bldc/conf_general.c

/*
 * conf_general.c
 *
 *  Created on: 14 sep 2014
 *      Author: benjamin
 */

#include "conf_general.h"
#include "ch.h"
#include "eeprom.h"
#include "mcpwm.h"
#include "hw.h"
#include "utils.h"

#include <string.h>

// Default configuration file
#ifdef MCCONF_OUTRUNNER1
#include "mcconf_outrunner1.h"
#elif defined MCCONF_OUTRUNNER2
#include "mcconf_outrunner2.h"
#elif defined MCCONF_OUTRUNNER_OR
#include "mcconf_outrunner_or.h"
#elif defined MCCONF_OUTRUNNER_BL
#include "mcconf_outrunner_bl.h"
#elif defined MCCONF_RCCAR1
#include "mcconf_rccar1.h"
#elif defined MCCONF_RCCAR2
#include "mcconf_rccar2.h"
#elif defined MCCONF_STEN
#include "mcconf_sten.h"
#elif defined MCCONF_GURGALOF
#include "mcconf_gurgalof.h"
#elif defined MCCONF_HDD
#include "mcconf_hdd.h"
#endif

// Parameters that can be overridden
#ifndef MCPWM_PWM_MODE
#define MCPWM_PWM_MODE					PWM_MODE_SYNCHRONOUS // Default PWM mode
#endif
#ifndef MCPWM_HALL_DIR
#define MCPWM_HALL_DIR					0		// Hall sensor direction [0 or 1]
#endif
#ifndef MCPWM_HALL_FWD_ADD
#define MCPWM_HALL_FWD_ADD				0		// Hall sensor offset fwd [0 to 5]
#endif
#ifndef MCPWM_HALL_REV_ADD
#define MCPWM_HALL_REV_ADD				0		// Hall sensor offset rev [0 to 5]
#endif
#ifndef MCPWM_MIN_VOLTAGE
#define MCPWM_MIN_VOLTAGE				8.0		// Minimum input voltage
#endif
#ifndef MCPWM_MAX_VOLTAGE
#define MCPWM_MAX_VOLTAGE				50.0	// Maximum input voltage
#endif
#ifndef MCPWM_RPM_MAX
#define MCPWM_RPM_MAX					100000.0	// The motor speed limit (Upper)
#endif
#ifndef MCPWM_RPM_MIN
#define MCPWM_RPM_MIN					-100000.0	// The motor speed limit (Lower)
#endif
#ifndef MCPWM_CURRENT_STARTUP_BOOST
#define MCPWM_CURRENT_STARTUP_BOOST		0.01	// The lowest duty cycle to use in current control mode (has to be > MCPWM_MIN_DUTY_CYCLE)
#endif
#ifndef MCPWM_RPM_LIMIT_NEG_TORQUE
#define MCPWM_RPM_LIMIT_NEG_TORQUE		true		// Use negative torque to limit the RPM
#endif
#ifndef MCPWM_CURR_MAX_RPM_FBRAKE
#define MCPWM_CURR_MAX_RPM_FBRAKE		1500	// Maximum electrical RPM to use full brake at
#endif
#ifndef MCPWM_SLOW_ABS_OVERCURRENT
#define MCPWM_SLOW_ABS_OVERCURRENT		false	// Use the filtered (and hence slower) current for the overcurrent fault detection
#endif
#ifndef MCPWM_COMM_MODE
#define MCPWM_COMM_MODE					COMM_MODE_INTEGRATE	// The commutation mode to use
#endif
#ifndef MCPWM_CYCLE_INT_LIMIT_HIGH_FAC
#define MCPWM_CYCLE_INT_LIMIT_HIGH_FAC	0.8		// Flux integrator limit percentage at MCPWM_CYCLE_INT_START_RPM_BR ERPM
#endif
#ifndef MCPWM_CYCLE_INT_START_RPM_BR
#define MCPWM_CYCLE_INT_START_RPM_BR	80000.0	// RPM border between the START and LOW interval
#endif
#ifndef MCPWM_FAULT_STOP_TIME
#define MCPWM_FAULT_STOP_TIME			3000	// Ignore commands for this duration in msec when faults occur
#endif
#ifndef MCPWM_LIM_TEMP_FET_START
#define MCPWM_LIM_TEMP_FET_START		80.0	// MOSFET temperature where current limiting should begin
#endif
#ifndef MCPWM_LIM_TEMP_FET_END
#define MCPWM_LIM_TEMP_FET_END			100.0	// MOSFET temperature where everything should be shut off
#endif
#ifndef MCPWM_LIM_TEMP_MOTOR_START
#define MCPWM_LIM_TEMP_MOTOR_START		80.0	// MOTOR temperature where current limiting should begin
#endif
#ifndef MCPWM_LIM_TEMP_MOTOR_END
#define MCPWM_LIM_TEMP_MOTOR_END		100.0	// MOTOR temperature where everything should be shut off
#endif
#ifndef MCPWM_MAX_FB_CURR_DIR_CHANGE
#define MCPWM_MAX_FB_CURR_DIR_CHANGE	10.0	// Maximum current during full brake during which a direction change is allowed
#endif

