feat(hepa-uv): add support for the safety relay in the new revision o…

…f the Hepa/UV module. (#782)

bootloader/firmware/stm32G4/CMakeLists.txt

@@ -170,8 +170,8 @@ endmacro()
 foreach_revision(
     PROJECT_NAME bootloader-hepa-uv
     CALL_FOREACH_REV hepauv_bootloader_loop
-    REVISIONS a1 b1
-    SOURCES hepauv_sources hepauv_sources
+    REVISIONS a1 b1 c1
+    SOURCES hepauv_sources hepauv_sources hepauv_sources
     NO_CREATE_IMAGE_HEX
     NO_CREATE_INSTALL_RULES
     )

cpp-utils/include/ot_utils/freertos/freertos_sleep.hpp

@@ -0,0 +1,12 @@
+#pragma once
+
+#include "FreeRTOS.h"
+#include "task.h"
+
+namespace ot_utils {
+namespace freertos_sleep {
+
+static void sleep(uint32_t time_ms) { if (time_ms > 0) vTaskDelay(pdMS_TO_TICKS(time_ms)); }
+
+}  // namespace freertos_sleep
+}  // namespace ot_utils

hepa-uv/firmware/CMakeLists.txt

@@ -44,7 +44,6 @@ set(HEPAUV_SRCS_A1
 )
 set(HEPAUV_SRCS_B1 ${HEPAUV_SRCS_A1})
 set(HEPAUV_SRCS_C1 ${HEPAUV_SRCS_B1})
-set(HEPAUV_SRCS_C2 ${HEPAUV_SRCS_C1})
 
 macro(hepa_uv_loop)
     set(_driver_suffix ${PROJECT_NAME}_${REVISION})
@@ -84,12 +83,12 @@ endmacro()
 
 foreach_revision(
     PROJECT_NAME hepa-uv
-    REVISIONS a1 b1
-    SOURCES HEPAUV_SRCS_A1 HEPAUV_SRCS_B1
+    REVISIONS a1 b1 c1
+    SOURCES HEPAUV_SRCS_A1 HEPAUV_SRCS_B1 HEPAUV_SRCS_C1
     CALL_FOREACH_REV hepa_uv_loop)
 
 alias_for_revision(PROJECT_NAME hepa-uv REVISION a1 REVISION_ALIAS proto)
-alias_for_revision(PROJECT_NAME hepa-uv REVISION b1 REVISION_ALIAS rev1)
+alias_for_revision(PROJECT_NAME hepa-uv REVISION c1 REVISION_ALIAS rev1)
 
 add_clang_tidy_target(
     TARGET_NAME hepa-uv-lint

hepa-uv/firmware/main_rev1.cpp

@@ -1,4 +1,5 @@
 #include <array>
+#include <optional>
 
 // clang-format off
 #include "FreeRTOS.h"
@@ -92,6 +93,17 @@ class EEPromHardwareInterface
 };
 static auto eeprom_hw_iface = EEPromHardwareInterface();
 
+#if PCB_PRIMARY_REVISION == 'a' || PCB_PRIMARY_REVISION == 'b'
+static constexpr std::optional<gpio::PinConfig> safety_relay_active =
+    std::nullopt;
+#else
+static std::optional<gpio::PinConfig> safety_relay_active =
+    gpio::PinConfig{// NOLINTNEXTLINE(cppcoreguidelines-pro-type-cstyle-cast)
+                    .port = nSAFETY_ACTIVE_MCU_PORT,
+                    .pin = nSAFETY_ACTIVE_MCU_PIN,
+                    .active_setting = nSAFETY_ACTIVE_AS};
+#endif
+
 static auto gpio_drive_pins = gpio_drive_hardware::GpioDrivePins{
     .door_open =
         gpio::PinConfig{
@@ -114,20 +126,23 @@ static auto gpio_drive_pins = gpio_drive_hardware::GpioDrivePins{
     .uv_push_button =
         gpio::PinConfig{
             // NOLINTNEXTLINE(cppcoreguidelines-pro-type-cstyle-cast)
-            .port = UV_NO_MCU_PORT,
-            .pin = UV_NO_MCU_PIN,
+            .port = nUV_PRESSED_PORT,
+            .pin = nUV_PRESSED_PIN,
         },
     .hepa_on_off =
         gpio::PinConfig{
             // NOLINTNEXTLINE(cppcoreguidelines-pro-type-cstyle-cast)
             .port = HEPA_ON_OFF_PORT,
             .pin = HEPA_ON_OFF_PIN,
             .active_setting = HEPA_ON_OFF_AS},
-    .uv_on_off = gpio::PinConfig{
-        // NOLINTNEXTLINE(cppcoreguidelines-pro-type-cstyle-cast)
-        .port = UV_ON_OFF_MCU_PORT,
-        .pin = UV_ON_OFF_MCU_PIN,
-        .active_setting = UV_ON_OFF_AS}};
+    .uv_on_off =
+        gpio::PinConfig{
+            // NOLINTNEXTLINE(cppcoreguidelines-pro-type-cstyle-cast)
+            .port = UV_ON_OFF_MCU_PORT,
+            .pin = UV_ON_OFF_MCU_PIN,
+            .active_setting = UV_ON_OFF_AS},
+    .safety_relay_active = safety_relay_active,
+};
 
