Dual Brushless Motor ESC, 10-62V, up to 50A per motor. Motors ganged or independent, multiple control input methods, cycle-by-cycle current limit, speed mode and torque mode control. Motors tiny to kW. Speed limit and other parameters easily set in firmware. As used in 'The Brushless Brutalist' locomotive - www.jons-workshop.com. See also Model Engineer magazine June-October 2019.

Dependencies:   mbed BufferedSerial Servo PCT2075 FastPWM

Update 17th August 2020 Radio control inputs completed

Revision:
10:e40d8724268a
Child:
11:bfb73f083009
--- /dev/null	Thu Jan 01 00:00:00 1970 +0000
+++ b/brushless_motor.cpp	Tue Jan 15 09:03:57 2019 +0000
@@ -0,0 +1,223 @@
+//  Cloned from 'DualBLS2018_06' on 23 November 2018
+#include "mbed.h"
+//#include    "users/mbed_official/code/mbed-dev/file/707f6e361f3e/targets/TARGET_STM/TARGET_STM32F4/TARGET_STM32F401xE/device/stm32f401xe.h"
+#include    "stm32f401xe.h"
+#include "DualBLS.h"
+#include "BufferedSerial.h"
+#include "FastPWM.h"
+#include "Servo.h"
+#include "brushless_motor.h"
+brushless_motor::brushless_motor    (PortOut * P , FastPWM * _maxV_ , FastPWM * _maxI_ , const uint16_t * lutptr, InterruptIn ** Hall)        //  Constructor
+{
+    //  Constructor
+    maxV = _maxV_;
+    maxI = _maxI_;
+    Hall_total = 0;  //  mode can be only 0, 8, 16 or 24, lut row select for Handbrake, Forward, Reverse, or Regen Braking
+    latest_pulses_per_sec = 0;
+    for (int i = 0; i < MAIN_LOOP_ITERATION_Hz; i++)
+        edge_count_table[i] = 0;
+//    if  (lutptr != A_tabl && lutptr != B_tabl)
+//        pc.printf   ("Fatal in 'motor' constructor, Invalid lut address\r\n");
+    Hall_tab_ptr = 0;
+    Motor_Port = P;
+//    pc.printf   ("In motor constructor, Motor port = %lx\r\n", P);
+    maxV->period_ticks      (MAX_PWM_TICKS + 1);  //  around 18 kHz
+    maxI->period_ticks      (MAX_PWM_TICKS + 1);
+    maxV->pulsewidth_ticks  (MAX_PWM_TICKS / 20);
+    maxI->pulsewidth_ticks  (MAX_PWM_TICKS / 30);
+    visible_mode    = REGENBRAKE;
+    inner_mode      = REGENBRAKE;
+    lut = lutptr;
+    Hindex[0] = Hindex[1]  = read_Halls    ();
+    ppstmp  = 0;
+    tickleon    = 0;
+    direction   = 0;
+    angle_cnt   = 0;        //  Incremented or decremented on each Hall event according to actual measured direction of travel
+    encoder_error_cnt = 0;  //  Incremented when Hall transition not recognised as either direction
+    Hall1 = Hall[0];
+    Hall2 = Hall[1];
+    Hall3 = Hall[2];
+    PPS     = 0;
+    RPM     = 0;
+    last_V = last_I = 0.0;
+    int x = read_Halls  ();
+    if  (x == 7)
+        dc_motor = true;
+    else
+        dc_motor = false;
+}
+
+bool    brushless_motor::motor_is_brushless   ()
+{
+    /*    int x = read_Halls  ();
+        if  (x < 1 || x > 6)
+            return  false;
+        return  true;
+        */
+    return  !dc_motor;
+}
+
+/**
+void    brushless_motor::direction_set   (int dir)  {
+Used to set direction according to mode data from eeprom
+*/
+void    brushless_motor::direction_set   (int dir)
+{
+    if  (dir != 0)
+        dir = FORWARD | REVERSE;  //  bits used in eor
+    direction = dir;
+}
+
+int     brushless_motor::read_Halls  ()
+{
+    int x = 0;
+    if  (*Hall1 != 0)    x |= 1;
+    if  (*Hall2 != 0)    x |= 2;
+    if  (*Hall3 != 0)    x |= 4;
+    return  x;
+}
+
+void    brushless_motor::high_side_off   ()
+{
+    uint16_t    p = *Motor_Port;
+    p &= lut[32];   //  KEEP_L_MASK_A or B
+    *Motor_Port = p;
+}
+
+void    brushless_motor::low_side_on   ()
+{
+//    uint16_t    p = *Motor_Port;
+//    p &= lut[31];   //  KEEP_L_MASK_A or B
+    *Motor_Port = lut[31];
+}
+
+void    brushless_motor::current_calc ()
+{
+    I.min = 0x0fffffff; //  samples are 16 bit
+    I.max = 0;
+    I.ave = 0;
+    uint16_t    sample;
+    for (int i = 0; i < CURRENT_SAMPLES_AVERAGED; i++)  {
+        sample  = current_samples[i];
+        I.ave += sample;
+        if  (I.min > sample)
+            I.min   = sample;
+        if  (I.max < sample)
+            I.max   = sample;
+    }
