Fix USB connection/battery charging issue.

Drivers/STM32L4xx_HAL_Driver/Src/stm32l4xx_hal_pcd_ex.c

@@ -379,6 +379,7 @@ HAL_StatusTypeDef HAL_PCDEx_DeActivateBCD(PCD_HandleTypeDef *hpcd)
   hpcd->battery_charging_active = 0U;
 
   USBx->BCDR &= ~(USB_BCDR_BCDEN);
+  USBx->BCDR &= ~(USB_BCDR_DCDEN);
 
   return HAL_OK;
 }

Inc/main.h

@@ -161,6 +161,7 @@ extern uint8_t mac_address[6];
 extern char error_message[80];
 extern int go_back_to_sleep;
 extern int usb_wake_state;
+extern int charging_enabled;
 
 #define CxxErrorHandler() _Error_Handler(const_cast<char*>(__FILE__), __LINE__)
 

Src/main.c

@@ -154,8 +154,8 @@ char error_message[80] __attribute__((section(".bss3"))) = {0};
 // USB power control -- need to renegotiate USB charging in STOP mode.
 int go_back_to_sleep __attribute__((section(".bss3")));
 int stop_now __attribute__((section(".bss3")));
-int usb_wake_state;
+int charging_enabled __attribute__((section(".bss3")));
-int usb_stop_state;
+int usb_wake_state __attribute__((section(".bss3")));
 
 /* USER CODE END PV */
 
@@ -182,6 +182,7 @@ extern void startAudioInputTask(void const * argument);
 extern void startModulatorTask(void const * argument);
 extern void beacon(void const * argument);
 extern void shutdown(void const * argument);
+void encode_serial_number(void);
 
 void HAL_TIM_MspPostInit(TIM_HandleTypeDef *htim);
                                 
@@ -247,14 +248,13 @@ void configure_gpio_for_stop()
     HAL_GPIO_DeInit(BAT_LEVEL_GPIO_Port, BAT_LEVEL_Pin);
     HAL_GPIO_DeInit(BAT_DIVIDER_GPIO_Port, BAT_DIVIDER_Pin);
 
-    usb_stop_state = HAL_GPIO_ReadPin(USB_POWER_GPIO_Port, USB_POWER_Pin);
+    if (charging_enabled)
-    if (HAL_GPIO_ReadPin(USB_POWER_GPIO_Port, USB_POWER_Pin) == GPIO_PIN_RESET)
     {
-        HAL_GPIO_WritePin(GPIOB, USB_CE_Pin, GPIO_PIN_SET);
+        HAL_GPIO_WritePin(GPIOB, USB_CE_Pin, GPIO_PIN_RESET);
-        GPIO_InitStruct.Pin = USB_CE_Pin;
+    }
-        GPIO_InitStruct.Mode = GPIO_MODE_ANALOG;
+    else
-        GPIO_InitStruct.Pull = GPIO_PULLUP;         // CE active low.
+    {
-        HAL_GPIO_Init(GPIOB, &GPIO_InitStruct);
+        HAL_GPIO_DeInit(USB_CE_GPIO_Port, USB_CE_Pin);  // Hi-Z
     }
 
     // Bluetooth module
@@ -340,6 +340,14 @@ void enable_debug_gpio()
     HAL_GPIO_Init(GPIOB, &GPIO_InitStruct);
 }
 
+/**
+ * Shutdown is used to enter stop mode in a clean state.  This ensures that
+ * all IP have been reset & re-initialized to their default state when
+ * entering low-power stop mode.  This is a work-around until we can
+ * determine what causes a high-discharge state after USB is enabled.
+ *
+ * @param argument is unused.
+ */
 void shutdown(void const * argument)
 {
     UNUSED(argument);
@@ -387,6 +395,7 @@ int main(void)
   if (!(RCC->CSR & RCC_CSR_SFTRSTF)) {
       go_back_to_sleep = 0;
       stop_now = 0;
+      usb_wake_state = 0;
   }
   /* USER CODE END 1 */
 
@@ -438,45 +447,47 @@ int main(void)
 
   encode_serial_number();
 
-  // The Bluetooth module is powered on during MX_GPIO_Init().  BT_CMD
+  if (!go_back_to_sleep) {
-  // has a weak pull-up on the BT module and is in OD mode.  Pull the
+      // The Bluetooth module is powered on during MX_GPIO_Init().  BT_CMD
-  // pin low during boot to enter Bluetooth programming mode.  Here the
+      // has a weak pull-up on the BT module and is in OD mode.  Pull the
-  // BT_CMD pin is switched to input mode to detect the state.  The
+      // pin low during boot to enter Bluetooth programming mode.  Here the
-  // TNC must be reset to exit programming mode.
+      // BT_CMD pin is switched to input mode to detect the state.  The
+      // TNC must be reset to exit programming mode.
 
