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Reduction of floats and implementation of overflow protection

This commit is contained in:
Javier Arigita 2020-04-26 08:36:15 +02:00
parent 12a3aacb98
commit c577a955b0
2 changed files with 79 additions and 43 deletions
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2
tasmota/my_user_config.h
View File

@ -683,7 +683,7 @@
#define THERMOSTAT_TEMP_FROST_PROTECT 40 // Default minimum temperature for frost protection, in tenths of degrees celsius #define THERMOSTAT_TEMP_FROST_PROTECT 40 // Default minimum temperature for frost protection, in tenths of degrees celsius
#define THERMOSTAT_TEMP_RAMPUP_DELTA_IN 4 // Default minimum delta temperature to target to get into rampup mode, in tenths of degrees celsius #define THERMOSTAT_TEMP_RAMPUP_DELTA_IN 4 // Default minimum delta temperature to target to get into rampup mode, in tenths of degrees celsius
#define THERMOSTAT_TEMP_RAMPUP_DELTA_OUT 2 // Default minimum delta temperature to target to get out of the rampup mode, in tenths of degrees celsius #define THERMOSTAT_TEMP_RAMPUP_DELTA_OUT 2 // Default minimum delta temperature to target to get out of the rampup mode, in tenths of degrees celsius
#define THERMOSTAT_TEMP_PI_RAMPUP_ACC_E 20 // Default accumulated error when switching from ramp-up controller to PI #define THERMOSTAT_TEMP_PI_RAMPUP_ACC_E 200 // Default accumulated error when switching from ramp-up controller to PI in hundreths of degrees celsius
#define THERMOSTAT_TIME_OUTPUT_DELAY 180 // Default output delay between state change and real actuation event (f.i. valve open/closed) #define THERMOSTAT_TIME_OUTPUT_DELAY 180 // Default output delay between state change and real actuation event (f.i. valve open/closed)
#define THERMOSTAT_TEMP_INIT 180 // Default init target temperature for the thermostat controller #define THERMOSTAT_TEMP_INIT 180 // Default init target temperature for the thermostat controller

120
tasmota/xdrv_39_thermostat.ino
View File

@ -22,7 +22,7 @@
#define XDRV_39 39 #define XDRV_39 39
// Enable/disable debugging // Enable/disable debugging
//#define DEBUG_THERMOSTAT #define DEBUG_THERMOSTAT
#ifdef DEBUG_THERMOSTAT #ifdef DEBUG_THERMOSTAT
#define DOMOTICZ_IDX1 791 #define DOMOTICZ_IDX1 791
@ -135,12 +135,12 @@ struct THERMOSTAT {
uint32_t timestamp_input_on = 0; // Timestamp of latest input On state uint32_t timestamp_input_on = 0; // Timestamp of latest input On state
uint32_t time_thermostat_total = 0; // Time thermostat on within a specific timeframe uint32_t time_thermostat_total = 0; // Time thermostat on within a specific timeframe
uint32_t time_ctr_checkpoint = 0; // Time to finalize the control cycle within the PI strategy or to switch to PI from Rampup uint32_t time_ctr_checkpoint = 0; // Time to finalize the control cycle within the PI strategy or to switch to PI from Rampup
uint32_t time_ctr_changepoint = 0; // Time until switching off output within the controller uint32_t time_ctr_changepoint = 0; // Time until switching off output within the controller in seconds
int32_t temp_measured_gradient = 0; // Temperature measured gradient from sensor in thousandths of degrees per hour int32_t temp_measured_gradient = 0; // Temperature measured gradient from sensor in thousandths of degrees per hour
int16_t temp_target_level = THERMOSTAT_TEMP_INIT; // Target level of the thermostat in tenths of degrees int16_t temp_target_level = THERMOSTAT_TEMP_INIT; // Target level of the thermostat in tenths of degrees
int16_t temp_target_level_ctr = THERMOSTAT_TEMP_INIT; // Target level set for the controller int16_t temp_target_level_ctr = THERMOSTAT_TEMP_INIT; // Target level set for the controller
