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Merge pull request #95 from leon927/bug_fixes
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Bug fixes and improvements
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@casainho
casainho authored May 27, 2019
2 parents e0a72cd + f0e87b1 commit ea20052
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Showing 11 changed files with 475 additions and 466 deletions.
8 changes: 6 additions & 2 deletions src/common/common.h
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Original file line number Diff line number Diff line change
Expand Up @@ -9,7 +9,11 @@
#ifndef COMMON_COMMON_H_
#define COMMON_COMMON_H_

#define ERROR_STATE_NO_ERRORS 0
#define ERROR_STATE_EBIKE_WHEEL_BLOCKED 1
#define NO_ERROR 0
#define ERROR_MOTOR_BLOCKED 1
#define ERROR_TORQUE_APPLIED_DURING_POWER_ON 2
#define ERROR_BRAKE_APPLIED_DURING_POWER_ON 3
#define ERROR_THROTTLE_APPLIED_DURING_POWER_ON 4
#define ERROR_NO_SPEED_SENSOR_DETECTED 5

#endif /* COMMON_COMMON_H_ */
4 changes: 3 additions & 1 deletion src/controller/compile.bat
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Original file line number Diff line number Diff line change
Expand Up @@ -3,4 +3,6 @@ PATH = %PATH%;C:\SDCC\usr\local\bin;%~dp0..\..\tools\cygwin\bin
make -f Makefile_windows clean

:: pass batch file parameters, e.g. THROTTLE=0
make -f Makefile_windows %*
make -f Makefile_windows %*

PAUSE
223 changes: 86 additions & 137 deletions src/controller/ebike_app.c
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Original file line number Diff line number Diff line change
Expand Up @@ -59,6 +59,7 @@ static uint16_t ui16_received_target_wheel_speed_x10 = 0;
static uint16_t ui16_target_wheel_speed_x10 = 0;

// variables for various system functions
volatile uint8_t ui8_system_state = NO_ERROR;
volatile uint16_t ui16_pas_pwm_cycles_ticks = (uint16_t) PAS_ABSOLUTE_MIN_CADENCE_PWM_CYCLE_TICKS;
volatile uint8_t ui8_g_pedaling_direction = 0;
uint8_t ui8_pas_cadence_rpm = 0;
Expand All @@ -75,7 +76,6 @@ uint16_t ui16_startup_boost_fade_variable_x256;
uint16_t ui16_startup_boost_fade_variable_step_amount_x256;



// variables for wheel speed
volatile uint16_t ui16_wheel_speed_sensor_pwm_cycles_ticks = (uint16_t) WHEEL_SPEED_SENSOR_MAX_PWM_CYCLE_TICKS;
uint8_t ui8_wheel_speed_max = 0;
Expand All @@ -87,13 +87,14 @@ volatile uint32_t ui32_wheel_speed_sensor_tick_counter = 0;
volatile struct_configuration_variables m_configuration_variables;

// variables for UART
#define UART_NUMBER_DATA_BYTES_TO_RECEIVE 8 // change this value depending on how many data bytes there is to receive ( Package = one start byte + data bytes + two bytes 16 bit CRC )
#define UART_NUMBER_DATA_BYTES_TO_SEND 23 // change this value depending on how many data bytes there is to send ( Package = one start byte + data bytes + two bytes 16 bit CRC )

volatile uint8_t ui8_received_package_flag = 0;
volatile uint8_t ui8_rx_buffer[11];
volatile uint8_t ui8_rx_buffer[UART_NUMBER_DATA_BYTES_TO_RECEIVE + 3];
volatile uint8_t ui8_rx_counter = 0;
volatile uint8_t ui8_tx_buffer[26];
volatile uint8_t ui8_tx_counter = 0;
volatile uint8_t ui8_tx_buffer[UART_NUMBER_DATA_BYTES_TO_SEND + 3];
volatile uint8_t ui8_i;
volatile uint8_t ui8_checksum;
volatile uint8_t ui8_byte_received;
volatile uint8_t ui8_state_machine = 0;
volatile uint8_t ui8_uart_received_first_package = 0;
Expand All @@ -110,11 +111,6 @@ uint16_t ui16_adc_motor_temperatured_accumulated = 0;
uint8_t ui8_m_adc_battery_target_current;



