ESP-Miner/main/tasks/power_management_task.c

#include <string.h>
#include "INA260.h"
#include "esp_log.h"
#include "freertos/FreeRTOS.h"
#include "freertos/task.h"
#include "global_state.h"
#include "math.h"
#include "mining.h"
#include "nvs_config.h"
#include "serial.h"
#include "TPS546.h"
#include "vcore.h"
#include "thermal.h"
#include "PID.h"
#include "power.h"
#include "asic.h"

#define POLL_RATE 1800
#define MAX_TEMP 90.0
#define THROTTLE_TEMP 75.0
#define THROTTLE_TEMP_RANGE (MAX_TEMP - THROTTLE_TEMP)

#define VOLTAGE_START_THROTTLE 4900
#define VOLTAGE_MIN_THROTTLE 3500
#define VOLTAGE_RANGE (VOLTAGE_START_THROTTLE - VOLTAGE_MIN_THROTTLE)

#define TPS546_THROTTLE_TEMP 105.0
#define TPS546_MAX_TEMP 145.0

static const char * TAG = "power_management";

double pid_input = 0.0;
double pid_output = 0.0;
double pid_setPoint = 60.0; // Default, will be overwritten by NVS
double pid_p = 15.0;        
double pid_i = 0.2;
double pid_d = 3.0;
double pid_d_startup = 20.0;  // Higher D value for startup

bool pid_startup_phase = true;
int pid_startup_counter = 0;

// Hold and Ramp startup D-term
#define PID_STARTUP_HOLD_DURATION 3  // Number of cycles to HOLD pid_d_startup
#define PID_STARTUP_RAMP_DURATION 17 // Number of cycles to RAMP DOWN D (Total startup duration PID_STARTUP_HOLD_DURATION + PID_STARTUP_RAMP_DURATION)


PIDController pid;

void POWER_MANAGEMENT_task(void * pvParameters)
{
    ESP_LOGI(TAG, "Starting");

    GlobalState * GLOBAL_STATE = (GlobalState *) pvParameters;

    PowerManagementModule * power_management = &GLOBAL_STATE->POWER_MANAGEMENT_MODULE;
    SystemModule * sys_module = &GLOBAL_STATE->SYSTEM_MODULE;

    pid_setPoint = (double)nvs_config_get_u16(NVS_CONFIG_TEMP_TARGET, pid_setPoint);

    // Initialize PID controller with pid_d_startup and PID_REVERSE directly
    pid_init(&pid, &pid_input, &pid_output, &pid_setPoint, pid_p, pid_i, pid_d_startup, PID_P_ON_E, PID_REVERSE);
    pid_set_sample_time(&pid, POLL_RATE - 1); // Sample time in ms
    pid_set_output_limits(&pid, 25, 100); // Output limits 25% to 100%
    pid_set_mode(&pid, AUTOMATIC);        // This calls pid_initialize() internally

    vTaskDelay(500 / portTICK_PERIOD_MS);
    uint16_t last_core_voltage = 0.0;

    power_management->frequency_value = nvs_config_get_u16(NVS_CONFIG_ASIC_FREQ, CONFIG_ASIC_FREQUENCY);
    ESP_LOGI(TAG, "ASIC Frequency: %.2fMHz", (float)power_management->frequency_value);
    uint16_t last_asic_frequency = power_management->frequency_value;
    
    while (1) {
        // Refresh PID setpoint from NVS in case it was changed via API
        pid_setPoint = (double)nvs_config_get_u16(NVS_CONFIG_TEMP_TARGET, pid_setPoint);

        power_management->voltage = Power_get_input_voltage(GLOBAL_STATE);
        power_management->power = Power_get_power(GLOBAL_STATE);

        power_management->fan_rpm = Thermal_get_fan_speed(&GLOBAL_STATE->DEVICE_CONFIG);
        power_management->chip_temp_avg = Thermal_get_chip_temp(GLOBAL_STATE);

        power_management->vr_temp = Power_get_vreg_temp(GLOBAL_STATE);

        // ASIC Thermal Diode will give bad readings if the ASIC is turned off
        // if(power_management->voltage < tps546_config.TPS546_INIT_VOUT_MIN){
        //     goto looper;
        // }

        //overheat mode if the voltage regulator or ASIC is too hot
        if ((power_management->vr_temp > TPS546_THROTTLE_TEMP || power_management->chip_temp_avg > THROTTLE_TEMP) && (power_management->frequency_value > 50 || power_management->voltage > 1000)) {
            ESP_LOGE(TAG, "OVERHEAT! VR: %fC ASIC %fC", power_management->vr_temp, power_management->chip_temp_avg );
            power_management->fan_perc = 100;
            Thermal_set_fan_percent(&GLOBAL_STATE->DEVICE_CONFIG, 1);

            // Turn off core voltage
            VCORE_set_voltage(GLOBAL_STATE, 0.0f);

            nvs_config_set_u16(NVS_CONFIG_ASIC_VOLTAGE, 1000);
            nvs_config_set_u16(NVS_CONFIG_ASIC_FREQ, 50);
            nvs_config_set_u16(NVS_CONFIG_FAN_SPEED, 100);
            nvs_config_set_u16(NVS_CONFIG_AUTO_FAN_SPEED, 0);
            nvs_config_set_u16(NVS_CONFIG_OVERHEAT_MODE, 1);
            exit(EXIT_FAILURE);
        }
        //enable the PID auto control for the FAN if set
        if (nvs_config_get_u16(NVS_CONFIG_AUTO_FAN_SPEED, 1) == 1) {
            if (power_management->chip_temp_avg >= 0) { // Ignore invalid temperature readings (-1)
                pid_input = power_management->chip_temp_avg;
                
