Merge remote-tracking branch 'origin/devel' into control-loop-refactor

CHANGELOG.md

@@ -1,5 +1,7 @@
 # Unreleased Features
 Please add a note of your changes below this heading if you make a Pull Request.
+### Added
+* [Mechanical brake support](docs/mechanical-brakes.md)
 
 ### Changed
 
@@ -63,6 +65,9 @@ Please add a note of your changes below this heading if you make a Pull Request.
 * `axis.motor.thermal_current_lim` has been removed. Instead a new property is available `axis.motor.effective_current_lim` which contains the effective current limit including any thermal limits.
 * `axis.motor.get_inverter_temp()`, `axis.motor.inverter_temp_limit_lower` and `axis.motor.inverter_temp_limit_upper` have been moved to seperate fet thermistor object under `axis.fet_thermistor`. `get_inverter_temp()` function has been renamed to `temp` and is now a read-only property.
 * `axis.config.counts_per_step` is now `axis.config.turns_per_step`
+* Outputs of `axis.sensorless_estimator` are now in turns/s instead of electrical rad/s
+* Fixed bug of high current during lockin-ramp caused by `motor::update()` expecting a torque command instead of current
+* Fixed bug where commanded velocity was extremely high just after sensorless ramp when using `input_mode` INPUT_MODE_VEL_RAMP caused by `vel_setpoint` and `axis.config.sensorless_ramp.vel` being in different units
 
 
 # Releases

Firmware/Board/v3/board.cpp

@@ -102,6 +102,7 @@ Encoder encoders[AXIS_COUNT] = {
 
 // TODO: this has no hardware dependency and should be allocated depending on config
 Endstop endstops[2 * AXIS_COUNT];
+MechanicalBrake mechanical_brakes[AXIS_COUNT];
 
 SensorlessEstimator sensorless_estimators[AXIS_COUNT];
 Controller controllers[AXIS_COUNT];
@@ -122,6 +123,7 @@ std::array<Axis, AXIS_COUNT> axes{{
         motors[0], // motor
         trap[0], // trap
         endstops[0], endstops[1], // min_endstop, max_endstop
+        mechanical_brakes[0], // mechanical brake
     },
     {
         1, // axis_num
@@ -141,6 +143,7 @@ std::array<Axis, AXIS_COUNT> axes{{
         motors[1], // motor
         trap[1], // trap
         endstops[2], endstops[3], // min_endstop, max_endstop
+        mechanical_brakes[1], // mechanical brake
     },
 }};
 

Firmware/MotorControl/axis.cpp

@@ -19,7 +19,8 @@ Axis::Axis(int axis_num,
            Motor& motor,
            TrapezoidalTrajectory& trap,
            Endstop& min_endstop,
-           Endstop& max_endstop)
+           Endstop& max_endstop,
+           MechanicalBrake& mechanical_brake)
     : axis_num_(axis_num),
       default_step_gpio_pin_(default_step_gpio_pin),
       default_dir_gpio_pin_(default_dir_gpio_pin),
@@ -33,6 +34,7 @@ Axis::Axis(int axis_num,
       trap_traj_(trap),
       min_endstop_(min_endstop),
       max_endstop_(max_endstop),
+      mechanical_brake_(mechanical_brake),
       current_limiters_(make_array(
           static_cast<CurrentLimiter*>(&fet_thermistor),
           static_cast<CurrentLimiter*>(&motor_thermistor))),
@@ -49,6 +51,7 @@ Axis::Axis(int axis_num,
     trap_traj_.axis_ = this;
     min_endstop_.axis_ = this;
     max_endstop_.axis_ = this;
+    mechanical_brake_.axis_ = this;
 }
 
 Axis::LockinConfig_t Axis::default_calibration() {
@@ -432,6 +435,7 @@ bool Axis::run_homing() {
 }
 
 bool Axis::run_idle_loop() {
+    mechanical_brake_.engage();
     set_step_dir_active(config_.enable_step_dir && config_.step_dir_always_on);
     while (requested_state_ == AXIS_STATE_UNDEFINED) {
         motor_.setup();

