Added battery charger code for the recorder and battery voltage statistics keeping for all platforms.

git-svn-id: svn://svn.rockbox.org/rockbox/trunk@1546 a1c6a512-1295-4272-9138-f99709370657

6 files changed, 247 insertions, 4 deletions

diff --git a/firmware/config-recorder.h b/firmware/config-recorder.h
index a365214451..9bcfc7bc60 100644
--- a/firmware/config-recorder.h
+++ b/firmware/config-recorder.h
@@ -12,3 +12,7 @@
 
 /* Define this if you have a MAS3587F */
 #define HAVE_MAS3587F
+
+/* Define this if you have charging control */
+#define HAVE_CHARGE_CTRL
+
diff --git a/firmware/drivers/adc.h b/firmware/drivers/adc.h
index 1ff5118238..0c05f4d0f8 100644
--- a/firmware/drivers/adc.h
+++ b/firmware/drivers/adc.h
@@ -40,6 +40,8 @@
 #define BATTERY_SCALE_FACTOR 6546
 #endif
 
+#define EXT_SCALE_FACTOR 14800
+
 unsigned short adc_read(int channel);
 void adc_init(void);
 
diff --git a/firmware/drivers/power.c b/firmware/drivers/power.c
index d3ce939ce2..559509fa67 100644
--- a/firmware/drivers/power.c
+++ b/firmware/drivers/power.c
@@ -22,12 +22,16 @@
 #include "adc.h"
 #include "power.h"
 
+#ifdef HAVE_CHARGE_CTRL
+bool charger_enabled = 0;
+#endif
+
 #ifndef SIMULATOR
 
 bool charger_inserted(void)
 {
 #ifdef ARCHOS_RECORDER
-    return adc_read(ADC_EXT_POWER) > 0x200;
+    return adc_read(ADC_EXT_POWER) > 0x100;
 #else
     return (PADR & 1) == 0;
 #endif
@@ -58,11 +62,14 @@ bool battery_level_safe(void)
 
 void charger_enable(bool on)
 {
-#ifdef ARCHOS_RECORDER
-    if(on)
+#ifdef HAVE_CHARGE_CTRL
+    if(on) {
         PBDR &= ~0x20;
-    else
+        charger_enabled = 1;
+    } else {
         PBDR |= 0x20;
+        charger_enabled = 0;
+    }
 #else
     on = on;
 #endif
diff --git a/firmware/drivers/power.h b/firmware/drivers/power.h
index f921b67d5e..fe7d443bef 100644
--- a/firmware/drivers/power.h
+++ b/firmware/drivers/power.h
@@ -26,6 +26,10 @@
 
 #define BATTERY_RANGE (BATTERY_LEVEL_FULL - BATTERY_LEVEL_EMPTY)
 
