Merge pull request #773 from dalathegreat/main

Update branch from main

Software/USER_SETTINGS.cpp

@@ -47,8 +47,10 @@ const char* mqtt_object_id_prefix =
     "be_";  // Custom prefix for MQTT object ID. Previously, the prefix was automatically set to "esp32-XXXXXX_"
 const char* mqtt_device_name =
     "Battery Emulator";  // Custom device name in Home Assistant. Previously, the name was automatically set to "BatteryEmulator_esp32-XXXXXX"
-#endif  // MQTT_MANUAL_TOPIC_OBJECT_NAME
-#endif  // USE_MQTT
+const char* ha_device_id =
+    "battery-emulator";  // Custom device ID in Home Assistant. Previously, the ID was always "battery-emulator"
+#endif                   // MQTT_MANUAL_TOPIC_OBJECT_NAME
+#endif                   // USE_MQTT
 
 #ifdef EQUIPMENT_STOP_BUTTON
 // Equipment stop button behavior. Use NC button for safety reasons.

Software/USER_SETTINGS.h

@@ -68,6 +68,7 @@
 //#define PWM_CONTACTOR_CONTROL //Enable this line to use PWM for CONTACTOR_CONTROL, which lowers power consumption and heat generation. CONTACTOR_CONTROL must be enabled.
 //#define NC_CONTACTORS         //Enable this line to control normally closed contactors. CONTACTOR_CONTROL must be enabled for this option. Extremely rare setting!
 //#define PERIODIC_BMS_RESET    //Enable to have the emulator powercycle the connected battery every 24hours via GPIO. Useful for some batteries like Nissan LEAF
+//#define REMOTE_BMS_RESET      //Enable to allow the emulator to remotely trigger a powercycle of the battery via MQTT. Useful for some batteries like Nissan LEAF
 
 /* Shunt/Contactor settings */
 //#define BMW_SBOX  // SBOX relay control & battery current/voltage measurement

Software/src/battery/TESLA-BATTERY.cpp

@@ -901,6 +901,16 @@ void update_values_battery() {  //This function maps all the values fetched via
     datalayer.battery.info.min_cell_voltage_mV = MIN_CELL_VOLTAGE_NCA_NCM;
     datalayer.battery.info.max_cell_voltage_deviation_mV = MAX_CELL_DEVIATION_NCA_NCM;
   }
+
+  // During forced balancing request via webserver, we allow the battery to exceed normal safety parameters
+  if (datalayer.battery.settings.user_requests_balancing) {
+    datalayer.battery.status.real_soc = 9900;  //Force battery to show up as 99% when balancing
+    datalayer.battery.info.max_design_voltage_dV = datalayer.battery.settings.balancing_max_pack_voltage_dV;
+    datalayer.battery.info.max_cell_voltage_mV = datalayer.battery.settings.balancing_max_cell_voltage_mV;
+    datalayer.battery.info.max_cell_voltage_deviation_mV =
+        datalayer.battery.settings.balancing_max_deviation_cell_voltage_mV;
+    datalayer.battery.status.max_charge_power_W = datalayer.battery.settings.balancing_float_power_W;
+  }
 #endif  // TESLA_MODEL_3Y_BATTERY
 
   // Update webserver datalayer

Software/src/battery/TESLA-BATTERY.h

@@ -10,10 +10,11 @@
 #define MAXDISCHARGEPOWERALLOWED 60000  // 60000W we use a define since the value supplied by Tesla is always 0
 
 /* Do not change the defines below */
-#define RAMPDOWN_SOC 900            // 90.0 SOC% to start ramping down from max charge power towards 0 at 100.00%
-#define RAMPDOWNPOWERALLOWED 15000  // What power we ramp down from towards top balancing
-#define FLOAT_MAX_POWER_W 200       // W, what power to allow for top balancing battery
-#define FLOAT_START_MV 20           // mV, how many mV under overvoltage to start float charging
+#define RAMPDOWN_SOC 900  // 90.0 SOC% to start ramping down from max charge power towards 0 at 100.00%
+#define RAMPDOWNPOWERALLOWED \
+  15000  // What power we ramp down from towards top balancing (usually same as MAXCHARGEPOWERALLOWED)
+#define FLOAT_MAX_POWER_W 200  // W, what power to allow for top balancing battery
+#define FLOAT_START_MV 20      // mV, how many mV under overvoltage to start float charging
 