 static auto& hepauv_queues = hepauv_tasks::get_main_queues();
 
@@ -140,7 +155,7 @@ extern "C" void HAL_GPIO_EXTI_Callback(uint16_t GPIO_Pin) {
         case DOOR_OPEN_MCU_PIN:
         case REED_SW_MCU_PIN:
         case HEPA_NO_MCU_PIN:
-        case UV_NO_MCU_PIN:
+        case nUV_PRESSED_PIN:
             if (hepauv_queues.hepa_queue != nullptr) {
                 static_cast<void>(hepauv_queues.hepa_queue->try_write_isr(
                     GPIOInterruptChanged{.pin = GPIO_Pin}));

hepa-uv/firmware/utility_gpio.c

@@ -94,10 +94,10 @@ void uv_push_button_input_gpio_init(void) {
     __HAL_RCC_GPIOC_CLK_ENABLE();
     /*Configure GPIO pin UV_NO_MCU : PC2 */
     GPIO_InitTypeDef GPIO_InitStruct = {0};
-    GPIO_InitStruct.Pin = UV_NO_MCU_PIN;
+    GPIO_InitStruct.Pin = nUV_PRESSED_PIN;
     GPIO_InitStruct.Mode = GPIO_MODE_IT_RISING;
     GPIO_InitStruct.Pull = GPIO_NOPULL;
-    HAL_GPIO_Init(UV_NO_MCU_PORT, &GPIO_InitStruct);
+    HAL_GPIO_Init(nUV_PRESSED_PORT, &GPIO_InitStruct);
 }
 
 /**
@@ -134,6 +134,22 @@ void uv_on_off_output_init() {
     HAL_GPIO_Init(UV_ON_OFF_MCU_PORT, &GPIO_InitStruct);
 }
 
+/**
+ * @brief nSAFETY_ACTIVE_MCU GPIO Initialization Function
+ * @param None
+ * @retval None
+*/
+void safety_relay_active_input_init() {
+    /* GPIO Ports Clock Enable */
+    __HAL_RCC_GPIOB_CLK_ENABLE();
+    /*Configure GPIO pin nSAFETY_ACTIVE_MCU: PB5 */
+    GPIO_InitTypeDef GPIO_InitStruct = {0};
+    GPIO_InitStruct.Pin = nSAFETY_ACTIVE_MCU_PIN;
+    GPIO_InitStruct.Mode = GPIO_MODE_INPUT;
+    GPIO_InitStruct.Pull = GPIO_NOPULL;
+    HAL_GPIO_Init(nSAFETY_ACTIVE_MCU_PORT, &GPIO_InitStruct);
+}
+
 /**
  * @brief NVIC EXTI interrupt priority Initialization
  * @param None
@@ -168,4 +184,5 @@ void utility_gpio_init(void) {
     hepa_on_off_output_init();
     uv_push_button_input_gpio_init();
     uv_on_off_output_init();
+    safety_relay_active_input_init();
 }

include/bootloader/core/ids.h

@@ -165,6 +165,7 @@ typedef enum {
     can_errorcode_over_pressure = 0xd,
     can_errorcode_door_open = 0xe,
     can_errorcode_reed_open = 0xf,
+    can_errorcode_safety_relay_inactive = 0x11,
 } CANErrorCode;
 
 /** Tool types detected on Head. */

include/can/core/ids.hpp

@@ -167,6 +167,7 @@ enum class ErrorCode {
     over_pressure = 0xd,
     door_open = 0xe,
     reed_open = 0xf,
+    safety_relay_inactive = 0x11,
 };
 
