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https://github.com/NawfalMotii79/PLFM_RADAR.git
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fix(mcu): MCU-A1 — replace 25 C cooling stub with 70/60 C hysteresis
Cooling-fan trip in main.cpp's periodic temperature block was a 25 C dev stub that latched the fan ON at room temperature on every boot. Replaced with production thermal control: ON at 70 C, OFF at 60 C. The 10 C dead-band prevents relay/fan chatter near the threshold; the 70 C ON point sits below the 75 C SAFE-mode gate in checkSystemHealth() so the fan engages before the system shuts down. Driven from the existing `temperature` global (max of 8 sensors, populated just above by the GAP-3 fix) instead of re-OR'ing the eight Temperature_N variables — single source of truth, and the diag now prints the actual peak temperature on each transition. Added test_mcu_a1_cooling_hysteresis (9 cases) covering cold-start, upward crossing, dead-band hold, downward crossing, and a regression guard at 30 C that would have engaged the fan under the old stub. MCU regression now 77/77.
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Jason
@@ -2179,16 +2179,25 @@ int main(void)
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DIAG("PA", "System temperature (max of 8 sensors) = %.1f C", (double)temperature);
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}
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//(20 mV/°C on TMP37) QPA2962 RF amplifier Operating Temp. Range, TBASE min−40 normal+25 max+85 °C
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int Max_Temp = 25;
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if((Temperature_1>Max_Temp)||(Temperature_2>Max_Temp)||(Temperature_3>Max_Temp)||(Temperature_4>Max_Temp)
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||(Temperature_5>Max_Temp)||(Temperature_6>Max_Temp)||(Temperature_7>Max_Temp)||(Temperature_8>Max_Temp))
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{
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// MCU-A1: production thermal limits for QPA2962 (TBASE max +85 °C).
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// Cooling fan turns ON at 70 °C and OFF at 60 °C — 10 °C hysteresis
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// prevents relay/fan chatter near the threshold. The system-level
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// hard overtemp gate at checkSystemHealth() (>75 °C → SAFE mode)
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// sits above the cooling ON point so the fan gets a chance to act
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// before shutdown. Was previously a 25 °C dev-bench stub that kept
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// the fan latched on at room temperature.
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static bool cooling_on = false;
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const float COOLING_ON_C = 70.0f;
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const float COOLING_OFF_C = 60.0f;
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float t_max = temperature; // populated above as max of 8 sensors
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if (!cooling_on && t_max > COOLING_ON_C) {
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cooling_on = true;
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HAL_GPIO_WritePin(EN_DIS_COOLING_GPIO_Port, EN_DIS_COOLING_Pin, GPIO_PIN_SET);
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DIAG_WARN("PA", "Over-temp detected (>%d C) -- cooling ENABLED", Max_Temp);
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}
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else{
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DIAG_WARN("PA", "Over-temp %.1f C > %.0f C -- cooling ENABLED", (double)t_max, (double)COOLING_ON_C);
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} else if (cooling_on && t_max < COOLING_OFF_C) {
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cooling_on = false;
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HAL_GPIO_WritePin(EN_DIS_COOLING_GPIO_Port, EN_DIS_COOLING_Pin, GPIO_PIN_RESET);
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DIAG("PA", "Temp %.1f C < %.0f C -- cooling DISABLED", (double)t_max, (double)COOLING_OFF_C);
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}
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/* [GAP-3 FIX 4] Periodic IDQ re-read — the Idq_reading[] array was only
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@@ -66,6 +66,7 @@ TESTS_MOCK_ONLY := test_bug2_ad9523_double_setup \
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TESTS_STANDALONE := test_bug12_pa_cal_loop_inverted \
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test_bug13_dac2_adc_buffer_mismatch \
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test_bug16_runradar_shadows_globals \
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test_mcu_a1_cooling_hysteresis \
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test_gap3_iwdg_config \
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test_gap3_temperature_max \
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test_gap3_idq_periodic_reread \
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@@ -159,6 +160,9 @@ test_bug13_dac2_adc_buffer_mismatch: test_bug13_dac2_adc_buffer_mismatch.c
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test_bug16_runradar_shadows_globals: test_bug16_runradar_shadows_globals.c
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$(CC) $(CFLAGS) $< -o $@
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test_mcu_a1_cooling_hysteresis: test_mcu_a1_cooling_hysteresis.c
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$(CC) $(CFLAGS) $< -o $@
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# Gap-3 safety tests -- mock-only (needs spy log for GPIO sequence)
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test_gap3_emergency_stop_rails: test_gap3_emergency_stop_rails.c $(MOCK_OBJS)
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$(CC) $(CFLAGS) $(INCLUDES) $< $(MOCK_OBJS) -o $@
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@@ -0,0 +1,95 @@
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/*******************************************************************************
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* test_mcu_a1_cooling_hysteresis.c
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*
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* MCU-A1: cooling-fan threshold was a 25 C dev stub that latched the fan ON
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* at room temperature. Production fix raises the threshold to 70 C with a
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* 60 C off point (10 C hysteresis) so the fan does not chatter near the
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* trip point.
