saltylab-firmware

seb/saltylab-firmware

Fork 0

Commit Graph

Author	SHA1	Message	Date
sl-controls	2b06161cb4	feat: Motor current monitoring and overload protection (Issue #584 ) Adds ADC-based motor current sensing with configurable overload threshold, soft PWM limiting, hard cutoff on sustained overload, and auto-recovery. Changes: - include/motor_current.h: MotorCurrentState enum (NORMAL/SOFT_LIMIT/COOLDOWN), thresholds (5A hard, 4A soft, 2s overload, 10s cooldown), full API - src/motor_current.c: reads battery_adc_get_current_ma() each tick (reuses existing ADC3 IN13/PC3 DMA sampling); linear PWM scale in soft-limit zone (scale256 fixed-point); fault counter + one-tick fault_pending flag for main-loop fault log integration; telemetry at MOTOR_CURR_TLM_HZ (5 Hz) - include/pid_flash.h: add pid_sched_entry_t (16 bytes), pid_sched_flash_t (128 bytes at 0x0807FF40), PID_SCHED_MAX_BANDS=6, pid_flash_load_schedule(), pid_flash_save_all() — fixes missing types needed by jlink.h (Issue #550) - src/pid_flash.c: implement flash_write_words() helper, pid_flash_load_schedule(), pid_flash_save_all() — single sector-7 erase covers both schedule and PID records - include/jlink.h: add JLINK_TLM_MOTOR_CURRENT (0x86), jlink_tlm_motor_current_t (8 bytes: current_ma, limit_pct, state, fault_count), jlink_send_motor_current_tlm() - src/jlink.c: implement jlink_send_motor_current_tlm() (14-byte frame) Motor overload state machine: MC_NORMAL : current_ma < 4000 mA — full PWM authority MC_SOFT_LIMIT : 4000-5000 mA — linear reduction (0% at 4A → 100% at 5A) MC_COOLDOWN : >5A sustained 2s → zero output for 10s then NORMAL Main-loop integration: motor_current_tick(now_ms); if (motor_current_fault_pending()) fault_log_append(FAULT_MOTOR_OVERCURRENT); cmd = motor_current_apply_limit(balance_pid_output()); motor_current_send_tlm(now_ms); Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>	2026-03-14 12:25:29 -04:00
sl-firmware	19a30a1c4f	feat: PID auto-tune for balance mode (Issue #531 ) Implement Ziegler-Nichols relay feedback auto-tuning with flash persistence: Firmware (STM32F722): - pid_flash.c/h: erase+write Kp/Ki/Kd to flash sector 7 (0x0807FFC0), magic-validated; load on boot to restore saved tune - jlink.h: add JLINK_CMD_PID_SAVE (0x0A) and JLINK_TLM_PID_RESULT (0x83) with jlink_tlm_pid_result_t struct and pid_save_req flag in JLinkState - jlink.c: dispatch JLINK_CMD_PID_SAVE -> pid_save_req; add jlink_send_pid_result() to confirm flash write outcome over USART1 - main.c: load saved PID from flash after balance_init(); handle pid_save_req in main loop (disarmed-only, erase stalls CPU ~1s) Jetson ROS2 (saltybot_pid_autotune): - pid_autotune_node.py: add Ki to Ziegler-Nichols formula (ZN PID: Kp=0.6Ku, Ki=1.2Ku/Tu, Kd=0.075KuTu); add JLink serial client that sends JLINK_CMD_PID_SET + JLINK_CMD_PID_SAVE after tuning completes - autotune_config.yaml: add jlink_serial_port and jlink_baud_rate params Trigger: ros2 service call /saltybot/autotune_pid std_srvs/srv/Trigger Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>	2026-03-07 09:56:19 -05:00

Author

SHA1

Message

Date

sl-controls

2b06161cb4

feat: Motor current monitoring and overload protection (Issue #584 )

Adds ADC-based motor current sensing with configurable overload threshold,
soft PWM limiting, hard cutoff on sustained overload, and auto-recovery.

Changes:
- include/motor_current.h: MotorCurrentState enum (NORMAL/SOFT_LIMIT/COOLDOWN),
  thresholds (5A hard, 4A soft, 2s overload, 10s cooldown), full API
- src/motor_current.c: reads battery_adc_get_current_ma() each tick (reuses
  existing ADC3 IN13/PC3 DMA sampling); linear PWM scale in soft-limit zone
  (scale256 fixed-point); fault counter + one-tick fault_pending flag for
  main-loop fault log integration; telemetry at MOTOR_CURR_TLM_HZ (5 Hz)
- include/pid_flash.h: add pid_sched_entry_t (16 bytes), pid_sched_flash_t
  (128 bytes at 0x0807FF40), PID_SCHED_MAX_BANDS=6, pid_flash_load_schedule(),
  pid_flash_save_all() — fixes missing types needed by jlink.h (Issue #550)
- src/pid_flash.c: implement flash_write_words() helper, pid_flash_load_schedule(),
  pid_flash_save_all() — single sector-7 erase covers both schedule and PID records
- include/jlink.h: add JLINK_TLM_MOTOR_CURRENT (0x86), jlink_tlm_motor_current_t
  (8 bytes: current_ma, limit_pct, state, fault_count), jlink_send_motor_current_tlm()
- src/jlink.c: implement jlink_send_motor_current_tlm() (14-byte frame)

Motor overload state machine:
  MC_NORMAL     : current_ma < 4000 mA — full PWM authority
  MC_SOFT_LIMIT : 4000-5000 mA — linear reduction (0% at 4A → 100% at 5A)
  MC_COOLDOWN   : >5A sustained 2s → zero output for 10s then NORMAL

Main-loop integration:
  motor_current_tick(now_ms);
  if (motor_current_fault_pending()) fault_log_append(FAULT_MOTOR_OVERCURRENT);
  cmd = motor_current_apply_limit(balance_pid_output());
  motor_current_send_tlm(now_ms);

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

2026-03-14 12:25:29 -04:00

sl-firmware

19a30a1c4f

feat: PID auto-tune for balance mode (Issue #531 )

Implement Ziegler-Nichols relay feedback auto-tuning with flash persistence:

Firmware (STM32F722):
- pid_flash.c/h: erase+write Kp/Ki/Kd to flash sector 7 (0x0807FFC0),
  magic-validated; load on boot to restore saved tune
- jlink.h: add JLINK_CMD_PID_SAVE (0x0A) and JLINK_TLM_PID_RESULT (0x83)
  with jlink_tlm_pid_result_t struct and pid_save_req flag in JLinkState
- jlink.c: dispatch JLINK_CMD_PID_SAVE -> pid_save_req; add
  jlink_send_pid_result() to confirm flash write outcome over USART1
- main.c: load saved PID from flash after balance_init(); handle
  pid_save_req in main loop (disarmed-only, erase stalls CPU ~1s)

Jetson ROS2 (saltybot_pid_autotune):
- pid_autotune_node.py: add Ki to Ziegler-Nichols formula (ZN PID:
  Kp=0.6Ku, Ki=1.2Ku/Tu, Kd=0.075KuTu); add JLink serial client that
  sends JLINK_CMD_PID_SET + JLINK_CMD_PID_SAVE after tuning completes
- autotune_config.yaml: add jlink_serial_port and jlink_baud_rate params

Trigger: ros2 service call /saltybot/autotune_pid std_srvs/srv/Trigger

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

2026-03-07 09:56:19 -05:00

2 Commits