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2b06161cb4
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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>
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2026-03-14 12:25:29 -04:00 |
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