charge_manager: Enter safe mode at boot

Charge port / current selection often needs to be significantly altered
when a battery cannot provide sufficient charge, so have charge_manager
initially enter safe mode. After a battery with sufficient capacity has
been identified, charge manager will leave safe mode, and port / current
selection will return to standard rules.

BUG=chromium:777596
BRANCH=None
TEST=Pass charge_manager unit tests. On kevin, remove battery, attach
Apple PD charger, verify safe mode is not exited and device does not
brown out. Hot-plug battery and verify safe mode is exited. Next,
remove battery, attach to Samus, verify safe mode is not exited and
device doesn't brown out. Hot-plug battery, verify that safe mode is
exited and no active charge port, due to dual-role exclusion.

Change-Id: I7784865750087a037aad8dbbac058b22c77ba6d4
Signed-off-by: Shawn Nematbakhsh <shawnn@chromium.org>
Reviewed-on: https://chromium-review.googlesource.com/733954
Commit-Ready: Shawn N <shawnn@chromium.org>
Tested-by: Shawn N <shawnn@chromium.org>
Reviewed-by: Vincent Palatin <vpalatin@chromium.org>

18 files changed, 5 insertions, 223 deletions

diff --git a/board/coral/board.c b/board/coral/board.c
index 650b89d317..a862541c1b 100644
--- a/board/coral/board.c
+++ b/board/coral/board.c
@@ -593,17 +593,6 @@ int board_set_active_charge_port(int charge_port)
 {
 	enum bd9995x_charge_port bd9995x_port;
 	int bd9995x_port_select = 1;
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
 
 	switch (charge_port) {
 	case USB_PD_PORT_ANX74XX:
@@ -632,7 +621,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return bd9995x_select_input_port(bd9995x_port, bd9995x_port_select);
 }
diff --git a/board/elm/board.c b/board/elm/board.c
index 6d7d9746bb..701f61ac6c 100644
--- a/board/elm/board.c
+++ b/board/elm/board.c
@@ -289,17 +289,6 @@ int board_set_active_charge_port(int charge_port)
 			    charge_port < CONFIG_USB_PD_PORT_COUNT);
 	/* check if we are source VBUS on the port */
 	int source = gpio_get_level(GPIO_USB_C0_5V_EN);
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
 
 	if (is_real_port && source) {
 		CPRINTF("Skip enable p%d", charge_port);
@@ -316,7 +305,6 @@ int board_set_active_charge_port(int charge_port)
 		gpio_set_level(GPIO_USB_C0_CHARGE_L, 0);
 	}
 
-	initialized = 1;
 	return EC_SUCCESS;
 }
 
diff --git a/board/eve/board.c b/board/eve/board.c
index ca5b43d63c..d6b4d87c38 100644
--- a/board/eve/board.c
+++ b/board/eve/board.c
@@ -472,17 +472,6 @@ int board_set_active_charge_port(int charge_port)
 {
 	enum bd9995x_charge_port bd9995x_port;
 	int bd9995x_port_select = 1;
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
 
 	switch (charge_port) {
 	case 0:
@@ -511,7 +500,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return bd9995x_select_input_port(bd9995x_port, bd9995x_port_select);
 }
diff --git a/board/fizz/board.h b/board/fizz/board.h
index a1203c140a..1e79eb97a1 100644
--- a/board/fizz/board.h
+++ b/board/fizz/board.h
@@ -64,6 +64,7 @@
 
 /* Charger */
 #define CONFIG_CHARGE_MANAGER
+#undef  CONFIG_CHARGE_MANAGER_SAFE_MODE
 
 #define CONFIG_CHARGER_LIMIT_POWER_THRESH_CHG_MW 50000
 
diff --git a/board/grunt/board.c b/board/grunt/board.c
index cd2ebcd215..9a4b341ee7 100644
--- a/board/grunt/board.c
+++ b/board/grunt/board.c
@@ -356,18 +356,6 @@ int pd_snk_is_vbus_provided(int port)
  */
 int board_set_active_charge_port(int charge_port)
 {
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
-
 	switch (charge_port) {
 	case 0:
 		/* Don't charge from a source port */
@@ -395,7 +383,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return EC_SUCCESS;
 }
diff --git a/board/kahlee/board.c b/board/kahlee/board.c
index 3826d4a181..159063aa51 100644
--- a/board/kahlee/board.c
+++ b/board/kahlee/board.c
@@ -356,18 +356,6 @@ int pd_snk_is_vbus_provided(int port)
  */
 int board_set_active_charge_port(int charge_port)
 {
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
-
 	switch (charge_port) {
 	case 0:
 		/* Don't charge from a source port */
@@ -395,7 +383,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return EC_SUCCESS;
 }
diff --git a/board/kevin/board.c b/board/kevin/board.c
index c10a93c0bd..41d987597d 100644
--- a/board/kevin/board.c
+++ b/board/kevin/board.c
@@ -208,19 +208,6 @@ int board_set_active_charge_port(int charge_port)
 {
 	enum bd9995x_charge_port bd9995x_port;
 	int bd9995x_port_select = 1;
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON) {
-		CPRINTS("Bat critical, don't stop charging");
-		return -1;
-	}
 
