motor_ctrl: break when going to fast
[ros_wild_thumper.git] / avr / motor_ctrl / main.c
index d25271fe945993606b49214d756134f4f01f0049..abbf5386146205c5b52c55780f9b971015ecf2be 100644 (file)
 #define TWI_RESET      TWCR &= ~((1 << TWSTO) | (1 << TWEN)); TWI_ACK
 #define TWI_NAK                TWCR = (1<<TWINT) | (1<<TWEN) | (1<<TWIE)
 
-#define KP 0.045
-#define KI 2.298
-#define KD 0.0004
+#define KP 0.06
+#define KI 0.10
+#define KD 0.0
 #define PID_T 0.01
-// wheel diameter=12cm, encoder=48cpr, gear ratio=1:34, real wheel diameter: 0.12454m
-#define STEP_PER_M_AVG 4171.4
+// wheel diameter=12cm, encoder=48cpr, gear ratio=1:47, real wheel diameter: 0.12454m
+#define STEP_PER_M_AVG 5766.1
 #define STEP_PER_M_LEFT (STEP_PER_M_AVG)
 #define STEP_PER_M_RIGHT (STEP_PER_M_AVG)
 #define WHEEL_DIST 0.36923 // Real: 0.252
+#define PWM_BREAK INT16_MIN
 
 enum mode {
        MOTOR_MANUAL,
@@ -149,6 +150,10 @@ static volatile int16_t speed1_wish=0; // step/s
 static volatile int16_t speed2_wish=0;
 static volatile int16_t speed3_wish=0;
 static volatile int16_t speed4_wish=0;
+static volatile int16_t speed1_wish_old=0;
+static volatile int16_t speed2_wish_old=0;
+static volatile int16_t speed3_wish_old=0;
+static volatile int16_t speed4_wish_old=0;
 static volatile uint8_t run_update=0;
 static volatile int16_t speed1=0; // step/s
 static volatile int16_t speed2=0;
@@ -172,7 +177,7 @@ ISR(TWI_vect)
        static ufloat_t tmp_angle;
 
        switch (TWSR & 0xF8)
-       {  
+       {
                case 0x60: // start write
                        TWI_ACK;
                        ireg = 0;
@@ -687,12 +692,15 @@ static void update_motor(void) {
        static int16_t m3_old=SHRT_MIN;
        static int16_t m4_old=SHRT_MIN;
 
-       error_state = ~((PIND & 0x40)>>3 | (PINB & 0x07)) & 0xf;
+       error_state &= 0xf0; // clear lower bits
+       error_state |= ~((PIND & 0x40)>>3 | (PINB & 0x07)) & 0xf;
 
        if (m1_old != motor1) { // update only when changed
                if (motor1 == 0) {
                        // stop
                        PORTC &= ~(1 << 3) & ~(1 << 2);
+               } else if (motor1 == PWM_BREAK) {
+                       PORTC |= (1 << 3) | (1 << 2);
                } else if ((!motor1_switch && motor1 > 0) || (motor1_switch && motor1 < 0)) {
                        // forward
                        uint8_t tmp=PORTC;
@@ -715,6 +723,8 @@ static void update_motor(void) {
                if (motor2 == 0) {
                        // stop
                        PORTC &= ~(1 << 5) & ~(1 << 4);
+               } else if (motor2 == PWM_BREAK) {
+                       PORTC |= (1 << 5) | (1 << 4);
                } else if ((!motor2_switch && motor2 > 0) || (motor2_switch && motor2 < 0)) {
                        // forward
                        uint8_t tmp=PORTC;
@@ -737,6 +747,8 @@ static void update_motor(void) {
                if (motor3 == 0) {
                        // stop
                        PORTC &= ~(1 << 7) & ~(1 << 6);
+               } else if (motor3 == PWM_BREAK) {
+                       PORTC |= (1 << 7) | (1 << 6);
                } else if ((!motor3_switch && motor3 > 0) || (motor3_switch && motor3 < 0)) {
                        // forward
                        uint8_t tmp=PORTC;
@@ -759,6 +771,8 @@ static void update_motor(void) {
                if (motor4 == 0) {
                        // stop
                        PORTD &= ~(1 << 3) & ~(1 << 2);
+               } else if (motor4 == PWM_BREAK) {
+                       PORTD |= (1 << 3) | (1 << 2);
                } else if ((!motor4_switch && motor4 > 0) || (motor4_switch && motor4 < 0)) {
                        // forward
                        uint8_t tmp=PORTD;
@@ -790,7 +804,6 @@ static void update_pos(void) {
        int16_t pos4_diff;
        float diff_left_m, diff_right_m, angle_diff, translation;
        float pos_x_new, pos_y_new, angle_new;
-       int16_t speed_l, speed_r;
        float tmp_speed_lin, tmp_speed_rot;
        int16_t cur_pos1, cur_pos2, cur_pos3, cur_pos4;
        int16_t new_speed1, new_speed2, new_speed3, new_speed4;
@@ -825,10 +838,8 @@ static void update_pos(void) {
        pos_x_new = pos_x.f + cos(angle_new)*translation;
        pos_y_new = pos_y.f + sin(angle_new)*translation;
 