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*
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* This test replays the fixed cooling-control logic against a temperature
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* sweep and asserts (a) the fan stays off below the ON threshold from cold,
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* (b) it engages crossing 70 C upward, (c) it stays on through the 60-70 C
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* dead-band on the way down, and (d) it disengages below 60 C.
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******************************************************************************/
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#include <assert.h>
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#include <stdbool.h>
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#include <stdio.h>
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static const float COOLING_ON_C = 70.0f;
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static const float COOLING_OFF_C = 60.0f;
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/* Replays the post-fix cooling control inside main.cpp:2183-... */
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static bool step_cooling(bool cooling_on, float t_max)
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{
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if (!cooling_on && t_max > COOLING_ON_C) return true;
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else if (cooling_on && t_max < COOLING_OFF_C) return false;
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return cooling_on;
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}
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int main(void)
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{
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printf("=== MCU-A1: cooling-fan hysteresis (70 C ON / 60 C OFF) ===\n");
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bool fan = false;
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/* 1. Cold start: room temperature must NOT engage the fan
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* (this is the bug the 25 C stub caused). */
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printf(" Test 1: 25 C from cold ... ");
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fan = step_cooling(fan, 25.0f);
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assert(fan == false);
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printf("OFF, PASS\n");
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/* 2. Walking up through the dead band must not engage. */
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printf(" Test 2: 65 C from cold ... ");
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fan = step_cooling(fan, 65.0f);
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assert(fan == false);
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printf("OFF, PASS\n");
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/* 3. At the exact threshold (>, not >=) still off. */
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printf(" Test 3: 70.0 C exactly ... ");
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fan = step_cooling(fan, 70.0f);
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assert(fan == false);
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printf("OFF, PASS\n");
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/* 4. Crossing the trip point upward engages. */
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printf(" Test 4: 70.5 C ... ");
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fan = step_cooling(fan, 70.5f);
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assert(fan == true);
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printf("ON, PASS\n");
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/* 5. Cooling off into the dead band — fan must stay on. */
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printf(" Test 5: 65 C while ON ... ");
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fan = step_cooling(fan, 65.0f);
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assert(fan == true);
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printf("ON (hysteresis), PASS\n");
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/* 6. At the OFF threshold exactly, still on (uses <, not <=). */
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printf(" Test 6: 60.0 C exactly while ON ... ");
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fan = step_cooling(fan, 60.0f);
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assert(fan == true);
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printf("ON, PASS\n");
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/* 7. Crossing the OFF point disengages. */
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printf(" Test 7: 59.5 C while ON ... ");
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fan = step_cooling(fan, 59.5f);
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assert(fan == false);
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printf("OFF, PASS\n");
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/* 8. Spike-and-recover above the system overtemp gate (75 C) — the
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* fan engages well before checkSystemHealth() trips SAFE mode. */
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printf(" Test 8: 76 C engages cooling before 75 C SAFE-mode gate ... ");
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fan = step_cooling(fan, 76.0f);
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assert(fan == true);
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printf("ON, PASS\n");
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/* 9. The pre-fix 25 C stub would have set fan=true here. Confirm the
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* fixed logic does not. */
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printf(" Test 9: 30 C does NOT engage (regression guard for 25 C stub) ... ");
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fan = false;
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fan = step_cooling(fan, 30.0f);
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assert(fan == false);
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printf("OFF, PASS\n");
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printf("\n=== MCU-A1: ALL TESTS PASSED ===\n\n");
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return 0;
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}
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