 #define MAX_PACK_VOLTAGE_SX_NCMA 4600   // V+1, if pack voltage goes over this, charge stops
 #define MIN_PACK_VOLTAGE_SX_NCMA 3100   // V+1, if pack voltage goes over this, charge stops
@@ -22,10 +23,10 @@
 #define MAX_PACK_VOLTAGE_3Y_LFP 3880    // V+1, if pack voltage goes over this, charge stops
 #define MIN_PACK_VOLTAGE_3Y_LFP 2968    // V+1, if pack voltage goes below this, discharge stops
 #define MAX_CELL_DEVIATION_NCA_NCM 500  //LED turns yellow on the board if mv delta exceeds this value
-#define MAX_CELL_DEVIATION_LFP 200      //LED turns yellow on the board if mv delta exceeds this value
+#define MAX_CELL_DEVIATION_LFP 400      //LED turns yellow on the board if mv delta exceeds this value
 #define MAX_CELL_VOLTAGE_NCA_NCM 4250   //Battery is put into emergency stop if one cell goes over this value
 #define MIN_CELL_VOLTAGE_NCA_NCM 2950   //Battery is put into emergency stop if one cell goes below this value
-#define MAX_CELL_VOLTAGE_LFP 3550       //Battery is put into emergency stop if one cell goes over this value
+#define MAX_CELL_VOLTAGE_LFP 3650       //Battery is put into emergency stop if one cell goes over this value
 #define MIN_CELL_VOLTAGE_LFP 2800       //Battery is put into emergency stop if one cell goes below this value
 
 //#define EXP_TESLA_BMS_DIGITAL_HVIL    // Experimental parameter. Forces the transmission of additional CAN frames for experimental purposes, to test potential HVIL issues in 3/Y packs with newer firmware.

Software/src/communication/contactorcontrol/comm_contactorcontrol.cpp

@@ -94,14 +94,14 @@ void init_contactors() {
   pinMode(BMS_2_POWER, OUTPUT);
   digitalWrite(BMS_2_POWER, HIGH);
 #endif BMS_2_POWER
-#endif                     // HW with dedicated BMS pins
-#ifdef PERIODIC_BMS_RESET  // User has enabled BMS reset, turn on output on start
+#endif                                                        // HW with dedicated BMS pins
+#if defined(PERIODIC_BMS_RESET) || defined(REMOTE_BMS_RESET)  // User has enabled BMS reset, turn on output on start
   pinMode(BMS_POWER, OUTPUT);
   digitalWrite(BMS_POWER, HIGH);
 #ifdef BMS_2_POWER  //Hardware supports 2x BMS
   pinMode(BMS_2_POWER, OUTPUT);
   digitalWrite(BMS_2_POWER, HIGH);
-#endif BMS_2_POWER
+#endif  //BMS_2_POWER
 #endif  //PERIODIC_BMS_RESET
 }
 
@@ -222,17 +222,41 @@ void handle_contactors_battery2() {
 }
 #endif  // CONTACTOR_CONTROL_DOUBLE_BATTERY
 
-/* Once every 24 hours we remove power from the BMS_power pin for 30 seconds. This makes the BMS recalculate all SOC% and avoid memory leaks
+/* PERIODIC_BMS_RESET - Once every 24 hours we remove power from the BMS_power pin for 30 seconds.
+REMOTE_BMS_RESET - Allows the user to remotely powercycle the BMS by sending a command to the emulator via MQTT.
+
+This makes the BMS recalculate all SOC% and avoid memory leaks
 During that time we also set the emulator state to paused in order to not try and send CAN messages towards the battery
 Feature is only used if user has enabled PERIODIC_BMS_RESET in the USER_SETTINGS */
 
 void handle_BMSpower() {
-#ifdef PERIODIC_BMS_RESET
+#if defined(PERIODIC_BMS_RESET) || defined(REMOTE_BMS_RESET)
   // Get current time
   currentTime = millis();
 
+#ifdef PERIODIC_BMS_RESET
   // Check if 24 hours have passed since the last power removal
-  if (currentTime - lastPowerRemovalTime >= powerRemovalInterval && !isBMSResetActive) {
+  if (currentTime - lastPowerRemovalTime >= powerRemovalInterval) {
+    start_bms_reset();
+  }
+#endif  //PERIODIC_BMS_RESET
+
+  // If power has been removed for 30 seconds, restore the power and resume the emulator
+  if (isBMSResetActive && currentTime - lastPowerRemovalTime >= powerRemovalDuration) {
+    // Reapply power to the BMS
+    digitalWrite(BMS_POWER, HIGH);
+
+    //Resume the battery pause and CAN communication
+    setBatteryPause(false, false, false, false);
+
+    isBMSResetActive = false;  // Reset the power removal flag
+  }
+#endif  //defined(PERIODIC_BMS_RESET) || defined(REMOTE_BMS_RESET)
+}
+
+void start_bms_reset() {
+#if defined(PERIODIC_BMS_RESET) || defined(REMOTE_BMS_RESET)
+  if (!isBMSResetActive) {
     lastPowerRemovalTime = currentTime;  // Record the time when BMS reset was started
 