// EEPROM settings
#define EEPROM_BASE_MCCONF		1000
#define EEPROM_BASE_APPCONF		2000

// Global variables
uint16_t VirtAddVarTab[NB_OF_VAR];

void conf_general_init(void) {
	// First, make sure that all relevant virtual addresses are assigned for page swapping.
	memset(VirtAddVarTab, 0, sizeof(VirtAddVarTab));

	int ind = 0;
	for (unsigned int i = 0;i < (sizeof(app_configuration) / 2);i++) {
		VirtAddVarTab[ind++] = EEPROM_BASE_MCCONF + i;
	}

	for (unsigned int i = 0;i < (sizeof(app_configuration) / 2);i++) {
		VirtAddVarTab[ind++] = EEPROM_BASE_APPCONF + i;
	}

	FLASH_Unlock();
	FLASH_ClearFlag(FLASH_FLAG_OPERR | FLASH_FLAG_WRPERR | FLASH_FLAG_PGAERR |
			FLASH_FLAG_PGPERR | FLASH_FLAG_PGSERR);
	EE_Init();
}

/**
 * Read app_configuration from EEPROM. If this fails, default values will be used.
 *
 * @param conf
 * A pointer to a app_configuration struct to write the read configuration to.
 */
void conf_general_read_app_configuration(app_configuration *conf) {
	bool is_ok = true;
	uint8_t *conf_addr = (uint8_t*)conf;
	uint16_t var;

	for (unsigned int i = 0;i < (sizeof(app_configuration) / 2);i++) {
		if (EE_ReadVariable(EEPROM_BASE_APPCONF + i, &var) == 0) {
			conf_addr[2 * i] = (var >> 8) & 0xFF;
			conf_addr[2 * i + 1] = var & 0xFF;
		} else {
			is_ok = false;
			break;
		}
	}

	// Set the default configuration
	if (!is_ok) {
		memset(conf, 0, sizeof(app_configuration));
		conf->timeout_msec = 1000;
		conf->timeout_brake_current = 0.0;
		conf->app_to_use = APP_NONE;

		conf->app_ppm_ctrl_type = PPM_CTRL_TYPE_CURRENT;
		conf->app_ppm_pid_max_erpm = 15000;
		conf->app_ppm_hyst = 0.15;
		conf->app_ppm_pulse_start = 1.0;
		conf->app_ppm_pulse_width = 1.0;
		conf->app_ppm_rpm_lim_start = 200000.0;
		conf->app_ppm_rpm_lim_end = 250000.0;

		conf->app_uart_baudrate = 115200;

		conf->app_chuk_ctrl_type = CHUK_CTRL_TYPE_CURRENT_NOREV;
		conf->app_chuk_hyst = 0.15;
		conf->app_chuk_rpm_lim_start = 20000.0;
		conf->app_chuk_rpm_lim_end = 25000.0;
	}
}

/**
 * Write app_configuration to EEPROM.
 *
 * @param conf
 * A pointer to the configuration that should be stored.
 */
bool conf_general_store_app_configuration(app_configuration *conf) {
	mcpwm_release_motor();

	utils_sys_lock_cnt();
	RCC_APB1PeriphClockCmd(RCC_APB1Periph_WWDG, DISABLE);

	bool is_ok = true;
	uint8_t *conf_addr = (uint8_t*)conf;
	uint16_t var;

	FLASH_ClearFlag(FLASH_FLAG_OPERR | FLASH_FLAG_WRPERR | FLASH_FLAG_PGAERR |
			FLASH_FLAG_PGPERR | FLASH_FLAG_PGSERR);

	for (unsigned int i = 0;i < (sizeof(app_configuration) / 2);i++) {
		var = (conf_addr[2 * i] << 8) & 0xFF00;
		var |= conf_addr[2 * i + 1] & 0xFF;

		if (EE_WriteVariable(EEPROM_BASE_APPCONF + i, var) != FLASH_COMPLETE) {
			is_ok = false;
			break;
		}
	}

