External Brake resistor

[Matt303]

Hi @runger I have got the ADC reading correctly, I learnt you can’t use pinmode in the setup ( took me a while to figure that out ) I can’t get PWM to work at all.
If I use:

void* pwm1params;
pwm1params = _configure1PWM(1000, A_PWM);
_writeDutyCycle1PWM(50, pwm1params);

It just crashes everything, if I comment out:

_writeDutyCycle1PWM(50, pwm1params);

I get an error no timer found on pin 32, I suspect there is no timer spare or can be configured for that pin. I have tried using pin mode output etc with no luck, even analogwrite doesn’t work.

On another note I have noticed the controller can get into an uncontrollable state, even disable and enable again doesn’t fix it, I have to do power cycle for it to come right. When it get’s in this state I have noticed the voltage Q and D will go to the max ( 12v in my case ) and not go back down, the q stays at 12v and d changes and motors goes nuts. To get in this state happens if the speed is to fast and goes out of sync or motor disabled during movement ( not at all times ) I would have thought when you disable the motor all these values should be reset? It’s like the PID keeps calculating and winding up even though the motor isn’t running.

What are your thoughts?

[runger]

@Matt303

I get an error no timer found on pin 32, I suspect there is no timer spare or can be configured for that pin. I have tried using pin mode output etc with no luck, even analogwrite doesn’t work.

It sounds like there is no timer on this pin. Although it might be worth checking the PinMap_TIM in the board’s files, if you can manage to do that. Users have been reporting problems with commented out lines in the PinMap_TIM leading to timers which are actually present not being found.

@Matt303

To get in this state happens if the speed is to fast and goes out of sync or motor disabled during movement ( not at all times ) I would have thought when you disable the motor all these values should be reset?

This can be due to several issues.

Firstly, be careful. Suddenly stopping a running motor will cause large inductive spikes, which the B-G431-ESC1 seems to be poorly protected against. Don’t fry your board!
Even if they don’t cause permanent damage, they can cause things to go out of whack and the MCU to freeze or reset.

If the MCU is running, Serial output continues, but the behaviour is as you describe, then it is possible that the sensor data got messed up - this can be again due to the voltage spike, or it can be due to the very fast change in speed causing the sensor’s bandwidth to be exceeded. For absolute sensors such as SPI or I2C based magnetic sensors, this will fix itself quickly and should not lead to the problems you describe. For encoders or hall sensors, missing some steps means the angle is permanently wrong thereafter - I suppose this could be what’s happening to you?

[robca]

@Matt303

I get an error no timer found on pin 32, I suspect there is no timer spare or can be configured for that pin. I have tried using pin mode output etc with no luck, even analogwrite doesn’t work.

Unless I looked wrong, pin 32 is PA_15. There is a big problem with the PeripheralPins_B_G431B_ESC1.c file, where most of the timer pins are commented out (even if they exist and are available). That has nothing to do with the options being greyed out (that is a VScode UI issue). The variant files for the G431 ESC are improperly commented out.

Go into that file, uncomment line 131 (or 132 if you plan to use TIM8 instead of the default TIM2 assigned to PA15) and recompile everything.

There are a lot of weird things happening with the G431 ESC pin naming at the moment…

[Matt303]

Hi @runger bit of an update, I have got almost everything working. I can’t get the PWM function working.

void* pwm1params;
pwm1params = _configure1PWM(1000, A_PWM);
_writeDutyCycle1PWM(50, pwm1params);

The analog write is working, so currently using that.

The other problem I have is when ever I disable the motor under load or in motion the PIDs keep calculating and give motor full voltage/current when I enable the motor again. Is there away to set all these to 0 and stop calculations while motor is disabled?

Here is the motor protection code for the B_G431B_ESC1 so far with braking and works well if anyone else is interested, it’s messy and unfinished, just add to your libs folder.