-       speed_l = (new_speed1+new_speed2)/2;
-       speed_r = (new_speed3+new_speed4)/2;
-       tmp_speed_lin = (speed_l + speed_r)/(2.0*STEP_PER_M_AVG);
-       tmp_speed_rot = (speed_r - speed_l)/(M_PI*WHEEL_DIST*STEP_PER_M_AVG);
+       tmp_speed_lin = translation/PID_T;
+       tmp_speed_rot = angle_diff/PID_T;
 
        // copy from tmp
        cli();
@@ -860,63 +871,118 @@ static void update_pid(void) {
        static int32_t esum3=0;
        static int32_t esum4=0;
 
+       // protect motors from damage if stalling
+       if (labs(esum1) > 140000 && speed1 == 0) {
+               motor1 = 0;
+               motor1_mode = MOTOR_MANUAL;
+               error_state |= (1<<4);
+               esum1 = 0;
+       }       
+       if (labs(esum2) > 140000 && speed2 == 0) {
+               motor2 = 0;
+               motor2_mode = MOTOR_MANUAL;
+               error_state |= (1<<5);
+               esum2 = 0;
+       }       
+       if (labs(esum3) > 140000 && speed3 == 0) {
+               motor3 = 0;
+               motor3_mode = MOTOR_MANUAL;
+               error_state |= (1<<6);
+               esum3 = 0;
+       }       
+       // protect motors from damage if stalling
+       if (labs(esum4) > 140000 && speed4 == 0) {
+               motor4 = 0;
+               motor4_mode = MOTOR_MANUAL;
+               error_state |= (1<<7);
+               esum4 = 0;
+       }       
+
        if (motor1_mode == MOTOR_PID) {
+               if (speed1_wish != speed1_wish_old) {
+                       if (abs(speed1_wish - speed1_wish_old) > 500) esum1 = 0;
+                       speed1_wish_old = speed1_wish;
+               }
+
                if (speed1_wish == 0) {
                        motor1 = 0;
                        eold1 = 0;
-                       esum1 = 0;
+                       error_state &= ~(1<<4);
                } else {
                        int16_t e = speed1_wish - speed1;
                        esum1+=e;
                        motor1 = KP*e + KI*PID_T*esum1 + KD/PID_T*(e - eold1);
                        eold1 = e;
 
-                        if (motor1 > 255) motor1 = 255;
+                       if (motor1 > 0 && speed1_wish < 0) motor1=PWM_BREAK;
+                       else if (motor1 < 0 && speed1_wish > 0) motor1=PWM_BREAK;
+                       else if (motor1 > 255) motor1 = 255;
                        else if (motor1 < -255) motor1 = -255;
                }
        }
        if (motor2_mode == MOTOR_PID) {
+               if (speed2_wish != speed2_wish_old) {
+                       if (abs(speed2_wish - speed2_wish_old) > 500) esum2 = 0;
+                       speed2_wish_old = speed2_wish;
+               }
+
                if (speed2_wish == 0) {
                        motor2 = 0;
                        eold2 = 0;
-                       esum2 = 0;
+                       error_state &= ~(1<<5);
                } else {
                        int16_t e = speed2_wish - speed2;
                        esum2+=e;
                        motor2 = KP*e + KI*PID_T*esum2 + KD/PID_T*(e - eold2);
                        eold2 = e;
 