// safe tests
uint8_t safe_tests_state_machine = 0;
uint8_t safe_tests_state_machine_counter = 0;

static uint8_t ui8_m_motor_enabled = 1;

static uint8_t ui8_m_brake_is_set = 0;
Expand All @@ -124,6 +120,7 @@ static void ebike_app_set_battery_max_current (uint8_t ui8_value);
static void ebike_app_set_target_adc_battery_max_current (uint8_t ui8_value);

static void communications_controller (void);
static void uart_receive_package (void);
static void uart_send_package (void);

static void throttle_read (void);
Expand All @@ -141,14 +138,13 @@ static void apply_walk_assist(uint8_t *ui8_p_adc_target_current);
static void apply_cruise (uint8_t *ui8_target_current);
static void apply_throttle(uint8_t ui8_throttle_value, uint8_t *ui8_target_current);

static void check_system(void);

// variables for BOOST function
static void boost_run_statemachine (void);
static uint8_t apply_boost (uint8_t ui8_pas_cadence, uint8_t ui8_max_current_boost_state, uint8_t *ui8_target_current);
static void apply_boost_fade_out (uint8_t *ui8_target_current);

static void safe_tests(void);


void ebike_app_init (void)
{
Expand All @@ -168,6 +164,7 @@ void ebike_app_controller (void)
calc_motor_temperature();
ebike_control_motor();
communications_controller();
check_system();
}


Expand Down Expand Up @@ -348,12 +345,8 @@ static void ebike_control_motor (void)
m_configuration_variables.ui8_temperature_current_limiting_value = 255;
}

// execute some safe tests
safe_tests();

// let's force our target current to 0 if brake is set or if there are errors
if(ui8_m_brake_is_set ||
m_configuration_variables.ui8_error_states != ERROR_STATE_NO_ERRORS)
if(ui8_m_brake_is_set || ui8_system_state != NO_ERROR)
{
ui8_m_adc_battery_target_current = 0;
}
Expand Down Expand Up @@ -390,23 +383,7 @@ static void ebike_control_motor (void)
ui8_g_duty_cycle = 0;
}

/*************************************************************************************************************
NOTE:
If the battery_target_current == 0 AND configuration_variables.ui8_walk_assist == 1 AND
wheel speed is below threshold for walk assist function AND brake is not set AND there are no
errors detected in function "safe_tests", set the target duty cycle to walk assist target PWM.
apply_walk_assist
If the battery_target_current == 0 AND configuration_variables.ui8_walk_assist == 1 AND
wheel speed is above threshold for cruise function AND brake is not set AND there are no
errors detected in function "safe_tests", set the target duty cycle to cruise target PWM.
If the battery_target_current == 0 AND ui8_startup_enable == 0 AND brake is not set AND there are no
errors detected in function "safe_tests", set the target duty cycle to max (255) and the current will be
controlled by the battery current controller. Else set the target duty cycle to 0.
*************************************************************************************************************/

// set target motor PWM
if(m_configuration_variables.ui8_walk_assist && ui8_m_brake_is_set == 0 && ui8_m_motor_enabled)
{
if(ui16_wheel_speed_x10 < WALK_ASSIST_CRUISE_THRESHOLD_SPEED_X10)
Expand All @@ -431,20 +408,32 @@ static void ebike_control_motor (void)

static void communications_controller (void)
{
uint32_t ui32_temp;

#ifndef DEBUG_UART

uart_receive_package ();

uart_send_package ();

#endif
}


static void uart_receive_package(void)
{
uint32_t ui32_temp;

if (ui8_received_package_flag)
{
// verify crc of the package
// validation of the package data
ui16_crc_rx = 0xffff;
for (ui8_i = 0; ui8_i < 9; ui8_i++)

for (ui8_i = 0; ui8_i <= UART_NUMBER_DATA_BYTES_TO_RECEIVE; ui8_i++)
{
crc16 (ui8_rx_buffer[ui8_i], &ui16_crc_rx);
}

// see if CRC is ok...
if (((((uint16_t) ui8_rx_buffer [10]) << 8) + ((uint16_t) ui8_rx_buffer [9])) == ui16_crc_rx)
// if CRC is correct read the package (16 bit value and therefore last two bytes)
if (((((uint16_t) ui8_rx_buffer [UART_NUMBER_DATA_BYTES_TO_RECEIVE + 2]) << 8) + ((uint16_t) ui8_rx_buffer [UART_NUMBER_DATA_BYTES_TO_RECEIVE + 1])) == ui16_crc_rx)
{
ui8_master_comm_package_id = ui8_rx_buffer [1];

