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Old 05-29-2015, 03:06 PM   #1871 (permalink)
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Originally Posted by MPaulHolmes View Post
That is looking good. You should now try maybe 3000 or 4000 (or more?) for kp, and gradually increase ki in that situation too (starting small). haha. I bet you can get even faster convergence.
Is Kp 2000 and Ki 320 OK for a test spin on the motor? It looks reasonable to me ...

I agree that the response could be better but I still don't really understand what shape you are looking for. Fastest possible drop to 0 with only one small overshoot? But this motor was a test that I could do inside while it was cold in the garage .... and it's summer now! This has taken me *MUCH* longer than I was expecting.

If those values are OK, what code should I be running to do the test spin? It would be nice to prove out the encoder signal, verify the throttle response, and get some scope traces for this 5 HP motor.

Then I'd like to move the test setup to the garage and work on the Siemens AC motor that is coupled to the Warp 9 DC motor. I'll likely grab 1/3 of the pack from my car, approx 130VDC 60 a-h renault/nissan leaf pack.

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Old 05-29-2015, 07:01 PM   #1872 (permalink)
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9mS (your convergence time) may be OK. I don't know. My motor ended up with a convergence time of around 1.3mS. Now you need to find the rotor time constant. It's another test where you have to run through a variety of values. The nice thing is, the motor will spin each time you test one of those time constant values. One of them will give the highest RPM. But before you try that, you should probably just try some code where you manually turn the post, and see the encoder position through the serial port. We need to know that's working before you can do the rotor time constant test. I'll send that this weekend.
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Old 05-29-2015, 07:40 PM   #1873 (permalink)
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Quote:
Originally Posted by MPaulHolmes View Post
But before you try that, you should probably just try some code where you manually turn the post, and see the encoder position through the serial port. We need to know that's working before you can do the rotor time constant test. I'll send that this weekend.
That sounds great ... I'm not so confident that the encoder signal is good. Please remember that pulses per revolution needs to be a value I can set (it's not 512)

I'm doing another hour of testing or so tonight, on the DC controller, before we leave for the lake. I can go through the code you send me on the weekend, but testing will have to wait until Monday night.
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Old 05-30-2015, 03:25 AM   #1874 (permalink)
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Quote:
Originally Posted by thingstodo View Post
...I agree that the response could be better but I still don't really understand what shape you are looking for. Fastest possible drop to 0 with only one small overshoot? But this motor was a test that I could do inside while it was cold in the garage .... and it's summer now! This has taken me *MUCH* longer than I was expecting...
Thank you to thingstodo and Paul for posting their efforts in getting the controller set up. It is answering many of the questions that i would have had to ask later anyway.
Sounds like once you confirm the encoder works with the controller you will quickly move into garage testing the big motor.
Good luck.
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Old 05-30-2015, 10:48 PM   #1875 (permalink)
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Originally Posted by Astro View Post
Sounds like once you confirm the encoder works with the controller you will quickly move into garage testing the big motor.
Good luck.
That's the plan!

Quote:
Thank you to thingstodo and Paul for posting their efforts in getting the controller set up. It is answering many of the questions that i would have had to ask later anyway.
Thanks for the encouragement
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Old 05-30-2015, 10:55 PM   #1876 (permalink)
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Results from Friday night

Is there a maximum for Ki-id? Somewhere between 3000 and 4000 ... like maybe 3276? I think I ran into a limit since doing run-pi-test after ki-id 4000 did not work.

Best results (I think) were in file 86, kp 3000, ki 1000. See if you agree.

file 88 is where I ran into run-pi-test not working. File 89 as well, but I ran a test at kp 3000, ki 250
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Old 06-02-2015, 12:25 AM   #1877 (permalink)
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Monday evening results

loaded hex file - OK

run-encoder-test works ... the logs are attached

The encoder pulses per revolution should be 1000. But it appears to be around 4000 somehow.

The x on the number messed me up for a bit - the encoder counts are decimal.

Entirely reproducible values for the encoder counts. The values seem to make sense, except that they are 4x as many as they should show?

In any case, I think I can progress to checking the rotor constant. What do you say, Paul?

BTW - I added doc as I progressed through the encoder test
Attached Files
File Type: txt 100.txt (1.1 KB, 13 views)
File Type: txt 101.txt (849 Bytes, 17 views)
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Old 06-17-2015, 12:17 PM   #1878 (permalink)
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Move to the garage

I have not had a lot of time lately, and neither has Paul.

This is not really an update. I hope to get some pictures posted this week but actual progress is limited.

I can still make some progress on the 5 HP motor in my basement, but I took the plunge and moved the controller to my garage.

The battery pack from my Mazda is now in the garage (pending battery box construction). It is strapped for 375V now. The siemens AC motor is coupled to the warp9 with some scrap wood. I'm working on how to make mounts that will withstand more torque - like maybe 400 foot-lbs or so. First tests on the Siemens can be at 375V and then when I need to run the Warp9 as well, I'll do 3 parallel strings of 125V. I will likely need to re-tune with the different voltage but it sounds like I will need a few tries to get good at it, so I may as well!

The laptop, the throttle, the contactors, etc are not in the garage right now - I need to find a way to keep my feline (and the static electricity, hairballs, etc) out of the test area. Anyone with a cat knows how much of a challenge THAT is.

*Edit - pictures from left to right:
- Battery pack alone
- entire mess, battery pack on the left, controller top middle, motors coupled on right
- controller with cover off (not cat-proof)
- motors coupled
- motors coupled, from the top, showing joy coupler and 2 x 4 mounting between motor frames (need to work on this part)
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Last edited by thingstodo; 06-19-2015 at 07:08 PM.. Reason: Add pictures
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Old 07-06-2015, 01:38 AM   #1879 (permalink)
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Hi guys,

Had to play a bit of catch up since my last visit. Paul sorry to hear about your incident, my sincere hopes everything is sorted by now and let us know if you need any help.

I'm wondering if anyone has looked into the DC Boost converter since I'm resuming work on that.
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Old 07-18-2015, 12:49 AM   #1880 (permalink)
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Cool

Quote:
Originally Posted by cts_casemod View Post
Hi guys,

Had to play a bit of catch up since my last visit. Paul sorry to hear about your incident, my sincere hopes everything is sorted by now and let us know if you need any help.

I'm wondering if anyone has looked into the DC Boost converter since I'm resuming work on that.
First, I'd like to thank thingstodo & paul for their debugging tenacity!

Sorry, but I've been a bit out of the loop 'cause of an internet shut-down (1 month!! Don't use Excede or Wildblue if you like your sanity...) Also, I installed a new motor in a '97 4runner 'cause of a blown head-gasket.

ANYWAY... I've been thinking more about the boost converter idea. My initial impression was to KISS, thus just build a higher voltage battery pack. However, a new project has my interest - one of those cool old ****light**** English sports cars. To do it justice, everything must be light ( "build in more lightness" ). I've come to realize that a boost converter+battery pack will be lighter than a big battery pack.. - yes, I'm a bit slow.

So, yes, I'm interested - I think the idea has some great potential.

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