+#ifdef HAVE_CHARGE_CTRL
+extern bool charger_enabled;
+#endif
+
 bool charger_inserted(void);
 void charger_enable(bool on);
 void ide_power_enable(bool on);
diff --git a/firmware/powermgmt.c b/firmware/powermgmt.c
new file mode 100644
index 0000000000..940d37ea16
--- /dev/null
+++ b/firmware/powermgmt.c
@@ -0,0 +1,177 @@
+/***************************************************************************
+ *             __________               __   ___.
+ *   Open      \______   \ ____   ____ |  | _\_ |__   _______  ___
+ *   Source     |       _//  _ \_/ ___\|  |/ /| __ \ /  _ \  \/  /
+ *   Jukebox    |    |   (  <_> )  \___|    < | \_\ (  <_> > <  <
+ *   Firmware   |____|_  /\____/ \___  >__|_ \|___  /\____/__/\_ \
+ *                     \/            \/     \/    \/            \/
+ * $Id$
+ *
+ * Copyright (C) 2002 by Heikki Hannikainen
+ *
+ * All files in this archive are subject to the GNU General Public License.
+ * See the file COPYING in the source tree root for full license agreement.
+ *
+ * This software is distributed on an "AS IS" basis, WITHOUT WARRANTY OF ANY
+ * KIND, either express or implied.
+ *
+ ****************************************************************************/
+#include "config.h"
+#include "sh7034.h"
+#include "kernel.h"
+#include "thread.h"
+#include "system.h"
+#include "debug.h"
+#include "panic.h"
+#include "adc.h"
+#include "string.h"
+#include "power.h"
+#include "powermgmt.h"
+
+#ifndef SIMULATOR
+
+static char power_stack[DEFAULT_STACK_SIZE];
+static char power_thread_name[] = "power";
+
+unsigned short power_history[POWER_HISTORY_LEN];
+#ifdef HAVE_CHARGE_CTRL
+char power_message[POWER_MESSAGE_LEN] = "";
+char charge_restart_level = CHARGE_RESTART_HI;
+#endif
+
+/*
+ * This power thread maintains a history of battery voltage
+ * and should, in the future, enable charging when it's needed
+ * and power is available, and disable it when the battery is full.
+ * Battery 'fullness' can be determined by the voltage drop, see:
+ *
+ * http://www.nimhbattery.com/nimhbattery-faq.htm questions 3 & 4
+ * http://www.powerpacks-uk.com/Charging%20NiMh%20Batteries.htm
+ * http://www.angelfire.com/electronic/hayles/charge1.html (soft start idea)
+ * http://www.powerstream.com/NiMH.htm (discouraging)
+ * http://www.panasonic.com/industrial/battery/oem/images/pdf/nimhchar.pdf
+ * http://www.duracell.com/oem/Pdf/others/nimh_5.pdf (discharging)
+ * http://www.duracell.com/oem/Pdf/others/nimh_6.pdf (charging)
+ *
+ * Charging logic which we're starting with (by Linus, Hes, Bagder):
+ *
+ *  1) max 16 hrs charge time (just in negative delta detection fails)
+ *  2) Stop at negative delta of 5 mins
+ *  3) Stop at 15 mins of zero-delta or below
+ *  4) minimum of 15 mins charge time before 2) is applied
+ *  5) after end of charging, wait for charge go down 80%
+ *     before charging again if in 'no-use overnight charging mode'
+ *     and down to 10% if in 'fixed-location mains-powered usage mode'
+ */
+
+static void power_thread(void)
+{
+    int i;
+    int avg;
+#ifdef HAVE_CHARGE_CTRL
+    int delta;
+    int charged_time = 0;
+#endif
+    
+    while (1)
+    {
+        DEBUGF("power_thread woke up\n");
+        /* make POWER_AVG measurements and calculate an average of that to
+         * reduce the effect of backlights/disk spinning/other variation
+         */
+        avg = 0;
+        for (i = 0; i < POWER_AVG; i++) {
+            avg += adc_read(ADC_UNREG_POWER);
+            sleep(15);
+        }
+        avg = avg / POWER_AVG;
+        
+        /* rotate the power history */
+        for (i = 0; i < POWER_HISTORY_LEN-1; i++)
+            power_history[i] = power_history[i+1];
+        
+        /* insert new value in the end, in decivolts 8-) */
+        power_history[POWER_HISTORY_LEN-1] = (avg * BATTERY_SCALE_FACTOR) / 10000;
+        
+#ifdef HAVE_CHARGE_CTRL
+        if (charger_inserted()) {
+            if (charger_enabled) {
+                /* charger inserted and enabled */
+                charged_time++;
+                if (charged_time > CHARGE_MAX_TIME) {
+                    DEBUGF("power: charged_time > CHARGE_MAX_TIME, enough!\n");
+                    /* have charged too long and deltaV detection did not work! */
+                    charger_enable(false);
+                    snprintf(power_message, POWER_MESSAGE_LEN, "Chg tmout %d min", CHARGE_MAX_TIME);
+                    /* Perhaps we should disable charging for several
+                       hours from this point, just to be sure. */
+                } else {
+                    if (charged_time > CHARGE_MIN_TIME) {
+                        /* have charged continuously over the minimum charging time,
+                         * so we monitor for deltaV going negative. Multiply things
+                         * by 100 to get more accuracy without floating point arithmetic.
+                         * power_history[] contains decivolts.
+                         */
+                        delta = 0;
+                        for (i = 0; i < CHARGE_END_NEGD; i++)
+                            delta += power_history[POWER_HISTORY_LEN-1-i]*100 - power_history[POWER_HISTORY_LEN-1-i-1]*100;
+                        delta = delta / CHARGE_END_NEGD;
+                        
+                        if (delta < -50) { /* delta < -0.3 V */
+                            DEBUGF("power: short-term negative delta, enough!\n");
+                            charger_enable(false);
+                            snprintf(power_message, POWER_MESSAGE_LEN, "end negd %d %dmin", delta, charged_time);
+                        } else {
+                            /* if we didn't disable the charger in the previous test, check for low positive delta */
+                            delta = 0;
+                            for (i = 0; i < CHARGE_END_ZEROD; i++)
+                                delta += power_history[POWER_HISTORY_LEN-1-i]*100 - power_history[POWER_HISTORY_LEN-1-i-1]*100;
+                            delta = delta / CHARGE_END_ZEROD;
+                            
+                            if (delta <= 5) { /* delta of <= 0.005 V */
+                                DEBUGF("power: long-term small positive delta, enough!\n");
+                                charger_enable(false);
+                                snprintf(power_message, POWER_MESSAGE_LEN, "end lowd %d %dmin", delta, charged_time);
+                            }
+                        }
+                    }
+                }
+            } else {
+                /* charged inserted but not enabled */
+                /* if battery is not full, enable charging */
+                if (battery_level() < charge_restart_level) {
+                    DEBUGF("power: charger inserted and battery not full, enabling\n");
+                    charger_enable(true);
+                    charged_time = 0;
+                    snprintf(power_message, POWER_MESSAGE_LEN, "Chg started at %d%%", battery_level());
+                }
+            }
+        } else {
+            /* charger not inserted */
+            if (charger_enabled) {
+                /* charger not inserted but was enabled */
+                DEBUGF("power: charger disconnected, disabling\n");
+                charger_enable(false);
+                snprintf(power_message, POWER_MESSAGE_LEN, "Charger disc");
+            }
+            /* charger not inserted and disabled, so we're discharging */
+        }
+#endif /* HAVE_CHARGE_CTRL*/
+        
+        /* sleep for roughly a minute */
+        sleep(HZ*(60-POWER_AVG*15));
+    }
+}
+
+void power_init(void)
+{
+    /* init history to 0 */
+    memset(power_history, 0x00, sizeof(power_history));
+
+#ifdef HAVE_CHARGE_CTRL
+    snprintf(power_message, POWER_MESSAGE_LEN, "Powermgmt started");
+#endif
+    create_thread(power_thread, power_stack, sizeof(power_stack), power_thread_name);
+}
+
+#endif
diff --git a/firmware/powermgmt.h b/firmware/powermgmt.h
new file mode 100644
index 0000000000..068fd5d4b5
--- /dev/null
+++ b/firmware/powermgmt.h
@@ -0,0 +1,49 @@
+/***************************************************************************
+ *             __________               __   ___.
+ *   Open      \______   \ ____   ____ |  | _\_ |__   _______  ___
+ *   Source     |       _//  _ \_/ ___\|  |/ /| __ \ /  _ \  \/  /
+ *   Jukebox    |    |   (  <_> )  \___|    < | \_\ (  <_> > <  <
+ *   Firmware   |____|_  /\____/ \___  >__|_ \|___  /\____/__/\_ \
+ *                     \/            \/     \/    \/            \/
+ * $Id$
+ *
+ * Copyright (C) 2002 by Heikki Hannikainen
+ *
+ * All files in this archive are subject to the GNU General Public License.
+ * See the file COPYING in the source tree root for full license agreement.
+ *
+ * This software is distributed on an "AS IS" basis, WITHOUT WARRANTY OF ANY
+ * KIND, either express or implied.
+ *
+ ****************************************************************************/
+#ifndef _POWERMGMT_H_
+#define _POWERMGMT_H_
+
+#ifndef SIMULATOR
+
+#define POWER_HISTORY_LEN 2*60   /* 2 hours of samples, one per minute */
+#define POWER_AVG         3      /* how many samples to take for each measurement */
+
+#define CHARGE_END_NEGD   6      /* stop when N minutes have passed with
+                                  * avg delta being < -0.3 V */
+#define CHARGE_END_ZEROD  30     /* stop when N minutes have passed with
+                                  * avg delta being < 0.005 V */
+
+#ifdef HAVE_CHARGE_CTRL
+#define POWER_MESSAGE_LEN 32     /* power thread status message */
+#define CHARGE_MAX_TIME   16*60  /* minutes: maximum charging time */
+#define CHARGE_MIN_TIME   10     /* minutes: minimum charging time */
+#define CHARGE_RESTART_HI 90     /* %: when to restart charging in 'charge' mode */
+#define CHARGE_RESTART_LO 10     /* %: when to restart charging in 'discharge' mode */
+
+extern char power_message[POWER_MESSAGE_LEN];
+extern char charge_restart_level;
+#endif /* HAVE_CHARGE_CTRL */
+
+extern unsigned short power_history[POWER_HISTORY_LEN];
+
+void power_init(void);
+
+#endif
+
+#endif