#include #include #include "motor_task.h" #include "mt6701_sensor.h" #include "tlv_sensor.h" #include "util.h" static const float DEAD_ZONE_DETENT_PERCENT = 0.2; static const float DEAD_ZONE_RAD = 1 * _PI / 180; static const float IDLE_VELOCITY_EWMA_ALPHA = 0.001; static const float IDLE_VELOCITY_RAD_PER_SEC = 0.05; static const uint32_t IDLE_CORRECTION_DELAY_MILLIS = 500; static const float IDLE_CORRECTION_MAX_ANGLE_RAD = 5 * PI / 180; static const float IDLE_CORRECTION_RATE_ALPHA = 0.0005; MotorTask::MotorTask(const uint8_t task_core) : Task("Motor", 1200, 1, task_core) { queue_ = xQueueCreate(5, sizeof(Command)); assert(queue_ != NULL); } MotorTask::~MotorTask() {} // BLDC motor & driver instance BLDCMotor motor = BLDCMotor(1); BLDCDriver6PWM driver = BLDCDriver6PWM(PIN_UH, PIN_UL, PIN_VH, PIN_VL, PIN_WH, PIN_WL); #if SENSOR_TLV TlvSensor encoder = TlvSensor(); #elif SENSOR_MT6701 MT6701Sensor encoder = MT6701Sensor(); #endif // MagneticSensorI2C tlv = MagneticSensorI2C(AS5600_I2C); Commander command = Commander(Serial); void doMotor(char* cmd) { command.motor(&motor, cmd); } void MotorTask::run() { // Hardware-specific configuration: // TODO: make this easier to configure // Tune zero offset to the specific hardware (motor + mounted magnetic sensor). // SimpleFOC is supposed to be able to determine this automatically (if you omit params to initFOC), but // it seems to have a bug (or I've misconfigured it) that gets both the offset and direction very wrong! // So this value is based on experimentation. // TODO: dig into SimpleFOC calibration and find/fix the issue // float zero_electric_offset = -0.6; // original proto //float zero_electric_offset = 0.4; // handheld 1 // float zero_electric_offset = -0.8; // handheld 2 // float zero_electric_offset = 2.93; //0.15; // 17mm test // float zero_electric_offset = 0.66; // 15mm handheld float zero_electric_offset = 7.34; Direction foc_direction = Direction::CW; motor.pole_pairs = 7; driver.voltage_power_supply = 5; driver.init(); #if SENSOR_TLV encoder.init(Wire, false); #endif #if SENSOR_MT6701 encoder.init(); // motor.LPF_angle = LowPassFilter(0.05); #endif // motor.LPF_current_q = {0.01}; motor.linkDriver(&driver); motor.controller = MotionControlType::torque; motor.voltage_limit = 5; motor.velocity_limit = 10000; motor.linkSensor(&encoder); // Not actually using the velocity loop; but I'm using those PID variables // because SimpleFOC studio supports updating them easily over serial for tuning. motor.PID_velocity.P = 4; motor.PID_velocity.I = 0; motor.PID_velocity.D = 0.04; motor.PID_velocity.output_ramp = 10000; motor.PID_velocity.limit = 10; // motor.useMonitoring(Serial); motor.init(); encoder.update(); delay(10); motor.initFOC(zero_electric_offset, foc_direction); bool calibrate = false; Serial.println("Press Y to run calibration"); uint32_t t = millis(); while (millis() - t < 3000) { if (Serial.read() == 'Y') { calibrate = true; break; } delay(10); } if (calibrate) { motor.controller = MotionControlType::angle_openloop; motor.pole_pairs = 1; motor.initFOC(0, Direction::CW); float a = 0; for (uint8_t i = 0; i < 200; i++) { encoder.update(); motor.move(a); delay(1); } float start_sensor = encoder.getAngle(); for (; a < 3 * _2PI; a += 0.01) { encoder.update(); motor.move(a); delay(1); } for (uint8_t i = 0; i < 200; i++) { encoder.update(); delay(1); } float end_sensor = encoder.getAngle(); motor.voltage_limit = 0; motor.move(a); // Serial.println("Did motor turn counterclockwise? Press Y to continue, otherwise change motor wiring and restart"); // while (Serial.read() != 'Y') { // delay(10); // } Serial.println(); // TODO: check for no motor movement! Serial.print("Sensor measures positive for positive motor rotation: "); if (end_sensor > start_sensor) { Serial.println("YES, Direction=CW"); motor.initFOC(0, Direction::CW); } else { Serial.println("NO, Direction=CCW"); motor.initFOC(0, Direction::CCW); } // Rotate many electrical revolutions and measure mechanical angle traveled, to calculate pole-pairs uint8_t electrical_revolutions = 20; Serial.printf("Going to measure %d electrical revolutions...