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Inductance and resistance measurement and scaling fixes, various other fixes

This commit is contained in:
Benjamin Vedder 2021-10-15 22:25:07 +02:00
parent b6eb5852aa
commit d8a99fd0f1
11 changed files with 105 additions and 46 deletions
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5
CHANGELOG
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@ -34,6 +34,11 @@
* Added several AUX port modes.
* Added configurable safe start modes.
* Added fusion IMU filter.
* Added constant torque PAS mode.
* Correct scaling for resistance and inductance.
* Fixed inductance measurement bug with f_sw > 30k.
* Corrected inductance measurement algorithm.
* Fixed max power loss calculation.
=== FW 5.02 ===
* IMU calibration improvement.

6
conf_general.c
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@ -1068,7 +1068,7 @@ bool conf_general_measure_flux_linkage_openloop(float current, float duty,
float rad_s = rpm_now * ((2.0 * M_PI) / 60.0);
float v_mag = sqrtf(SQ(vq_avg) + SQ(vd_avg));
float i_mag = sqrtf(SQ(iq_avg) + SQ(id_avg));
*linkage = (v_mag - (2.0 / 3.0) * res * i_mag) / rad_s - (2.0 / 3.0) * i_mag * ind;
*linkage = (v_mag - res * i_mag) / rad_s - i_mag * ind;
mcconf->foc_motor_r = res;
mcconf->foc_motor_l = ind;
@ -1308,7 +1308,7 @@ static bool measure_r_l_imax(float current_min, float current_max,
return false;
}
if ((i * i * res_tmp) >= (max_power_loss / 3.0)) {
if ((i * i * res_tmp * 2.0) >= (max_power_loss / 5.0)) {
break;
}
}
@ -1319,7 +1319,7 @@ static bool measure_r_l_imax(float current_min, float current_max,
mc_interface_set_configuration(mcconf);
*l = mcpwm_foc_measure_inductance_current(i_last, 100, 0, 0) * 1e-6;
*i_max = sqrtf(max_power_loss / *r);
*i_max = sqrtf(max_power_loss / *r / 2.0);
utils_truncate_number(i_max, HW_LIM_CURRENT);
mcconf->foc_motor_r = res_old;

2
conf_general.h
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@ -24,7 +24,7 @@
#define FW_VERSION_MAJOR 5
#define FW_VERSION_MINOR 03
// Set to 0 for building a release and iterate during beta test builds
#define FW_TEST_VERSION_NUMBER 51
#define FW_TEST_VERSION_NUMBER 54
#include "datatypes.h"

2
confgenerator.h
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@ -8,7 +8,7 @@
#include <stdbool.h>
// Constants
#define MCCONF_SIGNATURE 3706516163
#define MCCONF_SIGNATURE 2393270318
#define APPCONF_SIGNATURE 763356168
// Functions

2
hwconf/hw_60.c
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@ -111,7 +111,7 @@ void hw_init_gpio(void) {
palSetPadMode(HW_HALL_ENC_GPIO3, HW_HALL_ENC_PIN3, PAL_MODE_INPUT_PULLUP);
// Phase filters
#ifdef HW60_IS_MK5
#ifdef PHASE_FILTER_GPIO
palSetPadMode(PHASE_FILTER_GPIO, PHASE_FILTER_PIN,
PAL_MODE_OUTPUT_PUSHPULL |
PAL_STM32_OSPEED_HIGHEST);

29
hwconf/hw_60.h
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@ -137,6 +137,35 @@
#define ADC_IND_SHUTDOWN 10
#endif
// -------- Current sensor test
#if 0
#undef ADC_IND_CURR1
#undef ADC_IND_CURR2
#undef ADC_IND_CURR3
#undef CURRENT_FILTER_ON
#undef CURRENT_FILTER_OFF
#define CURRENT_FILTER_OFF() palClearPad(HW_UART_RX_PORT, HW_UART_RX_PIN)
#define CURRENT_FILTER_ON() palClearPad(HW_UART_RX_PORT, HW_UART_RX_PIN)
#define ADC_IND_CURR1 6
#define ADC_IND_CURR2 7
#define ADC_IND_CURR3 10
#define HW_EARLY_INIT() palSetPadMode(HW_UART_TX_PORT, HW_UART_TX_PIN, PAL_MODE_OUTPUT_PUSHPULL); \
palSetPadMode(HW_UART_RX_PORT, HW_UART_RX_PIN, PAL_MODE_OUTPUT_PUSHPULL); \
palSetPad(HW_UART_TX_PORT, HW_UART_TX_PIN)
#define CURRENT_SHUNT_RES 1
#define CURRENT_AMP_GAIN (2.22e-3 * (4.7 / (4.7 + 2.2)))
#define APPCONF_APP_TO_USE APP_NONE
#endif
// ----------------------------
// ADC macros and settings
// Component parameters (can be overridden)

