Merge remote-tracking branch 'origin/main' into tcs-heater-upper-limit

CHANGELOG.md

@@ -22,6 +22,8 @@ will consitute of a breaking change warranting a new major release:
   equal or above v4. However, this software version is compatible to both v3 and v4 of the firmware.
 - The firmware version variables are global statics inititalized early during the program
   runtime now. This makes it possible to check the firmware version earlier.
+- The TCS controller will now always command heaters OFF when being blind for thermal
+  components (no sensors available), irrespective of current switch state.
 
 ## Fixed
 
@@ -29,6 +31,10 @@ will consitute of a breaking change warranting a new major release:
 - Small fixes for TMP1075 FDIR: Use strange and missed reply counters.
 - TCS controller: Last heater (S-band heater) was skipped for transition completion
   checks.
+- TCS controller: A helper member to track the elapsed heater control cycles was not reset
+  properly, which could lead to switch transitions being completed immediately. This can
+  lead to weird bugs like heaters being commanded ON twice and can potentially lead to
+  other bugs.
 - TMP1075: Devices did not go to OFF mode when being set faulty.
 - Update PL PCDU 1 in TCS mode tree on the EM.
 - TMP1075: Possibly ignored health commands.

mission/controller/ThermalController.cpp

@@ -1602,8 +1602,7 @@ void ThermalController::ctrlComponentTemperature(HeaterContext& htrCtx) {
     // No sensors available, so switch the heater off. We can not perform control tasks if we
     // are blind..
     if (chooseHeater(htrCtx.switchNr, htrCtx.redSwitchNr)) {
-      if (heaterCtrlAllowed() and
-          (heaterHandler.getSwitchState(htrCtx.switchNr) == HeaterHandler::SwitchState::ON)) {
+      if (heaterCtrlAllowed()) {
         heaterSwitchHelper(htrCtx.switchNr, HeaterHandler::SwitchState::OFF, currThermalComponent);
       }
     }
@@ -1687,11 +1686,13 @@ void ThermalController::checkLimitsAndCtrlHeater(HeaterContext& htrCtx) {
     return;
   }
 
-  htrCtx.switchState = heaterHandler.getSwitchState(htrCtx.switchNr);
+  htrCtx.switchState =
+      static_cast<HeaterHandler::SwitchState>(heaterInfo.heaterSwitchState[htrCtx.switchNr]);
   // Heater off
   if (htrCtx.switchState == HeaterHandler::SwitchState::OFF) {
     if (sensorTemp < htrCtx.tempLimit.opLowerLimit and heaterCtrlAllowed()) {
-      sif::info << "TCS: Heater " << static_cast<int>(currThermalComponent) << " ON" << std::endl;
+      sif::info << "TCS: Heater " << static_cast<int>(htrCtx.switchNr) << " for component "
+                << static_cast<int>(currThermalComponent) << " ON" << std::endl;
       heaterSwitchHelper(htrCtx.switchNr, HeaterHandler::SwitchState::ON, thermalComponent);
     } else {
       // Even if heater control is now allowed, we can update the state.
@@ -1706,8 +1707,8 @@ void ThermalController::checkLimitsAndCtrlHeater(HeaterContext& htrCtx) {
     if (thermalStates[currThermalComponent].heating) {
       // We are already in a heating cycle, so need to check whether heating task is complete.
       if (sensorTemp >= htrCtx.tempLimit.opLowerLimit + TEMP_OFFSET and heaterCtrlAllowed()) {
-        sif::info << "TCS: Heater " << static_cast<int>(currThermalComponent) << " OFF"
-                  << std::endl;
+        sif::info << "TCS: Heater " << static_cast<int>(htrCtx.switchNr) << " for component "
+                  << static_cast<int>(currThermalComponent) << " OFF" << std::endl;
         heaterSwitchHelper(htrCtx.switchNr, HeaterHandler::SwitchState::OFF, currThermalComponent);
         heaterStates[htrCtx.switchNr].switchTransition = true;
         heaterStates[htrCtx.switchNr].target = HeaterHandler::SwitchState::OFF;
@@ -1767,9 +1768,10 @@ void ThermalController::heaterTransitionControl(const HeaterSwitchStates& curren
           crossCheckHeaterStateOfComponentsWhenHeaterGoesOff(static_cast<heater::Switch>(i));
         }
         heaterStates[i].switchTransition = false;
+        heaterStates[i].heaterSwitchControlCycles = 0;
         continue;
       }
-      if (heaterStates[i].heaterSwitchControlCycles > 3) {
+      if (heaterStates[i].heaterSwitchControlCycles > 5) {
         heaterStates[i].switchTransition = false;
         heaterStates[i].heaterSwitchControlCycles = 0;
       }

mission/tcs/HeaterHandler.cpp

@@ -419,13 +419,13 @@ ReturnValue_t HeaterHandler::getAllSwitchStates(std::array<SwitchState, 8>& stat
 }
 
 bool HeaterHandler::allSwitchesOff() {
-  bool allSwitchesOrd = false;
   MutexGuard mg(handlerLock, LOCK_TYPE, LOCK_TIMEOUT, LOCK_CTX);
-  /* Or all switches. As soon one switch is on, allSwitchesOrd will be true */
   for (power::Switch_t switchNr = 0; switchNr < heater::NUMBER_OF_SWITCHES; switchNr++) {
-    allSwitchesOrd = allSwitchesOrd || heaterVec.at(switchNr).switchState;
+    if (heaterVec.at(switchNr).switchState == SwitchState::ON) {
+      return false;
     }
-  return !allSwitchesOrd;
+  }
+  return true;
 }
 
 MessageQueueId_t HeaterHandler::getCommandQueue() const { return commandQueue->getId(); }