int16_t temp_pi_accum_error = 0; // Temperature accumulated error for the PI controller in tenths of degrees int16_t temp_pi_accum_error = 0; // Temperature accumulated error for the PI controller in hundredths of degrees
int16_t temp_pi_error = 0; // Temperature error for the PI controller in tenths of degrees int16_t temp_pi_error = 0; // Temperature error for the PI controller in hundredths of degrees
int32_t time_proportional_pi; // Time proportional part of the PI controller int32_t time_proportional_pi; // Time proportional part of the PI controller
int32_t time_integral_pi; // Time integral part of the PI controller int32_t time_integral_pi; // Time integral part of the PI controller
int32_t time_total_pi; // Time total (proportional + integral) of the PI controller int32_t time_total_pi; // Time total (proportional + integral) of the PI controller
@ -183,7 +183,7 @@ struct THERMOSTAT {
/*********************************************************************************************/ /*********************************************************************************************/
void ThermostatInit() void ThermostatInit(void)
{ {
ExecuteCommandPower(Thermostat.output_relay_number, POWER_OFF, SRC_THERMOSTAT); // Make sure the Output is OFF ExecuteCommandPower(Thermostat.output_relay_number, POWER_OFF, SRC_THERMOSTAT); // Make sure the Output is OFF
// Init Thermostat.status bitfield: // Init Thermostat.status bitfield:
@ -198,7 +198,7 @@ void ThermostatInit()
Thermostat.status.counter_seconds = 0; Thermostat.status.counter_seconds = 0;
} }
bool ThermostatMinuteCounter() bool ThermostatMinuteCounter(void)
{ {
bool result = false; bool result = false;
Thermostat.status.counter_seconds++; // increment time Thermostat.status.counter_seconds++; // increment time
@ -229,7 +229,7 @@ uint8_t ThermostatSwitchStatus(uint8_t input_switch)
else return 255; else return 255;
} }
void ThermostatSignalProcessingSlow() void ThermostatSignalProcessingSlow(void)
{ {
if ((uptime - Thermostat.timestamp_temp_measured_update) > ((uint32_t)Thermostat.time_sens_lost * 60)) { // Check if sensor alive if ((uptime - Thermostat.timestamp_temp_measured_update) > ((uint32_t)Thermostat.time_sens_lost * 60)) { // Check if sensor alive
Thermostat.status.sensor_alive = IFACE_OFF; Thermostat.status.sensor_alive = IFACE_OFF;
@ -238,14 +238,14 @@ void ThermostatSignalProcessingSlow()
} }
} }
void ThermostatSignalProcessingFast() void ThermostatSignalProcessingFast(void)
{ {
if (ThermostatSwitchStatus(Thermostat.input_switch_number)) { // Check if input switch active and register last update if (ThermostatSwitchStatus(Thermostat.input_switch_number)) { // Check if input switch active and register last update
Thermostat.timestamp_input_on = uptime; Thermostat.timestamp_input_on = uptime;
} }
} }
void ThermostatCtrState() void ThermostatCtrState(void)
{ {
switch (Thermostat.status.controller_mode) { switch (Thermostat.status.controller_mode) {
case CTR_HYBRID: // Hybrid controller (Ramp-up + PI) case CTR_HYBRID: // Hybrid controller (Ramp-up + PI)
@ -258,7 +258,7 @@ void ThermostatCtrState()
} }
} }
void ThermostatHybridCtrPhase() void ThermostatHybridCtrPhase(void)
{ {
if (Thermostat.status.controller_mode == CTR_HYBRID) { if (Thermostat.status.controller_mode == CTR_HYBRID) {
switch (Thermostat.status.phase_hybrid_ctr) { switch (Thermostat.status.phase_hybrid_ctr) {
@ -300,7 +300,7 @@ void ThermostatHybridCtrPhase()
#endif #endif
} }
bool HeatStateAutoToManual() bool HeatStateAutoToManual(void)
{ {
bool change_state = false; bool change_state = false;
@ -314,7 +314,7 @@ bool HeatStateAutoToManual()
return change_state; return change_state;
} }
bool HeatStateManualToAuto() bool HeatStateManualToAuto(void)
{ {
bool change_state; bool change_state;
@ -330,7 +330,7 @@ bool HeatStateManualToAuto()
return change_state; return change_state;