24
hwconf/hw_es19.h
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@ -27,7 +27,7 @@
// HW properties
#define HW_HAS_3_SHUNTS
#define HW_HAS_PHASE_SHUNTS
#define HW_HAS_PHASE_FILTERS
//#define HW_HAS_PHASE_FILTERS
#define HW_HAS_SI8900
// Macros
@ -94,6 +94,28 @@
#define ADC_IND_TEMP_MOTOR 9
#define ADC_IND_VREFINT 12
// -------- Current sensor test
#if 1
#undef ADC_IND_CURR1
#undef ADC_IND_CURR2
#undef ADC_IND_CURR3
#undef CURRENT_FILTER_ON
#undef CURRENT_FILTER_OFF
#define ADC_IND_CURR1 6
#define ADC_IND_CURR2 7
#define ADC_IND_CURR3 10
#define CURRENT_SHUNT_RES 1
#define CURRENT_AMP_GAIN (2.22e-3 * (4.7 / (4.7 + 2.2)))
#define APPCONF_APP_TO_USE APP_NONE
#endif
// ----------------------------
// ADC macros and settings
// Component parameters (can be overridden)

18
hwconf/hw_rd2.h
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@ -255,34 +255,34 @@
#define MCCONF_L_MAX_ABS_CURRENT 480.0
#endif
#ifndef MCCONF_L_RPM_MAX
#define MCCONF_L_RPM_MAX 32000.0
#define MCCONF_L_RPM_MAX 30000.0
#endif
#ifndef MCCONF_L_RPM_MIN
#define MCCONF_L_RPM_MIN -32000.0
#define MCCONF_L_RPM_MIN -30000.0
#endif
#ifndef MCCONF_L_RPM_START
#define MCCONF_L_RPM_START 0.8
#define MCCONF_L_RPM_START 0.9
#endif
#ifndef MCCONF_FOC_CURRENT_KP
#define MCCONF_FOC_CURRENT_KP 0.0046
#define MCCONF_FOC_CURRENT_KP 0.01
#endif
#ifndef MCCONF_FOC_CURRENT_KI
#define MCCONF_FOC_CURRENT_KI 8.0
#define MCCONF_FOC_CURRENT_KI 6.0
#endif
#ifndef MCCONF_FOC_F_SW
#define MCCONF_FOC_F_SW 30000.0
#endif
#ifndef MCCONF_FOC_MOTOR_L
#define MCCONF_FOC_MOTOR_L 2.32e-6
#define MCCONF_FOC_MOTOR_L 5.0e-6
#endif
#ifndef MCCONF_FOC_MOTOR_R
#define MCCONF_FOC_MOTOR_R 0.004
#define MCCONF_FOC_MOTOR_R 0.0024
#endif
#ifndef MCCONF_FOC_MOTOR_FLUX_LINKAGE
#define MCCONF_FOC_MOTOR_FLUX_LINKAGE 0.00805
#define MCCONF_FOC_MOTOR_FLUX_LINKAGE 0.00796
#endif
#ifndef MCCONF_FOC_OBSERVER_GAIN
#define MCCONF_FOC_OBSERVER_GAIN 15.0e6
#define MCCONF_FOC_OBSERVER_GAIN 6.0e6
#endif
// Setup Info

2
mcconf/mcconf_default.h
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@ -72,7 +72,7 @@
#define MCCONF_L_RPM_START 0.8 // Fraction of full speed where RPM current limiting starts
#endif
#ifndef MCCONF_L_SLOW_ABS_OVERCURRENT
#define MCCONF_L_SLOW_ABS_OVERCURRENT true // Use the filtered (and hence slower) current for the overcurrent fault detection
#define MCCONF_L_SLOW_ABS_OVERCURRENT false // Use the filtered (and hence slower) current for the overcurrent fault detection
#endif
#ifndef MCCONF_L_MIN_DUTY
#define MCCONF_L_MIN_DUTY 0.005 // Minimum duty cycle

