增加故障诊断

iar/plsr.dep

@@ -3092,10 +3092,6 @@
                     <name>BICOMP</name>
                     <file> 283</file>
                 </tool>
-                <tool>
-                    <name>ICCARM</name>
-                    <file> 33</file>
-                </tool>
                 <tool>
                     <name>__cstat</name>
                     <file> 268</file>

plsr/command/plsr_command.c

@@ -99,6 +99,7 @@ void PlsrCommandOnSegFreqHoldWrite(uint16_t start_addr, uint16_t quantity)
         ((uint32_t)ReadHoldReg((uint16_t)(start_addr + 1U)) << 16);
     if ((f < 1U) || (f > 100000U))
     {
+        PlsrCommandSetFault(PLSR_ERR_FREQ_ILLEGAL);
         return;
     }
 

plsr/command/plsr_command.h

@@ -25,8 +25,11 @@
 #define PLSR_CTRL_BIT_STOP        (1U << 1)  /* 停止脉冲 */
 #define PLSR_CTRL_BIT_CLR         (1U << 2)  /* 清除状态信息 */
 
-#define PLSR_ERR_NONE             0U
-#define PLSR_ERR_SEG_FREQ         1U  /* 段频率非法（非 0 且越界，或解析后不在 1~100k） */
+#define PLSR_ERR_NONE             0x00U /* 无故障 */
+#define PLSR_ERR_PULSE_CNT        0x01U /* 脉冲输出个数与设置不一致（告警，继续） */
+#define PLSR_ERR_FREQ_UNREACH     0x02U /* 输出频率与设置不一致/三角达不到（告警，继续） */
+#define PLSR_ERR_CURVE_MISMATCH   0x03U /* 加减速曲线与设置不一致（告警，继续） */
+#define PLSR_ERR_FREQ_ILLEGAL     0x04U /* 脉冲频率非法（1~100k）（告警，禁止启动） */
 
 void PlsrCommandInit(void);
 void PlsrCommandPoll(void);

plsr/run_control/plsr_run_control.c

@@ -77,6 +77,11 @@ static uint8_t  s_pwm_on;
 static uint16_t s_run_accel_ms;
 static uint16_t s_run_decel_ms;
 
+/* 规划锁定的加/减速脉冲预算（EnterDecel 会改写 plan.dec_n，故另存） */
+static uint32_t s_plan_acc_n;
+static uint32_t s_plan_dec_n;
+static uint32_t s_decel_budget; /* 进入减速时的 remain，用于 0x03 */
+
 /** 策略层交给段处理的接口参数 */
 typedef struct {
     uint32_t f_from;
@@ -102,6 +107,10 @@ static uint16_t PlsrRunControlWaitTimeMs(const PlsrSeg_t *seg);
 static void PlsrRunControlPlanSeg(uint32_t total, uint32_t f_from,
                                   uint32_t f_tgt, uint32_t f_end,
                                   uint16_t accel_ms, uint16_t decel_ms);
+static void PlsrRunControlCheckPulseCntFault(void);
+static void PlsrRunControlCheckApproachCurveFault(uint8_t by_pulse_budget);
+static void PlsrRunControlOnApproachDone(void);
+static void PlsrRunControlCheckDecelCurveFault(void);
 static int32_t PlsrRunControlAbsLocalPos(void);
 static uint32_t PlsrRunControlClampSpeed(uint32_t spd);
 static uint8_t PlsrRunControlGetSegTargetFreq(int32_t freq_hz,
@@ -320,12 +329,57 @@ static void PlsrRunControlGotoNextOrFinish(uint16_t cur_seg)
     }
 }
 