     // Set emulator state to paused (Max Charge/Discharge = 0 & CAN = stop)

Software/src/communication/contactorcontrol/comm_contactorcontrol.h

@@ -15,6 +15,15 @@
  */
 void handle_BMSpower();
 
+/**
+ * @brief Start BMS reset sequence
+ *
+ * @param[in] void
+ *
+ * @return void
+ */
+void start_bms_reset();
+
 /**
  * @brief Contactor initialization
  *

Software/src/datalayer/datalayer.h

@@ -121,6 +121,21 @@ typedef struct {
   /** The user specified maximum allowed discharge voltage, in deciVolt. 3000 = 300.0 V */
   uint16_t max_user_set_discharge_voltage_dV = BATTERY_MAX_DISCHARGE_VOLTAGE;
 
+  /** Tesla specific settings that are edited on the fly when manually forcing a balance charge for LFP chemistry */
+  /* Bool for specifying if user has requested manual balancing */
+  bool user_requests_balancing = false;
+  /* Forced balancing max time & start timestamp */
+  uint32_t balancing_time_ms = 3600000;  //1h default, (60min*60sec*1000ms)
+  uint32_t balancing_start_time_ms = 0;  //For keeping track when balancing started
+  /* Max cell voltage during forced balancing */
+  uint16_t balancing_max_cell_voltage_mV = 3650;
+  /* Max cell deviation allowed during forced balancing */
+  uint16_t balancing_max_deviation_cell_voltage_mV = 400;
+  /* Float max power during forced balancing */
+  uint16_t balancing_float_power_W = 1000;
+  /* Maximum voltage for entire battery pack during forced balancing */
+  uint16_t balancing_max_pack_voltage_dV = 3940;
+
 } DATALAYER_BATTERY_SETTINGS_TYPE;
 
 typedef struct {

Software/src/devboard/mqtt/mqtt.cpp

@@ -5,6 +5,7 @@
 #include "../../../USER_SECRETS.h"
 #include "../../../USER_SETTINGS.h"
 #include "../../battery/BATTERIES.h"
+#include "../../communication/contactorcontrol/comm_contactorcontrol.h"
 #include "../../datalayer/datalayer.h"
 #include "../../lib/bblanchon-ArduinoJson/ArduinoJson.h"
 #include "../../lib/knolleary-pubsubclient/PubSubClient.h"
@@ -20,6 +21,7 @@ MyTimer check_global_timer(800);     // check timmer - low-priority MQTT checks,
 static String topic_name = "";
 static String object_id_prefix = "";
 static String device_name = "";
+static String device_id = "";
 
 // Tracking reconnection attempts and failures
 static unsigned long lastReconnectAttempt = 0;
@@ -90,6 +92,8 @@ SensorConfig sensorConfigs[] = {
 #endif  // DOUBLE_BATTERY
 };
 
+SensorConfig buttonConfigs[] = {{"BMSRESET", "Reset BMS", "", "", ""}};
+
 static String generateCommonInfoAutoConfigTopic(const char* object_id) {
   return "homeassistant/sensor/" + topic_name + "/" + String(object_id) + "/config";
 }
@@ -102,6 +106,14 @@ static String generateEventsAutoConfigTopic(const char* object_id) {
   return "homeassistant/sensor/" + topic_name + "/" + String(object_id) + "/config";
 }
 