} }
bool HeatStateAllToOff() bool HeatStateAllToOff(void)
{ {
bool change_state; bool change_state;
@ -341,7 +341,7 @@ bool HeatStateAllToOff()
return change_state; return change_state;
} }
void ThermostatState() void ThermostatState(void)
{ {
switch (Thermostat.status.thermostat_mode) { switch (Thermostat.status.thermostat_mode) {
case THERMOSTAT_OFF: // State if Off or Emergency case THERMOSTAT_OFF: // State if Off or Emergency
@ -394,14 +394,28 @@ void ThermostatOutputRelay(bool active)
} }
} }
void ThermostatCalculatePI() void ThermostatCalculatePI(void)
{ {
int32_t aux_time_error;
// Calculate error // Calculate error
Thermostat.temp_pi_error = Thermostat.temp_target_level_ctr - Thermostat.temp_measured; aux_time_error = (int32_t)(Thermostat.temp_target_level_ctr - Thermostat.temp_measured) * 10;
// Protect overflow
if (aux_time_error >= (int32_t)(INT16_MIN)) {
Thermostat.temp_pi_error = (int16_t)(INT16_MIN);
}
else if (aux_time_error <= (int32_t)INT16_MAX) {
Thermostat.temp_pi_error = (int16_t)INT16_MAX;
}
else {
Thermostat.temp_pi_error = (int16_t)aux_time_error;
}
// Kp = 100/PI.propBand. PI.propBand(Xp) = Proportional range (4K in 4K/200 controller) // Kp = 100/PI.propBand. PI.propBand(Xp) = Proportional range (4K in 4K/200 controller)
Thermostat.kP_pi = 100 / (uint16_t)(Thermostat.val_prop_band); Thermostat.kP_pi = 100 / (uint16_t)(Thermostat.val_prop_band);
// Calculate proportional // Calculate proportional
Thermostat.time_proportional_pi = ((int32_t)(Thermostat.temp_pi_error * (int16_t)Thermostat.kP_pi) * ((int32_t)Thermostat.time_pi_cycle * 60)) / 1000; Thermostat.time_proportional_pi = ((int32_t)(Thermostat.temp_pi_error * (int16_t)Thermostat.kP_pi) * ((int32_t)Thermostat.time_pi_cycle * 60)) / 10000;
// Minimum proportional action limiter // Minimum proportional action limiter
// If proportional action is less than the minimum action time // If proportional action is less than the minimum action time
@ -419,13 +433,14 @@ void ThermostatCalculatePI()
Thermostat.time_proportional_pi = ((int32_t)Thermostat.time_pi_cycle * 60); Thermostat.time_proportional_pi = ((int32_t)Thermostat.time_pi_cycle * 60);
} }
// Calculate integral // Calculate integral (resolution increased to avoid use of floats in consequent operations)
Thermostat.kI_pi = (uint16_t)(((float)Thermostat.kP_pi * ((float)((uint32_t)Thermostat.time_pi_cycle * 60) / (float)Thermostat.time_reset)) * 100); //Thermostat.kI_pi = (uint16_t)(((float)Thermostat.kP_pi * ((float)((uint32_t)Thermostat.time_pi_cycle * 60) / (float)Thermostat.time_reset)) * 100);
Thermostat.kI_pi = (uint16_t)((((uint32_t)Thermostat.kP_pi * (uint32_t)Thermostat.time_pi_cycle * 6000)) / (uint32_t)Thermostat.time_reset);
// Reset of antiwindup // Reset of antiwindup
// If error does not lay within the integrator scope range, do not use the integral // If error does not lay within the integrator scope range, do not use the integral
// and accumulate error = 0 // and accumulate error = 0
if (abs(Thermostat.temp_pi_error) > (int16_t)Thermostat.temp_reset_anti_windup) { if (abs((Thermostat.temp_pi_error) / 10) > Thermostat.temp_reset_anti_windup) {
Thermostat.time_integral_pi = 0; Thermostat.time_integral_pi = 0;
Thermostat.temp_pi_accum_error = 0; Thermostat.temp_pi_accum_error = 0;
} }
@ -440,13 +455,26 @@ void ThermostatCalculatePI()
// very high cummulated error when beingin hysteresis. This triggers high // very high cummulated error when beingin hysteresis. This triggers high
// integral actions // integral actions
// Update accumulated error
aux_time_error = (int32_t)Thermostat.temp_pi_accum_error + (int32_t)Thermostat.temp_pi_error;
// Protect overflow
if (aux_time_error >= (int32_t)INT16_MIN) {
Thermostat.temp_pi_accum_error = INT16_MIN;
}
