }
 

Firmware/firmwareLiBCM/src/BringupTester.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //Tests PCB (using custom external hardware)
 
 //Not used when deployed in vehicle

Firmware/firmwareLiBCM/src/BringupTester.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef bringuptester_h

Firmware/firmwareLiBCM/src/LTC68042cell.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //LTC6804 cell voltage data processor and related functions
@@ -289,7 +289,7 @@ bool LTC68042cell_nextVoltages(void)
     else if (presentState == LTC_STATE_FIRSTRUN)
     {
         //LTC6804 ICs were previously off
-        LTC68042configure_programVolatileDefaults(); 
+        LTC68042configure_programVolatileDefaults();
         startCellConversion();
         presentState = LTC_STATE_GATHER;
     }

Firmware/firmwareLiBCM/src/LTC68042cell.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef LTC68042cell_h
@@ -11,6 +11,8 @@
     #define GATHERING_CELL_DATA 0
     #define CELL_DATA_PROCESSED 1
 
+    #define LTC6804_MAX_CONVERSION_TIME_ms 5 //4.43 ms in '2kHz' sampling mode
+
     bool LTC68042cell_nextVoltages(void);
     void LTC68042cell_acquireAllCellVoltages(void);
 

Firmware/firmwareLiBCM/src/LTC68042configure.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //LTC6804 configuration functions
@@ -103,46 +103,50 @@ bool LTC68042configure_doesActualPackSizeMatchUserConfig(void)
 {
     bool helper_doesActualPackSizeMatchUserConfig = true;
 
-    if (gpio_keyStateNow() == GPIO_KEY_OFF) //we don't have time to run this test if the key is on when LiBCM first boots
-    {
-        LTC6804_adax(); //send any broadcast command
-        delay(6); //wait for all LTC6804 ICs to process this command
+    #if   defined RUN_BRINGUP_TESTER_MOTHERBOARD //don't verify cell count
+    #elif defined RUN_BRINGUP_TESTER_GRIDCHARGER //don't verify cell count
+    #else
+        if (gpio_keyStateNow() == GPIO_KEY_OFF) //we don't have time to run this test if the key is on when LiBCM first boots
+        {
+            LTC6804_adax(); //send any broadcast command
+            delay(6); //wait for all LTC6804 ICs to process this command
 
-        //read data back from either QTY4 ICs (if user selects PACK_IS_48S in config.h), or QTY5 ICs (if user selects PACK_IS_60S in config.h)
-        //we don't care about the actual data; only that the PEC error count doesn't increment 
-        uint8_t errorCount_allUserSpecifiedLTC6804s = LTC6804_rdaux(0,TOTAL_IC,FIRST_IC_ADDR); 
+            //read data back from either QTY4 ICs (if user selects PACK_IS_48S in config.h), or QTY5 ICs (if user selects PACK_IS_60S in config.h)
+            //we don't care about the actual data; only that the PEC error count doesn't increment 
+            uint8_t errorCount_allUserSpecifiedLTC6804s = LTC6804_rdaux(0,TOTAL_IC,FIRST_IC_ADDR); 
 
-        if (errorCount_allUserSpecifiedLTC6804s != 0) { helper_doesActualPackSizeMatchUserConfig = false; } //at least one IC had data transmissions errors
+            if (errorCount_allUserSpecifiedLTC6804s != 0) { helper_doesActualPackSizeMatchUserConfig = false; } //at least one IC had data transmissions errors
 
-        if (TOTAL_IC == 4)
-        {
-            uint8_t errorCount_onlyFifthLTC6804 = LTC6804_rdaux(0,1,FIRST_IC_ADDR+4); 
+            if (TOTAL_IC == 4)
+            {
+                uint8_t errorCount_onlyFifthLTC6804 = LTC6804_rdaux(0,1,FIRST_IC_ADDR+4); 
 
