3 files changed, 546 insertions, 4 deletions

diff --git a/firmware/target/sh/archos/recorder/power-recorder.c b/firmware/target/sh/archos/recorder/power-recorder.c
index d90c029890..8d7ea5fc51 100644
--- a/firmware/target/sh/archos/recorder/power-recorder.c
+++ b/firmware/target/sh/archos/recorder/power-recorder.c
@@ -25,9 +25,10 @@
 #include "kernel.h"
 #include "system.h"
 #include "power.h"
+#include "powermgmt-target.h"
 #include "usb.h"
 
-bool charger_enabled;
+static bool charger_on;
 
 void power_init(void)
 {
@@ -48,13 +49,18 @@ void charger_enable(bool on)
     if(on)
     {
         and_b(~0x20, &PBDRL);
-        charger_enabled = 1;
     } 
     else 
     {
         or_b(0x20, &PBDRL);
-        charger_enabled = 0;
     }
+
+    charger_on = on;
+}
+
+bool charger_enabled(void)
+{
+    return charger_on;
 }
 
 void ide_power_enable(bool on)
diff --git a/firmware/target/sh/archos/recorder/powermgmt-recorder.c b/firmware/target/sh/archos/recorder/powermgmt-recorder.c
index 6de5cc8037..7b1842016c 100644
--- a/firmware/target/sh/archos/recorder/powermgmt-recorder.c
+++ b/firmware/target/sh/archos/recorder/powermgmt-recorder.c
@@ -19,9 +19,13 @@
  * KIND, either express or implied.
  *
  ****************************************************************************/
-
 #include "config.h"
+#include "system.h"
+#include <sprintf.h>
+#include "debug.h"
+#include "storage.h"
 #include "adc.h"
+#include "power.h"
 #include "powermgmt.h"
 
 const unsigned short battery_level_dangerous[BATTERY_TYPES_COUNT] =
@@ -60,3 +64,434 @@ unsigned int battery_adc_voltage(void)
 {
     return (adc_read(ADC_UNREG_POWER) * BATTERY_SCALE_FACTOR) >> 10;
 }
+
+/** Charger control **/
+#ifdef CHARGING_DEBUG_FILE
+#include "file.h"
+#define DEBUG_FILE_NAME "/powermgmt.csv"
+#define DEBUG_MESSAGE_LEN 133
+static char debug_message[DEBUG_MESSAGE_LEN];
+static int fd = -1;          /* write debug information to this file */
+static int wrcount = 0;
+#endif /* CHARGING_DEBUG_FILE */
+
+/*
+ * For a complete description of the charging algorithm read
+ * docs/CHARGING_ALGORITHM.
+ */
+int long_delta;                     /* long term delta battery voltage */
+int short_delta;                    /* short term delta battery voltage */
+bool disk_activity_last_cycle = false;  /* flag set to aid charger time
+                                         * calculation */
+char power_message[POWER_MESSAGE_LEN] = ""; /* message that's shown in
+                                           debug menu */
+                                        /* percentage at which charging
+                                           starts */
+int powermgmt_last_cycle_startstop_min = 0; /* how many minutes ago was the
+                                           charging started or
+                                           stopped? */
+int powermgmt_last_cycle_level = 0;     /* which level had the
+                                           batteries at this time? */
+int trickle_sec = 0;                    /* how many seconds should the
+                                           charger be enabled per
+                                           minute for trickle
+                                           charging? */
+int pid_p = 0;                      /* PID proportional term */
+int pid_i = 0;                      /* PID integral term */
+
+static unsigned int target_voltage = TRICKLE_VOLTAGE; /* desired topoff/trickle
+                                                       * voltage level */
+static int charge_max_time_idle = 0; /* max. charging duration, calculated at
+                                      * beginning of charging */
+static int charge_max_time_now = 0; /* max. charging duration including
+                                     * hdd activity */
+static int minutes_disk_activity = 0; /* count minutes of hdd use during
+                                       * charging */
+static int last_disk_activity = CHARGE_END_LONGD + 1; /* last hdd use x mins ago */
+
+#ifdef CHARGING_DEBUG_FILE
+static void debug_file_close(void)
+{
+    if (fd >= 0) {
+        close(fd);
+        fd = -1;
+    }
+}
+
+static void debug_file_log(void)
+{
+    if (usb_inserted()) {
+        /* It is probably too late to close the file but we can try... */
+        debug_file_close();
+    }
+    else if (fd < 0) {
+        fd = open(DEBUG_FILE_NAME, O_WRONLY | O_APPEND | O_CREAT);
+
+        if (fd >= 0) {
+            snprintf(debug_message, DEBUG_MESSAGE_LEN,
+            "cycle_min, bat_millivolts, bat_percent, chgr_state"
+            " ,charge_state, pid_p, pid_i, trickle_sec\n");
+            write(fd, debug_message, strlen(debug_message));
+            wrcount = 99;   /* force a flush */
+        }
+    }
+    else {
+        snprintf(debug_message, DEBUG_MESSAGE_LEN,
+                "%d, %d, %d, %d, %d, %d, %d, %d\n",
+            powermgmt_last_cycle_startstop_min, battery_voltage(),
+            battery_level(), charger_input_state, charge_state,
+            pid_p, pid_i, trickle_sec);
+        write(fd, debug_message, strlen(debug_message));
+        wrcount++;
+    }
+}
+
+static void debug_file_sync(void)
+{
+    /*
+     * If we have a lot of pending writes or if the disk is spining,
+     * fsync the debug log file.