else if (aux_time_error <= (int32_t)INT16_MAX) {
Thermostat.temp_pi_accum_error = INT16_MAX;
}
else {
Thermostat.temp_pi_accum_error = (int16_t)aux_time_error;
}
// If we are under setpoint // If we are under setpoint
// AND we are within the hysteresis // AND we are within the hysteresis
// AND we are rising // AND we are rising
if ((Thermostat.temp_pi_error >= 0) if ((Thermostat.temp_pi_error >= 0)
&& (abs(Thermostat.temp_pi_error) <= (int16_t)Thermostat.temp_hysteresis) && (abs((Thermostat.temp_pi_error) / 10) <= (int16_t)Thermostat.temp_hysteresis)
&& (Thermostat.temp_measured_gradient > 0)) { && (Thermostat.temp_measured_gradient > 0)) {
Thermostat.temp_pi_accum_error += Thermostat.temp_pi_error;
// Reduce accumulator error 20% in each cycle // Reduce accumulator error 20% in each cycle
Thermostat.temp_pi_accum_error *= 0.8; Thermostat.temp_pi_accum_error *= 0.8;
} }
@ -454,13 +482,9 @@ void ThermostatCalculatePI()
// AND temperature is rising // AND temperature is rising
else if ((Thermostat.temp_pi_error < 0) else if ((Thermostat.temp_pi_error < 0)
&& (Thermostat.temp_measured_gradient > 0)) { && (Thermostat.temp_measured_gradient > 0)) {
Thermostat.temp_pi_accum_error += Thermostat.temp_pi_error;
// Reduce accumulator error 20% in each cycle // Reduce accumulator error 20% in each cycle
Thermostat.temp_pi_accum_error *= 0.8; Thermostat.temp_pi_accum_error *= 0.8;
} }
else {
Thermostat.temp_pi_accum_error += Thermostat.temp_pi_error;
}
// Limit lower limit of acumErr to 0 // Limit lower limit of acumErr to 0
if (Thermostat.temp_pi_accum_error < 0) { if (Thermostat.temp_pi_accum_error < 0) {
@ -468,7 +492,7 @@ void ThermostatCalculatePI()
} }
// Integral calculation // Integral calculation
Thermostat.time_integral_pi = (((int32_t)Thermostat.temp_pi_accum_error * (int32_t)Thermostat.kI_pi) * (int32_t)((uint32_t)Thermostat.time_pi_cycle * 60)) / 100000; Thermostat.time_integral_pi = (((int32_t)Thermostat.temp_pi_accum_error * (int32_t)Thermostat.kI_pi) * (int32_t)((uint32_t)Thermostat.time_pi_cycle * 60)) / 1000000;
// Antiwindup of the integrator // Antiwindup of the integrator
// If integral calculation is bigger than cycle time, adjust result // If integral calculation is bigger than cycle time, adjust result
@ -496,7 +520,7 @@ void ThermostatCalculatePI()
// If target value has been reached or we are over it]] // If target value has been reached or we are over it]]
if (Thermostat.temp_pi_error <= 0) { if (Thermostat.temp_pi_error <= 0) {
// If we are over the hysteresis or the gradient is positive // If we are over the hysteresis or the gradient is positive
if ((abs(Thermostat.temp_pi_error) > Thermostat.temp_hysteresis) if ((abs((Thermostat.temp_pi_error) / 10) > Thermostat.temp_hysteresis)
|| (Thermostat.temp_measured_gradient >= 0)) { || (Thermostat.temp_measured_gradient >= 0)) {
Thermostat.time_total_pi = 0; Thermostat.time_total_pi = 0;
} }
@ -506,7 +530,7 @@ void ThermostatCalculatePI()
// AND gradient is positive // AND gradient is positive
// then set value to 0 // then set value to 0
else if ((Thermostat.temp_pi_error > 0) else if ((Thermostat.temp_pi_error > 0)
&& (abs(Thermostat.temp_pi_error) <= Thermostat.temp_hysteresis) && (abs((Thermostat.temp_pi_error) / 10) <= Thermostat.temp_hysteresis)
&& (Thermostat.temp_measured_gradient > 0)) { && (Thermostat.temp_measured_gradient > 0)) {
Thermostat.time_total_pi = 0; Thermostat.time_total_pi = 0;
} }
@ -533,7 +557,7 @@ void ThermostatCalculatePI()
Thermostat.time_ctr_checkpoint = uptime + ((uint32_t)Thermostat.time_pi_cycle * 60); Thermostat.time_ctr_checkpoint = uptime + ((uint32_t)Thermostat.time_pi_cycle * 60);
} }
void ThermostatWorkAutomaticPI() void ThermostatWorkAutomaticPI(void)
{ {
char result_chr[FLOATSZ]; // Remove! char result_chr[FLOATSZ]; // Remove!