Expand Down Expand Up @@ -607,23 +596,21 @@ static void communications_controller (void)
// enable UART2 receive interrupt as we are now ready to receive a new package
UART2->CR2 |= (1 << 5);
}

uart_send_package ();
#endif
}

static void uart_send_package(void)
{
uint16_t ui16_temp;

// send the data to the LCD
// start up byte
ui8_tx_buffer[0] = 0x43;

// message ID
ui8_tx_buffer[1] = ui8_master_comm_package_id;
ui8_tx_buffer[2] = ui8_slave_comm_package_id;

ui16_temp = motor_get_adc_battery_voltage_filtered_10b();
// adc 10 bits battery voltage
ui16_temp = motor_get_adc_battery_voltage_filtered_10b();
ui8_tx_buffer[3] = (ui16_temp & 0xff);
ui8_tx_buffer[4] = ((uint8_t) (ui16_temp >> 4)) & 0x30;

Expand Down Expand Up @@ -684,7 +671,7 @@ static void uart_send_package(void)
{
case 0:
// error states
ui8_tx_buffer[19] = m_configuration_variables.ui8_error_states;
ui8_tx_buffer[19] = ui8_system_state;
break;

case 1:
Expand Down Expand Up @@ -723,15 +710,17 @@ static void uart_send_package(void)

// prepare crc of the package
ui16_crc_tx = 0xffff;
for (ui8_i = 0; ui8_i <= 23; ui8_i++)

for (ui8_i = 0; ui8_i <= UART_NUMBER_DATA_BYTES_TO_SEND; ui8_i++)
{
crc16 (ui8_tx_buffer[ui8_i], &ui16_crc_tx);
}
ui8_tx_buffer[24] = (uint8_t) (ui16_crc_tx & 0xff);
ui8_tx_buffer[25] = (uint8_t) (ui16_crc_tx >> 8) & 0xff;

ui8_tx_buffer[UART_NUMBER_DATA_BYTES_TO_SEND + 1] = (uint8_t) (ui16_crc_tx & 0xff);
ui8_tx_buffer[UART_NUMBER_DATA_BYTES_TO_SEND + 2] = (uint8_t) (ui16_crc_tx >> 8) & 0xff;

// send the full package to UART
for (ui8_i = 0; ui8_i <= 25; ui8_i++)
for (ui8_i = 0; ui8_i <= UART_NUMBER_DATA_BYTES_TO_SEND + 2; ui8_i++)
{
putchar (ui8_tx_buffer[ui8_i]);
}
Expand Down Expand Up @@ -1230,10 +1219,12 @@ void UART2_IRQHandler(void) __interrupt(UART2_IRQHANDLER)

case 1:
ui8_rx_buffer [ui8_rx_counter] = ui8_byte_received;

// increment index for next byte
ui8_rx_counter++;

// see if is the last byte of the package
if (ui8_rx_counter > 12)
// reset if it is the last byte of the package and index is out of bounds
if (ui8_rx_counter >= UART_NUMBER_DATA_BYTES_TO_RECEIVE + 3)
{
ui8_rx_counter = 0;
ui8_state_machine = 0;
Expand All @@ -1255,96 +1246,54 @@ struct_configuration_variables* get_configuration_variables (void)
}


static void safe_tests(void)
void check_system()
{
// enabe only next state machine if user has startup without pedal rotation
if(m_configuration_variables.ui8_motor_assistance_startup_without_pedal_rotation ||
(ui8_m_brake_is_set == 0) ||
m_configuration_variables.ui8_assist_level_factor_x10 ||
!m_configuration_variables.ui8_walk_assist)
#define MOTOR_BLOCKED_COUNTER_THRESHOLD 50 // 50 => 5 seconds
#define MOTOR_BLOCKED_BATTERY_CURRENT_THRESHOLD_X5 8 // 8 => (8 * 0.826) / 5 = 1.3216 ampere => (X) units = ((X * 0.826) / 5) ampere
#define MOTOR_BLOCKED_ERPS_THRESHOLD 10 // 10 ERPS
#define MOTOR_BLOCKED_RESET_COUNTER_THRESHOLD 100 // 100 => 10 seconds

static uint8_t ui8_motor_blocked_counter;
static uint8_t ui8_motor_blocked_reset_counter;