Firmware/MotorControl/axis.hpp

@@ -10,6 +10,7 @@ class Axis;
 #include "open_loop_controller.hpp"
 #include "trapTraj.hpp"
 #include "endstop.hpp"
+#include "mechanical_brake.hpp"
 #include "low_level.h"
 #include "utils.hpp"
 #include "task_timer.hpp"
@@ -105,7 +106,8 @@ class Axis : public ODriveIntf::AxisIntf {
             Motor& motor,
             TrapezoidalTrajectory& trap,
             Endstop& min_endstop,
-            Endstop& max_endstop);
+            Endstop& max_endstop,
+            MechanicalBrake& mechanical_brake);
 
     bool apply_config();
     void clear_config();
@@ -160,6 +162,7 @@ class Axis : public ODriveIntf::AxisIntf {
     TrapezoidalTrajectory& trap_traj_;
     Endstop& min_endstop_;
     Endstop& max_endstop_;
+    MechanicalBrake& mechanical_brake_;
     TaskTimes task_times_;
 
     // List of current_limiters and thermistors to

Firmware/MotorControl/encoder.hpp

@@ -6,9 +6,10 @@
 #include "utils.hpp"
 #include <autogen/interfaces.hpp>
 
+
 class Encoder : public ODriveIntf::EncoderIntf {
 public:
-    const uint32_t MODE_FLAG_ABS = 0x100;
+    static constexpr uint32_t MODE_FLAG_ABS = 0x100;
 
     struct Config_t {
         Mode mode = MODE_INCREMENTAL;

Firmware/MotorControl/main.cpp

@@ -45,6 +45,7 @@ static bool config_read_all() {
                   config_manager.read(&axes[i].trap_traj_.config_) &&
                   config_manager.read(&axes[i].min_endstop_.config_) &&
                   config_manager.read(&axes[i].max_endstop_.config_) &&
+                  config_manager.read(&axes[i].mechanical_brake_.config_) &&
                   config_manager.read(&motors[i].config_) &&
                   config_manager.read(&fet_thermistors[i].config_) &&
                   config_manager.read(&axes[i].motor_thermistor_.config_) &&
@@ -64,6 +65,7 @@ static bool config_write_all() {
                   config_manager.write(&axes[i].trap_traj_.config_) &&
                   config_manager.write(&axes[i].min_endstop_.config_) &&
                   config_manager.write(&axes[i].max_endstop_.config_) &&
+                  config_manager.write(&axes[i].mechanical_brake_.config_) &&
                   config_manager.write(&motors[i].config_) &&
                   config_manager.write(&fet_thermistors[i].config_) &&
                   config_manager.write(&axes[i].motor_thermistor_.config_) &&
@@ -83,6 +85,7 @@ static void config_clear_all() {
         axes[i].trap_traj_.config_ = {};
         axes[i].min_endstop_.config_ = {};
         axes[i].max_endstop_.config_ = {};
+        axes[i].mechanical_brake_.config_ = {};
         motors[i].config_ = {};
         fet_thermistors[i].config_ = {};
         axes[i].motor_thermistor_.config_ = {};
@@ -385,6 +388,13 @@ static void rtos_main(void*) {
     // must happen after communication is initialized
     pwm0_input.init();
 
