From 715a69db893ba61ddd0af4febbcd56cb57d66e07 Mon Sep 17 00:00:00 2001
From: Robin Mueller <robin.mueller.m@gmail.com>
Date: Wed, 15 Mar 2023 15:43:20 +0100
Subject: [PATCH] this should cover upper bound checking when heater is off

---
 mission/controller/ThermalController.cpp | 58 ++++++++++++++----------
 1 file changed, 35 insertions(+), 23 deletions(-)

diff --git a/mission/controller/ThermalController.cpp b/mission/controller/ThermalController.cpp
index e22d2b8a..42d79a2a 100644
--- a/mission/controller/ThermalController.cpp
+++ b/mission/controller/ThermalController.cpp
@@ -1539,8 +1539,33 @@ void ThermalController::checkLimitsAndCtrlHeater(heater::Switchers switchNr,
                                                  const TempLimits& tempLimit) {
   componentAboveCutOffLimit = false;
   componentAboveUpperLimit = false;
-  // if Heater off
+  auto tempTooHighHandler = [&](const char* whatLimit, bool heaterIsOn) {
+    heaterHandler.switchHeater(switchNr, HeaterHandler::SwitchState::OFF);
+    sif::info << "ThermalController::checkLimitsAndCtrlHeater: Reached " << whatLimit << ": Heater "
+              << static_cast<int>(thermalComponent) << " OFF" << std::endl;
+    heaterStates[switchNr].switchTransition = true;
+    if (heaterIsOn) {
+      heaterHandler.switchHeater(redSwitchNr, HeaterHandler::SwitchState::OFF);
+      heaterStates[redSwitchNr].switchTransition = true;
+    }
+  };
+  auto checkUpperLimits = [&](bool heaterIsOn) {
+    if (sensorTemp >= tempLimit.nopUpperLimit) {
+      componentAboveUpperLimit = true;
+      tempTooHighHandler("NOP-Limit", heaterIsOn);
+      overHeatEventToTrigger = ThermalComponentIF::COMPONENT_TEMP_OOL_HIGH;
+      return true;
+    } else if (sensorTemp >= tempLimit.opUpperLimit) {
+      componentAboveUpperLimit = true;
+      tempTooHighHandler("OP-Limit", heaterIsOn);
+      overHeatEventToTrigger = ThermalComponentIF::COMPONENT_TEMP_HIGH;
+      return true;
+    }
+    return false;
+  };
+  // Stay passive during switch transitions, wait for heater switching to complete.
   if (not heaterStates[switchNr].switchTransition) {
+    // Heater off
     if (not heaterHandler.checkSwitchState(switchNr)) {
       // TODO: check NOP limit and maybe trigger fdir
       if (sensorTemp < tempLimit.opLowerLimit) {
@@ -1552,10 +1577,11 @@ void ThermalController::checkLimitsAndCtrlHeater(heater::Switchers switchNr,
       } else {
         thermalStates[thermalComponent].heating = false;
       }
-
-      // if Heater on
+      checkUpperLimits(false);
+      // Heater on
     } else if (heaterHandler.checkSwitchState(switchNr)) {
       if (thermalStates[thermalComponent].heating) {
+        // We are already in a heating cycle, so need to check whether heating task is complete.
         if (sensorTemp >= tempLimit.opLowerLimit + TEMP_OFFSET) {
           heaterHandler.switchHeater(switchNr, HeaterHandler::SwitchState::OFF);
           sif::info << "ThermalController::checkLimitsAndCtrlHeater: Heater "
@@ -1564,28 +1590,14 @@ void ThermalController::checkLimitsAndCtrlHeater(heater::Switchers switchNr,
           thermalStates[thermalComponent].heating = false;
         }
       } else {
-        auto tempTooHighHandler = [&](const char* whatLimit) {
-          heaterHandler.switchHeater(switchNr, HeaterHandler::SwitchState::OFF);
-          sif::info << "ThermalController::checkLimitsAndCtrlHeater: Reached " << whatLimit
-                    << ": Heater " << static_cast<int>(thermalComponent) << " OFF" << std::endl;
-          heaterStates[switchNr].switchTransition = true;
-          if (heaterHandler.checkSwitchState(redSwitchNr)) {
-            heaterHandler.switchHeater(redSwitchNr, HeaterHandler::SwitchState::OFF);
-            heaterStates[redSwitchNr].switchTransition = true;
-          }
-        };
-        if (sensorTemp >= tempLimit.nopUpperLimit) {
-          componentAboveUpperLimit = true;
-          tempTooHighHandler("NOP-Limit");
-          overHeatEventToTrigger = ThermalComponentIF::COMPONENT_TEMP_OOL_HIGH;
-        } else if (sensorTemp >= tempLimit.opUpperLimit) {
-          componentAboveUpperLimit = true;
-          tempTooHighHandler("OP-Limit");
-          overHeatEventToTrigger = ThermalComponentIF::COMPONENT_TEMP_HIGH;
-        }
+        // This can happen if heater is used as alternative heater (no regular heating cycle), so we
+        // should still check the upper limits.
+        bool tooHighHandlerAlreadyCalled = checkUpperLimits(true);
         if (sensorTemp >= tempLimit.cutOffLimit) {
           componentAboveCutOffLimit = true;
-          tempTooHighHandler("CutOff-Limit");
+          if (not tooHighHandlerAlreadyCalled) {
+            tempTooHighHandler("CutOff-Limit", true);
+          }
         }
       }
     }