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Add currentsensor support - current limit functional

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- add currentsensor class
- add current limit to motorctl handle function
- add config options for curring limit for each motor
- update connection plan with more detailed driver-box overview
This commit is contained in:
jonny_l480 2023-08-21 09:52:43 +02:00
parent d51e8ae006
commit a6de6c4c10
8 changed files with 164 additions and 27 deletions
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BIN
connection-plan.drawio.pdf
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1
main/CMakeLists.txt
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@ -12,6 +12,7 @@ idf_component_register(
"wifi.c"
"http.cpp"
"auto.cpp"
"currentsensor.cpp"
INCLUDE_DIRS
"."
)

34
main/config.cpp
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@ -29,16 +29,28 @@ single100a_config_t configDriverRight = {
.pwmFreq = 10000
};
//TODO add motor name string -> then use as log tag?
//--- configure motor contol ---
motorctl_config_t configMotorControl = {
.msFadeAccel = 2400, //acceleration of the motor (ms it takes from 0% to 100%)
motorctl_config_t configMotorControlLeft = {
.msFadeAccel = 1900, //acceleration of the motor (ms it takes from 0% to 100%)
.msFadeDecel = 1000, //deceleration of the motor (ms it takes from 100% to 0%)
.currentMax = 10
.currentLimitEnabled = true,
.currentSensor_adc = ADC1_CHANNEL_6, //GPIO34
.currentSensor_ratedCurrent = 50,
.currentMax = 30
};
motorctl_config_t configMotorControlRight = {
.msFadeAccel = 1900, //acceleration of the motor (ms it takes from 0% to 100%)
.msFadeDecel = 1000, //deceleration of the motor (ms it takes from 100% to 0%)
.currentLimitEnabled = true,
.currentSensor_adc = ADC1_CHANNEL_4, //GPIO32
.currentSensor_ratedCurrent = 50,
.currentMax = 30
};
//create controlled motor instances
controlledMotor motorLeft(configDriverLeft, configMotorControl);
controlledMotor motorRight(configDriverRight, configMotorControl);
controlledMotor motorLeft(configDriverLeft, configMotorControlLeft);
controlledMotor motorRight(configDriverRight, configMotorControlRight);
@ -75,18 +87,18 @@ joystick_config_t configJoystick = {
.adc_x = ADC1_CHANNEL_3, //GPIO39
.adc_y = ADC1_CHANNEL_0, //GPIO36
//percentage of joystick range the coordinate of the axis snaps to 0 (0-100)
.tolerance_zeroX_per = 6,
.tolerance_zeroY_per = 7,
.tolerance_zeroX_per = 7, //6
.tolerance_zeroY_per = 10, //7
//percentage of joystick range the coordinate snaps to -1 or 1 before configured "_max" or "_min" threshold (mechanical end) is reached (0-100)
.tolerance_end_per = 4,
//threshold the radius jumps to 1 before the stick is at max radius (range 0-1)
.tolerance_radius = 0.08,
.tolerance_radius = 0.09,
//min and max adc values of each axis, !!!AFTER INVERSION!!! is applied:
.x_min = 1392, //=> x=-1
.x_max = 2815, //=> x=1
.y_min = 1370, //=> y=-1
.y_max = 2795, //=> y=1
.x_max = 2650, //=> x=1
.y_min = 1390, //=> y=-1
.y_max = 2640, //=> y=1
//invert adc measurement
.x_inverted = true,
.y_inverted = true