 	switch (charge_port) {
 	case 0: case 1:
@@ -240,7 +227,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return bd9995x_select_input_port(bd9995x_port, bd9995x_port_select);
 }
@@ -248,17 +234,6 @@ int board_set_active_charge_port(int charge_port)
 void board_set_charge_limit(int port, int supplier, int charge_ma,
 			    int max_ma, int charge_mv)
 {
-	/*
-	 * Ignore lower charge ceiling on PD transition if our battery is
-	 * critical, as we may brownout.
-	 */
-	if (supplier == CHARGE_SUPPLIER_PD &&
-	    charge_ma < 1500 &&
-	    charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON) {
-		CPRINTS("Using max ilim %d", max_ma);
-		charge_ma = max_ma;
-	}
-
 	charge_set_input_current_limit(MAX(charge_ma,
 			       CONFIG_CHARGER_INPUT_CURRENT), charge_mv);
 }
diff --git a/board/nautilus/board.c b/board/nautilus/board.c
index a8e1a7d630..97ccb674e6 100644
--- a/board/nautilus/board.c
+++ b/board/nautilus/board.c
@@ -708,7 +708,6 @@ DECLARE_HOOK(HOOK_AC_CHANGE, board_extpower, HOOK_PRIO_DEFAULT);
  */
 int board_set_active_charge_port(int charge_port)
 {
-	static uint8_t initialized;
 	/* charge port is a physical port */
 	int is_real_port = (charge_port >= 0 &&
 			    charge_port < CONFIG_USB_PD_PORT_COUNT);
@@ -721,13 +720,6 @@ int board_set_active_charge_port(int charge_port)
 		return EC_ERROR_INVAL;
 	}
 
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON) {
-		CPRINTS("Bat critical, don't stop charging");
-		return -1;
-	}
-
 	CPRINTF("New chg p%d", charge_port);
 
 	if (charge_port == CHARGE_PORT_NONE) {
@@ -743,7 +735,6 @@ int board_set_active_charge_port(int charge_port)
 					     GPIO_USB_C0_CHARGE_L, 0);
 	}
 
-	initialized = 1;
 	return EC_SUCCESS;
 }
 
diff --git a/board/nefario/board.c b/board/nefario/board.c
index 30657fcc78..9016198162 100644
--- a/board/nefario/board.c
+++ b/board/nefario/board.c
@@ -190,20 +190,6 @@ int board_set_active_charge_port(int charge_port)
 {
 	enum bd9995x_charge_port bd9995x_port;
 	int bd9995x_port_select = 1;
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    (charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON ||
-	    battery_get_disconnect_state() == BATTERY_DISCONNECTED)) {
-		CPRINTS("Bat critical, don't stop charging");
-		return -1;
-	}
 
 	CPRINTS("New chg p%d", charge_port);
 
@@ -224,25 +210,12 @@ int board_set_active_charge_port(int charge_port)
 		break;
 	}
 
-	initialized = 1;
 	return bd9995x_select_input_port(bd9995x_port, bd9995x_port_select);
 }
 
 void board_set_charge_limit(int port, int supplier, int charge_ma,
 			    int max_ma, int charge_mv)
 {
-	/*
-	 * Ignore lower charge ceiling on PD transition if our battery is
-	 * critical, as we may brownout.
-	 */
-	if (supplier == CHARGE_SUPPLIER_PD &&
-	    charge_ma < 1500 &&
-	    (charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON ||
-	    battery_get_disconnect_state() == BATTERY_DISCONNECTED)) {
-		CPRINTS("Using max ilim %d", max_ma);
-		charge_ma = max_ma;
-	}
-
 	charge_set_input_current_limit(
 		MAX(charge_ma, CONFIG_CHARGER_INPUT_CURRENT), charge_mv);
 }
diff --git a/board/poppy/board.c b/board/poppy/board.c
index b80be0b7dd..513f17441c 100644
--- a/board/poppy/board.c
+++ b/board/poppy/board.c
@@ -748,7 +748,6 @@ DECLARE_HOOK(HOOK_AC_CHANGE, board_extpower, HOOK_PRIO_DEFAULT);
  */
 int board_set_active_charge_port(int charge_port)
 {
-	static uint8_t initialized;
 	/* charge port is a physical port */
 	int is_real_port = (charge_port >= 0 &&
 			    charge_port < CONFIG_USB_PD_PORT_COUNT);
@@ -761,13 +760,6 @@ int board_set_active_charge_port(int charge_port)
 		return EC_ERROR_INVAL;
 	}
 