+    // Set up the CS pins for absolute encoders (TODO: move to GPIO init switch statement)
+    for(auto& axis : axes){
+        if(axis.encoder_.config_.mode & Encoder::MODE_FLAG_ABS){
+            axis.encoder_.abs_spi_cs_pin_init();
+        }
+    }
+
     // Try to initialized gate drivers for fault-free startup.
     // If this does not succeed, a fault will be raised and the idle loop will
     // periodically attempt to reinit the gate driver.
@@ -526,6 +536,7 @@ extern "C" int main(void) {
         if (mode == ODriveIntf::GPIO_MODE_DIGITAL ||
             mode == ODriveIntf::GPIO_MODE_DIGITAL_PULL_UP ||
             mode == ODriveIntf::GPIO_MODE_DIGITAL_PULL_DOWN ||
+            mode == ODriveIntf::GPIO_MODE_MECH_BRAKE ||
             mode == ODriveIntf::GPIO_MODE_ANALOG_IN) {
             GPIO_InitStruct.Alternate = 0;
         } else {
@@ -622,6 +633,11 @@ extern "C" int main(void) {
                 GPIO_InitStruct.Pull = GPIO_NOPULL;
                 GPIO_InitStruct.Speed = GPIO_SPEED_FREQ_LOW;
             } break;
+            case ODriveIntf::GPIO_MODE_MECH_BRAKE: {
+                GPIO_InitStruct.Mode = GPIO_MODE_OUTPUT_PP;
+                GPIO_InitStruct.Pull = GPIO_NOPULL;
+                GPIO_InitStruct.Speed = GPIO_SPEED_FREQ_LOW;
+            } break;
             default: {
                 odrv.misconfigured_ = true;
                 continue;

Firmware/MotorControl/mechanical_brake.cpp

@@ -0,0 +1,13 @@
+#include <odrive_main.h>
+
+void MechanicalBrake::engage() {
+	if (odrv.config_.gpio_modes[config_.gpio_num] == ODriveIntf::GPIO_MODE_MECH_BRAKE){
+		get_gpio(config_.gpio_num).write(config_.is_active_low ? 0 : 1);
+	}
+}
+
+void MechanicalBrake::release() {
+	if (odrv.config_.gpio_modes[config_.gpio_num] == ODriveIntf::GPIO_MODE_MECH_BRAKE){
+		get_gpio(config_.gpio_num).write(config_.is_active_low ? 1 : 0);
+	}
+}

Firmware/MotorControl/mechanical_brake.hpp

@@ -0,0 +1,25 @@
+#ifndef __MECHANICAL_BRAKE_HPP
+#define __MECHANICAL_BRAKE_HPP
+
+#include <autogen/interfaces.hpp>
+
+class MechanicalBrake : public ODriveIntf::MechanicalBrakeIntf  {
+   public:
+    struct Config_t {
+        uint16_t gpio_num = 0;
+        bool is_active_low = true;
+
+        // custom setters
+        MechanicalBrake* parent = nullptr;
+        void set_gpio_num(uint16_t value) { gpio_num = value; }
+    };
+
+    MechanicalBrake() {}
+
+    MechanicalBrake::Config_t config_;
+    Axis* axis_ = nullptr;
+
+    void release();
+    void engage();
+};
+#endif // __MECHANICAL_BRAKE_HPP

Firmware/MotorControl/motor.cpp

@@ -168,6 +168,8 @@ Motor::Motor(TIM_HandleTypeDef* timer,
  * @returns: True on success, false otherwise
  */
 bool Motor::arm(PhaseControlLaw<3>* control_law) {
+    axis_->mechanical_brake_.release();
+
     CRITICAL_SECTION() {
         control_law_ = control_law;
 

Firmware/MotorControl/odrive_main.h

@@ -140,6 +140,7 @@ inline ENUMTYPE operator ~ (ENUMTYPE a) { return static_cast<ENUMTYPE>(~static_c
 #include <thermistor.hpp>
 #include <trapTraj.hpp>
 #include <endstop.hpp>
+#include <mechanical_brake.hpp>
 #include <axis.hpp>
 #include <oscilloscope.hpp>
 #include <communication/communication.h>

Firmware/MotorControl/sensorless_estimator.cpp

@@ -82,8 +82,8 @@ bool SensorlessEstimator::update() {
     pll_pos_ = wrap_pm_pi(pll_pos_ + current_meas_period * pll_kp * delta_phase);
     // update PLL velocity
     phase_vel_ += current_meas_period * pll_ki * delta_phase;
-
-    vel_estimate_ = phase_vel_ / (2 * M_PI);
+    // convert to mechanical turns/s for controller usage.
+    vel_estimate_ = phase_vel_ / (std::max((float)axis_->motor_.config_.pole_pairs, 1.0f) * 2.0f * M_PI);
 
     return true;
 };