-  // Wait for BT module to settle.
+      // Wait for BT module to settle.
-  GPIO_InitTypeDef GPIO_InitStructure;
+      GPIO_InitTypeDef GPIO_InitStructure;
 
-  GPIO_InitStructure.Pin = BT_CMD_Pin;
+      GPIO_InitStructure.Pin = BT_CMD_Pin;
-  GPIO_InitStructure.Mode = GPIO_MODE_INPUT;
+      GPIO_InitStructure.Mode = GPIO_MODE_INPUT;
-  GPIO_InitStructure.Pull = GPIO_PULLUP;
+      GPIO_InitStructure.Pull = GPIO_PULLUP;
-  HAL_GPIO_Init(BT_CMD_GPIO_Port, &GPIO_InitStructure);
+      HAL_GPIO_Init(BT_CMD_GPIO_Port, &GPIO_InitStructure);
-  HAL_Delay(10);
+      HAL_Delay(10);
 
-  if (HAL_GPIO_ReadPin(BT_CMD_GPIO_Port, BT_CMD_Pin) == GPIO_PIN_RESET) {
+      if (HAL_GPIO_ReadPin(BT_CMD_GPIO_Port, BT_CMD_Pin) == GPIO_PIN_RESET) {
-      // Special test mode for programming the Bluetooth module.  The TNC
+          // Special test mode for programming the Bluetooth module.  The TNC
-      // has the BT_CMD pin actively being pulled low.  In this case we
+          // has the BT_CMD pin actively being pulled low.  In this case we
-      // power on the BT module with BT_CMD held low and wait here without
+          // power on the BT module with BT_CMD held low and wait here without
-      // initializing the UART.  We only exit via reset.
+          // initializing the UART.  We only exit via reset.
-      HAL_UART_MspDeInit(&huart3);
+          HAL_UART_MspDeInit(&huart3);
 
-      HAL_GPIO_WritePin(BT_RESET_GPIO_Port, BT_RESET_Pin, GPIO_PIN_RESET);
+          HAL_GPIO_WritePin(BT_RESET_GPIO_Port, BT_RESET_Pin, GPIO_PIN_RESET);
-      HAL_Delay(1);
+          HAL_Delay(1);
-      HAL_GPIO_WritePin(BT_RESET_GPIO_Port, BT_RESET_Pin, GPIO_PIN_SET);
+          HAL_GPIO_WritePin(BT_RESET_GPIO_Port, BT_RESET_Pin, GPIO_PIN_SET);
-      HAL_Delay(200);
+          HAL_Delay(200);
 
-      printf("Bluetooth programming mode\r\n");
+          printf("Bluetooth programming mode\r\n");
 
-      while (1);
+          while (1);
+      }
+
+      // Not in BT programming mode.  Switch BT_CMD back to OD mode.
+      HAL_GPIO_WritePin(BT_CMD_GPIO_Port, BT_CMD_Pin, GPIO_PIN_SET);
+      GPIO_InitStructure.Pin = BT_CMD_Pin;
+      GPIO_InitStructure.Mode = GPIO_MODE_OUTPUT_OD;
+      GPIO_InitStructure.Pull = GPIO_PULLUP;
+      HAL_GPIO_Init(BT_CMD_GPIO_Port, &GPIO_InitStructure);
   }
 
-  // Not in BT programming mode.  Switch BT_CMD back to OD mode.
-  HAL_GPIO_WritePin(BT_CMD_GPIO_Port, BT_CMD_Pin, GPIO_PIN_SET);
-  GPIO_InitStructure.Pin = BT_CMD_Pin;
-  GPIO_InitStructure.Mode = GPIO_MODE_OUTPUT_OD;
-  GPIO_InitStructure.Pull = GPIO_PULLUP;
-  HAL_GPIO_Init(BT_CMD_GPIO_Port, &GPIO_InitStructure);
-
   /* USER CODE END 2 */
 