@ -556,8 +580,9 @@ void ThermostatWorkAutomaticPI()
} }
} }
void ThermostatWorkAutomaticRampUp() void ThermostatWorkAutomaticRampUp(void)
{ {
int32_t aux_temp_delta;
uint32_t time_in_rampup; uint32_t time_in_rampup;
int16_t temp_delta_rampup; int16_t temp_delta_rampup;
@ -615,7 +640,18 @@ void ThermostatWorkAutomaticRampUp()
// Better Alternative -> (y-y1)/(x-x1) = ((y2-y1)/(x2-x1)) -> where y = temp (target) and x = time (to switch off, what its needed) // Better Alternative -> (y-y1)/(x-x1) = ((y2-y1)/(x2-x1)) -> where y = temp (target) and x = time (to switch off, what its needed)
// x = ((y-y1)/(y2-y1))*(x2-x1) + x1 - deadtime // x = ((y-y1)/(y2-y1))*(x2-x1) + x1 - deadtime
// Thermostat.time_ctr_changepoint = (uint32_t)(((float)(Thermostat.temp_target_level_ctr - Thermostat.temp_rampup_cycle) / (float)temp_delta_rampup) * (float)(time_total_rampup)) + (uint32_t)(Thermostat.time_rampup_nextcycle - (time_total_rampup)) - Thermostat.time_rampup_deadtime; // Thermostat.time_ctr_changepoint = (uint32_t)(((float)(Thermostat.temp_target_level_ctr - Thermostat.temp_rampup_cycle) / (float)temp_delta_rampup) * (float)(time_total_rampup)) + (uint32_t)(Thermostat.time_rampup_nextcycle - (time_total_rampup)) - Thermostat.time_rampup_deadtime;
Thermostat.time_ctr_changepoint = (uint32_t)(((float)(Thermostat.temp_target_level_ctr - Thermostat.temp_rampup_cycle) * (float)(time_total_rampup)) / (float)temp_delta_rampup) + (uint32_t)(Thermostat.time_rampup_nextcycle - (time_total_rampup)) - Thermostat.time_rampup_deadtime; //Thermostat.time_ctr_changepoint = (uint32_t)(((float)(Thermostat.temp_target_level_ctr - Thermostat.temp_rampup_cycle) * (float)(time_total_rampup)) / (float)temp_delta_rampup) + (uint32_t)(Thermostat.time_rampup_nextcycle - (time_total_rampup)) - Thermostat.time_rampup_deadtime;
aux_temp_delta = (int32_t)(Thermostat.temp_target_level_ctr - Thermostat.temp_rampup_cycle);
// Protect overflow, if temperature goes down set max
if ((aux_temp_delta < 0)
||(temp_delta_rampup <= 0)) {
Thermostat.time_ctr_changepoint = uptime + (uint32_t)(60 * Thermostat.time_rampup_max);
}
else {
Thermostat.time_ctr_changepoint = (uint32_t)(uint32_t)(((uint32_t)(aux_temp_delta) * (uint32_t)(time_total_rampup)) / (uint32_t)temp_delta_rampup) + (uint32_t)Thermostat.time_rampup_nextcycle - (uint32_t)time_total_rampup - (uint32_t)Thermostat.time_rampup_deadtime;
}
// Calculate temperature for switching off the output // Calculate temperature for switching off the output
// y = (((y2-y1)/(x2-x1))*(x-x1)) + y1 // y = (((y2-y1)/(x2-x1))*(x-x1)) + y1
@ -668,7 +704,7 @@ void ThermostatWorkAutomaticRampUp()
} }
} }
void ThermostatCtrWork() void ThermostatCtrWork(void)
{ {
switch (Thermostat.status.controller_mode) { switch (Thermostat.status.controller_mode) {
case CTR_HYBRID: // Hybrid controller (Ramp-up + PI) case CTR_HYBRID: // Hybrid controller (Ramp-up + PI)
