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Improved GUI front-end and docs.
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rombrew committed Apr 13, 2024
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Expand Up @@ -7,154 +7,154 @@ PMC is an open project that aims to build the quality permanent magnet
synchronous machine (PMSM) controller for use in a variety of scopes like RC or
electric transport.

## Brief

PMC is ready to use in most intended applications. You can flash any supported
third-party hardware to work with PMC or use our original hardware.

Read further in [doc/GettingStarted](doc/GettingStarted.md).

There are a few videos about PMC on [youtube](https://www.youtube.com/@romblv).

## Software features

* Sensorless vector control of PMSM by measurement of currents and voltages.
* Robust ORTEGA observer with gain scheduling against speed.
* Accurate KALMAN observer having convergence at HF injection.
* Flux weakening and MTPA control (**EXPERIMENTAL**).
* Three and two phase machine support.
* Hardware abstraction layer (HAL) over STM32F4 and STM32F7.
* Various controller hardware are supported (including VESC clones).
* Regular Command Line Interface (CLI) with autocompletion and history.
* Graphical front-end software based on
- Sensorless vector control of PMSM by measurement of currents and voltages.
- Robust ORTEGA observer with gain scheduling against speed.
- Accurate KALMAN observer having convergence at HF injection.
- Flux weakening and MTPA control (**EXPERIMENTAL**).
- Three and two phase machine support.
- Hardware abstraction layer (HAL) over STM32F4 and STM32F7.
- Various controller hardware are supported (including VESC clones).
- Regular Command Line Interface (CLI) with autocompletion and history.
- Graphical front-end software based on
[Nuklear](https://github.com/Immediate-Mode-UI/Nuklear) and
[SDL2](https://www.libsdl.org/).
* Non time-critical tasks are managed by
- Non time-critical tasks are managed by
[FreeRTOS](http://www.freertos.org/).
* USB protocol stack from
- USB protocol stack from
[CherryUSB](https://github.com/sakumisu/CherryUSB).
* Least Squares estimate library
- Least Squares estimate library
[LSE](https://github.com/rombrew/lse).

* Phase current sampling schemes includes two or three sensors configuration
- Phase current sampling schemes includes two or three sensors configuration
with inline or low-side placement.
* Self-adjustment of all onboard measurements (current and voltage) along
- Self-adjustment of all onboard measurements (current and voltage) along
symmetrical channels.

* Advanced SVPWM scheme provides:
* Reduced switching losses and fully utilised DC link voltage.
* Reduced voltage distortion for precise control.
* Voltage hopping to get accurate ADC measurements with inline current sensors.
* Prevent bootstrap circuit undervoltage condition.

* Terminal voltage measurements (TVM):
* Compensation of the voltage distortion caused by Dead-Time insertion.
* Back EMF voltage tracking to catch an already running machine.
* Self-test of the power stages integrity and machine wiring.
* Self-test of bootstrap retention time.

* Automated machine parameters identification (with no external tools):
* Stator DC resistance (Rs).
* Stator AC impedance in DQ frame (L1, L2, R).
* Rotor flux linkage constant (lambda).
* Mechanical moment of inertia (Ja).

* Automated configuration of external measurements:
* Discrete Hall sensors installation angles recognition.
* EABI resolution and direction adjustment.

* Operation at low or zero speed:
* Forced control that applies a current vector without feedback to
- Advanced SVPWM scheme provides:
- Reduced switching losses and fully utilised DC link voltage.
- Reduced voltage distortion for precise control.
- Voltage hopping to get accurate ADC measurements with inline current sensors.
- Prevent bootstrap circuit undervoltage condition.

- Terminal voltage measurements (TVM):
- Compensation of the voltage distortion caused by dead-time insertion.
- Back EMF voltage tracking to catch an already running machine.
- Self-test of the power stages integrity and machine wiring.
- Self-test of bootstrap retention time.

- Automated machine parameters identification (with no external tools):
- Stator DC resistance (Rs).
- Stator AC impedance in DQ frame (L1, L2, R).
- Rotor flux linkage constant (lambda).
- Mechanical moment of inertia (Ja).

- Automated configuration of external measurements:
- Discrete Hall sensors installation angles recognition.
- EABI resolution and direction adjustment.

- Operation at low or zero speed:
- Forced control that applies a current vector without feedback to
force rotor hold or spinup.
* Freewheeling.
* High Frequency Injection (HFI) based on magnetic saliency.
* Discrete Hall sensors.
* AB quadrature incremental encoder (EABI).
* Absolute encoder on SPI interface (AS5047).
* Analog Hall sensors and resolver decoder (**TODO**).

* Nested control loops:
* Detached voltage monitoring.
* Current control PI regulator with feedforward compensation.
* Speed control PID regulator with load torque compensation.
* Location control with constant acceleration regulator.

* Adjustable constraints:
* Phase current (forward and reverse, on HFI current, weakening D current,
with derate on PCB overheat or machine overheat).
* Machine voltage applied from VSI.
* DC link current consumption and regeneration.
* DC link overvoltage and undervoltage.
* Maximal speed and acceleration.
* Absolute location limits.

* Input control interfaces:
* Analog input knob with brake signal.
* RC servo pulse width modulation.
* CAN bus flexible configurable data transfers.
* STEP/DIR (or CW/CCW) interface (**EXPERIMENTAL**).
* Manual control through CLI or graphical front-end.
* Custom embedded application can implement any control strategy.

* Advanced CAN networking:
* Up to 30 nodes in peer network.
* Network survey on request (no heartbeat messages).
* Automated node address assignment.
* IO forwarding to log in to the remote node CLI.
* Flexible configurable data transfers.