Header

#ifndef motorProtection
#define motorProtection

#include "Arduino.h"
#include <SimpleFOC.h>


class mpClass{

  public:
    //Declare all Functions
    void begin();
    void loop();
    void reset();
    float readVbus();
    float readTemp();
    void doMotorProtectCommand(char *command);
    float mpPID(float SP, float PV, float P, float I, float D, float Min, float Max, float Cycle);

    void linkMotor(BLDCMotor*);
    void linkEncoder(Encoder*);
    void linkBLDCDriver6PWM(BLDCDriver6PWM*);
    void linkLowsideCurrentSense(LowsideCurrentSense*);

    float brake_P = 1;
    float brake_I = 10;
    float brake_D = 0;
    float brake_Min = 0;
    float brake_Max = 250;
    float brake_Cycle = 0;
    unsigned long update = 1000;

    float brakeEngageOffset = 0.25;
    float brakeEngageMaxOffset = 2.0;
    float brakeEngageMaxDisableOffset = 3.0;
    float brakeCutOffPeriod = 250;

    float temperature; 
    float tempCutOff = 60.0;
    float tempDelayPeriod = 500;

    float stallDelayPeriod = 100;
    float stallCurrentOffset = 0.1;
    float stallVoltageOffset = 0.1;

    float overCurrentOffset = 0.05;
    float overVoltageOffset = 0.05;
    float overCVDelayPeriod = 100;

    int mVelCnt = 6;
    float mVelOffset = 1;
    float mVelPeriod = 250;

    int mAngleCnt = 8;
    float mAngleOffset = 0.1;
    float mAnglePeriod = 500;

    int mCurrentQcnt = 10;
    float mCurrentQoffset = 1.5;
    float mCurrentQperiod = 100;

    int mCurrentDcnt = 10;
    float mCurrentDoffset = 1.5;
    float mCurrentDperiod = 100;

    int mVoltageQcnt = 10;
    float mVoltageQoffset = 1.5;
    float mVoltageQperiod = 200;

    int mVoltageDcnt = 10;
    float mVoltageDoffset = 1.5;
    float mVoltageDperiod = 200;

    class internal{
      public:
        bool oscillating(float input, int cnt, float offset, float period);
        float input;
        int cnt;
        float offset;
        float period;
      private:
        bool out;
        bool outNew;
        bool init;
        float oldValue;
        int cntUp;
        int cntDown;
        bool dirUp;
        bool dirDown;
        bool osOscillating;
    };

  private:

    float VBus;
    float pwmPID;
    float pwmDuty;

    bool motorVoscillation; 
    bool motorAoscillation; 
    bool currentQoscillation;
    bool currentDoscillation;
    bool voltageQoscillation;
    bool voltageDoscillation;

    byte brakeMode;
    #define brakeOff 1
    #define brakeEngage 2
    #define brakeEngageMax 3
    #define brakeEngageMaxDisableMotor 4 

    BLDCMotor* motor;
    Encoder* encoder;
    BLDCDriver6PWM* driver;
    LowsideCurrentSense* currentSense;



        

};
#endif

#include "motorProtection.h"

//Motor Protections will disable motor 
//Will self reset fault condition if in safe condition and allow you to enable motor again
//Motor Protection functions Include:
//Bus Overvoltage Braking
//Temperature Protection
//Stall Protection
//Over Current / Voltage Protection
//Oscillation Protection   

//Link all objects from main ( not all are needed but here for future )
void mpClass::linkMotor(BLDCMotor *motorReference){
  motor = motorReference;
}
void mpClass::linkEncoder(Encoder *encoderReference){
  encoder = encoderReference;
}
void mpClass::linkBLDCDriver6PWM(BLDCDriver6PWM *driverReference){
  driver = driverReference;
}
void mpClass::linkLowsideCurrentSense(LowsideCurrentSense *currentSenseReference){
  currentSense = currentSenseReference;
}