-            //the fifth LTC6804 (cells 49:60) should be unpowered (i.e. it should return errors)
-            if (errorCount_onlyFifthLTC6804 == 0) { helper_doesActualPackSizeMatchUserConfig = false; }
-        }
+                //the fifth LTC6804 (cells 49:60) should be unpowered (i.e. it should return errors)
+                if (errorCount_onlyFifthLTC6804 == 0) { helper_doesActualPackSizeMatchUserConfig = false; }
+            }
 
-        if (helper_doesActualPackSizeMatchUserConfig == false)
-        {
-            //fatal error
-            //alert user and then turn off
+            if (helper_doesActualPackSizeMatchUserConfig == false)
+            {
+                //fatal error
+                //alert user and then turn off
 
-            Serial.print(F("\nError: measured cell count disagrees with user specified cell count in config.h"));
+                Serial.print(F("\nError: measured cell count disagrees with user specified cell count in config.h"));
 
-            lcdTransmit_begin();
-            delay(50); //delay doesn't matter because this is a fatal error
-            lcdTransmit_displayOn();
-            delay(50); //delay doesn't matter because this is a fatal error
-            lcdTransmit_Warning(LCD_WARN_CELL_COUNT);
+                lcdTransmit_begin();
+                delay(50); //delay doesn't matter because this is a fatal error
+                lcdTransmit_displayOn();
+                delay(50); //delay doesn't matter because this is a fatal error
+                lcdTransmit_Warning(LCD_WARN_CELL_COUNT);
 
-            gpio_turnBuzzer_on_highFreq(); //call GPIO directly
-
-            wdt_disable(); //turn off watchdog to prevent reset
+                gpio_turnBuzzer_on_highFreq(); //call GPIO directly
+                
+                wdt_disable(); //turn off watchdog to prevent reset
 
-            delay(10000); //give the user enough time to read error message
-            gpio_turnLiBCM_off(); //game over... thanks for playing
+                delay(10000); //give the user enough time to read error message
+                gpio_turnLiBCM_off(); //game over... thanks for playing
+            }
         }
-    }
+    #endif
 
     return helper_doesActualPackSizeMatchUserConfig;
 }
@@ -152,12 +156,16 @@ bool LTC68042configure_doesActualPackSizeMatchUserConfig(void)
 void LTC68042configure_initialize(void)
 {
     spi_enable(SPI_CLOCK_DIV64); //JTS2doLater: increase clock speed //DIV16 & DIV32 work on bench
+}
 
-    #if   defined RUN_BRINGUP_TESTER_MOTHERBOARD //don't verify cell count
-    #elif defined RUN_BRINGUP_TESTER_GRIDCHARGER //don't verify cell count
-    #else
-        LTC68042configure_doesActualPackSizeMatchUserConfig(); //verify cell count matches
-    #endif
+/////////////////////////////////////////////////////////////////////////////////////////
+
+void LTC68042configure_pulseChipSelectLow(uint16_t lowPulsePeriod_us)
+{
+    digitalWrite(PIN_SPI_CS,LOW); //low edge wakes up LTC
+    delayMicroseconds(lowPulsePeriod_us); //wait specified time for LTC to wake  
+    digitalWrite(PIN_SPI_CS,HIGH);
+    lastTimeDataSent_millis = millis();
 }
 
 /////////////////////////////////////////////////////////////////////////////////////////
@@ -172,10 +180,7 @@ bool LTC68042configure_wakeupCore(void)
     if ((uint32_t)(millis() - lastTimeDataSent_millis) > T_SLEEP_WATCHDOG_MILLIS)
     { 
         //LTC6804 core (probably) asleep
-        digitalWrite(PIN_SPI_CS,LOW); //wake up core
-        delayMicroseconds(300); // Guarantees the LTC6804 is in standby (tWake = 300 us max)  
-        digitalWrite(PIN_SPI_CS,HIGH);
-        lastTimeDataSent_millis = millis();
+        LTC68042configure_pulseChipSelectLow(SPECIFIED_MAX_WAKEUP_TIME_LTCCORE_MICROSECONDS);
         wasCoreAlreadyAwake = LTC6804_CORE_JUST_WOKE_UP;
     }
 