\n", electrical_revolutions); motor.voltage_limit = 5; motor.move(a); Serial.println("Going to electrical zero..."); float destination = a + _2PI; for (; a < destination; a += 0.03) { encoder.update(); motor.move(a); delay(1); } Serial.println("pause..."); for (uint16_t i = 0; i < 1000; i++) { encoder.update(); delay(1); } Serial.println("Measuring..."); start_sensor = motor.sensor_direction * encoder.getAngle(); destination = a + electrical_revolutions * _2PI; for (; a < destination; a += 0.03) { encoder.update(); motor.move(a); delay(1); } for (uint16_t i = 0; i < 1000; i++) { encoder.update(); motor.move(a); delay(1); } end_sensor = motor.sensor_direction * encoder.getAngle(); motor.voltage_limit = 0; motor.move(a); if (fabsf(motor.shaft_angle - motor.target) > 1 * PI / 180) { Serial.println("ERROR: motor did not reach target!"); while(1) {} } float electrical_per_mechanical = electrical_revolutions * _2PI / (end_sensor - start_sensor); Serial.print("Electrical angle / mechanical angle (i.e. pole pairs) = "); Serial.println(electrical_per_mechanical); int measured_pole_pairs = (int)round(electrical_per_mechanical); Serial.printf("Pole pairs set to %d\n", measured_pole_pairs); delay(1000); // Measure mechanical angle at every electrical zero for several revolutions motor.voltage_limit = 5; motor.move(a); float offset_x = 0; float offset_y = 0; float destination1 = (floor(a / _2PI) + measured_pole_pairs / 2.) * _2PI; float destination2 = (floor(a / _2PI)) * _2PI; for (; a < destination1; a += 0.4) { motor.move(a); delay(100); for (uint8_t i = 0; i < 100; i++) { encoder.update(); delay(1); } float real_electrical_angle = _normalizeAngle(a); float measured_electrical_angle = _normalizeAngle( (float)(motor.sensor_direction * measured_pole_pairs) * encoder.getMechanicalAngle() - 0); float offset_angle = measured_electrical_angle - real_electrical_angle; offset_x += cosf(offset_angle); offset_y += sinf(offset_angle); Serial.print(degrees(real_electrical_angle)); Serial.print(", "); Serial.print(degrees(measured_electrical_angle)); Serial.print(", "); Serial.println(degrees(_normalizeAngle(offset_angle))); } for (; a > destination2; a -= 0.4) { motor.move(a); delay(100); for (uint8_t i = 0; i < 100; i++) { encoder.update(); delay(1); } float real_electrical_angle = _normalizeAngle(a); float measured_electrical_angle = _normalizeAngle( (float)(motor.sensor_direction * measured_pole_pairs) * encoder.getMechanicalAngle() - 0); float offset_angle = measured_electrical_angle - real_electrical_angle; offset_x += cosf(offset_angle); offset_y += sinf(offset_angle); Serial.print(degrees(real_electrical_angle)); Serial.print(", "); Serial.print(degrees(measured_electrical_angle)); Serial.print(", "); Serial.println(degrees(_normalizeAngle(offset_angle))); } motor.voltage_limit = 0; motor.move(a); float avg_offset_angle = atan2f(offset_y, offset_x); // Apply settings motor.pole_pairs = measured_pole_pairs; motor.zero_electric_angle = avg_offset_angle + _3PI_2; motor.voltage_limit = 5; motor.controller = MotionControlType::torque; Serial.print("\n\nRESULTS:\n zero electric angle: "); Serial.println(motor.zero_electric_angle); Serial.print(" direction: "); if (motor.sensor_direction == Direction::CW) { Serial.println("CW"); } else { Serial.println("CCW"); } Serial.printf(" pole pairs: %d\n", motor.pole_pairs); delay(2000); } Serial.println(motor.zero_electric_angle); command.add('M', &doMotor, "foo"); // command.add('D', &doDetents, "Detents"); motor.monitor_downsample = 0; // disable monitor at first - optional // disableCore0WDT(); float current_detent_center = motor.shaft_angle; KnobConfig config = { .num_positions = 2, .position = 0, .position_width_radians = 60 * _PI / 180, .detent_strength_unit = 0, }; float idle_check_velocity_ewma = 0; uint32_t last_idle_start = 0; uint32_t last_debug = 0; uint32_t last_publish = 0; while (1) { motor.loopFOC(); Command command; if (xQueueReceive(queue_, &command, 0) == pdTRUE) { switch (command.command_type) { case CommandType::CONFIG: { config = command.data.config; Serial.println("Got new config"); current_detent_center = motor.shaft_angle; #if SK_INVERT_ROTATION current_detent_center = -motor.shaft_angle; #endif // Update derivative factor of torque controller based on detent width. // If the D factor is large on coarse detents, the motor ends up making noise because the P&D factors amplify the noise from the sensor. // This is a piecewise linear function so that fine detents (small width) get a higher D factor and coarse detents get a small D factor. // Fine detents need a nonzero D factor to artificially create "clicks" each time a new value is reached (the P factor is small // for fine detents due to the smaller angular errors, and the existing P factor doesn't work well for very small angle changes (easy to // get runaway due to sensor noise & lag)). // TODO: consider eliminating this D factor entirely and just "play" a hardcoded