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Ralim / IronOS

Open Source Soldering Iron firmware
https://ralim.github.io/IronOS/
GNU General Public License v3.0
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BAD TIP at temps >400C #395

Closed dhiltonp closed 5 years ago

dhiltonp commented 5 years ago

I'm getting bad tip when I cross 400C or so.

Can you verify that it works for you?

https://github.com/Ralim/ts100/blob/master/workspace/TS100/src/main.cpp#L540

Ralim commented 5 years ago

Ah, with the new tip calibrations, some tips cant get up to 450C before they go out of range of the unit. Because the new tip profiles are more accurate some of the models can only hit around 430C before they are out of range of the ADC reading back the temperature.

Any chance you have a tip thermocouple you could verify temperature accuracy with ?

I'll merge in your update and then test this tonight either way :)

May need to limit the max selectable temperature depending on the tip.

dhiltonp commented 5 years ago

I think there's a little more to it than that, I could easily replicate it going to 400C, but I first noticed it when lowering the temperature from 320C to 300C.

I don't have a tip thermocouple. It could be useful...

Ralim commented 5 years ago

Ah ok, I'll have a look tonight, most likely I may need to tweak the PWM timing possibly, or may need to use filtered data for the testing of an open circuit tip.

I just picked up a really dirt cheap clone Hakko tip temperature unit :)

Ralim commented 5 years ago

I don't think this is your tip, reproducible on two of mine. Looking into this further as I have time.

Ralim commented 5 years ago

I'm going to have to look into this tomorrow. On all of my ts100 units here, I get 1 of two failure modes whenever I try and solder now. Either: a) On power up the unit is reading a high temperature >400C and is constantly drawing max power or b) The temperature regulates well but the OLED display locks up, and ignores all user input.

When compiled using gcc command line, with full LTO the binary is 3.5k smaller, and instead seems to trip the bad tip all the time whenever the output is on.

I have no idea what Atollic is doing in the first case, For the latter case I think its most likely PWM timings that I'll look into tomorrow.

dhiltonp commented 5 years ago

I built with sw4stm32 and didn't see either a or b.

When I set the iron to heat on power-on, I did see an undervoltage warning not present in older versions.

Ralim commented 5 years ago

Hmm interesting, Atollic is using a newer compiler than sw4stm32 so not sure what the compiler is changing.

Damn, need to update the code to pre-fill the voltage check buffer.

Ralim commented 5 years ago

I've pushed a small fix to master that helps with the startup voltage sensing (not ideal, but works)

Also after this change my ts100 is working really well.

However, trying to get this working on the TS80 now. It oscillates with a period of about 2 Hz with the current settings. What is your suggested tuning method here ?

dhiltonp commented 5 years ago

There are 2 tuning knobs - milliwatts to reach a target temperature and the oscillation period we average.

I'm surprised that you're having a period of 2HZ, the averaging period is set to 3.5s right now.

I suspect that the hard-coded mass is too high with your tip. Try cutting it in half (divide by 40 instead of 20).

Ralim commented 5 years ago

Bang on, reducing that mass dampened out oscillations very nicely.

Seven5555 commented 5 years ago

I'm not if this where this goes but it seems like the right place and thing to do. My TS100 constantly getting this "Bad Tip" message, since installing the new firmware over the stock firmware yesterday. I just got this a little over a week ago so it should not have bad tip.

I do want to thank you for creating this very cool firmware with all these much needed extra settings, I like it a lot for sure.

Dean

Ralim commented 5 years ago

@Seven5555 This is #422