 /** Error Severity levels. */

include/can/core/messages.hpp

@@ -1712,6 +1712,7 @@ struct GetHepaUVStateResponse
     uint8_t uv_light_on;
     uint32_t remaining_time_s;
     uint16_t uv_current_ma;
+    uint8_t safety_relay_active;
 
     template <bit_utils::ByteIterator Output, typename Limit>
     auto serialize(Output body, Limit limit) const -> uint8_t {
@@ -1720,6 +1721,7 @@ struct GetHepaUVStateResponse
         iter = bit_utils::int_to_bytes(uv_light_on, iter, limit);
         iter = bit_utils::int_to_bytes(remaining_time_s, iter, limit);
         iter = bit_utils::int_to_bytes(uv_current_ma, iter, limit);
+        iter = bit_utils::int_to_bytes(safety_relay_active, iter, limit);
         return iter - body;
     }
 

include/hepa-uv/core/uv_task.hpp

@@ -9,13 +9,15 @@
 #include "hepa-uv/core/messages.hpp"
 #include "hepa-uv/firmware/gpio_drive_hardware.hpp"
 #include "hepa-uv/firmware/uv_control_hardware.hpp"
+#include "ot_utils/freertos/freertos_sleep.hpp"
 #include "ot_utils/freertos/freertos_timer.hpp"
 
 namespace uv_task {
 
 // How long to keep the UV light on in seconds.
 static constexpr uint32_t DELAY_S = 60 * 15;      // 15 minutes
 static constexpr uint32_t MAX_DELAY_S = 60 * 60;  // 1hr max timeout
+static constexpr uint32_t DEBOUNCE_MS = 250;      // button debounce
 
 using TaskMessage = uv_task_messages::TaskMessage;
 
@@ -33,11 +35,15 @@ class UVMessageHandler {
           can_client{can_client},
           _timer(
               "UVTask", [ThisPtr = this] { ThisPtr->timer_callback(); },
-              DELAY_S * 1000) {
+              DELAY_S * 1000),
+          debounce_timer(
+              "UVTaskDebounce", [ThisPtr = this] { ThisPtr->debounce_cb(); },
+              DEBOUNCE_MS) {
         // get current state
         uv_push_button = gpio::is_set(drive_pins.uv_push_button);
         door_closed = gpio::is_set(drive_pins.door_open);
         reed_switch_set = gpio::is_set(drive_pins.reed_switch);
+        update_safety_relay_state();
         // turn off UV Ballast
         gpio::reset(drive_pins.uv_on_off);
     }
@@ -58,6 +64,19 @@ class UVMessageHandler {
         uv_push_button = false;
     }
 
+    // callback to debounce the irq signals
+    void debounce_cb() {
+        debounce_timer.stop();
+        set_uv_light_state(uv_push_button, uv_off_timeout_s);
+    }
+
+    // Helper to update safety relay state
+    void update_safety_relay_state() {
+        if (drive_pins.safety_relay_active.has_value())
+            safety_relay_active =
+                gpio::is_set(drive_pins.safety_relay_active.value());
+    }
+
     void visit(const std::monostate &) {}
 
     // Handle GPIO EXTI Interrupts here
@@ -67,17 +86,16 @@ class UVMessageHandler {
             return;
         }
 
+        // debounce
+        if (debounce_timer.is_running()) return;
+        debounce_timer.start();
+
         // update states
-        if (m.pin == drive_pins.uv_push_button.pin) {
+        door_closed = gpio::is_set(drive_pins.door_open);
+        reed_switch_set = gpio::is_set(drive_pins.reed_switch);
+        update_safety_relay_state();
+        if (m.pin == drive_pins.uv_push_button.pin)
             uv_push_button = !uv_push_button;
-        } else if (m.pin == drive_pins.door_open.pin) {
-            door_closed = gpio::is_set(drive_pins.door_open);
-        } else if (m.pin == drive_pins.reed_switch.pin) {
-            reed_switch_set = gpio::is_set(drive_pins.reed_switch);
-        }
-
-        // Drive the UV light
-        set_uv_light_state(uv_push_button, uv_off_timeout_s);
     }
 
     void visit(const can::messages::SetHepaUVStateRequest &m) {
@@ -89,13 +107,15 @@ class UVMessageHandler {
     }
 
     void visit(const can::messages::GetHepaUVStateRequest &m) {
+        update_safety_relay_state();
         uv_current_ma = uv_hardware.get_uv_light_current();
         auto resp = can::messages::GetHepaUVStateResponse{
             .message_index = m.message_index,
             .timeout_s = uv_off_timeout_s,
             .uv_light_on = uv_light_on,
             .remaining_time_s = (_timer.get_remaining_time() / 1000),
-            .uv_current_ma = uv_current_ma};
+            .uv_current_ma = uv_current_ma,
+            .safety_relay_active = safety_relay_active};
         can_client.send_can_message(can::ids::NodeId::host, resp);
     }
 