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON) {
-		CPRINTS("Bat critical, don't stop charging");
-		return -1;
-	}
-
 	CPRINTF("New chg p%d", charge_port);
 
 	if (charge_port == CHARGE_PORT_NONE) {
@@ -783,7 +775,6 @@ int board_set_active_charge_port(int charge_port)
 					     GPIO_USB_C0_CHARGE_L, 0);
 	}
 
-	initialized = 1;
 	return EC_SUCCESS;
 }
 
diff --git a/board/reef/board.c b/board/reef/board.c
index cff56b7657..4431adab25 100644
--- a/board/reef/board.c
+++ b/board/reef/board.c
@@ -585,17 +585,6 @@ int board_set_active_charge_port(int charge_port)
 {
 	enum bd9995x_charge_port bd9995x_port;
 	int bd9995x_port_select = 1;
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
 
 	switch (charge_port) {
 	case USB_PD_PORT_ANX74XX:
@@ -624,7 +613,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return bd9995x_select_input_port(bd9995x_port, bd9995x_port_select);
 }
diff --git a/board/reef_it8320/board.c b/board/reef_it8320/board.c
index a7f275a9f4..8256cd1a3e 100644
--- a/board/reef_it8320/board.c
+++ b/board/reef_it8320/board.c
@@ -370,17 +370,6 @@ int board_set_active_charge_port(int charge_port)
 {
 	enum bd9995x_charge_port bd9995x_port = 0;
 	int bd9995x_port_select = 1;
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
 
 	switch (charge_port) {
 	case 0:
@@ -409,7 +398,6 @@ int board_set_active_charge_port(int charge_port)
 	}
 
 	CPRINTS("New chg p%d", charge_port);
-	initialized = 1;
 
 	return bd9995x_select_input_port(bd9995x_port, bd9995x_port_select);
 }
diff --git a/board/rowan/board.c b/board/rowan/board.c
index b3e09679bd..31e0da5cea 100644
--- a/board/rowan/board.c
+++ b/board/rowan/board.c
@@ -303,17 +303,6 @@ int board_set_active_charge_port(int charge_port)
 			    charge_port < CONFIG_USB_PD_PORT_COUNT);
 	/* check if we are source VBUS on the port */
 	int source = gpio_get_level(GPIO_USB_C0_5V_EN);
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < 2)
-		return -1;
 
 	if (is_real_port && source) {
 		CPRINTF("Skip enable p%d", charge_port);
@@ -330,7 +319,6 @@ int board_set_active_charge_port(int charge_port)
 		gpio_set_level(GPIO_USB_C0_CHARGE_L, 0);
 	}
 
-	initialized = 1;
 	return EC_SUCCESS;
 }
 
diff --git a/board/samus_pd/board.c b/board/samus_pd/board.c
index 4a617ede97..3087b9ce03 100644
--- a/board/samus_pd/board.c
+++ b/board/samus_pd/board.c
@@ -475,6 +475,8 @@ static void board_update_battery_soc(int soc)
 {
 	if (batt_soc != soc) {
 		batt_soc = soc;
+		if (batt_soc >= CONFIG_CHARGE_MANAGER_BAT_PCT_SAFE_MODE_EXIT)
+			charge_manager_leave_safe_mode();
 		board_update_charge_limit(desired_charge_rate_ma);
 		hook_notify(HOOK_BATTERY_SOC_CHANGE);
 	}
diff --git a/board/samus_pd/board.h b/board/samus_pd/board.h
index 4aaae34fcc..300b308dac 100644
--- a/board/samus_pd/board.h
+++ b/board/samus_pd/board.h
@@ -21,6 +21,7 @@
 #define CONFIG_BOARD_PRE_INIT
 #define CONFIG_CHARGE_MANAGER
 #define CONFIG_CHARGE_RAMP_SW
+#undef  CONFIG_CMD_CHARGE_SUPPLIER_INFO
 #undef  CONFIG_CMD_HASH
 #undef  CONFIG_CMD_HCDEBUG
 #undef  CONFIG_CMD_I2C_SCAN
diff --git a/board/scarlet/board.c b/board/scarlet/board.c
index f496abcda9..f0899842ff 100644
--- a/board/scarlet/board.c
+++ b/board/scarlet/board.c
@@ -166,21 +166,6 @@ uint16_t tcpc_get_alert_status(void)
 
 int board_set_active_charge_port(int charge_port)
 {
-	static int initialized;
-
-	/*
-	 * Reject charge port disable if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    charge_port == CHARGE_PORT_NONE &&
-	    (charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON ||
-	    battery_get_disconnect_state() == BATTERY_DISCONNECTED)) {
-		CPRINTS("Bat critical, don't stop charging");
-		return -1;
-	}
-
 	CPRINTS("New chg p%d", charge_port);
 
 	switch (charge_port) {
@@ -198,25 +183,12 @@ int board_set_active_charge_port(int charge_port)
 		break;
 	}
 