//Create instance for function call per object
mpClass::internal VClass; 
mpClass::internal AClass; 
mpClass::internal CQClass;
mpClass::internal CDClass;
mpClass::internal VQClass;
mpClass::internal VDClass;

void mpClass::doMotorProtectCommand(char *mpCommand){
  switch (mpCommand[0]){
  case 'R':
    reset();
  break;
  case 'D':
    motor->disable();
  break;
  case 'E':
    motor->enable();
  break;
  case 'V':
    Serial.printf("Bus Voltage Reading: %f \n", readVbus());
  break;
  case 'T':
    Serial.printf("G431 Temperature: %f \n", readTemp());
  break;
  }
}

void mpClass::reset(){
  //Reset/Restart Driver reinitialize driver and motor calibration
  //TODO
}

bool mpClass::internal::oscillating(float input, int cnt, float offset, float period){
  if (!init){
    oldValue = fabs(input);
    init = true;
  }
  if (fabs(input) > (oldValue + offset)){
    dirUp = true;
    dirDown = false;
  }
  else if (fabs(input) < (oldValue - offset)){
    dirUp = false;
    dirDown = true;
  }
  else {
    dirUp = false;
    dirDown = false;
  }
  oldValue = fabs(input);

  if (dirUp)cntUp++;
  else if (dirDown)cntDown++;

  if (cntUp >= cnt && cntDown >= cnt){
    if(!osOscillating){
      out = true;
      osOscillating = true;
    }
    else{
      out = false;
    }
  }
  else{
    out = false;
  } 
  static long delayOscillating = millis();
  if (millis() - delayOscillating > period) {
    cntUp = 0;
    cntDown = 0;
    out = false;
    osOscillating = false;
    delayOscillating = millis(); 
  }
  return out;
}

//Important call from class and assign object for static variables!
//Must always be called in loop!
float mpClass::mpPID(float SP, float PV, float pGain, float iGain, float dGain, float Min, float Max, float Cycle){
  static unsigned long previousMicros;
  static float pErr;
  static float Err;
  static float P;
  static float I;
  static float D;  
  static float Out;
  if (micros() - previousMicros >= Cycle) {
    previousMicros = micros();
    Err   = (SP - PV);
    P     = (pGain * Err);
    I     = (I+(Err*iGain*Cycle));
    if(I > Max) I = Max; //Prevent Integral windup      
    else if(I < Min) I = Min;
    D     = (dGain*(pErr-Err)/Cycle);
    pErr  = Err;
    Out   = (P + I + D);
    if(Out < Min) Out = Min; //Clamp output to the limits
    else if(Out > Max) Out = Max;
  }
  return Out; 
}

float mpClass::readVbus(){
  float vbus = _readADCVoltageLowSide(A_VBUS, currentSense->params);            
  vbus = vbus * 10.7711;
  return vbus;
}

float mpClass::readTemp(){
  float tADC = _readADCVoltageLowSide(A_TEMPERATURE, currentSense->params);            
  static const float ResistorBalance = 4700.0;  
  static const float Beta  = 3425.0F;
  static const float RoomTempI = 1.0F/298.15F; //[K]
  static const float Rt = ResistorBalance * ((3.3F / tADC)-1);
  static const float R25 = 10000.0F;
  float temp = 1.0F/((log(Rt/R25)/Beta)+RoomTempI);
	temp = temp - 273.15;
  return temp;
}

void mpClass::begin() {
  driver->voltage_power_supply = readVbus();
  motor->voltage_limit = driver->voltage_power_supply;
}

void mpClass::loop(){
  static unsigned long previousMicros;
  if (micros() - previousMicros >= update) {
    previousMicros = micros();
    //Read Bus voltage
    VBus = readVbus();
    //Call PID
    pwmPID = mpPID(driver->voltage_power_supply, VBus, brake_P, brake_I, brake_D, brake_Min, brake_Max, brake_Cycle);  
    //Disable Motor If bus voltage to high, otherwise let's dump it through brake resistor
    static bool osBrake;
    if (VBus > (driver->voltage_power_supply + brakeEngageMaxDisableOffset) && (motor->shaft_velocity > 0.01)) {
      static long delay = millis();
      if (millis() - delay > brakeCutOffPeriod && !osBrake) {
        brakeMode = brakeEngageMaxDisableMotor;
        SIMPLEFOC_DEBUG("Bus Voltage to high, Disable Motor: ", VBus);
        delay = millis();
        osBrake = true; 
      }
    }
    else if (VBus > (driver->voltage_power_supply + brakeEngageMaxOffset) && (motor->shaft_velocity > 0.01)) {
      brakeMode = brakeEngageMax;
    }
    else if (VBus > (driver->voltage_power_supply + brakeEngageOffset) && (motor->shaft_velocity > 0.01)) {
      brakeMode = brakeEngage;
    }
    else if (VBus < (driver->voltage_power_supply + 0.1)) {
      brakeMode = brakeOff;
      osBrake = false;
    }

