add battery health info (#102)

* add health info

* Update README.md

* add logs

* add voltage mean count

* update republisher node

* fix typo

* Update panther_battery/src/adc_node.py

Co-authored-by: Krzysztof Wojciechowski <[email protected]>

* Update adc_node.py

* Update roboteq_republisher_node.py

* fix typo

---------

Co-authored-by: Dawid Kmak <[email protected]>
Co-authored-by: Krzysztof Wojciechowski <[email protected]>

panther_battery/README.md

@@ -29,3 +29,7 @@ Node publishing Panther battery state read from motor controllers. Used in Panth
 #### Subscribes
 
 - `/panther/driver/motor_controllers_state` [*panther_msgs/DriverState*]: current motor controllers' state and error flags.
+
+#### Parameters 
+
+- `~high_bat_temp` [*float*, default: **55.0**]: The temperature of the battery at which the battery health state is incorrect.

panther_battery/src/adc_node.py

@@ -1,6 +1,9 @@
 #!/usr/bin/python3
 
+from collections import defaultdict
 import math
+from threading import Lock
+from typing import Optional, Union
 
 import rospy
 
@@ -11,14 +14,22 @@
 
 class ADCNode:
     BAT02_DETECT_THRESH = 3.03
+    V_BAT_FATAL_MIN = 27.0
+    V_BAT_FATAL_MAX = 43.0
 
     def __init__(self, name: str) -> None:
         rospy.init_node(name, anonymous=False)
 
-        self._V_driv_front = None
-        self._V_driv_rear = None
-        self._I_driv_front = None
-        self._I_driv_rear = None
+        self._high_bat_temp = rospy.get_param('~high_bat_temp', 55.0)
+
+        self._driver_battery_last_info_time: Optional[float] = None
+        self._I_driv: Optional[float] = None
+        self._V_driv: Optional[float] = None
+
+        self._volt_mean_length = 10
+        self._V_bat_hist = defaultdict(lambda: [37.0] * self._volt_mean_length)
+        self._V_bat_mean = defaultdict(lambda: 37.0)
+        self._V_driv_mean: Optional[float] = None
 
         self._A = 298.15
         self._B = 3977.0
@@ -29,6 +40,8 @@ def __init__(self, name: str) -> None:
         self._battery_count = self._check_battery_count()
         self._battery_charging = True  # const for now, later this will be evaluated
 
+        self._lock = Lock()
+
         # -------------------------------
         #   Subscribers
         # -------------------------------
@@ -59,10 +72,14 @@ def __init__(self, name: str) -> None:
         rospy.loginfo(f'[{rospy.get_name()}] Node started')
 
     def _motor_controllers_state_cb(self, driver_state: DriverState) -> None:
-        self._V_driv_front = driver_state.front.voltage
-        self._V_driv_rear = driver_state.front.current
-        self._I_driv_front = driver_state.rear.voltage
-        self._I_driv_rear = driver_state.rear.current
+        with self._lock:
+            self._driver_battery_last_info_time = rospy.get_time()
+
+            driver_voltage = (driver_state.front.voltage + driver_state.rear.voltage) / 2.0
+            self._V_driv = driver_voltage
+            self._V_driv_mean = self._count_volt_mean('V_driv', driver_voltage)
+
+            self._I_driv = driver_state.front.current + driver_state.rear.current
 
     def _io_state_cb(self, io_state: IOState) -> None:
         self._charger_connected = io_state.charger_connected
@@ -175,6 +192,8 @@ def _publish_battery_msg(
         battery_msg.power_supply_technology = BatteryState.POWER_SUPPLY_TECHNOLOGY_LIPO
         battery_msg.present = True
 
+        V_bat_mean = self._count_volt_mean(bat_pub, V_bat)
+
         # check battery status
         if self._charger_connected:
             if battery_msg.percentage >= 1.0:
@@ -186,8 +205,43 @@ def _publish_battery_msg(
         else:
             battery_msg.power_supply_status = BatteryState.POWER_SUPPLY_STATUS_DISCHARGING
 
+        # check battery health
+        with self._lock:
+            error_msg = None
+            if V_bat_mean < self.V_BAT_FATAL_MIN:
+                battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_DEAD
+                error_msg = 'Battery voltage is critically low!'
+            elif V_bat_mean > self.V_BAT_FATAL_MAX:
+                battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_OVERVOLTAGE
+                error_msg = 'Battery overvoltage!'
+            elif temp_bat >= self._high_bat_temp:
+                battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_OVERHEAT
+                error_msg = 'Battery is overheating!'
+            elif self._driver_battery_last_info_time is None:
+                battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_UNKNOWN
+            elif (
+                rospy.get_time() - self._driver_battery_last_info_time < 0.1
+                and abs(V_bat_mean - self._V_driv_mean) > self.V_BAT_FATAL_MAX * 0.1
+            ):
+                battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_UNSPEC_FAILURE
+            else:
+                battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_GOOD
+
+        if error_msg is not None:
+            rospy.logerr_throttle_identical(10.0, f'[{rospy.get_name()}] {error_msg}')
+
         bat_pub.publish(battery_msg)
 