-	initialized = 1;
 	return EC_SUCCESS;
 }
 
 void board_set_charge_limit(int port, int supplier, int charge_ma,
 			    int max_ma, int charge_mv)
 {
-	/*
-	 * Ignore lower charge ceiling on PD transition if our battery is
-	 * critical, as we may brownout.
-	 */
-	if (supplier == CHARGE_SUPPLIER_PD &&
-	    charge_ma < 1500 &&
-	    (charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON ||
-	    battery_get_disconnect_state() == BATTERY_DISCONNECTED)) {
-		CPRINTS("Using max ilim %d", max_ma);
-		charge_ma = max_ma;
-	}
-
 	charge_set_input_current_limit(MAX(charge_ma,
 			       CONFIG_CHARGER_INPUT_CURRENT), charge_mv);
 }
diff --git a/board/servo_v4/board.h b/board/servo_v4/board.h
index 8b81800466..aef30865b6 100644
--- a/board/servo_v4/board.h
+++ b/board/servo_v4/board.h
@@ -91,6 +91,7 @@
 #undef CONFIG_TASK_PROFILING
 
 #define CONFIG_CHARGE_MANAGER
+#undef  CONFIG_CHARGE_MANAGER_SAFE_MODE
 #define CONFIG_USB_POWER_DELIVERY
 #define CONFIG_CMD_PD
 #define CONFIG_USB_PD_DUAL_ROLE
diff --git a/board/zoombini/board.c b/board/zoombini/board.c
index 59aca1962f..61aabdb543 100644
--- a/board/zoombini/board.c
+++ b/board/zoombini/board.c
@@ -256,24 +256,11 @@ int board_set_active_charge_port(int port)
 {
 	int is_real_port = (port >= 0 &&
 			    port < CONFIG_USB_PD_PORT_COUNT);
-	static int initialized;
 	int i;
 
 	if (!is_real_port && port != CHARGE_PORT_NONE)
 		return EC_ERROR_INVAL;
 
-	/*
-	 * Reject charge port none if our battery is critical and we
-	 * have yet to initialize a charge port - continue to charge using
-	 * charger ROM / POR settings.
-	 */
-	if (!initialized &&
-	    port == CHARGE_PORT_NONE &&
-	    charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON) {
-		CPRINTS("Bat critical, don't stop charging");
-		return EC_ERROR_BUSY;
-	}
-
 	CPRINTS("New chg p%d", port);
 
 	if (port == CHARGE_PORT_NONE) {
@@ -281,7 +268,6 @@ int board_set_active_charge_port(int port)
 		gpio_set_level(GPIO_USB_C0_CHARGE_EN_L, 1);
 		gpio_set_level(GPIO_USB_C1_CHARGE_EN_L, 1);
 		gpio_set_level(GPIO_USB_C2_CHARGE_EN_L, 1);
-		initialized = 1;
 		return EC_SUCCESS;
 	}
 
@@ -297,7 +283,6 @@ int board_set_active_charge_port(int port)
 	gpio_set_level(GPIO_USB_C0_CHARGE_EN_L, port != 0);
 	gpio_set_level(GPIO_USB_C1_CHARGE_EN_L, port != 1);
 	gpio_set_level(GPIO_USB_C2_CHARGE_EN_L, port != 2);
-	initialized = 1;
 
 	/*
 	 * Turn on the PP2 FET such that power actually flows and turn off the
@@ -316,18 +301,6 @@ void board_set_charge_limit(int port, int supplier, int charge_ma,
 			    int max_ma, int charge_mv)
 {
 	/*
-	 * Ignore lower charge ceiling on PD transition if our battery is
-	 * critical, as we may brownout.
-	 */
-	if (supplier == CHARGE_SUPPLIER_PD &&
-	    charge_ma < 1500 &&
-	    charge_get_percent() < CONFIG_CHARGER_MIN_BAT_PCT_FOR_POWER_ON) {
-		CPRINTS("Using max ilim %d", max_ma);
-		charge_ma = max_ma;
-	}
-
-
-	/*
 	 * To protect the charge inductor, at voltages above 18V we should
 	 * set the current limit to 2.7A.
 	 */