    switch(brakeMode)
    {
      case brakeOff:
        pwmDuty = 0;
      break;

      case brakeEngage:
        pwmDuty = pwmPID;
      break;

      case brakeEngageMax:
        pwmDuty = 245;
      break;

      case brakeEngageMaxDisableMotor:
        pwmDuty = 250;
        motor->disable();
      break;
    }

    analogWrite(A_PWM, pwmDuty);
    //TODO get the _writeDutyCycle1PWM working
    //Should not be using analogWrite
    //void* pwm1params;
    //pwm1params = _configure1PWM(1000, A_PWM);
    //_writeDutyCycle1PWM(0.5, pwm1params);

    static bool osTemp;
    temperature = readTemp();
    if (temperature > tempCutOff){
      static long delay = millis();
      if (millis() - delay > tempDelayPeriod && !osTemp) {
        motor->disable();
        SIMPLEFOC_DEBUG("Driver Over Temperature, Disable Motor: ", temperature);
        delay = millis();
        osTemp = true; 
      }
    }
    else{
      osTemp = false;
    }

    //Detect if motor has stalled and shutoff controller
    static bool osStall;
    if (fabs(motor->current.q) >= (motor->current_limit - stallCurrentOffset)) {
      if (fabs(motor->shaft_velocity) < 0.01){
        static long delay = millis();
        if (millis() - delay > stallDelayPeriod && !osStall) {
          SIMPLEFOC_DEBUG("Motor Stalled Current, Disable Motor: ", motor->current.q);
          motor->disable();
          delay = millis(); 
          osStall = true;
        }
      }
    }
    else if (fabs(motor->voltage.q) >= (motor->voltage_limit - stallVoltageOffset)) {
      if (fabs(motor->shaft_velocity) < 0.01){
        static long delay = millis();
        if (millis() - delay > stallDelayPeriod && !osStall) {
          SIMPLEFOC_DEBUG("Motor Stalled Voltage, Disable Motor: ", motor->voltage.q);
          motor->disable();
          delay = millis(); 
          osStall = true;
        }
      }
    }
    else{
      osStall = false;
    }

    //Over Current and Over Voltage Protection
    static bool osOverCV;
    if ((fabs(motor->current.q) >= (motor->current_limit + overCurrentOffset))){
      static long delay = millis();
      if (millis() - delay > overCVDelayPeriod && !osOverCV) {
        SIMPLEFOC_DEBUG("Motor Over Current, Disable Motor: ", motor->current.q);
        motor->disable();
        delay = millis(); 
        osOverCV = true;
      } 
    }
    else if (fabs(motor->voltage.q) >= (motor->voltage_limit + overVoltageOffset)){
      static long delay = millis();
      if (millis() - delay > overCVDelayPeriod && !osOverCV) {
        SIMPLEFOC_DEBUG("Motor Over Voltage, Disable Motor: ", motor->voltage.q);
        motor->disable();
        delay = millis(); 
        osOverCV = true;
      } 
    }
    else{
      osOverCV = false;
    }