   /* USER CODE BEGIN RTOS_MUTEX */
@@ -581,13 +592,16 @@ int main(void)
   if (HAL_OPAMP_Start(&hopamp1) != HAL_OK) Error_Handler();
   if (HAL_ADCEx_Calibration_Start(&hadc1, ADC_SINGLE_ENDED) != HAL_OK) Error_Handler();
 
-  // Initialize the BM78 Bluetooth module and the RTC date/time the first time we boot.
+  if (!go_back_to_sleep) {
-  if (!bm78_initialized()) {
+
-      bm78_initialize();
+      // Initialize the BM78 Bluetooth module and the RTC date/time the first time we boot.
-      memset(error_message, 0, sizeof(error_message));
+      if (!bm78_initialized()) {
-      // init_rtc_date_time();
+          bm78_initialize();
+          memset(error_message, 0, sizeof(error_message));
+          // init_rtc_date_time();
+      }
+      else bm78_wait_until_ready();
   }
-  else bm78_wait_until_ready();
 
   init_ioport();
   initCDC();
@@ -1269,7 +1283,7 @@ void stop2()
 {
   osThreadSuspendAll();
 
-  GPIO_PinState usb = HAL_GPIO_ReadPin(USB_POWER_GPIO_Port, USB_POWER_Pin);
+  int usb_stop_state = HAL_GPIO_ReadPin(USB_POWER_GPIO_Port, USB_POWER_Pin);
 
   HAL_OPAMP_DeInit(&hopamp1);
   HAL_TIM_PWM_DeInit(&htim1);
@@ -1279,10 +1293,11 @@ void stop2()
   HAL_UART_DeInit(&huart3);
 
   HAL_PWR_DisablePVD();
+  USB->BCDR = 0;
   HAL_PWREx_DisableVddUSB();
   HAL_ADCEx_EnterADCDeepPowerDownMode(&hadc1);
   configure_gpio_for_stop();
-  power_down_vdd();
+  if (!usb_stop_state) power_down_vdd();
 
   HAL_RCCEx_DisableLSCO();
 
@@ -1310,6 +1325,8 @@ void stop2()
       if (powerOnViaUSB()) {
           go_back_to_sleep = 0;
       }
+  } else {
+      charging_enabled = 0;
   }
   HAL_NVIC_SystemReset();
 }
@@ -1412,20 +1429,22 @@ void init_rtc_alarm()
 /* USER CODE END Header_StartDefaultTask */
 void StartDefaultTask(void const * argument)
 {
-  /* init code for USB_DEVICE */
-  MX_USB_DEVICE_Init();
-
   /* USER CODE BEGIN 5 */
-  printf("startDefaultTask\r\n");
   UNUSED(argument);
 
   if (HAL_GPIO_ReadPin(USB_POWER_GPIO_Port, USB_POWER_Pin) == GPIO_PIN_SET)
   {
+#ifdef KISS_LOGGING
     printf("VBUS detected\r\n");
+#endif
+    MX_USB_DEVICE_Init();
     HAL_PCD_MspInit(&hpcd_USB_FS);
+    HAL_PCDEx_ActivateBCD(&hpcd_USB_FS);
     HAL_PCDEx_BCD_VBUSDetect(&hpcd_USB_FS);
   } else {
+#ifdef KISS_LOGGING
     printf("VBUS not detected\r\n");
+#endif
   }
 /* Infinite loop */
   for(;;)
@@ -1474,6 +1493,8 @@ void _Error_Handler(char *file, int line)
 #endif
   snprintf(error_message, sizeof(error_message), "Error: %s:%d", file, line);
 
+  stop_now = 0;
+  go_back_to_sleep = 0;
   NVIC_SystemReset();
   /* USER CODE END Error_Handler_Debug */
 }

TNC/IOEventTask.cpp

@@ -45,18 +45,21 @@ void startIOEventTask(void const*)
         indicate_on();
 
         print_startup_banner();
+    }
 
-        auto& hardware = kiss::settings();
+    auto& hardware = kiss::settings();
 
