PIC24 Support Libraries: chap15/reflow

00001 /*
00002  * "Copyright (c) 2008 Robert B. Reese, Bryan A. Jones, J. W. Bruce ("AUTHORS")"
00003  * All rights reserved.
00004  * (R. Reese, reese_AT_ece.msstate.edu, Mississippi State University)
00005  * (B. A. Jones, bjones_AT_ece.msstate.edu, Mississippi State University)
00006  * (J. W. Bruce, jwbruce_AT_ece.msstate.edu, Mississippi State University)
00007  *
00008  * Permission to use, copy, modify, and distribute this software and its
00009  * documentation for any purpose, without fee, and without written agreement is
00010  * hereby granted, provided that the above copyright notice, the following
00011  * two paragraphs and the authors appear in all copies of this software.
00012  *
00013  * IN NO EVENT SHALL THE "AUTHORS" BE LIABLE TO ANY PARTY FOR
00014  * DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES ARISING OUT
00015  * OF THE USE OF THIS SOFTWARE AND ITS DOCUMENTATION, EVEN IF THE "AUTHORS"
00016  * HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
00017  *
00018  * THE "AUTHORS" SPECIFICALLY DISCLAIMS ANY WARRANTIES,
00019  * INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY
00020  * AND FITNESS FOR A PARTICULAR PURPOSE.  THE SOFTWARE PROVIDED HEREUNDER IS
00021  * ON AN "AS IS" BASIS, AND THE "AUTHORS" HAS NO OBLIGATION TO
00022  * PROVIDE MAINTENANCE, SUPPORT, UPDATES, ENHANCEMENTS, OR MODIFICATIONS."
00023  *
00024  * Please maintain this header in its entirety when copying/modifying
00025  * these files.
00026  *
00027  *
00028  */
00029 #include "pic24_all.h"
00030 #include <stdio.h>
00031 #include "reflow_oven.h"
00032 
00037 #define MIN_WETTING_TIME 60  //seconds
00038 
00039 //stat variables
00040 uint16 u16_peakTime;
00041 int16 i16_maxTemp;
00042 uint16 u16_startWetting;
00043 uint16 u16_endWetting;
00044 uint8 coolingFlag;
00045 uint16 u16_startReflow;
00046 uint16 u16_endReflow;
00047 
00048 void resetStats(void) {
00049   i16_maxTemp = 0;
00050   coolingFlag  = 0;
00051   u16_startWetting = 0;
00052   u16_endWetting = 0;
00053 }
00054 
00055 void printStats (void) {
00056   uint16 u16_wettingTime;
00057   uint16 u16_reflowTime;
00058   if (u16_endWetting == 0) u16_wettingTime = u16_tenthSeconds - u16_startWetting;
00059   else u16_wettingTime = u16_endWetting - u16_startWetting;
00060   if (u16_endReflow == 0) u16_reflowTime = u16_tenthSeconds - u16_startReflow;
00061   else u16_reflowTime = u16_endReflow - u16_startReflow;
00062 
00063   printf ("\nMax temp: %u, Temp Overshoot: %d, Wetting time: %d (s), Reflow Time: %d (s), Elapsed time: %u (s)\n",
00064           i16_maxTemp, i16_maxTemp - profiles[u8_currentProfile].i16_reflowTemp,
00065           u16_wettingTime/10, u16_reflowTime/10, u16_tenthSeconds/10 );
00066 }
00067 
00068 int16 updateStats(void) {
00069   int16 i16_tempC;
00070   i16_tempC = getCelsiusI16Temp();
00071   if (i16_tempC > i16_maxTemp) i16_maxTemp  = i16_tempC;
00072   if (i16_tempC > profiles[u8_currentProfile].i16_wetTemp &&
00073       u16_startWetting == 0) u16_startWetting = u16_tenthSeconds;
00074   if (coolingFlag && (i16_tempC < profiles[u8_currentProfile].i16_wetTemp)
00075       && u16_endWetting == 0)
00076     u16_endWetting = u16_tenthSeconds;
00077   if (i16_tempC > profiles[u8_currentProfile].i16_reflowTemp &&
00078       u16_startReflow == 0) u16_startReflow = u16_tenthSeconds;