-                        if (motor2 > 255) motor2 = 255;
+                       if (motor2 > 0 && speed2_wish < 0) motor2=PWM_BREAK;
+                       else if (motor2 < 0 && speed2_wish > 0) motor2=PWM_BREAK;
+                       else if (motor2 > 255) motor2 = 255;
                        else if (motor2 < -255) motor2 = -255;
                }
        }
        if (motor3_mode == MOTOR_PID) {
+               if (speed3_wish != speed3_wish_old) {
+                       if (abs(speed3_wish - speed3_wish_old) > 500) esum3 = 0;
+                       speed3_wish_old = speed3_wish;
+               }
+
                if (speed3_wish == 0) {
                        motor3 = 0;
                        eold3 = 0;
-                       esum3 = 0;
+                       error_state &= ~(1<<6);
                } else {
                        int16_t e = speed3_wish - speed3;
                        esum3+=e;
                        motor3 = KP*e + KI*PID_T*esum3 + KD/PID_T*(e - eold3);
                        eold3 = e;
 
-                        if (motor3 > 255) motor3 = 255;
+                       if (motor3 > 0 && speed3_wish < 0) motor3=PWM_BREAK;
+                       else if (motor3 < 0 && speed3_wish > 0) motor3=PWM_BREAK;
+                       else if (motor3 > 255) motor3 = 255;
                        else if (motor3 < -255) motor3 = -255;
                }
        }
        if (motor4_mode == MOTOR_PID) {
+               if (speed4_wish != speed4_wish_old) {
+                       if (abs(speed4_wish - speed4_wish_old) > 500) esum4 = 0;
+                       speed4_wish_old = speed4_wish;
+               }
+
                if (speed4_wish == 0) {
                        motor4 = 0;
                        eold4 = 0;
-                       esum4 = 0;
+                       error_state &= ~(1<<7);
                } else {
                        int16_t e = speed4_wish - speed4;
                        esum4+=e;
                        motor4 = KP*e + KI*PID_T*esum4 + KD/PID_T*(e - eold4);
                        eold4 = e;
 
-                        if (motor4 > 255) motor4 = 255;
+                       if (motor4 > 0 && speed4_wish < 0) motor4=PWM_BREAK;
+                       else if (motor4 < 0 && speed4_wish > 0) motor4=PWM_BREAK;
+                       else if (motor4 > 255) motor4 = 255;
                        else if (motor4 < -255) motor4 = -255;
                }
        }
@@ -1000,7 +1066,7 @@ int main(void) {
                        cmd_vel.bUpdate = 0;
                        sei();
 
-                       speed_wish_right = angle*M_PI*WHEEL_DIST/2 + speed;
+                       speed_wish_right = (angle*WHEEL_DIST)/2 + speed;
                        speed_wish_left = speed*2-speed_wish_right;
 
                        speed_wish_left*=STEP_PER_M_LEFT;
@@ -1008,17 +1074,17 @@ int main(void) {
 
                        if (aft_handicap > 0) {
                                speed1_wish = speed_wish_left * (100-aft_handicap)/100.0;
-                               speed4_wish = speed_wish_right * (100-aft_handicap)/100.0;
+                               speed3_wish = speed_wish_right * (100-aft_handicap)/100.0;
                        } else {
                                speed1_wish = speed_wish_left;
-                               speed4_wish = speed_wish_right;
+                               speed3_wish = speed_wish_right;
                        }
                        if (front_handicap > 0) {
                                speed2_wish = speed_wish_left * (100-front_handicap)/100.0;
-                               speed3_wish = speed_wish_right * (100-front_handicap)/100.0;
+                               speed4_wish = speed_wish_right * (100-front_handicap)/100.0;
                        } else {
                                speed2_wish = speed_wish_left;
-                               speed3_wish = speed_wish_right;
+                               speed4_wish = speed_wish_right;
                        }
                        motor1_mode = MOTOR_PID;
                        motor2_mode = MOTOR_PID;