@@ -192,10 +197,7 @@ void LTC68042configure_wakeupIsoSPI(void)
     if ((uint32_t)(millis() - lastTimeDataSent_millis) > T_IDLE_isoSPI_MILLIS)
     { 
         //LTC6804 isoSPI might be asleep (tIDLE elapsed)
-        digitalWrite(PIN_SPI_CS,LOW);
-        delayMicroseconds(10); //Guarantees isoSPI is in ready mode (tWAKE = 10 us max)
-        digitalWrite(PIN_SPI_CS,HIGH);
-        lastTimeDataSent_millis = millis();
+         LTC68042configure_pulseChipSelectLow(SPECIFIED_MAX_WAKEUP_TIME_isoSPI_MICROSECONDS);
     }
 }
 
@@ -254,6 +256,8 @@ void LTC68042configure_spiWriteRead(uint8_t tx_Data[],//array of data to be writ
     for (uint8_t i = 0; i < tx_len; i++) { spi_write(tx_Data[i]); }
     for (uint8_t i = 0; i < rx_len; i++) { rx_data[i] = (uint8_t)spi_read(0xFF); }
     digitalWrite(PIN_SPI_CS,HIGH);
+
+    lastTimeDataSent_millis = millis();
 }
 
 /////////////////////////////////////////////////////////////////////////////////////////

Firmware/firmwareLiBCM/src/LTC68042configure.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef LTC68042configure_h
@@ -25,6 +25,8 @@
     #define FIRST_IC_ADDR  2 //lowest address.  All additional IC addresses must be sequential
     #define CELLS_PER_IC  12 //Each LTC6804 measures QTY12 cells
 
+    #define SPECIFIED_MAX_WAKEUP_TIME_LTCCORE_MICROSECONDS 300 //guarantees LTC6804 is in 'standby' mode (tWake = 300 us max)
+    #define SPECIFIED_MAX_WAKEUP_TIME_isoSPI_MICROSECONDS   10 //guarantees isoSPI is in 'ready' mode (tWAKE = 10 us max)
 
      // |CHG | Dec  |Channels to convert   |
      // |----|------|----------------------|
@@ -191,4 +193,8 @@
 
     void LTC68042configure_setBalanceResistors(uint8_t icAddress, uint16_t cellBitmap, uint8_t softwareTimeout);
 
+    bool LTC68042configure_doesActualPackSizeMatchUserConfig(void);
+
+    void LTC68042configure_pulseChipSelectLow(uint16_t lowPulsePeriod_us);
+
 #endif

Firmware/firmwareLiBCM/src/LTC68042gpio.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //LTC6804 gpio (e.g. temperature) data and various functions

Firmware/firmwareLiBCM/src/LTC68042gpio.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef LTC68042gpio_h

Firmware/firmwareLiBCM/src/LTC68042result.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //The latest results gathered from LTC6804 are stored here.

Firmware/firmwareLiBCM/src/LTC68042result.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef LTC68042result_h

Firmware/firmwareLiBCM/src/LiControl.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 #include "libcm.h"
 

Firmware/firmwareLiBCM/src/LiControl.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef LiControl_h

Firmware/firmwareLiBCM/src/LiDisplay.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //LiDisplay (HMI) Serial Functions
@@ -90,7 +90,6 @@ const uint16_t editableParamMinMax[2][2] = {
 void LiDisplay_begin(void)
 {
     #ifdef LIDISPLAY_CONNECTED
-        Serial.print(F("\nLiDisplay BEGIN"));
 
         #ifdef BATTERY_TYPE_47AhFoMoCo
             #undef LIDISPLAY_GRIDCHARGE_PAGE_ID

Firmware/firmwareLiBCM/src/LiDisplay.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef lidisplay_h

Firmware/firmwareLiBCM/src/SoC.cpp

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 //maintains battery state of charge

Firmware/firmwareLiBCM/src/SoC.h

@@ -1,4 +1,4 @@
-//Copyright 2021-2023(c) John Sullivan
+//Copyright 2021-2024(c) John Sullivan
 //github.com/doppelhub/Honda_Insight_LiBCM
 
 #ifndef soc_h