75
main/currentsensor.cpp Normal file
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@ -0,0 +1,75 @@
extern "C" {
#include "hal/timer_types.h"
#include "esp_log.h"
}
#include "currentsensor.hpp"
//tag for logging
static const char * TAG = "current-sensors";
//--------------------------
//------- getVoltage -------
//--------------------------
//local function to get average voltage from adc
float getVoltage(adc1_channel_t adc, uint32_t samples){
//measure voltage
int measure = 0;
for (int j=0; j<samples; j++){
measure += adc1_get_raw(adc);
ets_delay_us(50);
}
return (float)measure / samples / 4096 * 3.3;
}
//=============================
//======== constructor ========
//=============================
currentSensor::currentSensor (adc1_channel_t adcChannel_f, float ratedCurrent_f){
//copy config
adcChannel = adcChannel_f;
ratedCurrent = ratedCurrent_f;
//init adc
adc1_config_width(ADC_WIDTH_BIT_12); //max resolution 4096
adc1_config_channel_atten(adcChannel, ADC_ATTEN_DB_11); //max voltage
//calibrate
calibrateZeroAmpere();
}
//============================
//=========== read ===========
//============================
float currentSensor::read(void){
//measure voltage
voltage = getVoltage(adcChannel, 30);
//scale voltage to current
if (voltage < centerVoltage){
current = (1 - voltage / centerVoltage) * -ratedCurrent;
} else if (voltage > centerVoltage){
current = (voltage - centerVoltage) / (3.3 - centerVoltage) * ratedCurrent;
}else {
current = 0;
}
ESP_LOGI(TAG, "read sensor adc=%d: voltage=%.3fV, centerVoltage=%.3fV => current=%.3fA", (int)adcChannel, voltage, centerVoltage, current);
return current;
}
//===============================
//===== calibrateZeroAmpere =====
//===============================
void currentSensor::calibrateZeroAmpere(void){
//measure voltage
float prev = centerVoltage;
centerVoltage = getVoltage(adcChannel, 100);
ESP_LOGW(TAG, "defined centerVoltage (0A) to %.3f (previous %.3f)", centerVoltage, prev);
}

20
main/currentsensor.hpp Normal file
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@ -0,0 +1,20 @@
#include <driver/adc.h>
//supported current sensor working method:
//0V = -ratedCurrent
//centerVoltage = 0A
//3.3V = ratedCurrent
class currentSensor{
public:
currentSensor (adc1_channel_t adcChannel_f, float ratedCurrent);
void calibrateZeroAmpere(void); //set current voltage to voltage representing 0A
float read(void); //get current ampere
private:
adc1_channel_t adcChannel;
float ratedCurrent;
uint32_t measure;
float voltage;
float current;
float centerVoltage = 3.3/2;
};

5
main/main.cpp
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@ -141,8 +141,8 @@ extern "C" void app_main(void) {
//--- set loglevel for individual tags ---
esp_log_level_set("main", ESP_LOG_INFO);
esp_log_level_set("buzzer", ESP_LOG_ERROR);
//esp_log_level_set("motordriver", ESP_LOG_DEBUG);
esp_log_level_set("motor-control", ESP_LOG_INFO);
//esp_log_level_set("motordriver", ESP_LOG_INFO);
//esp_log_level_set("motor-control", ESP_LOG_DEBUG);
//esp_log_level_set("evaluatedJoystick", ESP_LOG_DEBUG);
//esp_log_level_set("joystickCommands", ESP_LOG_DEBUG);
esp_log_level_set("button", ESP_LOG_INFO);
@ -151,6 +151,7 @@ extern "C" void app_main(void) {
esp_log_level_set("wifi", ESP_LOG_INFO);
esp_log_level_set("http", ESP_LOG_INFO);
esp_log_level_set("automatedArmchair", ESP_LOG_DEBUG);
//esp_log_level_set("current-sensors", ESP_LOG_INFO);
//----------------------------------------------