59
mcpwm_foc.c
View File

@ -1784,7 +1784,7 @@ float mcpwm_foc_measure_resistance(float current, int samples, bool stop_after)
timeout_configure(tout, tout_c, tout_ksw);
mc_interface_unlock();
return (voltage_avg / current_avg) * (2.0 / 3.0);
return voltage_avg / current_avg;
}
/**
@ -1821,15 +1821,19 @@ float mcpwm_foc_measure_inductance(float duty, int samples, float *curr, float *
stop_pwm_hw(motor);
motor->m_conf->foc_sensor_mode = FOC_SENSOR_MODE_HFI;
motor->m_conf->foc_hfi_voltage_start = duty * mc_interface_get_input_voltage_filtered() * (2.0 / 3.0);
motor->m_conf->foc_hfi_voltage_run = duty * mc_interface_get_input_voltage_filtered() * (2.0 / 3.0);
motor->m_conf->foc_hfi_voltage_max = duty * mc_interface_get_input_voltage_filtered() * (2.0 / 3.0);
motor->m_conf->foc_hfi_voltage_start = duty * mc_interface_get_input_voltage_filtered();
motor->m_conf->foc_hfi_voltage_run = duty * mc_interface_get_input_voltage_filtered();
motor->m_conf->foc_hfi_voltage_max = duty * mc_interface_get_input_voltage_filtered();
motor->m_conf->foc_sl_erpm_hfi = 20000.0;
motor->m_conf->foc_sample_v0_v7 = false;
motor->m_conf->foc_hfi_samples = HFI_SAMPLES_32;
motor->m_conf->foc_sample_high_current = false;
update_hfi_samples(motor->m_conf->foc_hfi_samples, motor);
if (motor->m_conf->foc_f_sw > 30.0e3) {
motor->m_conf->foc_f_sw = 30.0e3;
}
mcpwm_foc_set_configuration(motor->m_conf);
chThdSleepMilliseconds(1);
@ -1873,7 +1877,7 @@ float mcpwm_foc_measure_inductance(float duty, int samples, float *curr, float *
motor->m_conf->foc_hfi_samples = samples_old;
motor->m_conf->foc_sample_high_current = sample_high_current_old;
update_hfi_samples(motor->m_conf->foc_hfi_samples, motor);
mcpwm_foc_set_configuration(motor->m_conf);
mc_interface_unlock();
@ -1893,7 +1897,7 @@ float mcpwm_foc_measure_inductance(float duty, int samples, float *curr, float *
motor->m_hfi.fft_bin0_func((float*)motor->m_hfi.buffer_current, &real_bin0_i, &imag_bin0_i);
l_sum += real_bin0;
ld_lq_diff_sum += 2.0 * sqrtf(SQ(real_bin2) + SQ(imag_bin2));
ld_lq_diff_sum += 4.0 * sqrtf(SQ(real_bin2) + SQ(imag_bin2));
i_sum += real_bin0_i;
iterations++;
@ -1911,7 +1915,7 @@ float mcpwm_foc_measure_inductance(float duty, int samples, float *curr, float *
motor->m_conf->foc_hfi_samples = samples_old;
motor->m_conf->foc_sample_high_current = sample_high_current_old;
update_hfi_samples(motor->m_conf->foc_hfi_samples, motor);
mcpwm_foc_set_configuration(motor->m_conf);
mc_interface_unlock();
@ -1920,10 +1924,10 @@ float mcpwm_foc_measure_inductance(float duty, int samples, float *curr, float *
}
if (ld_lq_diff) {
*ld_lq_diff = (ld_lq_diff_sum / iterations) * 1e6 * (2.0 / 3.0);
*ld_lq_diff = (ld_lq_diff_sum / iterations) * 1e6;
}
return (l_sum / iterations) * 1e6 * (2.0 / 3.0);
return (l_sum / iterations) * 1e6;
}
/**
@ -3541,8 +3545,8 @@ void observer_update(float v_alpha, float v_beta, float i_alpha, float i_beta,
volatile mc_configuration *conf_now = motor->m_conf;
const float L = (3.0 / 2.0) * conf_now->foc_motor_l;
float R = (3.0 / 2.0) * conf_now->foc_motor_r;
const float L = conf_now->foc_motor_l;
float R = conf_now->foc_motor_r;
// Saturation compensation
const float sign = (motor->m_motor_state.iq * motor->m_motor_state.vq) >= 0.0 ? 1.0 : -1.0;
@ -3722,8 +3726,8 @@ static void control_current(volatile motor_all_state_t *motor, float dt) {
switch (conf_now->foc_cc_decoupling) {
case FOC_CC_DECOUPLING_CROSS:
dec_vd = state_m->iq_filter * motor->m_speed_est_fast * lq * (3.0 / 2.0);
dec_vq = state_m->id_filter * motor->m_speed_est_fast * ld * (3.0 / 2.0);
dec_vd = state_m->iq_filter * motor->m_speed_est_fast * lq;
dec_vq = state_m->id_filter * motor->m_speed_est_fast * ld;
break;
case FOC_CC_DECOUPLING_BEMF:
@ -3731,8 +3735,8 @@ static void control_current(volatile motor_all_state_t *motor, float dt) {
break;
case FOC_CC_DECOUPLING_CROSS_BEMF:
dec_vd = state_m->iq_filter * motor->m_speed_est_fast * lq * (3.0 / 2.0);