@@ -153,15 +173,40 @@ class UVMessageHandler {
             if (_timer.is_running()) _timer.stop();
         }
 
-        // Update the voltage usage of the uv light
+        // wait 10ms for safety relay, then update the states
+        ot_utils::freertos_sleep::sleep(100);
         uv_current_ma = uv_hardware.get_uv_light_current();
+        update_safety_relay_state();
+        if (uv_light_on && !safety_relay_active) {
+            // we tried to set the uv light, but the relay is not active
+            if (_timer.is_running()) {
+                gpio::reset(drive_pins.uv_on_off);
+                _timer.stop();
+                led_control_client.send_led_control_message(
+                    led_control_task_messages::PushButtonLED(UV_BUTTON, 0, 0,
+                                                             50, 0));
+            }
+            // send error
+            auto msg = can::messages::ErrorMessage{
+                .message_index = 0,
+                .severity = can::ids::ErrorSeverity::warning,
+                .error_code = can::ids::ErrorCode::safety_relay_inactive,
+            };
+            can_client.send_can_message(can::ids::NodeId::host, msg);
+
+            uv_push_button = false;
+            uv_light_on = false;
+            uv_current_ma = 0;
+            return;
+        }
 
         // TODO: send state change CAN message to host
     }
 
     // state tracking variables
     bool door_closed = false;
     bool reed_switch_set = false;
+    bool safety_relay_active = false;
     bool uv_push_button = false;
     bool uv_light_on = false;
     uint32_t uv_off_timeout_s = DELAY_S;
@@ -172,6 +217,7 @@ class UVMessageHandler {
     LEDControlClient &led_control_client;
     CanClient &can_client;
     ot_utils::freertos_timer::FreeRTOSTimer _timer;
+    ot_utils::freertos_timer::FreeRTOSTimer debounce_timer;
 };
 
 /**

include/hepa-uv/firmware/gpio_drive_hardware.hpp

@@ -1,16 +1,20 @@
 #pragma once
 
+#include <optional>
+
 #include "common/firmware/gpio.hpp"
 
 namespace gpio_drive_hardware {
 
+// NOLINTNEXTLINE(cppcoreguidelines-pro-type-member-init)
 struct GpioDrivePins {
     gpio::PinConfig door_open;
     gpio::PinConfig reed_switch;
     gpio::PinConfig hepa_push_button;
     gpio::PinConfig uv_push_button;
     gpio::PinConfig hepa_on_off;
     gpio::PinConfig uv_on_off;
+    std::optional<gpio::PinConfig> safety_relay_active = std::nullopt;
 };
 
 }  // namespace gpio_drive_hardware

include/hepa-uv/firmware/utility_gpio.h

@@ -88,12 +88,9 @@ void utility_gpio_init();
 #define UV_ON_OFF_MCU_PORT GPIOA
 #define UV_ON_OFF_MCU_PIN GPIO_PIN_4
 #define UV_ON_OFF_AS GPIO_PIN_RESET
-// UV_NO_MCU PC2
-#define UV_NO_MCU_PORT GPIOC
-#define UV_NO_MCU_PIN GPIO_PIN_2
-// UV_ADC PA3
-#define UV_ADC_PORT GPIOC
-#define UV_ADC_PIN GPIO_PIN_3
+// nUV_PRESSED PC2
+#define nUV_PRESSED_PORT GPIOC
+#define nUV_PRESSED_PIN GPIO_PIN_2
 // UV_B_CTRL PC5
 #define UV_B_CTRL_PORT GPIOC
 #define UV_B_CTRL_PIN GPIO_PIN_5
@@ -105,4 +102,8 @@ void utility_gpio_init();
 #define UV_R_CTRL_PIN GPIO_PIN_1
 // UV_W_CTRL PB2
 #define UV_W_CTRL_PORT GPIOB
-#define UV_W_CTRL_PIN GPIO_PIN_2
+#define UV_W_CTRL_PIN GPIO_PIN_2
+// nSAFETY_ACTIVE_MCU PB5
+#define nSAFETY_ACTIVE_MCU_PORT GPIOB
+#define nSAFETY_ACTIVE_MCU_PIN GPIO_PIN_5
+#define nSAFETY_ACTIVE_AS GPIO_PIN_RESET