    //Detect if Motor is in an uncontrollable state ie oscillating
    motorVoscillation = VClass.oscillating(VClass.input = motor->shaft_velocity, VClass.cnt = mVelCnt, VClass.offset = mVelOffset, VClass.period = mVelPeriod);
    motorAoscillation = AClass.oscillating(AClass.input = motor->shaft_angle, AClass.cnt = mAngleCnt, AClass.offset = mAngleOffset, AClass.period = mAnglePeriod);
    currentQoscillation = CQClass.oscillating(CQClass.input = motor->current.q, CQClass.cnt = mCurrentQcnt, CQClass.offset = mCurrentQoffset, CQClass.period = mCurrentQperiod);
    currentDoscillation = CDClass.oscillating(CDClass.input = motor->current.d, CDClass.cnt = mCurrentDcnt, CDClass.offset = mCurrentDoffset, CDClass.period = mCurrentDperiod);
    voltageQoscillation = VQClass.oscillating(VQClass.input = motor->voltage.q, VQClass.cnt = mVoltageQcnt, VQClass.offset = mVoltageQoffset, VQClass.period = mVoltageQperiod);
    voltageDoscillation = VDClass.oscillating(VDClass.input = motor->voltage.d, VDClass.cnt = mVoltageDcnt, VDClass.offset = mVoltageDoffset, VDClass.period = mVoltageDperiod);
    if (motorVoscillation   ||
        motorAoscillation   ||
        currentQoscillation || 
        currentDoscillation ||
        voltageQoscillation ||
        voltageDoscillation){
      SIMPLEFOC_DEBUG("Motor Oscillating, Disable Motor");
      motor->disable();
    }
    if (motorVoscillation) SIMPLEFOC_DEBUG("Motor Shaft Velocity Oscillating");
    else if (motorAoscillation) SIMPLEFOC_DEBUG("Motor Shaft Angle Oscillating", motorAoscillation);
    else if (currentQoscillation) SIMPLEFOC_DEBUG("Motor current Q Oscillating");
    else if (currentDoscillation) SIMPLEFOC_DEBUG("Motor current D Oscillating");
    else if (voltageQoscillation) SIMPLEFOC_DEBUG("Motor voltage Q Oscillating");
    else if (voltageDoscillation) SIMPLEFOC_DEBUG("Motor voltage D Oscillating");
  }
}

How to use: Add these your main file

//Motor Protection Instance 
mpClass mProtection;

void doProtection(char *cmd){
  mProtection.doMotorProtectCommand(cmd);
}

//ADD to your Setup/Begin

  pinMode(A_PWM, OUTPUT);
  //Enable SimpleFOC Debugging
  SimpleFOCDebug::enable(&Serial);

   // use monitoring with serial 
  Serial.begin(115200);

//Call at end of your setup!

  //Motor Protection Settings
  //Link all objects for motor protection class
  mProtection.linkMotor(&motor);
  mProtection.linkEncoder(&encoder);
  mProtection.linkBLDCDriver6PWM(&driver);
  mProtection.linkLowsideCurrentSense(&currentSense);
  //Protection update rate in microseconds
  mProtection.update = 250;
  //Brake PID Paremeters
  mProtection.brake_P = 10;
  mProtection.brake_I = 100;
  mProtection.brake_D = 0;
  mProtection.brake_Min = 0;
  mProtection.brake_Max = 250;
  mProtection.brake_Cycle = 0;
  //Brake Trigger (driver power supply + Offset amount above vbus)
  mProtection.brakeEngageOffset = 0.25;
  mProtection.brakeEngageOffset = 2.0;
  mProtection.brakeEngageMaxDisableOffset = 3.0;
  mProtection.brakeCutOffPeriod = 200;
  //Temperature Settings
  mProtection.tempCutOff = 60.0;
  mProtection.tempDelayPeriod = 500;
  //Stall Detection
  mProtection.stallDelayPeriod = 100;
  mProtection.stallCurrentOffset = 0.1;
  mProtection.stallVoltageOffset = 0.1;
  //Over Current/Voltage Protection
  mProtection.overCurrentOffset = 0.05;
  mProtection.overVoltageOffset = 0.05;
  mProtection.overCVDelayPeriod = 100;
  //Oscillating Detection
  //Shaft Velocity 
  mProtection.mVelCnt = 6;
  mProtection.mVelOffset = 1;
  mProtection.mVelPeriod = 250;
  //Shaft Angle
  mProtection.mAngleCnt = 8;
  mProtection.mAngleOffset = 0.1;
  mProtection.mAnglePeriod = 250;
  //Current Q
  mProtection.mCurrentQcnt = 10;
  mProtection.mCurrentQoffset = 1.5;
  mProtection.mCurrentQperiod = 250;
  //Current D
  mProtection.mCurrentDcnt = 10;
  mProtection.mCurrentDoffset = 1.5;
  mProtection.mCurrentDperiod = 250;
  //Voltage Q
  mProtection.mVoltageQcnt = 10;
  mProtection.mVoltageQoffset = 1.5;
  mProtection.mVoltageQperiod = 250;
  //Voltage D
  mProtection.mVoltageDcnt = 10;
  mProtection.mVoltageDoffset = 1.5;
  mProtection.mVoltageDperiod = 250;
  //Add Cammand for Motor Protection
  command.add('P', doProtection, (char*)"Motor Protection");
  //Call Motor Protection Setup
  _delay(500);
  mProtection.begin();