+    def _count_volt_mean(self, label: Union[rospy.Publisher, str], new_val: float) -> float:
+        # Updates the average by adding the newest and removing the oldest component of mean value,
+        # in order to avoid recalculating the entire sum every time.
+        self._V_bat_mean[label] += (new_val - self._V_bat_hist[label][0]) / self._volt_mean_length
+
+        self._V_bat_hist[label].pop(0)
+        self._V_bat_hist[label].append(new_val)
+
+        return self._V_bat_mean[label]
+
     @staticmethod
     def _read_file(path: str) -> int:
         with open(path, 'r') as file:

panther_battery/src/roboteq_republisher_node.py

@@ -1,6 +1,7 @@
 #!/usr/bin/python3
 
 from threading import Lock
+from typing import Optional
 
 import rospy
 
@@ -10,11 +11,19 @@
 
 
 class RoboteqRepublisherNode:
+    V_BAT_FATAL_MIN = 27.0
+    V_BAT_FATAL_MAX = 43.0
+
     def __init__(self, name: str) -> None:
         rospy.init_node(name, anonymous=False)
 
-        self._battery_voltage = None
-        self._battery_current = None
+        self._battery_voltage: Optional[float] = None
+        self._battery_current: Optional[float] = None
+        self._battery_voltage_mean = 37.0
+
+        self._volt_mean_length = 10
+        self._battery_voltage_hist = [37.0] * self._volt_mean_length
+
         self._battery_timeout = 1.0
         self._last_battery_info_time = rospy.get_time()
         self._lock = Lock()
@@ -44,9 +53,12 @@ def __init__(self, name: str) -> None:
 
     def _motor_controllers_state_cb(self, msg: DriverState) -> None:
         with self._lock:
+            new_voltage = (msg.front.voltage + msg.rear.voltage) / 2.0
+
             self._last_battery_info_time = rospy.get_time()
-            self._battery_voltage = (msg.front.voltage + msg.rear.voltage) / 2.0
+            self._battery_voltage = new_voltage
             self._battery_current = msg.front.current + msg.rear.current
+            self._update_volt_mean(new_voltage)
 
     def _battery_pub_timer_cb(self, *args) -> None:
         with self._lock:
@@ -55,25 +67,48 @@ def _battery_pub_timer_cb(self, *args) -> None:
             battery_msg.capacity = 20.0
             battery_msg.design_capacity = 20.0
             battery_msg.power_supply_technology = BatteryState.POWER_SUPPLY_TECHNOLOGY_LIPO
+
             if (
                 self._battery_voltage == None
                 or self._battery_current == None
                 or rospy.get_time() - self._last_battery_info_time > self._battery_timeout
             ):
                 battery_msg.power_supply_status = BatteryState.POWER_SUPPLY_STATUS_UNKNOWN
             else:
-                battery_msg.power_supply_status = BatteryState.POWER_SUPPLY_STATUS_DISCHARGING
                 battery_msg.voltage = self._battery_voltage
                 battery_msg.temperature = float('nan')
                 battery_msg.current = self._battery_current
                 battery_msg.percentage = (battery_msg.voltage - 32.0) / 10.0
                 battery_msg.charge = battery_msg.percentage * battery_msg.design_capacity
                 battery_msg.present = True
-                # TODO:
-                # battery_msg.power_supply_health
+
+                # TODO: check battery status
+                battery_msg.power_supply_status = BatteryState.POWER_SUPPLY_STATUS_DISCHARGING
+
+                # check battery health
+                error_msg = None
+                if self._battery_voltage < self.V_BAT_FATAL_MIN:
+                    battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_DEAD
+                    error_msg = 'Battery voltage is critically low!'
+                elif self._battery_voltage > self.V_BAT_FATAL_MAX:
+                    battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_OVERVOLTAGE
+                    error_msg = 'Battery overvoltage!'
+                else:
+                    battery_msg.power_supply_health = BatteryState.POWER_SUPPLY_HEALTH_GOOD
+
+                if error_msg is not None:
+                    rospy.logerr_throttle_identical(10.0, f'[{rospy.get_name()}] {error_msg}')
 
             self._battery_pub.publish(battery_msg)
 
+    def _update_volt_mean(self, new_val: float) -> float:
+        # Updates the average by adding the newest and removing the oldest component of mean value,
+        # in order to avoid recalculating the entire sum every time.
+        self._battery_voltage_mean += (new_val - self._battery_voltage_hist[0]) / self._volt_mean_length
+
+        self._battery_voltage_hist.pop(0)
+        self._battery_voltage_hist.append(new_val)
+
 
 def main():
     roboteq_republisher_node = RoboteqRepublisherNode('roboteq_republisher_node')