+/** 0x01：段正常结束时实际脉冲 ≠ 本段目标（告警，不停） */
+static void PlsrRunControlCheckPulseCntFault(void)
+{
+    if ((s_target > 0) && (s_done != s_target))
+    {
+        PlsrCommandSetFault(PLSR_ERR_PULSE_CNT);
+    }
+}
+
+/**
+ * 0x03：加速段结束时，相内脉冲与规划 acc_n 不一致。
+ * by_pulse_budget：因 n 走到预算而收尾，须精确相等；因频率提前到位则仅超额时报。
+ */
+static void PlsrRunControlCheckApproachCurveFault(uint8_t by_pulse_budget)
+{
+    if (s_plan_acc_n == 0U)
+    {
+        return;
+    }
+    if (by_pulse_budget != 0U)
+    {
+        if (s_pulse_rt.n != s_plan_acc_n)
+        {
+            PlsrCommandSetFault(PLSR_ERR_CURVE_MISMATCH);
+        }
+    }
+    else if (s_pulse_rt.n > s_plan_acc_n)
+    {
+        PlsrCommandSetFault(PLSR_ERR_CURVE_MISMATCH);
+    }
+}
+
+/** 0x03：减速段在段末核对相内脉冲与进入减速时的预算 */
+static void PlsrRunControlCheckDecelCurveFault(void)
+{
+    if ((s_phase == PH_DECEL) && (s_decel_budget > 0U) &&
+        (s_pulse_rt.n != s_decel_budget))
+    {
+        PlsrCommandSetFault(PLSR_ERR_CURVE_MISMATCH);
+    }
+}
+
 static void PlsrRunControlAfterSegDone(void)
 {
     PlsrCfg_t *cfg = PlsrParamGetCfg();
     PlsrSeg_t *seg = PlsrParamGetSeg(s_cur_seg);
     uint8_t keep_pwm;
 
+    PlsrRunControlCheckPulseCntFault();
+    PlsrRunControlCheckDecelCurveFault();
+
     /* 先脱离 RUN，避免脉冲 ISR 重入 */
     s_state = RC_IDLE;
 
@@ -421,7 +475,7 @@ static uint8_t PlsrRunControlBlocksFollowKeep(uint16_t cur_seg)
  * 调用/等待策略：根据发送模式、等待条件、衔接状态，解析本段
  * f_from / f_end / accel_ms / decel_ms。段内处理不读 wait_type。
  *
- * @return 1 成功；0 下一段目标频非法（仅后续无缝衔接时）
+ * @return 1 成功
  */
 static uint8_t PlsrRunControlResolveSegCallIo(uint16_t seg_0, uint32_t f_tgt,
                                              PlsrSegCallIo_t *io)
@@ -498,7 +552,14 @@ static uint8_t PlsrRunControlResolveSegCallIo(uint16_t seg_0, uint32_t f_tgt,
                                            cfg->default_speed,
                                            &io->f_end) == 0U)
         {
-            return 0U;
+            /* 下一段频率非法：本段先止速收尾，下一段 Begin 再报 0x04 */
+            io->f_end = PlsrAccelCurveResolveEndHz(cfg->end_speed,
+                                                    f_tgt,
+                                                    cfg->default_speed,
+                                                    cfg->start_speed,
+                                                    cfg->end_speed,
+                                                    io->accel_ms,
+                                                    io->decel_ms);
         }
     }
     return 1U;
@@ -686,6 +747,7 @@ static void PlsrRunControlEnterDecel(uint32_t from_hz, uint32_t remain_pulses)
 {
     PlsrRunControlEnterPhase(PH_DECEL, from_hz);
 
+    s_decel_budget = remain_pulses;
     s_accel_plan.acc_n = 0U;
     s_accel_plan.const_n = 0U;
     s_accel_plan.dec_n = remain_pulses;
@@ -712,6 +774,19 @@ static void PlsrRunControlEnterDecel(uint32_t from_hz, uint32_t remain_pulses)
     }
 }
 
+/** 离开加速相时做 0x03 诊断 */
+static void PlsrRunControlOnApproachDone(void)
+{
+    uint8_t by_budget;
+
+    if (s_phase != PH_APPROACH)
+    {
+        return;
+    }
+    by_budget = ((s_plan_acc_n > 0U) && (s_pulse_rt.n >= s_plan_acc_n)) ? 1U : 0U;
+    PlsrRunControlCheckApproachCurveFault(by_budget);
+}
+
 /**
  * 进匀速：写一次 f_tgt，之后 ISR 不改 ARR（复用缓存）。
  */
@@ -789,6 +864,7 @@ static void PlsrRunControlRefreshProfile(uint8_t do_start)
              (next <= s_accel_plan.f_tgt)))
         {
             next = s_accel_plan.f_tgt;
+            PlsrRunControlOnApproachDone();
             if ((PlsrRunControlHasDecel() != 0U) &&
                 (remain <= s_accel_plan.dec_n))
             {
@@ -837,6 +913,24 @@ static void PlsrRunControlPlanSeg(uint32_t total, uint32_t f_from,
                        decel_ms,
                        cfg->accel_mode);
 