00079   if (coolingFlag && (i16_tempC < profiles[u8_currentProfile].i16_reflowTemp)
00080       && u16_endReflow == 0)
00081     u16_endReflow = u16_tenthSeconds;
00082   return(i16_tempC);
00083 }
00084 
00085 uint16 tempToPower(int16 i16_t) {
00086   uint16 u16_i;
00087 
00088   for (u16_i=0; u16_i <= 100; u16_i++) {
00089     if (fdata.caldata.temp[u16_i] >= i16_t) return(u16_i);
00090   }
00091   reportError("Reflow application error: Unable to find power setting for target temp");
00092   return(0);
00093 }
00094 
00095 void doRampUp(int16 i16_targetTemp, uint16 u16_targetTime) {
00096   int16 i16_tempC, i16_lastTemp;
00097   uint8  u8_endPower;
00098   uint16 u16_endTime;
00099 
00100   u16_endTime =  u16_tenthSeconds + u16_targetTime*10;  //end time does not change
00101   i16_tempC = updateStats();  //get current temp;
00102   u8_endPower = tempToPower(i16_targetTemp);
00103   setPower(100);  //need to heat this up
00104   do {
00105     i16_tempC = updateStats(); //get current temp;
00106     printf("Current temp/time: %u %u Power: %u\n",i16_tempC,u16_tenthSeconds, getPower());
00107     DELAY_MS(1000);
00108     if (u16_tenthSeconds > u16_endTime) return;
00109   } while ((i16_targetTemp - i16_tempC) > 10 );
00110   setPower(30); // near target temp
00111   i16_lastTemp = i16_tempC;
00112   do {
00113     DELAY_MS(1000);
00114     i16_tempC = updateStats();
00115     printf("Current temp/time: %u %u Power: %u\n",i16_tempC,u16_tenthSeconds, getPower());
00116     if ((i16_tempC <  i16_lastTemp) && (i16_tempC < i16_targetTemp ) ) {
00117       //temp is decreasing
00118       setPower(u8_endPower);
00119     } else  setPower(30);
00120     i16_lastTemp = i16_tempC;
00121   } while (u16_tenthSeconds < u16_endTime);
00122 }
00123 
00124 /* Oven cools down so slowly just turn off power and wait
00125  for target time */
00126 #if 0
00127 void doRampDown (int16 i16_targetTemp, uint16 u16_targetTime) {
00128   int16 i16_tempC;
00129 
00130   setPower(0);
00131   while (u16_targetTime) {
00132     i16_tempC = updateStats();
00133     printf("Current temp/time: %u %u Power: %u\n",i16_tempC,u16_tenthSeconds, getPower());
00134     DELAY_MS(1000);
00135     u16_targetTime--;
00136   }
00137 }
00138 #endif
00139 void doRampDown(void) {
00140   int16 i16_tempC;
00141   uint16 u16_wetTime;
00142   uint8  u8_openDoorFlag;
00143 
00144   setPower(0);
00145   u8_openDoorFlag = 0;
00146   do {
00147     u16_wetTime = u16_tenthSeconds - u16_startWetting;
00148     if ((u16_wetTime > MIN_WETTING_TIME) && !u8_openDoorFlag) {
00149       printf("\n\nWetting time is met, open door to aid cooling\n");
00150       u8_openDoorFlag = 1;
00151     }
00152     i16_tempC = updateStats();
00153     printf("Current temp/time: %u %u Power: %u\n",i16_tempC,u16_tenthSeconds, getPower());
00154     DELAY_MS(1000);
00155   } while (i16_tempC > 100);
00156 }
00157 
00158 
00159 void doHold (int16 i16_targetTemp, uint16 u16_targetTime) {
00160   uint16 u16_endTime, u16_maxExitTime;
00161   int16 i16_tempC, i16_lastTemp;
00162   uint8 u8_endPower;
00163 
00164   //maximum time to wait before reaching target temp
00165   u16_maxExitTime =  u16_tenthSeconds + u16_targetTime*10*5;
00166   i16_tempC = updateStats(); //get current temp;
00167   u8_endPower = tempToPower(i16_targetTemp);