@ -690,7 +726,7 @@ void ThermostatCtrWork()
} }
} }
void ThermostatWork() void ThermostatWork(void)
{ {
switch (Thermostat.status.thermostat_mode) { switch (Thermostat.status.thermostat_mode) {
case THERMOSTAT_OFF: // State if Off or Emergency case THERMOSTAT_OFF: // State if Off or Emergency
@ -719,7 +755,7 @@ void ThermostatWork()
ThermostatOutputRelay(output_command); ThermostatOutputRelay(output_command);
} }
void ThermostatDiagnostics() void ThermostatDiagnostics(void)
{ {
// TODOs: // TODOs:
// 1. Check time max for output switch on not exceeded // 1. Check time max for output switch on not exceeded
@ -727,7 +763,7 @@ void ThermostatDiagnostics()
// 3. Check maximum power at output switch not exceeded // 3. Check maximum power at output switch not exceeded
} }
void ThermostatController() void ThermostatController(void)
{ {
ThermostatState(); ThermostatState();
ThermostatWork(); ThermostatWork();
@ -748,21 +784,21 @@ bool ThermostatTimerArm(int16_t tempVal)
return result; return result;
} }
void ThermostatTimerDisarm() void ThermostatTimerDisarm(void)
{ {
Thermostat.temp_target_level = THERMOSTAT_TEMP_INIT; Thermostat.temp_target_level = THERMOSTAT_TEMP_INIT;
Thermostat.status.thermostat_mode = THERMOSTAT_OFF; Thermostat.status.thermostat_mode = THERMOSTAT_OFF;
} }
#ifdef DEBUG_THERMOSTAT #ifdef DEBUG_THERMOSTAT
void ThermostatVirtualSwitch() void ThermostatVirtualSwitch(void)
{ {
char domoticz_in_topic[] = DOMOTICZ_IN_TOPIC; char domoticz_in_topic[] = DOMOTICZ_IN_TOPIC;
Response_P(DOMOTICZ_MES, DOMOTICZ_IDX1, (0 == Thermostat.status.status_output) ? 0 : 1, ""); Response_P(DOMOTICZ_MES, DOMOTICZ_IDX1, (0 == Thermostat.status.status_output) ? 0 : 1, "");
MqttPublish(domoticz_in_topic); MqttPublish(domoticz_in_topic);
} }
void ThermostatVirtualSwitchCtrState() void ThermostatVirtualSwitchCtrState(void)
{ {
char domoticz_in_topic[] = DOMOTICZ_IN_TOPIC; char domoticz_in_topic[] = DOMOTICZ_IN_TOPIC;
Response_P(DOMOTICZ_MES, DOMOTICZ_IDX2, (0 == Thermostat.status.phase_hybrid_ctr) ? 0 : 1, ""); Response_P(DOMOTICZ_MES, DOMOTICZ_IDX2, (0 == Thermostat.status.phase_hybrid_ctr) ? 0 : 1, "");
@ -1095,12 +1131,12 @@ void CmndTimeRampupCycleSet(void)
void CmndTempRampupPiAccErrSet(void) void CmndTempRampupPiAccErrSet(void)
{ {
if (XdrvMailbox.data_len > 0) { if (XdrvMailbox.data_len > 0) {
uint8_t value = (uint8_t)(CharToFloat(XdrvMailbox.data) * 10); uint16_t value = (uint8_t)(CharToFloat(XdrvMailbox.data) * 100);
if ((value >= 0) && (value <= 250)) { if ((value >= 0) && (value <= 2500)) {
Thermostat.temp_rampup_pi_acc_error = value; Thermostat.temp_rampup_pi_acc_error = value;
} }
} }
ResponseCmndFloat((float)(Thermostat.temp_rampup_pi_acc_error) / 10, 1); ResponseCmndFloat((float)(Thermostat.temp_rampup_pi_acc_error) / 100, 1);
} }
void CmndTimePiProportRead(void) void CmndTimePiProportRead(void)