+    I.ave /= CURRENT_SAMPLES_AVERAGED;
+}
+
+
+void    brushless_motor::raw_V_pwm    (int    v)
+{
+    if  (v < 1) v = 1;
+    if  (v > MAX_PWM_TICKS) v = MAX_PWM_TICKS;
+    maxV->pulsewidth_ticks  (v);
+}
+
+void    brushless_motor::set_V_limit (double p)  //  Sets max motor voltage. Use set_V_limit (last_V) to restore previous setting
+{
+    if  (p < 0.0)
+        p = 0.0;
+    if  (p > 1.0)
+        p = 1.0;
+    last_V = p;     //  for read by diagnostics
+    p *= 0.95;   //  need limit, ffi see MCP1630 data
+    p   = 1.0 - p;  //  because pwm is wrong way up
+    maxV->pulsewidth_ticks  ((int)(p * MAX_PWM_TICKS));  //  PWM output to MCP1630 inverted motor pwm as MCP1630 inverts
+}
+
+void    brushless_motor::set_I_limit (double p)     //  Sets max motor current. pwm integrated to dc ref voltage level
+{
+    int a;
+    if  (p < 0.0)
+        p = 0.0;
+    if  (p > 1.0)
+        p = 1.0;
+    last_I = p;
+    a = (int)(p * MAX_PWM_TICKS);
+    if  (a > MAX_PWM_TICKS)
+        a = MAX_PWM_TICKS;
+    if  (a < 0)
+        a = 0;
+    maxI->pulsewidth_ticks  (a);  //  PWM
+}
+
+uint32_t    brushless_motor::pulses_per_sec   ()       //  call this once per 'MAIN_LOOP_REPEAT_TIME_US= 31250' main loop pass to keep count = edges per sec
+{
+    //  Can also test for motor running or not here
+    if  (dc_motor)
+        return  0;
+    if  (ppstmp == Hall_total)  {
+//    if  (dc_motor || ppstmp == Hall_total)  {
+        moving_flag  = false;       //  Zero Hall transitions since previous call - motor not moving
+        tickleon    = TICKLE_TIMES;
+    } else    {
+        moving_flag  = true;
+        ppstmp = Hall_total;
+    }
+    latest_pulses_per_sec = ppstmp - edge_count_table[Hall_tab_ptr];
+    edge_count_table[Hall_tab_ptr] = ppstmp;
+    Hall_tab_ptr++;
+    if  (Hall_tab_ptr >= MAIN_LOOP_ITERATION_Hz)
+        Hall_tab_ptr = 0;
+    PPS = latest_pulses_per_sec;
+    RPM = (latest_pulses_per_sec * 60) / 24;
+    return  latest_pulses_per_sec;
+}
+
+bool    brushless_motor::is_moving ()
+{
+    return  moving_flag;
+}
+
+/**
+bool    brushless_motor::set_mode (int m)
+Use to set motor to one mode of HANDBRAKE, FORWARD, REVERSE, REGENBRAKE.
+If this causes change of mode, also sets V and I to zero.
+*/
+bool    brushless_motor::set_mode (int m)
+{
+    if  ((m != HANDBRAKE) && (m != FORWARD) && (m != REVERSE) && (m !=REGENBRAKE))  {
+//        pc.printf   ("Error in set_mode, invalid mode %d\r\n", m);
+        return  false;
+    }
+    if  (visible_mode != m) {   //  Mode change, kill volts and amps to be safe
+        set_V_limit (0.0);
+        set_I_limit (0.0);
+        visible_mode = m;
+    }
+    if  (m == FORWARD || m == REVERSE)
+        m ^= direction;
+    inner_mode = m;     //  idea is to use inner_mode only in lut addressing, keep 'visible_mode' true regardless of setup data in eeprom
+    return  true;
+}
+
+void    brushless_motor::Hall_change  ()
+{
+    const   int32_t delta_theta_lut[] = {   //  Looks up -1 for forward move detected, +1 for reverse move detected, 0 for error or unknown
+        0, 0, 0, 0, 0, 0, 0, 0,     //  Previous Hindex was 0
+        0, 0, 0,-1, 0, 1, 0, 0,     //  Previous Hindex was 1
+        0, 0, 0, 1, 0, 0,-1, 0,     //  Previous Hindex was 2
+        0, 1,-1, 0, 0, 0, 0, 0,     //  Previous Hindex was 3
+        0, 0, 0, 0, 0,-1, 1, 0,     //  Previous Hindex was 4
+        0,-1, 0, 0, 1, 0, 0, 0,     //  Previous Hindex was 5
+        0, 0, 1, 0,-1, 0, 0, 0,     //  Previous Hindex was 6
+        0, 0, 0, 0, 0, 0, 0, 0,     //  Previous Hindex was 7
+    }  ;
+    int32_t delta_theta = delta_theta_lut[(Hindex[1] << 3) | Hindex[0]];
+    if  (delta_theta == 0)
+        encoder_error_cnt++;
+    else
+        angle_cnt += delta_theta;
+    *Motor_Port = lut[inner_mode | Hindex[0]];  //  changed mode to inner_mode 27/04/18
+    Hall_total++;
+    Hindex[1] = Hindex[0];
+}
+
+void    brushless_motor::motor_set  ()
+{
+    Hindex[0]  = read_Halls    ();
+    *Motor_Port = lut[inner_mode | Hindex[0]];
+}