+    /*
+     * 0x02：规划后峰值低于设定目标 → 脉冲不够爬到目标频（三角等）
+     * 告警，仍按当前规划继续跑。
+     */
+    if ((f_tgt > f_from) && (s_accel_plan.f_tgt < f_tgt))
+    {
+        PlsrCommandSetFault(PLSR_ERR_FREQ_UNREACH);
+    }
+    else if ((f_tgt < f_from) && (s_accel_plan.f_tgt > f_tgt))
+    {
+        PlsrCommandSetFault(PLSR_ERR_FREQ_UNREACH);
+    }
+
+    /* 0x03 对照用：规划预算（运行中 s_accel_plan.acc_n 可能被改写） */
+    s_plan_acc_n = s_accel_plan.acc_n;
+    s_plan_dec_n = s_accel_plan.dec_n;
+    s_decel_budget = 0U;
+
     /* 运行层使用规划后的实际起始频率。 */
     f_start = s_accel_plan.f_cur;
 
@@ -1003,24 +1097,14 @@ static void PlsrRunControlBeginSeg(uint16_t seg_0)
 
     if (PlsrRunControlGetSegTargetFreq(seg->freq_hz, cfg->default_speed, &f_tgt) == 0U)
     {
-        PlsrCommandSetFault(PLSR_ERR_SEG_FREQ);
-        s_busy = 1U;
-        s_target = 0;
-        s_done = 0;
-        PlsrRunControlAfterSegDone();
+        /* 0x04：频率非法，禁止启动/切段 */
+        PlsrCommandSetFault(PLSR_ERR_FREQ_ILLEGAL);
+        PlsrRunControlFinishAll();
         return;
     }
 
     /* 策略层解析起/止速与加减速；段内只跑 PlanSeg */
-    if (PlsrRunControlResolveSegCallIo(seg_0, f_tgt, &io) == 0U)
-    {
-        PlsrCommandSetFault(PLSR_ERR_SEG_FREQ);
-        s_busy = 1U;
-        s_target = 0;
-        s_done = 0;
-        PlsrRunControlAfterSegDone();
-        return;
-    }
+    (void)PlsrRunControlResolveSegCallIo(seg_0, f_tgt, &io);
 
     total = (uint32_t)s_target;
     PlsrRunControlPlanSeg(total, io.f_from, f_tgt, io.f_end,
@@ -1102,6 +1186,19 @@ uint8_t PlsrRunControlStart(uint16_t start_seg_1based)
     }
 
     cfg = PlsrParamGetCfg();
+    {
+        PlsrSeg_t *seg = PlsrParamGetSeg((uint16_t)(start_seg_1based - 1U));
+        uint32_t f_chk;
+
+        /* 启动前校验首段频率；非法则写 0x04 且不进入运行 */
+        if (PlsrRunControlGetSegTargetFreq(seg->freq_hz,
+                                           cfg->default_speed,
+                                           &f_chk) == 0U)
+        {
+            PlsrCommandSetFault(PLSR_ERR_FREQ_ILLEGAL);
+            return 0U;
+        }
+    }
     s_follow_cont = 0U;
     s_chain_valid = 0U;
     s_chain_freq = 0U;
@@ -1145,6 +1242,7 @@ uint8_t PlsrRunControlChangeFreq(uint32_t new_tgt_hz)
     }
     if ((new_tgt_hz < 1U) || (new_tgt_hz > 100000U))
     {
+        PlsrCommandSetFault(PLSR_ERR_FREQ_ILLEGAL);
         return 0U;
     }
     if (s_done >= s_target)
@@ -1342,6 +1440,7 @@ void PlsrRunControlOnPulseIsr(void)
              (next <= s_accel_plan.f_tgt)))
         {
             next = s_accel_plan.f_tgt;
+            PlsrRunControlOnApproachDone();
             if ((PlsrRunControlHasDecel() != 0U) &&
                 (remain <= s_accel_plan.dec_n))
             {