-        if (! hardware.load() or reset_requested or !hardware.crc_ok())
+    if (! hardware.load() or reset_requested or !hardware.crc_ok())
-        {
+    {
-            if (reset_requested) {
+        if (reset_requested) {
-                INFO("Hardware reset requested.");
+            INFO("Hardware reset requested.");
-            }
-
-            hardware.init();
-            hardware.store();
         }
+
+        hardware.init();
+        hardware.store();
+    }
+
+    if (!go_back_to_sleep) {
         hardware.debug();
 
         audio::init_log_volume();
@@ -96,9 +99,13 @@ void startIOEventTask(void const*)
         }
     } else {
         if (!usb_wake_state) {
+            DEBUG("USB disconnected -- shutdown");
             shutdown(0);
         } else {
-            osTimerStart(usbShutdownTimerHandle, 2000);
+            DEBUG("USB connected -- negotiate");
+            HAL_GPIO_WritePin(BT_SLEEP_GPIO_Port, BT_SLEEP_Pin,
+                GPIO_PIN_RESET);
+            osTimerStart(usbShutdownTimerHandle, 5000);
         }
     }
 
@@ -135,9 +142,11 @@ void startIOEventTask(void const*)
                 break;
             case CMD_USB_DISCONNECTED:
                 INFO("VBUS Lost");
+                charging_enabled = 0;
                 if (powerOffViaUSB()) {
                     shutdown(0); // ***NO RETURN***
                 } else {
+                    hpcd_USB_FS.Instance->BCDR = 0;
                     HAL_PCD_MspDeInit(&hpcd_USB_FS);
                     HAL_GPIO_WritePin(USB_CE_GPIO_Port, USB_CE_Pin, GPIO_PIN_SET);
                     if (ioport != getUsbPort())
@@ -257,6 +266,7 @@ void startIOEventTask(void const*)
                 break;
             case CMD_USB_CONNECTED:
                 INFO("VBUS Detected");
+                MX_USB_DEVICE_Init();
                 HAL_PCD_MspInit(&hpcd_USB_FS);
                 hpcd_USB_FS.Instance->BCDR = 0;
                 HAL_PCDEx_ActivateBCD(&hpcd_USB_FS);
@@ -265,24 +275,26 @@ void startIOEventTask(void const*)
             case CMD_USB_CHARGE_ENABLE:
                 INFO("USB charging enabled");
                 HAL_GPIO_WritePin(USB_CE_GPIO_Port, USB_CE_Pin, GPIO_PIN_RESET);
+                charging_enabled = 1;
+                if (go_back_to_sleep) shutdown(0);
                 break;
             case CMD_USB_DISCOVERY_COMPLETE:
                 INFO("USB discovery complete");
                 osTimerStop(usbShutdownTimerHandle);
-                if (go_back_to_sleep) shutdown(0);
                 USBD_Start(&hUsbDeviceFS);
                 initCDC();
                 break;
             case CMD_USB_DISCOVERY_ERROR:
                 // This happens when powering VBUS from a bench supply.
                 osTimerStop(usbShutdownTimerHandle);
+                HAL_PCDEx_DeActivateBCD(&hpcd_USB_FS);
                 if (HAL_GPIO_ReadPin(USB_POWER_GPIO_Port, USB_POWER_Pin) == GPIO_PIN_SET)
                 {
                     INFO("Not a recognized USB charging device");
                     INFO("USB charging enabled");
                     HAL_GPIO_WritePin(USB_CE_GPIO_Port, USB_CE_Pin, GPIO_PIN_RESET);
+                    charging_enabled = 1;
                 }
-                hpcd_USB_FS.Instance->BCDR = 0;
                 if (go_back_to_sleep) shutdown(0);
                 break;
             case CMD_BT_DEEP_SLEEP:

TNC/KissHardware.cpp

@@ -26,7 +26,7 @@ int powerOffViaUSB(void)
 
 namespace mobilinkd { namespace tnc { namespace kiss {
 
-const char FIRMWARE_VERSION[] = "1.0.0";
+const char FIRMWARE_VERSION[] = "1.0.1";
 const char HARDWARE_VERSION[] = "Mobilinkd TNC3 2.1.1";
 
 Hardware& settings()