00168   if (i16_tempC < i16_targetTemp)setPower(100) ;
00169   while (i16_tempC < i16_targetTemp) {  //we need to reach the target reflow hold temperature
00170     DELAY_MS(1000);
00171     i16_tempC = updateStats();
00172     printf("Current temp/time: %u %u Power: %u\n",i16_tempC,u16_tenthSeconds, getPower());
00173     if (u16_tenthSeconds > u16_maxExitTime)return;
00174   }
00175   i16_lastTemp = i16_tempC;
00176   u16_endTime =  u16_tenthSeconds + u16_targetTime*10;
00177   do {
00178     DELAY_MS(1000);
00179     i16_tempC = updateStats();
00180     printf("Current temp/time: %u %u Power: %u\n",i16_tempC, u16_tenthSeconds, getPower());
00181     if ((i16_tempC <  i16_lastTemp) && (i16_tempC < i16_targetTemp ) ) {
00182       //temp is decreasing
00183       setPower(u8_endPower);
00184     } else  setPower(30);
00185     i16_lastTemp = i16_tempC;
00186   } while (u16_tenthSeconds < u16_endTime);
00187 }
00188 
00189 
00190 void doReflow(void) {
00191 
00192   uint8 u8_rdyFlag,u8_c;
00193   uint16 i16_tempC;
00194 
00195   u8_rdyFlag = 0;
00196   do {
00197     printf("\n\nOpen door, place board in oven, close door.\n");
00198     printf("Turn 'TEMP' knob to 'Toast On/Bake Off'\n");
00199     printf("Ensure that end of thermocouple is not touching\n");
00200     printf("the board or metal. \n");
00201     printf("Enter 'y' to continue or 'n' to exit...\n");
00202     u8_c = inCharEcho();
00203     if (u8_c == 'n') return;
00204   } while (u8_c != 'y');
00205 
00206   u16_tenthSeconds = 0;
00207   u8_c = ZEROCROSS;
00208   while (u8_c == ZEROCROSS) {
00209     if (u16_tenthSeconds > 4) break;
00210     doHeartbeat();
00211   }
00212   if (u16_tenthSeconds > 4) {
00213     printf("\nExiting, power is not on to oven, cannot detect 60Hz cycling.\n");
00214     return;
00215   }
00216   u16_tenthSeconds = 0;
00217   resetStats();
00218 //preheat
00219   i16_tempC = getCelsiusI16Temp();
00220   printf("\nStart Preheat (temp = %uC)\n",i16_tempC);
00221   doRampUp(profiles[u8_currentProfile].i16_preheatTemp,
00222            profiles[u8_currentProfile].u16_preheatTime);
00223 //soak
00224   i16_tempC = getCelsiusI16Temp();
00225   printf("\nStart Soak (temp = %uC), Elapsed time: %u s\n",i16_tempC,
00226          u16_tenthSeconds/10);
00227   doRampUp(profiles[u8_currentProfile].i16_soakTemp,
00228            profiles[u8_currentProfile].u16_soakTime);
00229 //reflow
00230   printf("\nStart Reflow (temp = %uC), Elapsed time: %u s\n",i16_tempC,
00231          u16_tenthSeconds/10);
00232   doRampUp(profiles[u8_currentProfile].i16_reflowTemp,
00233            profiles[u8_currentProfile].u16_reflowTime);
00234   printf("\nStart Reflow Hold (temp = %uC), Elapsed time: %u s\n",i16_tempC,
00235          u16_tenthSeconds/10);
00236   doHold(profiles[u8_currentProfile].i16_reflowTemp,
00237          profiles[u8_currentProfile].u16_reflowHoldTime);
00238 //initial cooldown
00239 
00240   coolingFlag = 1;
00241   setPower(0);
00242   printf("\nStart Cool1 (temp = %uC), Elapsed time: %u s\n",i16_tempC,
00243          u16_tenthSeconds/10);
00244   doRampDown();
00245 #if 0
00246 
00247   doRampDown(profiles[u8_currentProfile].i16_coolTemp,
00248              profiles[u8_currentProfile].u16_coolTime);
00249 //
00250 #endif
00251 
00252   printStats();
00253 
00254 }
00255 
00256
chap15/reflow_operate.c