+static String generateButtonTopic(const char* subtype) {
+  return "homeassistant/button/" + topic_name + "/" + String(subtype);
+}
+
+static String generateButtonAutoConfigTopic(const char* subtype) {
+  return generateButtonTopic(subtype) + "/config";
+}
+
 #endif  // HA_AUTODISCOVERY
 
 static std::vector<EventData> order_events;
@@ -130,7 +142,7 @@ static void publish_common_info(void) {
       }
       doc["enabled_by_default"] = true;
       doc["expire_after"] = 240;
-      doc["device"]["identifiers"][0] = "battery-emulator";
+      doc["device"]["identifiers"][0] = ha_device_id;
       doc["device"]["manufacturer"] = "DalaTech";
       doc["device"]["model"] = "BatteryEmulator";
       doc["device"]["name"] = device_name;
@@ -235,7 +247,7 @@ static void publish_cell_voltages(void) {
         doc["enabled_by_default"] = true;
         doc["expire_after"] = 240;
         doc["value_template"] = "{{ value_json.cell_voltages[" + String(i) + "] }}";
-        doc["device"]["identifiers"][0] = "battery-emulator";
+        doc["device"]["identifiers"][0] = ha_device_id;
         doc["device"]["manufacturer"] = "DalaTech";
         doc["device"]["model"] = "BatteryEmulator";
         doc["device"]["name"] = device_name;
@@ -264,7 +276,7 @@ static void publish_cell_voltages(void) {
         doc["enabled_by_default"] = true;
         doc["expire_after"] = 240;
         doc["value_template"] = "{{ value_json.cell_voltages[" + String(i) + "] }}";
-        doc["device"]["identifiers"][0] = "battery-emulator";
+        doc["device"]["identifiers"][0] = ha_device_id;
         doc["device"]["manufacturer"] = "DalaTech";
         doc["device"]["model"] = "BatteryEmulator";
         doc["device"]["name"] = device_name;
@@ -343,7 +355,7 @@ void publish_events() {
     doc["json_attributes_topic"] = state_topic;
     doc["json_attributes_template"] = "{{ value_json | tojson }}";
     doc["enabled_by_default"] = true;
-    doc["device"]["identifiers"][0] = "battery-emulator";
+    doc["device"]["identifiers"][0] = ha_device_id;
     doc["device"]["manufacturer"] = "DalaTech";
     doc["device"]["model"] = "BatteryEmulator";
     doc["device"]["name"] = device_name;
@@ -400,6 +412,66 @@ void publish_events() {
 #endif  // HA_AUTODISCOVERY
 }
 
+static void publish_buttons_discovery(void) {
+#ifdef HA_AUTODISCOVERY
+  static bool mqtt_first_transmission = true;
+  if (mqtt_first_transmission == true) {
+    mqtt_first_transmission = false;
+
+#ifdef DEBUG_LOG
+    logging.println("Publishing buttons discovery");
+#endif  // DEBUG_LOG
+
+    static JsonDocument doc;
+    for (int i = 0; i < sizeof(buttonConfigs) / sizeof(buttonConfigs[0]); i++) {
+      SensorConfig& config = buttonConfigs[i];
+      doc["name"] = config.name;
+      doc["unique_id"] = config.object_id;
+      doc["command_topic"] = generateButtonTopic(config.object_id);
+      doc["enabled_by_default"] = true;
+      doc["expire_after"] = 240;
+      doc["device"]["identifiers"][0] = ha_device_id;
+      doc["device"]["manufacturer"] = "DalaTech";
+      doc["device"]["model"] = "BatteryEmulator";
+      doc["device"]["name"] = device_name;
+      doc["origin"]["name"] = "BatteryEmulator";
+      doc["origin"]["sw"] = String(version_number) + "-mqtt";
+      doc["origin"]["url"] = "https://github.com/dalathegreat/Battery-Emulator";
+      serializeJson(doc, mqtt_msg);
+      mqtt_publish(generateButtonAutoConfigTopic(config.object_id).c_str(), mqtt_msg, true);
+      doc.clear();
+    }
+  }
+#endif  // HA_AUTODISCOVERY
+}
+
+static void subscribe() {
+  for (int i = 0; i < sizeof(buttonConfigs) / sizeof(buttonConfigs[0]); i++) {
+    SensorConfig& config = buttonConfigs[i];
+    const char* topic = generateButtonTopic(config.object_id).c_str();
+#ifdef DEBUG_LOG
+    logging.printf("Subscribing to topic: [%s]\n", topic);
+#endif  // DEBUG_LOG
+    client.subscribe(topic);
+  }
+}
+
+void mqtt_message_received(char* topic, byte* payload, unsigned int length) {
+#ifdef DEBUG_LOG
+  logging.printf("MQTT message arrived: [%s]\n", topic);
+#endif  // DEBUG_LOG
+
+#ifdef REMOTE_BMS_RESET
+  const char* bmsreset_topic = generateButtonTopic("BMSRESET").c_str();
+  if (strcmp(topic, bmsreset_topic) == 0) {
+#ifdef DEBUG_LOG
+    logging.println("Triggering BMS reset");
+#endif  // DEBUG_LOG
+    start_bms_reset();
+  }
+#endif  // REMOTE_BMS_RESET
+}
+
 /* If we lose the connection, get it back */
 static bool reconnect() {
 // attempt one reconnection
@@ -414,6 +486,10 @@ static bool reconnect() {
     clear_event(EVENT_MQTT_DISCONNECT);
     set_event(EVENT_MQTT_CONNECT, 0);
     reconnectAttempts = 0;  // Reset attempts on successful connection
+#ifdef HA_AUTODISCOVERY
+    publish_buttons_discovery();
+#endif
+    subscribe();
 #ifdef DEBUG_LOG
     logging.println("connected");
 #endif  // DEBUG_LOG
@@ -440,16 +516,18 @@ void init_mqtt(void) {
   topic_name = mqtt_topic_name;
   object_id_prefix = mqtt_object_id_prefix;
   device_name = mqtt_device_name;
+  device_id = ha_device_id;
 #else
   // Use default naming based on WiFi hostname for topic, object ID prefix, and device name
   topic_name = "battery-emulator_" + String(WiFi.getHostname());
   object_id_prefix = String(WiFi.getHostname()) + String("_");
   device_name = "BatteryEmulator_" + String(WiFi.getHostname());
-
+  device_id = "battery-emulator";
 #endif
 #endif
 