// if the motor blocked error is enabled start resetting it
if (ui8_system_state == ERROR_MOTOR_BLOCKED)
{
switch(safe_tests_state_machine)
// increment motor blocked reset counter with 100 milliseconds
ui8_motor_blocked_reset_counter++;

// check if the counter has counted to the set threshold for reset
if (ui8_motor_blocked_reset_counter > MOTOR_BLOCKED_RESET_COUNTER_THRESHOLD)
{
// start when torque sensor or throttle or walk assist / cruise
case 0:
if(ui8_torque_sensor > 12 ||
ui8_throttle)
{
safe_tests_state_machine_counter = 0;
safe_tests_state_machine = 1;
break;
}
break;

// wait during 5 seconds for bicyle wheel speed > 4km/h, if not we have an error
case 1:
safe_tests_state_machine_counter++;

// timeout of 10 seconds, not less to be higher than value on torque_sensor_read ()
// hopefully, 10 seconds is safe enough value, mosfets may not burn in 10 seconds if ebike wheel is blocked
if(safe_tests_state_machine_counter > 100)
{
m_configuration_variables.ui8_error_states |= ERROR_STATE_EBIKE_WHEEL_BLOCKED;
safe_tests_state_machine_counter = 0;
safe_tests_state_machine = 2;
break;
}

// bicycle wheel is rotating so we are safe
if(ui16_wheel_speed_x10 > 40) // seems that 4 km/h may be the min value we can measure for the bicycle wheel speed
{
safe_tests_state_machine_counter = 0;
safe_tests_state_machine = 3;
break;
}

// if release of: torque sensor AND throttle AND walk assist / cruise -> restart
if(ui8_torque_sensor < 12 &&
ui8_throttle == 0)
{
safe_tests_state_machine = 0;
}
break;

// wait 3 consecutive seconds for torque sensor and throttle and walk assist / cruise == 0, then restart
case 2:
if(ui8_torque_sensor < 12 &&
ui8_throttle == 0)
{
safe_tests_state_machine_counter++;

if(safe_tests_state_machine_counter > 30)
{
m_configuration_variables.ui8_error_states &= ~ERROR_STATE_EBIKE_WHEEL_BLOCKED;
safe_tests_state_machine = 0;
break;
}
}
// keep reseting the counter so we keep on this state
else
{
safe_tests_state_machine_counter = 0;
}
break;

// wait for bicycle wheel to be stopped so we can start again our state machine
case 3:
if(ui16_wheel_speed_x10 == 0)
{
safe_tests_state_machine = 0;
break;
}
break;

default:
safe_tests_state_machine = 0;
break;
// reset motor blocked error code
ui8_system_state = NO_ERROR;

// reset the counter that clears the motor blocked error
ui8_motor_blocked_reset_counter = 0;
}
}
else
{
// keep reseting state machine
m_configuration_variables.ui8_error_states &= ~ERROR_STATE_EBIKE_WHEEL_BLOCKED; // disable error state in case it was enabled
safe_tests_state_machine = 0;
// if battery current (x5) is over the current threshold (x5) and the motor ERPS is below threshold start setting motor blocked error code
if ((motor_get_adc_battery_current_filtered_10b() > MOTOR_BLOCKED_BATTERY_CURRENT_THRESHOLD_X5) && (ui16_motor_get_motor_speed_erps() < MOTOR_BLOCKED_ERPS_THRESHOLD))
{
// increment motor blocked counter with 100 milliseconds
ui8_motor_blocked_counter++;

// check if motor is blocked for more than some safe threshold
if (ui8_motor_blocked_counter > MOTOR_BLOCKED_COUNTER_THRESHOLD)
{
// set motor blocked error code
ui8_system_state = ERROR_MOTOR_BLOCKED;

// reset motor blocked counter as the error code is set
ui8_motor_blocked_counter = 0;
}
}
else
{
// current is below the threshold and/or motor ERPS is above the threshold so reset the counter
ui8_motor_blocked_counter = 0;
}
}
}
}
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