motor_heating_model.h

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#ifndef ETHERCAT_HARDWARE__MOTOR_HEATING_MODEL_H
#define ETHERCAT_HARDWARE__MOTOR_HEATING_MODEL_H

#include "ethercat_hardware/MotorTemperature.h"
#include "ethercat_hardware/MotorTraceSample.h"
#include "ethercat_hardware/ActuatorInfo.h"

#include "realtime_tools/realtime_publisher.h"
#include "diagnostic_updater/DiagnosticStatusWrapper.h"

#include <boost/utility.hpp>
#include <boost/thread/mutex.hpp>
#include <boost/shared_ptr.hpp>

#include <vector>
#include <string>

namespace ethercat_hardware
{


struct MotorHeatingModelParameters
{
  double housing_to_ambient_thermal_resistance_;
  double winding_to_housing_thermal_resistance_;
  double winding_thermal_time_constant_;
  double housing_thermal_time_constant_;
  double max_winding_temperature_;
}  __attribute__ ((__packed__));


struct MotorHeatingModelParametersEepromConfig
{
  uint16_t major_;                      
  uint16_t minor_;                      
  bool  enforce_;                       
  uint8_t  pad1[3];
  MotorHeatingModelParameters params_;  
  uint8_t  pad2[204];
  uint32_t crc32_;                      
 
  static const unsigned EEPROM_PAGE = 4093; // Acutator info on page 4095, MCB config on 4094

  bool verifyCRC(void) const;
  void generateCRC(void);
} __attribute__ ((__packed__));


class MotorHeatingModel;

class MotorHeatingModelCommon : private boost::noncopyable
{
public:
  MotorHeatingModelCommon(ros::NodeHandle nh);
  
  MotorHeatingModelCommon();


  bool initialize();
  
  void attach(boost::shared_ptr<MotorHeatingModel> model);

  bool update_save_files_;    
  std::string save_directory_; 
  bool load_save_files_; 
  bool disable_halt_;
  bool enable_model_;
  bool publish_temperature_;

protected:
  bool createSaveDirectory();

  boost::thread save_thread_;
  void saveThreadFunc();

  std::vector< boost::shared_ptr<MotorHeatingModel> > models_; 

  boost::mutex mutex_;
};



class MotorHeatingModel : private boost::noncopyable
{
public:

  MotorHeatingModel(const MotorHeatingModelParameters &motor_params,
                    const std::string &actuator_name,
                    const std::string &hwid,
                    const std::string &save_directory
                    );

  bool startTemperaturePublisher();

  bool update(double heating_power, double ambient_temperature, double duration);
  bool update(const ethercat_hardware::MotorTraceSample &sample, 
              const ethercat_hardware::ActuatorInfo &actuator_info,
              double ambient_temperature, double duration)
  {
    double heating_power = calculateMotorHeatPower(sample, actuator_info);
    return update(heating_power, ambient_temperature, duration);
  }  

  bool hasOverheated() const {return overheat_;}
  double getWindingTemperature() {return winding_temperature_;}
  double getHousingTemperature() {return housing_temperature_;}


  void reset();


  void updateFromDowntime(double downtime, double saved_ambient_temperature);


  double updateFromDowntimeWithInterval(double downtime, 
                                        double saved_ambient_temperature, 
                                        double interval, 
                                        unsigned cycles);


  double calculateMotorHeatPower(const ethercat_hardware::MotorTraceSample &sample,
                                 const ethercat_hardware::ActuatorInfo &actuator_info);
  

  bool loadTemperatureState();


  bool saveTemperatureState();


  void diagnostics(diagnostic_updater::DiagnosticStatusWrapper &d);




protected:
  // Following values are calculated from motor parameters.  
  // They are more useful when peforming motor model calculations
  // 
  // Thermal is conducance amount of heat power tranfered for a 
  // given temperature differential
  // Thermal conductance units : Watt/C
  // Thermal conductance =  1 / Thermal resistance
  //
  // Thermal mass (or Thermal capicitance) : Energy required to 
  // raise temperature of object 1 degree.
  // Thermal mass units :  C/Joule
  // Thermal mass = Thermal time constant / thermal resistance  

  double winding_to_housing_thermal_conductance_;
  double housing_to_ambient_thermal_conductance_;
  double winding_thermal_mass_inverse_;
  double housing_thermal_mass_inverse_;

  
  double winding_temperature_;
  double housing_temperature_;
  double ambient_temperature_;

  boost::mutex mutex_;

  bool overheat_;

  double heating_energy_sum_;
  double ambient_temperature_sum_;
  double duration_since_last_sample_;
  //double trace_sample_interval_;
  realtime_tools::RealtimePublisher<ethercat_hardware::MotorTemperature> *publisher_;

  MotorHeatingModelParameters motor_params_;
  std::string actuator_name_;  
  std::string save_filename_;  
  std::string hwid_;  
};


}; //end namepace ethercat_hardware

#endif //ETHERCAT_HARDWARE__MOTOR_HEATING_MODEL_H