                // Hold and Ramp logic for startup D value
                if (pid_startup_phase) {
                    pid_startup_counter++; // Increment counter at the start of each startup phase cycle
                    
                    if (pid_startup_counter >= (PID_STARTUP_HOLD_DURATION + PID_STARTUP_RAMP_DURATION)) {
                        // Transition complete, switch to normal D value
                        pid_set_tunings(&pid, pid_p, pid_i, pid_d); // Use normal pid_d
                        pid_startup_phase = false;
                        ESP_LOGI(TAG, "PID startup phase complete, switching to normal D value: %.1f", pid_d);
                    } else if (pid_startup_counter > PID_STARTUP_HOLD_DURATION) {
                        // In RAMP DOWN phase
                        int ramp_counter = pid_startup_counter - PID_STARTUP_HOLD_DURATION;
                        double current_d = pid_d_startup - ((pid_d_startup - pid_d) * (double)ramp_counter / PID_STARTUP_RAMP_DURATION);
                        pid_set_tunings(&pid, pid_p, pid_i, current_d);
                        ESP_LOGI(TAG, "PID startup ramp phase: %d/%d (Total cycle: %d), current D: %.1f", 
                                 ramp_counter, PID_STARTUP_RAMP_DURATION, pid_startup_counter, current_d);
                    } else {
                        // In HOLD phase, ensure pid_d_startup is used.
                        // pid_init already set it with pid_d_startup. If pid_p or pid_i changed dynamically,
                        // this call ensures pid_d_startup is maintained.
                        pid_set_tunings(&pid, pid_p, pid_i, pid_d_startup);
                        ESP_LOGI(TAG, "PID startup hold phase: %d/%d, holding D at: %.1f", 
                                 pid_startup_counter, PID_STARTUP_HOLD_DURATION, pid_d_startup);
                    }
                }
                // If not in startup_phase, PID tunings remain as set (either normal or last startup value if just exited)
                
                pid_compute(&pid);
                // Uncomment for debugging PID output directly after compute
                // ESP_LOGD(TAG, "DEBUG: PID raw output: %.2f%%, Input: %.1f, SetPoint: %.1f", pid_output, pid_input, pid_setPoint);

                power_management->fan_perc = (uint16_t) pid_output;
                Thermal_set_fan_percent(&GLOBAL_STATE->DEVICE_CONFIG, pid_output / 100.0);
                ESP_LOGI(TAG, "Temp: %.1f°C, SetPoint: %.1f°C, Output: %.1f%% (P:%.1f I:%.1f D_val:%.1f D_start_val:%.1f)",
                         pid_input, pid_setPoint, pid_output, pid.dispKp, pid.dispKi, pid.dispKd, pid_d_startup); // Log current effective Kp, Ki, Kd
            } else {
                if (GLOBAL_STATE->SYSTEM_MODULE.ap_enabled) {
                    ESP_LOGW(TAG, "AP mode with invalid temperature reading: %.1f°C - Setting fan to 70%%", power_management->chip_temp_avg);
                    power_management->fan_perc = 70;
                    Thermal_set_fan_percent(&GLOBAL_STATE->DEVICE_CONFIG, 0.7);
                } else {
                    ESP_LOGW(TAG, "Ignoring invalid temperature reading: %.1f°C", power_management->chip_temp_avg);
                }
            }
        } else { // Manual fan speed
            float fs = (float) nvs_config_get_u16(NVS_CONFIG_FAN_SPEED, 100);
            power_management->fan_perc = fs;
            Thermal_set_fan_percent(&GLOBAL_STATE->DEVICE_CONFIG, (float) fs / 100.0);
        }

        uint16_t core_voltage = nvs_config_get_u16(NVS_CONFIG_ASIC_VOLTAGE, CONFIG_ASIC_VOLTAGE);
        uint16_t asic_frequency = nvs_config_get_u16(NVS_CONFIG_ASIC_FREQ, CONFIG_ASIC_FREQUENCY);

        if (core_voltage != last_core_voltage) {
            ESP_LOGI(TAG, "setting new vcore voltage to %umV", core_voltage);
            VCORE_set_voltage(GLOBAL_STATE, (double) core_voltage / 1000.0);
            last_core_voltage = core_voltage;
        }

        if (asic_frequency != last_asic_frequency) {
            ESP_LOGI(TAG, "New ASIC frequency requested: %uMHz (current: %uMHz)", asic_frequency, last_asic_frequency);
            
            bool success = ASIC_set_frequency(GLOBAL_STATE, (float)asic_frequency);
            
            if (success) {
                power_management->frequency_value = (float)asic_frequency;
            }
            
            last_asic_frequency = asic_frequency;
        }

        // Check for changing of overheat mode
        uint16_t new_overheat_mode = nvs_config_get_u16(NVS_CONFIG_OVERHEAT_MODE, 0);
        
        if (new_overheat_mode != sys_module->overheat_mode) {
            sys_module->overheat_mode = new_overheat_mode;
            ESP_LOGI(TAG, "Overheat mode updated to: %d", sys_module->overheat_mode);
        }

        VCORE_check_fault(GLOBAL_STATE);

        // looper:
        vTaskDelay(POLL_RATE / portTICK_PERIOD_MS);
    }
}