+     */
+    if (wrcount > 10 || (wrcount > 0 && storage_disk_is_active())) {
+        if (fd >= 0)
+            fsync(fd);
+
+        wrcount = 0;
+    }
+}
+#else /* !CHARGING_DEBUG_FILE */
+#define debug_file_close()
+#define debug_file_log()
+#define debug_file_sync()
+#endif /* CHARGING_DEBUG_FILE */
+
+/*
+ * Do tasks that should be done every step.
+ */
+static void do_frequent_tasks(void)
+{
+    if (storage_disk_is_active()) {
+        /* flag hdd use for charging calculation */
+        disk_activity_last_cycle = true;
+    }
+
+    debug_file_sync();
+}
+
+/*
+ * The charger was just plugged in.  If the battery level is
+ * nearly charged, just trickle.  If the battery is low, start
+ * a full charge cycle.  If the battery level is in between,
+ * top-off and then trickle.
+ */
+static void charger_plugged(void)
+{
+    int battery_percent = battery_level();
+
+    pid_p = 0;
+    pid_i = 0;
+    powermgmt_last_cycle_level = battery_percent;
+    powermgmt_last_cycle_startstop_min = 0;
+
+    snprintf(power_message, POWER_MESSAGE_LEN, "Charger plugged in");
+
+    if (battery_percent > START_TOPOFF_CHG) {
+
+        if (battery_percent >= START_TRICKLE_CHG) {
+            charge_state = TRICKLE;
+            target_voltage = TRICKLE_VOLTAGE;
+        }
+        else {
+            charge_state = TOPOFF;
+            target_voltage = TOPOFF_VOLTAGE;
+        }
+    }
+    else {
+        /*
+         * Start the charger full strength
+         */
+        int i = CHARGE_MAX_MIN_1500 * get_battery_capacity() / 1500;
+        charge_max_time_idle = i * (100 + 35 - battery_percent) / 100;
+
+        if (charge_max_time_idle > i)
+            charge_max_time_idle = i;
+
+        charge_max_time_now = charge_max_time_idle;
+
+        snprintf(power_message, POWER_MESSAGE_LEN,
+                 "ChgAt %d%% max %dm", battery_percent,
+                 charge_max_time_now);
+
+        /*
+         * Enable the charger after the max time calc is done,
+         * because battery_level depends on if the charger is
+         * on.
+         */
+        DEBUGF("power: charger inserted and battery"
+               " not full, charging\n");
+        trickle_sec  = 60;
+        long_delta   = short_delta = 999999;
+        charge_state = CHARGING;
+    }
+}
+
+/*
+ * The charger was just unplugged.
+ */
+static void charger_unplugged(void)
+{
+    DEBUGF("power: charger disconnected, disabling\n");
+
+    charger_enable(false);
+    powermgmt_last_cycle_level = battery_level();
+    powermgmt_last_cycle_startstop_min = 0;
+    trickle_sec  = 0;
+    pid_p        = 0;
+    pid_i        = 0;
+    charge_state = DISCHARGING;
+    snprintf(power_message, POWER_MESSAGE_LEN, "Charger: discharge");
+}
+
+static void charging_step(void)
+{
+    int i;
+
+    /* alter charge time max length with extra disk use */
+    if (disk_activity_last_cycle) {
+        minutes_disk_activity++;
+        charge_max_time_now = charge_max_time_idle +
+                              minutes_disk_activity*2 / 5;
+        disk_activity_last_cycle = false;
+        last_disk_activity = 0;
+    }
+    else {
+        last_disk_activity++;
+    }
+
+    /*
+     * Check the delta voltage over the last X minutes so we can do
+     * our end-of-charge logic based on the battery level change
+     * (no longer use minimum time as logic for charge end has 50
+     * minutes minimum charge built in).
+     */
+    if (powermgmt_last_cycle_startstop_min > CHARGE_END_SHORTD) {
+        short_delta = power_history[0] -
+                      power_history[CHARGE_END_SHORTD - 1];
+    }
+
+    if (powermgmt_last_cycle_startstop_min > CHARGE_END_LONGD) {
+        /*
+         * Scan the history: the points where measurement is taken need to
+         * be fairly static. Check prior to short delta 'area'. Also only
+         * check first and last 10 cycles (delta in middle OK).
+         */
+        long_delta = power_history[0] -
+                     power_history[CHARGE_END_LONGD - 1];
+
+        for (i = CHARGE_END_SHORTD; i < CHARGE_END_SHORTD + 10; i++)
+        {
+            if ((power_history[i] - power_history[i+1]) >  50 ||
+                (power_history[i] - power_history[i+1]) < -50) {
+                long_delta = 777777;
+                break;
+            }
+        }
+
+        for (i = CHARGE_END_LONGD - 11; i < CHARGE_END_LONGD - 1 ; i++)
+        {
+            if ((power_history[i] - power_history[i+1]) >  50 ||
+                (power_history[i] - power_history[i+1]) < -50) {
+                long_delta = 888888;
+                break;
+            }
+        }
+    }
+
+    snprintf(power_message, POWER_MESSAGE_LEN,
+             "Chg %dm, max %dm", powermgmt_last_cycle_startstop_min,
+             charge_max_time_now);
+
+    /*
+     * End of charge criteria (any qualify):
+     * 1) Charged a long time
+     * 2) DeltaV went negative for a short time ( & long delta static)
+     * 3) DeltaV was negative over a longer period (no disk use only)
+     *
+     * Note: short_delta and long_delta are millivolts
+     */
+    if (powermgmt_last_cycle_startstop_min >= charge_max_time_now ||
+        (short_delta <= -50 && long_delta < 50) ||
+        (long_delta  < -20 && last_disk_activity > CHARGE_END_LONGD)) {
+
+        int battery_percent = battery_level();
+
+        if (powermgmt_last_cycle_startstop_min > charge_max_time_now) {
+            DEBUGF("power: powermgmt_last_cycle_startstop_min > charge_max_time_now, "
+                   "enough!\n");
+            /*
+             * Have charged too long and deltaV detection did not
+             * work!
+             */
+             snprintf(power_message, POWER_MESSAGE_LEN,
+                     "Chg tmout %d min", charge_max_time_now);
+            /*
+             * Switch to trickle charging.  We skip the top-off
+             * since we've effectively done the top-off operation
+             * already since we charged for the maximum full
+             * charge time.
+             */
+            powermgmt_last_cycle_level = battery_percent;
+            powermgmt_last_cycle_startstop_min = 0;
+            charge_state = TRICKLE;
+
+            /*
+             * Set trickle charge target to a relative voltage instead
+             * of an arbitrary value - the fully charged voltage may
+             * vary according to ambient temp, battery condition etc.
+             * Trickle target is -0.15v from full voltage acheived.
+             * Topup target is -0.05v from full voltage.