* Available information:
* Machine state (electrical position, speed, load torque).
* DC link voltage and current consumption.
* Information from temperature sensors.
* Total distance traveled.
* Battery energy (Wh) and charge (Ah) consumed.
* Fuel gauge percentage.
- Freewheeling.
- High Frequency Injection (HFI) based on magnetic saliency.
- Discrete Hall sensors.
- AB quadrature incremental encoder (EABI).
- Absolute encoder on SPI interface (AS5047).
- Analog Hall sensors and resolver decoder (**TODO**).

- Nested control loops:
- Detached voltage monitoring.
- Current control PI regulator with feedforward compensation.
- Speed control PID regulator with load torque compensation.
- Location control with constant acceleration regulator.

- Adjustable constraints:
- Phase current (forward and reverse, on HFI current, weakening D current).
- Hardware overtemperature protection (decrease phase current or halt).
- Machine voltage applied from VSI.
- DC link current consumption and regeneration.
- DC link overvoltage and undervoltage.
- Maximal speed (forward and reverse) and acceleration.
- Absolute location maximal and minimal limit.

- Input control interfaces:
- Analog input knob with brake signal.
- RC servo pulse width modulation.
- CAN bus flexible configurable data transfers.
- STEP/DIR (or CW/CCW) interface (**EXPERIMENTAL**).
- Manual control through CLI or graphical front-end.
- Custom embedded application can implement any control strategy.

- Advanced CAN networking:
- Up to 30 nodes in peer network.
- Network survey on request (no heartbeat messages).
- Automated node address assignment.
- IO forwarding to log in to the remote node CLI.
- Flexible configurable data transfers.

- Available information:
- Machine state (electrical position, speed, load torque, etc.)
- DC link voltage and current consumption.
- Information from temperature sensors.
- Total distance traveled.
- Battery energy (Wh) and charge (Ah) consumed.
- Fuel gauge percentage.

## Hardware specification (`REV5A`)

* Dimension: 82mm x 55mm x 35mm.
* Weight: 40g (PCB) or about 400g (with wires and heatsink).
* Wires: 10 AWG.
* Connector: XT90-S and bullet 5.5mm.
* Battery voltage from 5v to 50v.
* Phase current up to 120A (with IPT007N06N, 60v, 0.75 mOhm).
* Light capacitor bank (4 x 4.7uF + 2 x 330uF).
* PWM frequency from 20 to 60 kHz.
* STM32F405RG microcontroller (Cortex-M4F at 168 MHz).

* Onboard sensors:
* Two current shunts (0.5 mOhm) with amplifiers (AD8418) give a
- Dimension: 82mm x 55mm x 35mm.
- Weight: 40g (PCB) or about 400g (with wires and heatsink).
- Wires: 10 AWG.
- Connector: XT90-S and bullet 5.5mm.
- Battery voltage from 5v to 50v.
- Phase current up to 120A (with IPT007N06N, 60v, 0.75 mOhm).
- Light capacitor bank (4 x 4.7uF + 2 x 330uF).
- PWM frequency from 20 to 60 kHz.
- STM32F405RG microcontroller (Cortex-M4F at 168 MHz).

- Onboard sensors:
- Two current shunts (0.5 mOhm) with amplifiers (AD8418) give a
measuring range of 165A.
* Battery voltage from 0 to 60v.
* Three terminal voltages from 0 to 60v.
* Temperature of PCB with NTC resistor.

* Machine interfaces:
* Discrete Hall sensors or EABI encoder (5v pull-up).
* External NTC resistor (e.g. machine temperature sensing).

* Control interfaces:
* CAN transceiver with optional termination resistor on PCB (5v).
* USART to bootload and configure (3.3v).
* RC servo PWM or STEP/DIR (5v pull-up).
* Two analog input channels (from 0 to 6v).

* Auxiliary interfaces:
* SPI port with alternative functions: ADC, DAC, GPIO (3.3v).
* BOOT pin combined with SWDIO to use embedded bootloader.
* External FAN control (5v, ~0.5A).

* Power conversion:
* Battery voltage to 5v buck (~1A).
* 5v to 12v boost (~100 mA).
* 5v to 3.3v linear (~400 mA).

## Status

Now we can declare that PMC is ready to use in most intended applications. But
it may be difficult to configure the PMC for some types of machines.

There are a few videos about PMC on [youtube](https://www.youtube.com/@romblv).

Read further in [doc/GettingStarted](doc/GettingStarted.md).
- Battery voltage from 0 to 60v.
- Three terminal voltages from 0 to 60v.
- Temperature of PCB with NTC resistor.

- Machine interfaces:
- Discrete Hall sensors or EABI encoder (5v pull-up).
- External NTC resistor (e.g. machine temperature sensing).

- Control interfaces:
- CAN transceiver with optional termination resistor on PCB (5v).
- USART to bootload and configure (3.3v).
- RC servo PWM or STEP/DIR (5v pull-up).
- Two analog input channels (from 0 to 6v).

- Auxiliary interfaces:
- SPI port with alternative functions: ADC, DAC, GPIO (3.3v).
- BOOT pin combined with SWDIO to use embedded bootloader.
- External FAN control (5v, ~0.5A).

- Power conversion:
- Battery voltage to 5v buck (~1A).
- 5v to 12v boost (~100 mA).
- 5v to 3.3v linear (~400 mA).

## TODO

* Make a detailed documentation.
* Improve GUI front-end software.
* Add pulse output signal.
* Make a drawing of the heatsink case for `REV5A`.
* Design the new hardware for 120v battery voltage.
- Make a detailed documentation.
- Improve GUI front-end software.
- Add pulse output signal.
- Make a drawing of the heatsink case for `REV5A`.
- Design the new hardware for 120v battery voltage.

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