//Run this in the loop after motor.move

//Call Motor Protection Loop
  mProtection.loop();

Here is the braking circuit I am using with the B_G431B_ESC1

Hopefully it helps others and is a good start, I will add to my github when I have everything working correctly

[Valentine]

@Matt303

the braking circuit I am using

Very interesting.

I’m having a little problem understanding, you have R2 270R then a D1 15v zener, is this enough to supply the driver booster circuit? At 24v this would supply barely 44mA to IR2104. Also you will be burning 0.5W through R2 all the time, that’s a lot of power to dissipate continuously, you need a really large footprint resistor to sink that heat, like 2512 or at least 2010. In addition IR2104 is a low power driver, is this enough to open high current mosfets well?

Cheers,
Valentine

[Matt303]

Hi @Valentine Yes 270R is fine, currently using 470R at 24V and is working fine and not getting hot, used this calculator. Zener diode voltage regulator calculator and Formulas I have not made pcb yet, just done with perf board at the moment. I’m only using 1khz PWM and did a test with 10khz and circuit was fine and fet gates on the scope were fine. I think the driver uses a lot less than the 200ma listed in the datasheet

[Valentine]

@Matt303

I think the driver uses a lot less than the 200ma listed in the datasheet

Thanks, just curious. Excellent job, very educational.

Valentine

[runger]

@Matt303

I can’t get the PWM function working.

Hmmm… the parameter to _writeDutyCycle1PWM is a float in the range [0,1], not an integer percentage… could that be the issue?

Otherwise I will have to test it out for you, it really should be working.

[Matt303]

Hi @runger I did try 0-1 , but will give it another go. Do you know how I can disable the motor and stop the PIDs from calculating?

[runger]

Hey,

I think you want to set target = 0 velocity/torque before calling motor.disable()
or before re-enabling it.

Actually the PID does not run when the motor is disabled. But of course if you re-enable it and it is far from the set target value, it will have a large response. Also the PID depends on the delta-T, and while this will be limited to max 1ms for cases when it is larger than 0.5s, it could still lead to quite a large I-term in the PID.

You have quite a bit of code there, so I have not looked at it all in detail, but here is one thing I noted:

This one will lead to quite trapezoidal commutation waveforms:
motor->voltage_limit = driver->voltage_power_supply;
better is perhaps:
motor->voltage_limit = driver->voltage_power_supply / 2.0f;

→ Motor voltage limit acts on Uq which can be positive or negative. Driver limit and driver power supply voltage is absolute, starting at 0. Setting motor limit to half the driver limit will mean that voltage always stays in driver limit range. If you set it any higher, you will get clipping for the high voltages, and a “flat top” to your sine-waves.

[Matt303]

Hi @runger thanks a lot for that clear explanation… that explains why motor starts behaving erratically at high speeds, If I increased power supply voltage from 12v to 24v it would run at that speed fine. I will add that and test it all out.

I was going to try this code to reset the PID and voltage values to the motor while motor is disabled. What are your thoughts about doing this?

   static bool osReset;
   if (!motor->enabled){
      if(!osReset){
        motor->PID_current_q.reset();
        motor->PID_current_d.reset();
        motor->voltage.q = 0;
        motor->voltage.d = 0;
        osReset = true;
      }
    }
    else{
      osReset = false;
    }