47
main/motorctl.cpp
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@ -8,16 +8,19 @@ static const char * TAG = "motor-control";
//======== constructor ========
//=============================
//constructor, simultaniously initialize instance of motor driver 'motor' with provided config (see below line after ':')
controlledMotor::controlledMotor(single100a_config_t config_driver, motorctl_config_t config_control): motor(config_driver) {
//copy parameters for controlling the motor
config = config_control;
//copy configured default fading durations to actually used variables
msFadeAccel = config.msFadeAccel;
msFadeDecel = config.msFadeDecel;
controlledMotor::controlledMotor(single100a_config_t config_driver, motorctl_config_t config_control):
motor(config_driver),
cSensor(config_control.currentSensor_adc, config_control.currentSensor_ratedCurrent) {
//copy parameters for controlling the motor
config = config_control;
//copy configured default fading durations to actually used variables
msFadeAccel = config.msFadeAccel;
msFadeDecel = config.msFadeDecel;
init();
//TODO: add currentsensor object here
}
init();
//TODO: add currentsensor object here
//currentSensor cSensor(config.currentSensor_adc, config.currentSensor_ratedCurrent);
}
@ -26,6 +29,7 @@ controlledMotor::controlledMotor(single100a_config_t config_driver, motorctl_co
//============================
void controlledMotor::init(){
commandQueue = xQueueCreate( 1, sizeof( struct motorCommand_t ) );
//cSensor.calibrateZeroAmpere(); //TODO do this regularly e.g. in idle?
}
@ -56,9 +60,8 @@ void fade(float * dutyNow, float dutyTarget, float dutyIncrement){
//function that controls the motor driver and handles fading/ramp and current limit
void controlledMotor::handle(){
//TODO: current sensor
//TODO: delay when switching direction?
//TODO: History: skip fading when motor was running fast recently
//TODO: History: skip fading when motor was running fast recently / alternatively add rot-speed sensor
//--- receive commands from queue ---
if( xQueueReceive( commandQueue, &commandReceive, ( TickType_t ) 0 ) )
@ -123,7 +126,8 @@ void controlledMotor::handle(){
//--- fade duty to target (up and down) ---
//----- fading -----
//fade duty to target (up and down)
//TODO: this needs optimization (can be more clear and/or simpler)
if (dutyDelta > 0) { //difference positive -> increasing duty (-100 -> 100)
if (dutyNow < 0) { //reverse, decelerating
@ -143,7 +147,6 @@ void controlledMotor::handle(){
}
//previous approach: (resulted in bug where accel/decel fade is swaped in reverse)
// //--- fade up ---
// //dutyDelta is higher than IncrementUp -> fade up
@ -168,6 +171,24 @@ void controlledMotor::handle(){
// }
//----- current limit -----
if ((config.currentLimitEnabled) && (dutyDelta != 0)){
currentNow = cSensor.read();
if (fabs(currentNow) > config.currentMax){
float dutyOld = dutyNow;
//adaptive decrement:
//Note current exceeded twice -> twice as much decrement: TODO: decrement calc needs finetuning, currently random values
dutyIncrementDecel = (currentNow/config.currentMax) * ( usPassed / ((float)msFadeDecel * 1500) ) * 100;
float currentLimitDecrement = ( (float)usPassed / ((float)1000 * 1000) ) * 100; //1000ms from 100 to 0
if (dutyNow < -currentLimitDecrement) {
dutyNow += currentLimitDecrement;
} else if (dutyNow > currentLimitDecrement) {
dutyNow -= currentLimitDecrement;
}
ESP_LOGW(TAG, "current limit exceeded! now=%.3fA max=%.1fA => decreased duty from %.3f to %.3f", currentNow, config.currentMax, dutyOld, dutyNow);
}
}
//define motorstate from converted duty -100 to 100
//apply target duty and state to motor driver

9
main/motorctl.hpp
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@ -10,6 +10,7 @@ extern "C"
}
#include "motordrivers.hpp"
#include "currentsensor.hpp"
//-------------------------------------
@ -32,6 +33,9 @@ typedef struct motorCommands_t {
typedef struct motorctl_config_t {
uint32_t msFadeAccel; //acceleration of the motor (ms it takes from 0% to 100%)
uint32_t msFadeDecel; //deceleration of the motor (ms it takes from 100% to 0%)
bool currentLimitEnabled;
adc1_channel_t currentSensor_adc;
float currentSensor_ratedCurrent;
float currentMax;
} motorctl_config_t;
@ -52,6 +56,8 @@ class controlledMotor {
void setFade(fadeType_t fadeType, bool enabled); //enable/disable acceleration or deceleration fading
void setFade(fadeType_t fadeType, uint32_t msFadeNew); //set acceleration or deceleration fade time
bool toggleFade(fadeType_t fadeType); //toggle acceleration or deceleration on/off
//TODO set current limit
private:
@ -59,11 +65,12 @@ class controlledMotor {
void init(); //creates currentsensor objects, motordriver objects and queue
//--- objects ---
//TODO: add currentsensor object
//motor driver
single100a motor;
//queue for sending commands to the separate task running the handle() function very fast
QueueHandle_t commandQueue = NULL;
//current sensor
currentSensor cSensor;
//--- variables ---
//struct for storing control specific parameters