	RCC_APB1PeriphClockCmd(RCC_APB1Periph_WWDG, ENABLE);
	utils_sys_unlock_cnt();

	return is_ok;
}

/**
 * Read mc_configuration from EEPROM. If this fails, default values will be used.
 *
 * @param conf
 * A pointer to a mc_configuration struct to write the read configuration to.
 */
void conf_general_read_mc_configuration(mc_configuration *conf) {
	bool is_ok = true;
	uint8_t *conf_addr = (uint8_t*)conf;
	uint16_t var;

	for (unsigned int i = 0;i < (sizeof(mc_configuration) / 2);i++) {
		if (EE_ReadVariable(EEPROM_BASE_MCCONF + i, &var) == 0) {
			conf_addr[2 * i] = (var >> 8) & 0xFF;
			conf_addr[2 * i + 1] = var & 0xFF;
		} else {
			is_ok = false;
			break;
		}
	}

	if (!is_ok) {
		conf->pwm_mode = MCPWM_PWM_MODE;
		conf->comm_mode = MCPWM_COMM_MODE;

		conf->l_current_max = MCPWM_CURRENT_MAX;
		conf->l_current_min = MCPWM_CURRENT_MIN;
		conf->l_in_current_max = MCPWM_IN_CURRENT_MAX;
		conf->l_in_current_min = MCPWM_IN_CURRENT_MIN;
		conf->l_abs_current_max = MCPWM_MAX_ABS_CURRENT;
		conf->l_min_erpm = MCPWM_RPM_MIN;
		conf->l_max_erpm = MCPWM_RPM_MAX;
		conf->l_max_erpm_fbrake = MCPWM_CURR_MAX_RPM_FBRAKE;
		conf->l_min_vin = MCPWM_MIN_VOLTAGE;
		conf->l_max_vin = MCPWM_MAX_VOLTAGE;
		conf->l_slow_abs_current = MCPWM_SLOW_ABS_OVERCURRENT;
		conf->l_rpm_lim_neg_torque = MCPWM_RPM_LIMIT_NEG_TORQUE;
		conf->l_temp_fet_start = MCPWM_LIM_TEMP_FET_START;
		conf->l_temp_fet_end = MCPWM_LIM_TEMP_FET_END;
		conf->l_temp_motor_start = MCPWM_LIM_TEMP_MOTOR_START;
		conf->l_temp_motor_end = MCPWM_LIM_TEMP_MOTOR_END;

		conf->lo_current_max = conf->l_current_max;
		conf->lo_current_min = conf->l_current_min;
		conf->lo_in_current_max = conf->l_in_current_max;
		conf->lo_in_current_min = conf->l_in_current_min;

		conf->sl_is_sensorless = MCPWM_IS_SENSORLESS;
		conf->sl_min_erpm = MCPWM_MIN_RPM;
		conf->sl_max_fullbreak_current_dir_change = MCPWM_MAX_FB_CURR_DIR_CHANGE;
		conf->sl_min_erpm_cycle_int_limit = MCPWM_CYCLE_INT_LIMIT_MIN_RPM;
		conf->sl_cycle_int_limit = MCPWM_CYCLE_INT_LIMIT;
		conf->sl_cycle_int_limit_high_fac = MCPWM_CYCLE_INT_LIMIT_HIGH_FAC;
		conf->sl_cycle_int_rpm_br = MCPWM_CYCLE_INT_START_RPM_BR;
		conf->sl_bemf_coupling_k = MCPWM_BEMF_INPUT_COUPLING_K;

		conf->hall_dir = MCPWM_HALL_DIR;
		conf->hall_fwd_add = MCPWM_HALL_FWD_ADD;
		conf->hall_rev_add = MCPWM_HALL_REV_ADD;

		conf->s_pid_kp = MCPWM_PID_KP;
		conf->s_pid_ki = MCPWM_PID_KI;
		conf->s_pid_kd = MCPWM_PID_KD;
		conf->s_pid_min_rpm = MCPWM_PID_MIN_RPM;

		conf->cc_startup_boost_duty = MCPWM_CURRENT_STARTUP_BOOST;
		conf->cc_min_current = MCPWM_CURRENT_CONTROL_MIN;
		conf->cc_gain = MCPWM_CURRENT_CONTROL_GAIN;

		conf->m_fault_stop_time_ms = MCPWM_FAULT_STOP_TIME;
	}
}

/**
 * Write mc_configuration to EEPROM.
 *
 * @param conf
 * A pointer to the configuration that should be stored.
 */
bool conf_general_store_mc_configuration(mc_configuration *conf) {
	mcpwm_release_motor();

	utils_sys_lock_cnt();
	RCC_APB1PeriphClockCmd(RCC_APB1Periph_WWDG, DISABLE);

	bool is_ok = true;
	uint8_t *conf_addr = (uint8_t*)conf;
	uint16_t var;