haptic "click" (e.g. a quick burst of torque in each // direction) whenever the position changes when the detent width is too small for the P factor to work well. const float derivative_lower_strength = config.detent_strength_unit * 0.08; const float derivative_upper_strength = config.detent_strength_unit * 0.02; const float derivative_position_width_lower = radians(3); const float derivative_position_width_upper = radians(8); const float raw = derivative_lower_strength + (derivative_upper_strength - derivative_lower_strength)/(derivative_position_width_upper - derivative_position_width_lower)*(config.position_width_radians - derivative_position_width_lower); motor.PID_velocity.D = CLAMP( raw, min(derivative_lower_strength, derivative_upper_strength), max(derivative_lower_strength, derivative_upper_strength) ); break; } case CommandType::HAPTIC: { float strength = command.data.haptic.press ? 5 : 1.5; motor.move(strength); for (uint8_t i = 0; i < 3; i++) { motor.loopFOC(); delay(1); } motor.move(-strength); for (uint8_t i = 0; i < 3; i++) { motor.loopFOC(); delay(1); } motor.move(0); motor.loopFOC(); break; } } } idle_check_velocity_ewma = motor.shaft_velocity * IDLE_VELOCITY_EWMA_ALPHA + idle_check_velocity_ewma * (1 - IDLE_VELOCITY_EWMA_ALPHA); if (fabsf(idle_check_velocity_ewma) > IDLE_VELOCITY_RAD_PER_SEC) { last_idle_start = 0; } else { if (last_idle_start == 0) { last_idle_start = millis(); } } // If we are not moving and we're close to the center (but not exactly there), slowly adjust the centerpoint to match the current position if (last_idle_start > 0 && millis() - last_idle_start > IDLE_CORRECTION_DELAY_MILLIS && fabsf(motor.shaft_angle - current_detent_center) < IDLE_CORRECTION_MAX_ANGLE_RAD) { current_detent_center = motor.shaft_angle * IDLE_CORRECTION_RATE_ALPHA + current_detent_center * (1 - IDLE_CORRECTION_RATE_ALPHA); // if (millis() - last_debug > 100) { // last_debug = millis(); // Serial.print("Moving detent center. "); // Serial.print(current_detent_center); // Serial.print(" "); // Serial.println(motor.shaft_angle); // } } float angle_to_detent_center = motor.shaft_angle - current_detent_center; #if SK_INVERT_ROTATION angle_to_detent_center = -motor.shaft_angle - current_detent_center; #endif if (angle_to_detent_center > config.position_width_radians * config.snap_point && (config.num_positions <= 0 || config.position > 0)) { current_detent_center += config.position_width_radians; angle_to_detent_center -= config.position_width_radians; config.position--; } else if (angle_to_detent_center < -config.position_width_radians * config.snap_point && (config.num_positions <= 0 || config.position < config.num_positions - 1)) { current_detent_center -= config.position_width_radians; angle_to_detent_center += config.position_width_radians; config.position++; } float dead_zone_adjustment = CLAMP( angle_to_detent_center, fmaxf(-config.position_width_radians*DEAD_ZONE_DETENT_PERCENT, -DEAD_ZONE_RAD), fminf(config.position_width_radians*DEAD_ZONE_DETENT_PERCENT, DEAD_ZONE_RAD)); bool out_of_bounds = config.num_positions > 0 && ((angle_to_detent_center > 0 && config.position == 0) || (angle_to_detent_center < 0 && config.position == config.num_positions - 1)); motor.PID_velocity.limit = 10; //out_of_bounds ? 10 : 3; motor.PID_velocity.P = out_of_bounds ? config.endstop_strength_unit * 4 : config.detent_strength_unit * 4; if (fabsf(motor.shaft_velocity) > 60) { // Don't apply torque if velocity is too high (helps avoid positive feedback loop/runaway) motor.move(0); } else { float torque = motor.PID_velocity(-angle_to_detent_center + dead_zone_adjustment); #if SK_INVERT_ROTATION torque = -torque; #endif motor.move(torque); } if (millis() - last_publish > 10) { publish({ .current_position = config.position, .sub_position_unit = -angle_to_detent_center / config.position_width_radians, .config = config, }); last_publish = millis(); } motor.monitor(); // command.run(); delay(1); } } void MotorTask::setConfig(const KnobConfig& config) { Command command = { .command_type = CommandType::CONFIG, .data = { .config = config, } }; xQueueSend(queue_, &command, portMAX_DELAY); } void MotorTask::playHaptic(bool press) { Command command = { .command_type = CommandType::HAPTIC, .data = { .haptic = { .press = press, }, } }; xQueueSend(queue_, &command, portMAX_DELAY); } void MotorTask::addListener(QueueHandle_t queue) { listeners_.push_back(queue); } void MotorTask::publish(const KnobState& state) { for (auto listener : listeners_) { xQueueOverwrite(listener, &state); } }