+             */
+            target_voltage = power_history[0] - 150;
+
+        }
+        else {
+            if(short_delta <= -5) {
+                DEBUGF("power: short-term negative"
+                       " delta, enough!\n");
+                snprintf(power_message, POWER_MESSAGE_LEN,
+                         "end negd %d %dmin", short_delta,
+                         powermgmt_last_cycle_startstop_min);
+                target_voltage = power_history[CHARGE_END_SHORTD - 1] - 50;
+            }
+            else {
+                DEBUGF("power: long-term small "
+                       "positive delta, enough!\n");
+                snprintf(power_message, POWER_MESSAGE_LEN,
+                         "end lowd %d %dmin", long_delta,
+                         powermgmt_last_cycle_startstop_min);
+                target_voltage = power_history[CHARGE_END_LONGD - 1] - 50;
+            }
+
+            /*
+             * Switch to top-off charging.
+             */
+            powermgmt_last_cycle_level = battery_percent;
+            powermgmt_last_cycle_startstop_min = 0;
+            charge_state = TOPOFF;
+        }
+    }
+}
+
+static void topoff_trickle_step(void)
+{
+    unsigned int millivolts;
+
+    /*
+     *Time to switch from topoff to trickle?
+     */
+    if (charge_state == TOPOFF &&
+        powermgmt_last_cycle_startstop_min > TOPOFF_MAX_MIN) {
+
+        powermgmt_last_cycle_level = battery_level();
+        powermgmt_last_cycle_startstop_min = 0;
+        charge_state = TRICKLE;
+        target_voltage = target_voltage - 100;
+    }
+    /*
+     * Adjust trickle charge time (proportional and integral terms).
+     * Note: I considered setting the level higher if the USB is
+     * plugged in, but it doesn't appear to be necessary and will
+     * generate more heat [gvb].
+     */
+    millivolts = battery_voltage();
+
+    pid_p = ((signed)target_voltage - (signed)millivolts) / 5;
+    if (pid_p <= PID_DEADZONE && pid_p >= -PID_DEADZONE)
+        pid_p = 0;
+
+    if ((unsigned)millivolts < target_voltage) {
+        if (pid_i < 60)
+            pid_i++; /* limit so it doesn't "wind up" */
+    }
+    else {
+        if (pid_i > 0)
+            pid_i--; /* limit so it doesn't "wind up" */
+    }
+
+    trickle_sec = pid_p + pid_i;
+
+    if (trickle_sec > 60)
+        trickle_sec = 60;
+
+    if (trickle_sec < 0)
+        trickle_sec = 0;
+}
+
+void charging_algorithm_step(void)
+{
+    static int pwm_counter = 0; /* PWM total cycle in steps */
+    static int pwm_duty = 0;    /* PWM duty cycle in steps */
+
+    switch (charger_input_state)
+    {
+    case CHARGER_PLUGGED:
+        charger_plugged();
+        break;
+
+    case CHARGER_UNPLUGGED:
+        charger_unplugged();
+        break;
+
+    case CHARGER:
+    case NO_CHARGER:
+        do_frequent_tasks();
+
+        if (pwm_counter > 0) {
+            if (pwm_duty > 0 && --pwm_duty <= 0)
+                charger_enable(false); /* Duty cycle expired */
+
+            if (--pwm_counter > 0)
+                return;
+
+            /* PWM cycle is complete */
+            powermgmt_last_cycle_startstop_min++;
+            debug_file_log();
+        }
+        break;
+    }
+
+    switch (charge_state)
+    {
+    case CHARGING:
+        charging_step();
+        break;
+
+    case TOPOFF:
+    case TRICKLE:
+        topoff_trickle_step();        
+        break;
+
+    case DISCHARGING:
+    default:
+        break;
+    }
+
+    /* If 100%, ensure pwm_on never expires and briefly disables the
+     * charger. */
+    pwm_duty = (trickle_sec < 60) ? trickle_sec*2 : 0;
+    pwm_counter = 60*2;
+    charger_enable(trickle_sec > 0);
+}
+
+#ifdef CHARGING_DEBUG_FILE
+void charging_algorithm_close(void)
+{
+    debug_file_close();
+}
+#endif /* CHARGING_DEBUG_FILE */
+
+/* Returns true if the unit is charging the batteries. */
+bool charging_state(void)
+{
+    return charge_state == CHARGING;
+}
diff --git a/firmware/target/sh/archos/recorder/powermgmt-target.h b/firmware/target/sh/archos/recorder/powermgmt-target.h
new file mode 100644
index 0000000000..8fa2521f09
--- /dev/null
+++ b/firmware/target/sh/archos/recorder/powermgmt-target.h
@@ -0,0 +1,101 @@
+/***************************************************************************
+ *             __________               __   ___.