	FLASH_ClearFlag(FLASH_FLAG_OPERR | FLASH_FLAG_WRPERR | FLASH_FLAG_PGAERR |
			FLASH_FLAG_PGPERR | FLASH_FLAG_PGSERR);

	for (unsigned int i = 0;i < (sizeof(mc_configuration) / 2);i++) {
		var = (conf_addr[2 * i] << 8) & 0xFF00;
		var |= conf_addr[2 * i + 1] & 0xFF;

		if (EE_WriteVariable(EEPROM_BASE_MCCONF + i, var) != FLASH_COMPLETE) {
			is_ok = false;
			break;
		}
	}

	RCC_APB1PeriphClockCmd(RCC_APB1Periph_WWDG, ENABLE);
	utils_sys_unlock_cnt();

	return is_ok;
}

bool conf_general_detect_motor_param(float current, float min_rpm, float low_duty,
		float *int_limit, float *bemf_coupling_k) {

	int ok_steps = 0;

	mc_configuration mcconf = *mcpwm_get_configuration();

	mcpwm_set_min_rpm(min_rpm);
	mcpwm_set_comm_mode(COMM_MODE_DELAY);
	mcpwm_set_current(current);

	// Spin up the motor
	for (int i = 0;i < 5000;i++) {
		if (mcpwm_get_duty_cycle_now() < 0.6) {
			chThdSleepMilliseconds(1);
		} else {
			ok_steps++;
			break;
		}
	}

	// Release the motor and wait a few commutations
	mcpwm_set_current(0.0);
	int tacho = mcpwm_get_tachometer_value(0);
	for (int i = 0;i < 2000;i++) {
		if ((mcpwm_get_tachometer_value(0) - tacho) < 3) {
			chThdSleepMilliseconds(1);
		} else {
			ok_steps++;
			break;
		}
	}

	// Average the cycle integrator for 50 commutations
	mcpwm_read_reset_avg_cycle_integrator();
	tacho = mcpwm_get_tachometer_value(0);
	for (int i = 0;i < 3000;i++) {
		if ((mcpwm_get_tachometer_value(0) - tacho) < 50) {
			chThdSleepMilliseconds(1);
		} else {
			ok_steps++;
			break;
		}
	}

	*int_limit = mcpwm_read_reset_avg_cycle_integrator();

	// Wait for the motor to slow down
	for (int i = 0;i < 5000;i++) {
		if (mcpwm_get_duty_cycle_now() > low_duty) {
			chThdSleepMilliseconds(1);
		} else {
			ok_steps++;
			break;
		}
	}
	mcpwm_set_duty(low_duty);

	// Average the cycle integrator for 100 commutations
	mcpwm_read_reset_avg_cycle_integrator();
	tacho = mcpwm_get_tachometer_value(0);
	float rpm_sum = 0.0;
	float rpm_iterations = 0.0;
	for (int i = 0;i < 3000;i++) {
		if ((mcpwm_get_tachometer_value(0) - tacho) < 100) {
			rpm_sum += mcpwm_get_rpm();
			rpm_iterations += 1;
			chThdSleepMilliseconds(1);
		} else {
			ok_steps++;
			break;
		}
	}

	float avg_cycle_integrator_running = mcpwm_read_reset_avg_cycle_integrator();
	float rpm = rpm_sum / rpm_iterations;

	mcpwm_set_current(0.0);

	// Try to figure out the coupling factor
	avg_cycle_integrator_running -= *int_limit;
	avg_cycle_integrator_running /= (float)ADC_Value[ADC_IND_VIN_SENS];
	avg_cycle_integrator_running *= rpm;
	*bemf_coupling_k = avg_cycle_integrator_running;

	// Restore settings
	mcpwm_set_comm_mode(mcconf.comm_mode);
	mcpwm_set_min_rpm(mcconf.sl_min_erpm);

	return ok_steps == 5 ? true : false;
}