dec_vq = state_m->id_filter * motor->m_speed_est_fast * ld * (3.0 / 2.0);
dec_vd = state_m->iq_filter * motor->m_speed_est_fast * lq;
dec_vq = state_m->id_filter * motor->m_speed_est_fast * ld;
dec_bemf = motor->m_speed_est_fast * conf_now->foc_motor_flux_linkage;
break;
@ -3794,18 +3798,17 @@ static void control_current(volatile motor_all_state_t *motor, float dt) {
conf_now->foc_hfi_voltage_run, conf_now->foc_hfi_voltage_max);
}
utils_truncate_number_abs(&hfi_voltage, state_m->v_bus * (2.0 / 3.0) * 0.9);
utils_truncate_number_abs(&hfi_voltage, state_m->v_bus * 0.9);
if (motor->m_hfi.is_samp_n) {
float sample_now = (utils_tab_sin_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] * state_m->i_alpha -
utils_tab_cos_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] * state_m->i_beta);
float current_sample = sample_now - motor->m_hfi.prev_sample;
float di = (sample_now - motor->m_hfi.prev_sample);
motor->m_hfi.buffer_current[motor->m_hfi.ind] = current_sample;
motor->m_hfi.buffer_current[motor->m_hfi.ind] = di;
if (current_sample > 0.01) {
motor->m_hfi.buffer[motor->m_hfi.ind] = ((hfi_voltage / 2.0 - conf_now->foc_motor_r *
current_sample) / (conf_now->foc_f_sw * current_sample));
if (di > 0.01) {
motor->m_hfi.buffer[motor->m_hfi.ind] = ((hfi_voltage / 2.0 - conf_now->foc_motor_r * di) / (conf_now->foc_f_sw * di));
}
motor->m_hfi.ind++;
@ -3814,14 +3817,14 @@ static void control_current(volatile motor_all_state_t *motor, float dt) {
motor->m_hfi.ready = true;
}
mod_alpha_tmp += hfi_voltage * utils_tab_sin_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / ((2.0 / 3.0) * state_m->v_bus);
mod_beta_tmp -= hfi_voltage * utils_tab_cos_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / ((2.0 / 3.0) * state_m->v_bus);
mod_alpha_tmp += hfi_voltage * utils_tab_sin_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / state_m->v_bus;
mod_beta_tmp -= hfi_voltage * utils_tab_cos_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / state_m->v_bus;
} else {
motor->m_hfi.prev_sample = utils_tab_sin_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] * state_m->i_alpha -
utils_tab_cos_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] * state_m->i_beta;
mod_alpha_tmp -= hfi_voltage * utils_tab_sin_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / ((2.0 / 3.0) * state_m->v_bus);
mod_beta_tmp += hfi_voltage * utils_tab_cos_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / ((2.0 / 3.0) * state_m->v_bus);
mod_alpha_tmp -= hfi_voltage * utils_tab_sin_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / state_m->v_bus;
mod_beta_tmp += hfi_voltage * utils_tab_cos_32_1[motor->m_hfi.ind * motor->m_hfi.table_fact] / state_m->v_bus;
}
utils_saturate_vector_2d(&mod_alpha_tmp, &mod_beta_tmp, SQRT3_BY_2 * 0.95);
@ -4597,8 +4600,8 @@ static void terminal_tmp(int argc, const char **argv) {
// float linkage = conf_now->foc_motor_flux_linkage;
float linkage = sqrtf(SQ(m_motor_1.m_observer_x1) + SQ(m_motor_1.m_observer_x2));
rpm_est += (motor_state->vq - (3.0 / 2.0) * R * motor_state->iq) / linkage;
res_est += -(motor_state->speed_rad_s * linkage - motor_state->vq) / (motor_state->iq * (3.0 / 2.0));
rpm_est += (motor_state->vq - R * motor_state->iq) / linkage;
res_est += -(motor_state->speed_rad_s * linkage - motor_state->vq) / motor_state->iq;
samples += 1.0;
chThdSleep(1);

2
terminal.c
View File

@ -1201,7 +1201,7 @@ void terminal_process_string(char *str) {
commands_printf("measure_linkage_openloop [current] [duty] [erpm_per_sec] [motor_res] [motor_ind]");
commands_printf(" Run the motor in openloop FOC and measure the flux linkage");
commands_printf(" example measure_linkage 5 0.5 1000 0.076 0.000015");
commands_printf(" example measure_linkage_openloop 5 0.5 1000 0.076 0.000015");
commands_printf(" tip: measure the resistance with measure_res first");
commands_printf("foc_state");