   client.setServer(MQTT_SERVER, MQTT_PORT);
+  client.setCallback(mqtt_message_received);
 #ifdef DEBUG_LOG
   logging.println("MQTT initialized");
 #endif  // DEBUG_LOG

Software/src/devboard/mqtt/mqtt.h

@@ -47,6 +47,7 @@ extern const char* mqtt_password;
 extern const char* mqtt_topic_name;
 extern const char* mqtt_object_id_prefix;
 extern const char* mqtt_device_name;
+extern const char* ha_device_id;
 
 extern char mqtt_msg[MQTT_MSG_BUFFER_SIZE];
 

Software/src/devboard/safety/safety.cpp

@@ -238,6 +238,26 @@ void update_machineryprotection() {
   if (datalayer.battery.status.max_charge_power_W == 0) {
     datalayer.battery.status.max_charge_current_dA = 0;
   }
+
+  //Decrement the forced balancing timer incase user requested it
+  if (datalayer.battery.settings.user_requests_balancing) {
+    // If this is the start of the balancing period, capture the current time
+    if (datalayer.battery.settings.balancing_start_time_ms == 0) {
+      datalayer.battery.settings.balancing_start_time_ms = millis();
+      set_event(EVENT_BALANCING_START, 0);
+    } else {
+      clear_event(EVENT_BALANCING_START);
+    }
+
+    // Check if the elapsed time exceeds the balancing time
+    if (millis() - datalayer.battery.settings.balancing_start_time_ms >= datalayer.battery.settings.balancing_time_ms) {
+      datalayer.battery.settings.user_requests_balancing = false;
+      datalayer.battery.settings.balancing_start_time_ms = 0;  // Reset the start time
+      set_event(EVENT_BALANCING_END, 0);
+    } else {
+      clear_event(EVENT_BALANCING_END);
+    }
+  }
 }
 
 //battery pause status begin

Software/src/devboard/utils/events.cpp

@@ -159,6 +159,8 @@ void init_events(void) {
   events.entries[EVENT_SOC_PLAUSIBILITY_ERROR].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_SOC_UNAVAILABLE].level = EVENT_LEVEL_WARNING;
   events.entries[EVENT_KWH_PLAUSIBILITY_ERROR].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_BALANCING_START].level = EVENT_LEVEL_INFO;
+  events.entries[EVENT_BALANCING_END].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_BATTERY_EMPTY].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_BATTERY_FULL].level = EVENT_LEVEL_INFO;
   events.entries[EVENT_BATTERY_FROZEN].level = EVENT_LEVEL_INFO;
@@ -302,6 +304,10 @@ const char* get_event_message_string(EVENTS_ENUM_TYPE event) {
       return "Warning: SOC not sent by BMS. Calibrate BMS via app.";
     case EVENT_KWH_PLAUSIBILITY_ERROR:
       return "Info: kWh remaining reported by battery not plausible. Battery needs cycling.";
+    case EVENT_BALANCING_START:
+      return "Info: Balancing has started";
+    case EVENT_BALANCING_END:
+      return "Info: Balancing has ended";
     case EVENT_BATTERY_EMPTY:
       return "Info: Battery is completely discharged";
     case EVENT_BATTERY_FULL: