j/cable-length-cutter
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Merge branch 'dev' into stepper

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Hardware works so far
Firmware needs improvement: stepper moves but too jerky also not linked
to control task yet
This commit is contained in:
jonny_ji7 2023-03-02 23:32:18 +01:00
commit 9595940004
15 changed files with 1753 additions and 93 deletions
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3
.gitignore vendored
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@ -10,3 +10,6 @@ build
# freecad backup files
*.FCStd1
# kicad backup files
pcb/*/*backups/

2
connection-plan.drawio
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File diff suppressed because one or more lines are too long

BIN
connection-plan.drawio.pdf
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8
main/config.hpp
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@ -12,7 +12,7 @@ extern "C" {
//===================================
//4x stepper mosfet outputs for VFD
#define GPIO_VFD_FWD GPIO_NUM_4 //ST4
#define GPIO_VFD_REV GPIO_NUM_16 //ST3
#define GPIO_VFD_REV GPIO_NUM_5 //mos2
#define GPIO_VFD_D0 GPIO_NUM_2 //ST2
#define GPIO_VFD_D1 GPIO_NUM_15 //ST1
//#define GPIO_VFD_D2 GPIO_NUM_15 //ST1 (D2 only used with 7.5kw vfd)
@ -86,9 +86,9 @@ extern "C" {
//--------------------------
//enable stepper test mode (dont start control and encoder task)
//#define STEPPER_TEST
#define STEPPER_STEP_PIN GPIO_NUM_18 //(mos1)
#define STEPPER_DIR_PIN GPIO_NUM_5 //(mos2)
#define STEPPER_EN_PIN GPIO_NUM_0 //not connected (stepper always on)
#define STEPPER_STEP_PIN GPIO_NUM_18 //mos1
#define STEPPER_DIR_PIN GPIO_NUM_16 //ST3
#define STEPPER_EN_PIN GPIO_NUM_0 //not connected (-> stepper always on)
//more detailed options for testing are currently defined in guide-stepper.cpp

176
main/guide-stepper.cpp
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@ -22,8 +22,10 @@ extern "C"
#define STEPPER_TEST_TRAVEL 65 //mm
//
#define MIN 0
#define MAX 60
#define MIN_MM 0
#define MAX_MM 60
#define POS_MAX_STEPS MAX_MM * STEPPER_STEPS_PER_MM
#define POS_MIN_STEPS MIN_MM * STEPPER_STEPS_PER_MM
#define SPEED_MIN 2.0 //mm/s
@ -36,7 +38,7 @@ extern "C"
#define STEPPER_STEPS_PER_MM STEPPER_STEPS_PER_ROT/4
#define D_CABLE 6
#define D_REEL 155 //actual 170
#define D_REEL 160 //actual 170
#define PI 3.14159
@ -47,90 +49,72 @@ extern "C"
static DendoStepper step;
static const char *TAG = "stepper"; //tag for logging
static int stepp_lengthNow = 0; //length measured in mm
static int lengthPrev = 0; //length last check
static bool stepp_direction = true;
static uint64_t posNow = 0;
static uint32_t posNow = 0;
//----------------------
//----- functions ------
//----------------------
//move left and right or reverse while winding
void travelDist(int length){
//uint64_t posNow = step.getPositionMm();
//move axis certain Steps (relative) between left and right or reverse when negative
void travelSteps(int stepsTarget){
//posNow = step.getPositionMm(); //not otherwise controlled, so no update necessary
int stepsToGo, remaining;
int d, remaining;
d = abs(length);
if(length < 0) stepp_direction = !stepp_direction; //invert direction in reverse mode
stepsToGo = abs(stepsTarget);
if(stepsTarget < 0) stepp_direction = !stepp_direction; //invert direction in reverse mode
while (d != 0){
while (stepsToGo != 0){
//--- currently moving right ---
if (stepp_direction == true){ //currently moving right
remaining = MAX - posNow; //calc remaining distance fom current position to limit
if (d > remaining){ //new distance will exceed limit
step.runAbsMm (MAX); //move to limit
posNow=MAX;
remaining = POS_MAX_STEPS - posNow; //calc remaining distance fom current position to limit
if (stepsToGo > remaining){ //new distance will exceed limit
step.runAbs (POS_MAX_STEPS); //move to limit
while(step.getState() != 1) vTaskDelay(1); //wait for move to finish
posNow = POS_MAX_STEPS;
stepp_direction = false; //change current direction for next iteration
d = d - remaining; //decrease target length by already traveled distance
printf(" --- changed direction (L) --- \n ");
stepsToGo = stepsToGo - remaining; //decrease target length by already traveled distance
ESP_LOGI(TAG, " --- moved to max -> change direction (L) --- \n ");
}
else { //target distance does not reach the limit
step.runAbsMm (posNow + d); //move by (remaining) distance to reach target length
printf("moving to %lld\n", posNow+d);
posNow += d;
d = 0; //finished, reset target length (could as well exit loop/break)
step.runAbs (posNow + stepsToGo); //move by (remaining) distance to reach target length
while(step.getState() != 1) vTaskDelay(1); //wait for move to finish
ESP_LOGD(TAG, "moving to %d\n", posNow+stepsToGo);
posNow += stepsToGo;
stepsToGo = 0; //finished, reset target length (could as well exit loop/break)
}
}
//--- currently moving left ---
else {
remaining = posNow - MIN;
if (d > remaining){
step.runAbsMm (MIN);
posNow=0;
remaining = posNow - POS_MIN_STEPS;
if (stepsToGo > remaining){
step.runAbs (POS_MIN_STEPS);
while(step.getState() != 1) vTaskDelay(2); //wait for move to finish
posNow = POS_MIN_STEPS;
stepp_direction = true;
d = d - remaining;
printf(" --- changed direction (R) --- \n ");
stepsToGo = stepsToGo - remaining;
ESP_LOGI(TAG, " --- moved to min -> change direction (R) --- \n ");
}
else {
step.runAbsMm (posNow - d); //when moving left the coordinate has to be decreased
printf("moving to %lld\n", posNow-d);
posNow -= d;
d = 0;
step.runAbs (posNow - stepsToGo); //when moving left the coordinate has to be decreased
while(step.getState() != 1) vTaskDelay(2); //wait for move to finish
ESP_LOGD(TAG, "moving to %d\n", posNow - stepsToGo);
posNow -= stepsToGo;
stepsToGo = 0;
}
}
}
if(length < 0) stepp_direction = !stepp_direction; //undo inversion of stepp_direction after reverse mode is finished
if(stepsTarget < 0) stepp_direction = !stepp_direction; //undo inversion of stepp_direction after reverse mode is finished
return;
}
//calculate time needed for certain length (NOT NEEDED/ DELETE)
//float mmToS(int l){
//
// double accel = SPEED_MAX / (ACCEL_MS/1000);
// double t_accelMax = ACCEL_MS/1000;
// double l_accelMax = accel * t_accelMax * t_accelMax;
//
// printf("accel=%.2lf mm/s2 __ t_accelMAX=%.2lfs __ l_accelMax=%.2lfmm\n", accel, t_accelMax, l_accelMax);
// if (l < l_accelMax){
// return sqrt(l / accel);
// } else {
// return t_accelMax + (l - l_accelMax) / SPEED_MAX;
// }
//}
//move axis certain Mm (relative) between left and right or reverse when negative
void travelMm(int length){
travelSteps(length * STEPPER_STEPS_PER_MM);
}
//define zero/start position
@ -138,9 +122,9 @@ void travelDist(int length){
//TODO: limit switch
void home() {
ESP_LOGW(TAG, "auto-home...");
step.setSpeedMm(120, 120, 100);
step.runInf(0);
vTaskDelay(2000 / portTICK_PERIOD_MS);
step.setSpeedMm(100, 500, 10);
step.runInf(1);
vTaskDelay(1500 / portTICK_PERIOD_MS);
step.stop();
step.resetAbsolute();
ESP_LOGW(TAG, "auto-home finished");
@ -177,9 +161,9 @@ void updateSpeedFromAdc() {
//---------------------
//------- TASK --------
//---------------------
//----------------------------
//---- TASK stepper-test -----
//----------------------------
void task_stepper_test(void *pvParameter)
{
init_stepper();
@ -187,41 +171,75 @@ void task_stepper_test(void *pvParameter)
while (1) {
updateSpeedFromAdc();
step.runPosMm(-STEPPER_TEST_TRAVEL);
step.runPosMm(STEPPER_TEST_TRAVEL);
while(step.getState() != 1) vTaskDelay(2);
ESP_LOGI(TAG, "finished moving right => moving left");
updateSpeedFromAdc();
step.runPosMm(STEPPER_TEST_TRAVEL);
step.runPosMm(-STEPPER_TEST_TRAVEL);
while(step.getState() != 1) vTaskDelay(2); //1=idle
ESP_LOGI(TAG, "finished moving left => moving right");
}
}
//----------------------------
//----- TASK stepper-ctl -----
//----------------------------
void task_stepper_ctl(void *pvParameter)
{
//variables
int encStepsNow = 0; //get curret steps of encoder
int encStepsPrev = 0; //steps at last check
int encStepsDelta = 0; //steps changed since last iteration
double cableLen = 0;
double travelStepsExact = 0; //steps axis has to travel
double travelStepsPartial = 0;
int travelStepsFull = 0;
double travelMm = 0;
double turns = 0;
float potiModifier;
init_stepper();
home();
while(1){
//get current length
stepp_lengthNow = encoder_getLenMm();
encStepsNow = encoder_getSteps();
int lengthDelta = stepp_lengthNow - lengthPrev;
//TODO add modifier e.g. poti value
int travel = lengthDelta * D_CABLE / (PI * D_REEL); //calc distance to move
ESP_LOGI(TAG, "delta: %d travel: %d",lengthDelta, travel);
//FIXME: rounding issue? e.g. 1.4 gets lost
if (abs(travel) > 1){ //when ready to move axis by at least 1 millimeter
ESP_LOGI(TAG, "EXCEEDED: delta: %d travel: %d",lengthDelta, travel);
travelDist(travel);
while(step.getState() != 1) vTaskDelay(2); //wait for move to finish
lengthPrev = stepp_lengthNow; //update length
//calculate change
encStepsDelta = encStepsNow - encStepsPrev; //FIXME MAJOR BUG: when resetting encoder/length in control task, diff will be huge!
//read potentiometer and normalize (0-1) to get a variable for testing
potiModifier = (float) gpio_readAdc(ADC_CHANNEL_POTI) / 4095; //0-4095 -> 0-1
//ESP_LOGI(TAG, "current poti-modifier = %f", potiModifier);
//calculate steps to move
cableLen = (double)encStepsDelta * 1000 / ENCODER_STEPS_PER_METER;
turns = cableLen / (PI * D_REEL);
travelMm = turns * D_CABLE;
travelStepsExact = travelMm * STEPPER_STEPS_PER_MM + travelStepsPartial; //convert mm to steps and add not moved partial steps
travelStepsPartial = 0;
travelStepsFull = (int)travelStepsExact;
//move axis when ready to move at least 1 step
if (abs(travelStepsFull) > 1){
travelStepsPartial = fmod(travelStepsExact, 1); //save remaining partial steps to be added in the next iteration
ESP_LOGD(TAG, "cablelen=%.2lf, turns=%.2lf, travelMm=%.3lf, travelStepsExact: %.3lf, travelStepsFull=%d, partialStep=%.3lf", cableLen, turns, travelMm, travelStepsExact, travelStepsFull, travelStepsPartial);
ESP_LOGI(TAG, "MOVING %d steps", travelStepsFull);
//TODO: calculate variable speed for smoother movement? for example intentionally lag behind and calculate speed according to buffered data
step.setSpeedMm(35, 100, 50);
//testing: get speed from poti
//step.setSpeedMm(35, 1000*potiModifier+1, 1000*potiModifier+1);
travelSteps(travelStepsExact);
encStepsPrev = encStepsNow; //update previous length
}
else {
vTaskDelay(5);
//TODO use encoder queue to only run this check at encoder event?
vTaskDelay(2);
}
}
}

9
main/main.cpp
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@ -86,15 +86,20 @@ extern "C" void app_main()
esp_log_level_set("buzzer", ESP_LOG_ERROR);
esp_log_level_set("switches-analog", ESP_LOG_WARN);
esp_log_level_set("control", ESP_LOG_INFO);
esp_log_level_set("stepper", ESP_LOG_INFO);
esp_log_level_set("stepper", ESP_LOG_DEBUG);
esp_log_level_set("Dendostepper", ESP_LOG_WARN); //stepper lib
esp_log_level_set("calc", ESP_LOG_WARN); //stepper lib
#ifdef STEPPER_TEST
//create task for stepper testing
xTaskCreate(task_stepper_test, "task_stepper-test", configMINIMAL_STACK_SIZE * 3, NULL, 5, NULL);
xTaskCreate(task_stepper_test, "task_stepper_test", configMINIMAL_STACK_SIZE * 3, NULL, 5, NULL);
#else
//create task for controlling the machine
xTaskCreate(task_control, "task_control", configMINIMAL_STACK_SIZE * 3, NULL, 5, NULL);
//create task for controlling the machine
xTaskCreate(task_stepper_ctl, "task_stepper_ctl", configMINIMAL_STACK_SIZE * 3, NULL, 5, NULL);
//create task for handling the buzzer
xTaskCreate(&task_buzzer, "task_buzzer", 2048, NULL, 2, NULL);
#endif

0
pcb/4swToAdc.kicad_prl → pcb/4swToAdc/4swToAdc.kicad_prl
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0
pcb/4swToAdc.kicad_pro → pcb/4swToAdc/4swToAdc.kicad_pro
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0
pcb/4swToAdc.kicad_sch → pcb/4swToAdc/4swToAdc.kicad_sch
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0
pcb/4swToAdc_stripboard-calc.ods → pcb/4swToAdc/4swToAdc_stripboard-calc.ods
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BIN
pcb/stepper-filter/filter_stripboard.ods Normal file
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Binary file not shown.

75
pcb/stepper-filter/stepper-filter.kicad_prl Normal file
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@ -0,0 +1,75 @@
{
"board": {
"active_layer": 0,
"active_layer_preset": "",
"auto_track_width": true,
"hidden_nets": [],
"high_contrast_mode": 0,
"net_color_mode": 1,
"opacity": {
"pads": 1.0,
"tracks": 1.0,
"vias": 1.0,
"zones": 0.6
},
"ratsnest_display_mode": 0,
"selection_filter": {
"dimensions": true,
"footprints": true,
"graphics": true,
"keepouts": true,
"lockedItems": true,
"otherItems": true,
"pads": true,
"text": true,
"tracks": true,
"vias": true,
"zones": true
},
"visible_items": [
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"visible_layers": "fffffff_ffffffff",
"zone_display_mode": 0
},
"meta": {
"filename": "stepper-filter.kicad_prl",
"version": 3
},
"project": {
"files": []
}
}

294
pcb/stepper-filter/stepper-filter.kicad_pro Normal file
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@ -0,0 +1,294 @@
{
"board": {
"layer_presets": []
},
"boards": [],
"cvpcb": {
"equivalence_files": []
},
"erc": {
"erc_exclusions": [],
"meta": {
"version": 0
},
"pin_map": [
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"rule_severities": {
"bus_definition_conflict": "error",
"bus_entry_needed": "error",
"bus_label_syntax": "error",
"bus_to_bus_conflict": "error",
"bus_to_net_conflict": "error",
"different_unit_footprint": "error",
"different_unit_net": "error",
"duplicate_reference": "error",
"duplicate_sheet_names": "error",
"extra_units": "error",
"global_label_dangling": "warning",
"hier_label_mismatch": "error",
"label_dangling": "error",
"lib_symbol_issues": "warning",
"multiple_net_names": "warning",
"net_not_bus_member": "warning",
"no_connect_connected": "warning",
"no_connect_dangling": "warning",
"pin_not_connected": "error",
"pin_not_driven": "error",
"pin_to_pin": "warning",
"power_pin_not_driven": "error",
"similar_labels": "warning",
"unannotated": "error",
"unit_value_mismatch": "error",
"unresolved_variable": "error",
"wire_dangling": "error"
}
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"libraries": {
"pinned_footprint_libs": [],
"pinned_symbol_libs": []
},
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"filename": "stepper-filter.kicad_pro",
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"net_settings": {
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"clearance": 0.2,
"diff_pair_gap": 0.25,
"diff_pair_via_gap": 0.25,
"diff_pair_width": 0.2,
"line_style": 0,
"microvia_diameter": 0.3,
"microvia_drill": 0.1,
"name": "Default",
"pcb_color": "rgba(0, 0, 0, 0.000)",
"schematic_color": "rgba(0, 0, 0, 0.000)",
"track_width": 0.25,
"via_diameter": 0.8,
"via_drill": 0.4,
"wire_width": 6.0
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"net_colors": null
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"pcbnew": {
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"idf": "",
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"specctra_dsn": "",
"step": "",
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"spice_adjust_passive_values": false,
"spice_external_command": "spice \"%I\"",
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"subpart_id_separator": 0
},
"sheets": [
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"text_variables": {}
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1265
pcb/stepper-filter/stepper-filter.kicad_sch Normal file
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File diff suppressed because it is too large Load Diff

6
sdkconfig
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@ -732,10 +732,10 @@ CONFIG_LOG_DEFAULT_LEVEL_INFO=y
# CONFIG_LOG_DEFAULT_LEVEL_DEBUG is not set
# CONFIG_LOG_DEFAULT_LEVEL_VERBOSE is not set
CONFIG_LOG_DEFAULT_LEVEL=3
CONFIG_LOG_MAXIMUM_EQUALS_DEFAULT=y
# CONFIG_LOG_MAXIMUM_EQUALS_DEFAULT is not set
# CONFIG_LOG_MAXIMUM_LEVEL_DEBUG is not set
# CONFIG_LOG_MAXIMUM_LEVEL_VERBOSE is not set
CONFIG_LOG_MAXIMUM_LEVEL=3
CONFIG_LOG_MAXIMUM_LEVEL_VERBOSE=y
CONFIG_LOG_MAXIMUM_LEVEL=5
CONFIG_LOG_COLORS=y
CONFIG_LOG_TIMESTAMP_SOURCE_RTOS=y
# CONFIG_LOG_TIMESTAMP_SOURCE_SYSTEM is not set