Firmware/Tupfile.lua

@@ -190,6 +190,7 @@ sources = {
     'MotorControl/encoder.cpp',
     'MotorControl/endstop.cpp',
     'MotorControl/async_estimator.cpp',
+    'MotorControl/mechanical_brake.cpp',
     'MotorControl/controller.cpp',
     'MotorControl/foc.cpp',
     'MotorControl/open_loop_controller.cpp',

Firmware/odrive-interface.yaml

@@ -468,6 +468,7 @@ interfaces:
       trap_traj: TrapezoidalTrajectory
       min_endstop: Endstop
       max_endstop: Endstop
+      mechanical_brake: MechanicalBrake
       task_times:
         c_is_class: False
         attributes:
@@ -990,7 +991,6 @@ interfaces:
           accel_limit: float32
           decel_limit: float32
 
-
   ODrive.Endstop:
     c_is_class: True
     attributes:
@@ -1004,6 +1004,22 @@ interfaces:
           is_active_high: bool
           debounce_ms: {type: uint32, c_setter: set_debounce_ms}
 
+  ODrive.MechanicalBrake:
+    c_is_class: True
+    attributes:
+      config:
+        c_is_class: False
+        attributes:
+          gpio_num: {type: uint16, c_setter: set_gpio_num}
+          is_active_low: bool
+    functions:
+      engage:
+        doc: |
+          This function engages the mechanical brake if one is present and enabled.
+      release:
+        doc: |
+          This function releases the mecahncal brake if one is present and enabled.
+
   ODrive.TaskTimer:
     c_is_class: True
     attributes:
@@ -1039,6 +1055,7 @@ valuetypes:
       Enc0: {doc: The pin is used by quadrature encoder 0.}
       Enc1: {doc: The pin is used by quadrature encoder 1.}
       Enc2: {doc: This mode is not supported on ODrive v3.x.}
+      MechBrake: {doc: This is to support external mechanical brakes.}
 
   ODrive.Can.Protocol:
     values: {Simple: }

docs/_data/index.yaml

@@ -17,6 +17,8 @@ sections:
         url: /encoders
       - title: Homing & Endstops
         url: /endstops
+      - title: Mechanical Brakes
+        url: /mechanical-brakes
       - title: Thermistors
         url: /thermistors
       - title: Control & Tuning

docs/commands.md

@@ -81,15 +81,15 @@ All variables that are part of a `[...].config` object can be saved to non-volat
 ## Setting up sensorless
 The ODrive can run without encoder/hall feedback, but there is a minimum speed, usually around a few hunderd RPM.
 
-To give an example, suppose you have a motor with 7 pole pairs, and you want to spin it at 3000 RPM. Then you would set the `input_vel` to `3000 * 2*pi/60 * 7 = 2199 rad/s electrical`.
-
-Below are some suggested starting parameters that you can use. Note that you _must_ set the `pm_flux_linkage` correctly for sensorless mode to work.
+Below are some suggested starting parameters that you can use. Note that you _must_ set the `pm_flux_linkage` correctly for sensorless mode to work. Motor calibration and setup must also be completed before sensorless mode will work.
 
 ```
 odrv0.axis0.controller.config.vel_gain = 0.01
 odrv0.axis0.controller.config.vel_integrator_gain = 0.05
 odrv0.axis0.controller.config.control_mode = 2
-odrv0.axis0.controller.input_vel = 400
+odrv0.axis0.controller.input_vel = 10
+odrv0.axis0.controller.config.vel_limit = <a value greater than input_vel>
+odrv0.axis0.motor.config.current_lim = 2 * odrv0.axis0.config.sensorless_ramp.current
 odrv0.axis0.sensorless_estimator.config.pm_flux_linkage = 5.51328895422 / (<pole pairs> * <motor kv>)
 odrv0.axis0.config.enable_sensorless_mode = True
 ```