feat: add simple stall detection with threshold + debounce
- Add STALL_THRESHOLD (8A) and STALL_CONFIRM_SAMPLES (3) config - Add 500ms stabilization delay after direction change to prevent false positives - Add stall warning banner in web UI - Stop motor and pingpong when stall detected Algorithm: If active current > 8A for 3 consecutive samples (300ms), and motor has been running for at least 500ms, trigger stall callback.
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@@ -40,6 +40,12 @@
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// Current logging interval for data collection
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#define CURRENT_LOG_INTERVAL_MS 100 // Log current readings every 100ms
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// Simple Stall Detection
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// Based on clean data: Running ~2A, Stall ~17A (8.5x difference)
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#define STALL_THRESHOLD 8.0f // Amps - midpoint between 2A run and 17A stall
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#define STALL_CONFIRM_SAMPLES 3 // Debounce: 3 samples = 300ms at 100ms interval
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#define STALL_STABILIZE_MS 500 // Ignore current spikes for 500ms after direction change
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// Web Server
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#define HTTP_PORT 80
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@@ -4,6 +4,9 @@
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#include <Arduino.h>
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#include "config.h"
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// Stall callback function type
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typedef void (*StallCallback)();
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class MotorController {
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public:
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void begin();
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@@ -18,6 +21,11 @@ public:
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float getCurrentLeft(); // Current in amps (reverse direction)
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float getCurrentActive(); // Current from active direction
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// Stall detection
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bool isStalled();
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void setStallCallback(StallCallback callback);
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void resetStallDetection();
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// Pingpong mode (time-based only)
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void startPingpong(int speed, int timeMs, int speedRandomPercent, int timeRandomPercent);
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void stopPingpong();
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@@ -48,11 +56,18 @@ private:
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unsigned long _pingpongLastSwitch = 0;
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int _pingpongDirection = 1;
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// Stall detection state
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bool _stalled = false;
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int _stallConfirmCount = 0;
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StallCallback _stallCallback = nullptr;
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unsigned long _lastDirectionChangeTime = 0;
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void applyMotorState();
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float readCurrentSense(int pin);
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void calibrateCurrentOffset();
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void updatePingpong();
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int applyRandomness(int baseValue, int randomPercent);
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void checkStall();
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};
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extern MotorController motor;
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