Some progress to report for Sep 8
Load new firmware into AC controller
- power is off to controller and PICkit 3
- plug PICKit 3 into controller
- plug USB into laptop
- turn on 12V to controller
- load MPLAB IPE V2.30
- connect to controller
- load hex file ACControllerproject150908 autotune.hex
- program controller
- turn off 12V
- eject USB and remove
- disconnect PICKit 3 from ACController board
Connect serial from laptop to controller
load hypterterminal
load accontroller settings 115200,n,8,1 no flow control
power up controll 12V
After pre-charge, welcome message AC controller firmware, ver. 1.0
following Paul's instructions - I will be typing in run-pi-test
Before I do that, set up:
- whole scene video on my gopro
- audio on my old phone with a headset
- my phone recording a closeup of the DC motor since you can't really see the AC motor
The first run, nothing appeared to happen when I did run-pi-test. So I shut
things down and did it again. This time when nothing appeared to happen, I started to mess around with the throttle pot. The program (after a couple of minutes, and when I wasn't watching) put out ALL of the numbers from 62 up to the maximum in multiples of 62. That seems strange. This is after autotune 2 stopped recording.
I stopped the video and audio capture, turned everything off, then started up the video and audio, then started the text capture (autotune 3), powered up the high voltage, then the low voltage.
The motor started running! So I messed with the throttle until it stopped.
Then I ran run-pi-test
I got 2 numbers, 03844 and 04774
I stopped the video and audio capture, text capture and read through Paul's instructions
Armed with a value for kP, I don't know what to do to get Ki. I read through the ecomodder forum again.
Ahh - i is k / 62 (that's why the steps are set to 62). So 3844/62= 62, 4774/62=77
Start with k 3844, i 62
run-rotor-test
the controller and motor buzzed for several seconds and stopped.
Turn it all off and try again with 4774 and 77
the controller did not buzz this time
and the contactors appeared to cycle for no reason
and then I received the startup message from the controller again
The 12V battery is down to 8V. That's a problem. Connect it to a charger and go back to testing. The controller does not respond well. The contactors cycle again. Perhaps the dead contactor that I left connected to hear when the output cycles is taking a bunch of current? Disconnect it and cap off the wires.
12V battery is up to 10.2V with the charger on it ... so it is *WAY* down on the discharge curve (small lithium pack). The charger outputs 3A so I will wait until the 12V reaches 12V as a minimum.
Up the capture to autotune 5
k 4774
i 77
run-rotor-test
The controller buzzed for a while, finally starting the motor shaft turning .. at maybe 40 or 50 rpm. The motor slows down over time and when the test is complete, the values printed out are .. 0s?
The output from autotune 5 is 0, a bunch of 0's
Shut off the video and audio, shut off the system, start it all back up
autotune 6
k 3844
i 62
run-rotor-test
The controller buzzes for a while, just like last time. The motor shaft starts to turn at 40 or 50 rpm, just like last time. The motor slows down over time and when the test is complete, the values are printed out ..
The output is 0's again.
Maybe I need to remove the coupler for the DC motor and let the motor spin more freely during the test?
I have some video to edit, and see if I can get the voice-over to work. I have not done video with multiple sources before so it will be a bit of an experiment.
I did a motor spin test in there somewhere as well. The controller makes a loud buzzing until the motor begins to turn, then if I back off the throttle the noise sort of goes away. More throttle buzzes more but does not turn the motor faster.
EDIT BELOW ---
There are 9 videos, 2 - 8 minutes each. Be warned - the video work is not done well (the separate audio experiment did not go well, the editing software did not digest the Gopro footage and allow for windowed zoom) and the audio is a bit hard to hear (refer to audio experiment comment). Lots of stuff happens off-camera (refer to gopro footage comments).
Video 1
https://youtu.be/J15KnjW2CbI
Video 2
https://youtu.be/4XcoedWKTPk
But if you suffer through the videos and follow along with the problems, it's sorta like getting the experience of troubleshooting without having to do it yourself ... so I've been told by at least one person .. your mileage may vary!
Video 3
https://youtu.be/8ZFoPcTN2As
Video 4
https://youtu.be/lcaJat9hp9Y
Video 5
https://youtu.be/x1Umb_ckRpU
Video 6
https://youtu.be/TgTP6M2FwLc
Video 7
https://youtu.be/kpVN9Cad8J0
Video 8
https://youtu.be/pxDl0BxKrLw
Video 9
https://youtu.be/KicuUhKoibU