Add branch plan documentation and sample current log data

- plans/remove-stall-detection-branch.md: Documents what was removed, data analysis, and next steps - src/current_loggin.log: Sample current data showing clear stall signatures
2026-02-05 21:10:07 +02:00
parent dd274202bb
commit 3aec7250c9
2 changed files with 232 additions and 0 deletions
--- a/plans/remove-stall-detection-branch.md
+++ b/plans/remove-stall-detection-branch.md
@@ -0,0 +1,104 @@
+# Branch: feature/remove-stall-detection
+
+## Summary
+
+Removed all stall detection logic to collect clean current data with new beefy PSU before reimplmenting simpler stall detection.
+
+## Problem
+
+The original stall detection was overly complex with:
+- Delta-based spike detection with EMA averaging
+- Under-current detection
+- Repeated spike detection for oscillating patterns  
+- Multiple timing thresholds and stabilization periods
+- 16 configuration parameters
+
+This complexity was trying to compensate for a weak PSU that couldn't provide enough current, causing unreliable stall detection.
+
+## What Was Removed
+
+### config.h
+- `STALL_DELTA_THRESHOLD` 
+- `STALL_EMA_ALPHA`
+- `STALL_EMA_BASELINE`
+- `STALL_STABILIZE_MS`
+- `STALL_CONFIRM_MS`
+- `DISABLE_STALL_DETECT`
+- `STALL_UNDERCURRENT_THRESHOLD`
+- `STALL_UNDERCURRENT_MS`
+- `STALL_CANDIDATE_COUNT`
+- `STALL_CANDIDATE_WINDOW_MS`
+
+### motor.h / motor.cpp
+- `checkStall()` function (~115 lines)
+- `resetStallDetection()` function
+- `isStalled()` method
+- `setStallCallback()` method
+- `getPingpongStallReturn()` method
+- All stall-related member variables
+
+### webserver.cpp
+- Stall warning UI banner
+- "Return on stall only" checkbox
+- `stalled` and `ppStallReturn` from status JSON
+
+### main.cpp
+- `onMotorStall()` callback function
+
+## What Was Added
+
+- `CURRENT_LOG_INTERVAL_MS` config (100ms)  
+- Frequent current logging: `CURRENT: R=%.2fA L=%.2fA dir=%d spd=%d`
+- "Motor: STOPPED (manual)" message
+
+## Current Data Analysis
+
+See [src/current_loggin.log](../src/current_loggin.log) for sample data.
+
+### Running Current (motor moving freely)
+- **Range:** 0.67A - 2.64A
+- **Average:** ~1.5-2.0A
+
+### Stall Current (motor blocked at end stop)
+- **Range:** 16.8A - 21.0A  
+- **Average:** ~17-18A
+
+### Key Observations
+1. **Clear separation:** Running ~2A vs Stall ~17A = 8.5x difference
+2. **Fast transition:** Stall spike happens within 1-2 samples (100-200ms)
+3. **Initial spike:** Can see 3.77A or 5.35A briefly before full stall current
+4. **Gradual decay:** Stall current trends down slightly over time (~21A → ~17A)
+
+## Next Step: Simple Stall Detection
+
+Based on the clean data, implement a simple threshold-based stall detection:
+
+### Proposed Algorithm
+```
+IF motor is running (dir != 0 AND speed > 0):
+    IF active_current > STALL_THRESHOLD for STALL_CONFIRM_SAMPLES:
+        STALL DETECTED
+```
+
+### Proposed Config (much simpler)
+```c
+#define STALL_THRESHOLD 8.0f      // Amps - midpoint between 2A run and 17A stall
+#define STALL_CONFIRM_SAMPLES 3   // Debounce: 3 samples = 300ms at 100ms interval
+```
+
+### Why This Should Work
+- With beefy PSU, running current is stable ~2A
+- Stall current is clearly ~17A+
+- No need for EMA averaging or complex spike detection
+- Simple threshold + debounce is enough
+
+## Files Changed
+
+| File | Lines Removed | Lines Added |
+|------|---------------|-------------|
+| config.h | 16 | 2 |
+| motor.h | 26 | 0 |
+| motor.cpp | 180 | 1 |
+| webserver.cpp | 50 | 5 |
+| main.cpp | 12 | 1 |
+| **Total** | **284** | **9** |
--- a/src/current_loggin.log
+++ b/src/current_loggin.log
@@ -0,0 +1,128 @@
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+CURRENT: R=0.00A L=0.00A dir=0 spd=0
+Motor: dir=1, speed=0%, pwm=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+CURRENT: R=0.00A L=0.00A dir=1 spd=0