+ *   Open      \______   \ ____   ____ |  | _\_ |__   _______  ___
+ *   Source     |       _//  _ \_/ ___\|  |/ /| __ \ /  _ \  \/  /
+ *   Jukebox    |    |   (  <_> )  \___|    < | \_\ (  <_> > <  <
+ *   Firmware   |____|_  /\____/ \___  >__|_ \|___  /\____/__/\_ \
+ *                     \/            \/     \/    \/            \/
+ * $Id$
+ *
+ * Copyright (C) 2002 by Heikki Hannikainen, Uwe Freese
+ * Revisions copyright (C) 2005 by Gerald Van Baren
+ *
+ * This program is free software; you can redistribute it and/or
+ * modify it under the terms of the GNU General Public License
+ * as published by the Free Software Foundation; either version 2
+ * of the License, or (at your option) any later version.
+ *
+ * This software is distributed on an "AS IS" basis, WITHOUT WARRANTY OF ANY
+ * KIND, either express or implied.
+ *
+ ****************************************************************************/
+#ifndef POWERMGMT_TARGET_H
+#define POWERMGMT_TARGET_H
+
+/*
+ * Define CHARGING_DEBUG_FILE to create a csv (spreadsheet) with battery
+ * information in it (one sample per minute/connect/disconnect).
+ *
+ * This is only for very low level debug.
+ */
+#undef CHARGING_DEBUG_FILE
+
+
+/* stop when N minutes have passed with avg delta being < -0.05 V */
+#define CHARGE_END_SHORTD       6
+/* stop when N minutes have passed with avg delta being < -0.02 V */
+#define CHARGE_END_LONGD       50
+
+/* Battery % to start at top-off */
+#define START_TOPOFF_CHG       85
+/* Battery % to start at trickle */
+#define START_TRICKLE_CHG      95
+/* power thread status message */
+#define POWER_MESSAGE_LEN      32
+/* minutes: maximum charging time for 1500 mAh batteries
+ * actual max time depends also on BATTERY_CAPACITY! */
+#define CHARGE_MAX_MIN_1500   450
+/* minutes: minimum charging time */     
+#define CHARGE_MIN_MIN         10
+/* After charging, go to top off charge. How long should top off charge be? */
+#define TOPOFF_MAX_MIN         90
+/* which voltage is best? (millivolts) */
+#define TOPOFF_VOLTAGE       5650
+/* After top off charge, go to trickle harge. How long should trickle
+ * charge be? */
+#define TRICKLE_MAX_MIN       720 /* 12 hrs */
+/* which voltage is best? (millivolts) */
+#define TRICKLE_VOLTAGE      5450
+/* initial trickle_sec for topoff */
+#define START_TOPOFF_SEC       25
+/* initial trickle_sec for trickle */
+#define START_TRICKLE_SEC      15
+
+#define PID_DEADZONE            4    /* PID proportional deadzone */
+
+extern char power_message[POWER_MESSAGE_LEN];
+
+extern int long_delta;          /* long term delta battery voltage */
+extern int short_delta;         /* short term delta battery voltage */
+
+extern int powermgmt_last_cycle_startstop_min; /* how many minutes ago was
+                                                  the charging started or
+                                                  stopped? */
+extern int powermgmt_last_cycle_level;         /* which level had the batteries
+                                                  at this time? */
+
+extern int pid_p;                /* PID proportional term */
+extern int pid_i;                /* PID integral term */
+extern int trickle_sec;          /* how many seconds should the
+                                    charger be enabled per
+                                    minute for trickle
+                                    charging? */
+void charger_enable(bool on);
+bool charger_enabled(void);
+
+/* Battery filter lengths in samples */
+#define BATT_AVE_SAMPLES 32
+
+/* No init to do */
+static inline void powermgmt_init_target(void) {}
+void charging_algorithm_step(void);
+
+#ifdef CHARGING_DEBUG_FILE
+/* Need to flush and close debug file */
+void charging_algorithm_close(void);
+#else
+/* No poweroff operation to do */
+static inline void charging_algorithm_close(void) {}
+#endif
+
+#endif /* POWERMGMT_TARGET_H */