+Motor: dir=-1, speed=0%, pwm=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+CURRENT: R=0.00A L=0.00A dir=-1 spd=0
+Motor: dir=-1, speed=100%, pwm=255
+CURRENT: R=0.00A L=0.88A dir=-1 spd=100
+CURRENT: R=0.00A L=2.07A dir=-1 spd=100
+CURRENT: R=0.00A L=1.49A dir=-1 spd=100
+CURRENT: R=0.00A L=2.56A dir=-1 spd=100
+CURRENT: R=0.00A L=1.25A dir=-1 spd=100
+Motor: dir=-1, speed=100%, pwm=255
+CURRENT: R=0.00A L=1.10A dir=-1 spd=100
+CURRENT: R=0.00A L=2.18A dir=-1 spd=100
+CURRENT: R=0.00A L=1.36A dir=-1 spd=100
+CURRENT: R=0.00A L=1.28A dir=-1 spd=100
+CURRENT: R=0.00A L=2.39A dir=-1 spd=100
+CURRENT: R=0.00A L=1.47A dir=-1 spd=100
+CURRENT: R=0.00A L=1.25A dir=-1 spd=100
+CURRENT: R=0.00A L=1.31A dir=-1 spd=100
+CURRENT: R=0.00A L=2.02A dir=-1 spd=100
+CURRENT: R=0.00A L=1.36A dir=-1 spd=100
+CURRENT: R=0.00A L=2.35A dir=-1 spd=100
+CURRENT: R=0.00A L=1.24A dir=-1 spd=100
+CURRENT: R=0.00A L=1.57A dir=-1 spd=100
+CURRENT: R=0.00A L=2.64A dir=-1 spd=100
+CURRENT: R=0.00A L=1.32A dir=-1 spd=100
+CURRENT: R=0.00A L=2.52A dir=-1 spd=100
+CURRENT: R=0.00A L=3.77A dir=-1 spd=100
+CURRENT: R=0.00A L=21.04A dir=-1 spd=100
+CURRENT: R=0.00A L=18.61A dir=-1 spd=100
+CURRENT: R=0.00A L=19.38A dir=-1 spd=100
+CURRENT: R=0.00A L=17.53A dir=-1 spd=100
+CURRENT: R=0.00A L=17.53A dir=-1 spd=100
+CURRENT: R=0.00A L=17.50A dir=-1 spd=100
+CURRENT: R=0.00A L=17.41A dir=-1 spd=100
+CURRENT: R=0.00A L=17.30A dir=-1 spd=100
+CURRENT: R=0.00A L=17.28A dir=-1 spd=100
+CURRENT: R=0.00A L=17.21A dir=-1 spd=100
+CURRENT: R=0.00A L=17.17A dir=-1 spd=100
+CURRENT: R=0.00A L=17.06A dir=-1 spd=100
+CURRENT: R=0.00A L=16.99A dir=-1 spd=100
+Motor: dir=1, speed=100%, pwm=255
+CURRENT: R=0.00A L=0.00A dir=1 spd=100
+CURRENT: R=1.77A L=0.00A dir=1 spd=100
+CURRENT: R=1.36A L=0.00A dir=1 spd=100
+CURRENT: R=2.19A L=0.00A dir=1 spd=100
+CURRENT: R=2.10A L=0.00A dir=1 spd=100
+CURRENT: R=1.18A L=0.00A dir=1 spd=100
+CURRENT: R=1.36A L=0.00A dir=1 spd=100
+CURRENT: R=1.24A L=0.00A dir=1 spd=100
+CURRENT: R=1.50A L=0.00A dir=1 spd=100
+CURRENT: R=1.45A L=0.00A dir=1 spd=100
+CURRENT: R=2.01A L=0.00A dir=1 spd=100
+CURRENT: R=1.64A L=0.00A dir=1 spd=100
+CURRENT: R=2.10A L=0.00A dir=1 spd=100
+CURRENT: R=1.31A L=0.00A dir=1 spd=100
+CURRENT: R=2.34A L=0.00A dir=1 spd=100
+CURRENT: R=1.90A L=0.00A dir=1 spd=100
+CURRENT: R=1.46A L=0.00A dir=1 spd=100
+CURRENT: R=1.60A L=0.00A dir=1 spd=100
+CURRENT: R=2.27A L=0.00A dir=1 spd=100
+CURRENT: R=1.96A L=0.00A dir=1 spd=100
+CURRENT: R=3.08A L=0.00A dir=1 spd=100
+CURRENT: R=15.12A L=0.00A dir=1 spd=100
+CURRENT: R=18.53A L=0.00A dir=1 spd=100
+CURRENT: R=20.75A L=0.00A dir=1 spd=100
+CURRENT: R=19.59A L=0.00A dir=1 spd=100
+CURRENT: R=18.54A L=0.00A dir=1 spd=100
+CURRENT: R=17.88A L=0.00A dir=1 spd=100
+CURRENT: R=17.35A L=0.00A dir=1 spd=100
+CURRENT: R=17.06A L=0.00A dir=1 spd=100
+CURRENT: R=16.99A L=0.00A dir=1 spd=100
+CURRENT: R=16.85A L=0.00A dir=1 spd=100
+CURRENT: R=16.90A L=0.00A dir=1 spd=100
+CURRENT: R=16.84A L=0.00A dir=1 spd=100
+CURRENT: R=16.81A L=0.00A dir=1 spd=100
+Motor: dir=-1, speed=100%, pwm=255
+CURRENT: R=0.00A L=5.35A dir=-1 spd=100
+CURRENT: R=0.00A L=0.46A dir=-1 spd=100
+CURRENT: R=0.00A L=2.29A dir=-1 spd=100
+CURRENT: R=0.00A L=0.86A dir=-1 spd=100
+CURRENT: R=0.00A L=2.22A dir=-1 spd=100
+CURRENT: R=0.00A L=1.90A dir=-1 spd=100
+CURRENT: R=0.00A L=1.00A dir=-1 spd=100
+CURRENT: R=0.00A L=1.33A dir=-1 spd=100
+CURRENT: R=0.00A L=1.42A dir=-1 spd=100
+CURRENT: R=0.00A L=1.27A dir=-1 spd=100
+CURRENT: R=0.00A L=1.25A dir=-1 spd=100
+CURRENT: R=0.00A L=2.21A dir=-1 spd=100
+CURRENT: R=0.00A L=0.67A dir=-1 spd=100
+CURRENT: R=0.00A L=0.85A dir=-1 spd=100
+Motor: STOPPED (manual)
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100
+CURRENT: R=0.00A L=0.00A dir=0 spd=100