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feat: add dual BTS7960 motor driver support

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- Refactor MotorController to parameterized class with MotorPins struct
- Add motor1 and motor2 instances with shared enable pins (GPIO 14, 27)
- Motor 2 uses GPIO 32/33 for PWM, GPIO 36/39 for current sense
- Update web UI with side-by-side dual motor control panels
- Add per-motor API endpoints (/motor1/*, /motor2/*)
- Add emergency stop button for both motors
- Legacy endpoints map to motor1 for backwards compatibility
- Update readme and AGENTS.md documentation
This commit is contained in:
devdesk
2026-02-06 15:05:13 +02:00
parent 252f0e1ec2
commit f157d3abc5
8 changed files with 608 additions and 230 deletions
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13
AGENTS.md
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@@ -4,7 +4,7 @@ This file provides guidance to agents when working with code in this repository.
## Project Overview
PlatformIO project for ESP32 LOLIN32 Rev1 controlling BTS7960 dual H-bridge motor driver (12V DC).
PlatformIO project for ESP32 LOLIN32 Rev1 controlling **two BTS7960 dual H-bridge motor drivers** for a differential drive robot (12V DC).
## Build Commands
@@ -17,8 +17,11 @@ pio device monitor # Serial monitor (115200 baud)
## Hardware-Specific Notes
- **Board**: ESP32 LOLIN32 Rev1 (use `lolin32` in platformio.ini)
- **Motor Driver**: BTS7960 dual H-bridge - requires 4 GPIO pins (RPWM=25, LPWM=26, R_EN=27, L_EN=14)
- **Power**: 12V DC input to motor driver - logic level is 3.3V compatible with ESP32
- **Motor Drivers**: 2× BTS7960 dual H-bridge - shared enable pins, independent PWM and current sense
- **Motor 1**: RPWM=25, LPWM=26, R_IS=34, L_IS=35 (PWM channels 0,1)
- **Motor 2**: RPWM=32, LPWM=33, R_IS=36, L_IS=39 (PWM channels 2,3)
- **Shared enables**: R_EN=27, L_EN=14 (both drivers enable together)
- **Power**: 12V DC input to motor drivers - logic level is 3.3V compatible with ESP32
- **WiFi**: Connects to SSID 'tami' with static IP 10.81.2.185
- **Reference**: https://deepbluembedded.com/arduino-bts7960-dc-motor-driver/
@@ -27,5 +30,7 @@ pio device monitor # Serial monitor (115200 baud)
- Use built-in `WebServer` library (NOT ESPAsyncWebServer - has enum compatibility issues with ESP32 Arduino 3.x)
- WebServer requires `handleClient()` call in loop() - unlike async version
- LEDC PWM at 20kHz reduces motor noise
- Enable pins (R_EN, L_EN) must be HIGH before PWM works
- Enable pins (R_EN, L_EN) must be HIGH before PWM works - configured once by first motor init
- **BTS7960 is 3.3V compatible**: Inputs are TTL/CMOS compatible (VIL<0.8V, VIH>2.0V) - ESP32 GPIOs work directly without level shifters (per BTN7960 datasheet section 5.4.1)
- **MotorController is parameterized**: Instances `motor1` and `motor2` are created with `MotorPins` struct
- **Legacy compatibility**: `motor` macro aliases to `motor1`, legacy `/speed` and `/direction` endpoints map to motor1

47
include/config.h
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@@ -11,22 +11,51 @@
#define SUBNET IPAddress(255, 255, 255, 0)
#define DNS IPAddress(10, 81, 2, 1)
// BTS7960 Pin Definitions
#define L_EN_PIN 14 // Left Enable
#define LPWM_PIN 26 // Left PWM (Reverse)
#define L_IS_PIN 35 // Left Current Sense (ADC input only)
// Shared Enable Pins (both drivers share these)
#define R_EN_PIN 27 // Right Enable (shared)
#define L_EN_PIN 14 // Left Enable (shared)
#define R_EN_PIN 27 // Right Enable
#define RPWM_PIN 25 // Right PWM (Forward)
#define R_IS_PIN 34 // Right Current Sense (ADC input only)
// Motor 1 BTS7960 Pin Definitions
#define RPWM1_PIN 25 // Right PWM Motor 1 (Forward)
#define LPWM1_PIN 26 // Left PWM Motor 1 (Reverse)
#define R_IS1_PIN 34 // Right Current Sense Motor 1 (ADC input only)
#define L_IS1_PIN 35 // Left Current Sense Motor 1 (ADC input only)
// Motor 2 BTS7960 Pin Definitions
#define RPWM2_PIN 32 // Right PWM Motor 2 (Forward)
#define LPWM2_PIN 33 // Left PWM Motor 2 (Reverse)
#define R_IS2_PIN 36 // Right Current Sense Motor 2 (ADC input only - VP)
#define L_IS2_PIN 39 // Left Current Sense Motor 2 (ADC input only - VN)
// PWM Configuration
#define PWM_FREQ 20000 // 20kHz - reduces motor noise
#define PWM_RESOLUTION 8 // 8-bit resolution (0-255)
#define PWM_CHANNEL_R 0 // LEDC channel for RPWM
#define PWM_CHANNEL_L 1 // LEDC channel for LPWM
#define PWM_CHANNEL_R1 0 // LEDC channel for Motor 1 RPWM
#define PWM_CHANNEL_L1 1 // LEDC channel for Motor 1 LPWM
#define PWM_CHANNEL_R2 2 // LEDC channel for Motor 2 RPWM
#define PWM_CHANNEL_L2 3 // LEDC channel for Motor 2 LPWM
#define MIN_PWM_PERCENT 20 // Minimum PWM when motor is running (%)
// Motor pin configuration structure
struct MotorPins {
uint8_t rpwm; // Right PWM pin (forward)
uint8_t lpwm; // Left PWM pin (reverse)
uint8_t r_is; // Right current sense pin
uint8_t l_is; // Left current sense pin
uint8_t pwm_channel_r; // LEDC PWM channel for right
uint8_t pwm_channel_l; // LEDC PWM channel for left
};
// Motor 1 pin configuration
const MotorPins MOTOR1_PINS = {
RPWM1_PIN, LPWM1_PIN, R_IS1_PIN, L_IS1_PIN, PWM_CHANNEL_R1, PWM_CHANNEL_L1
};
// Motor 2 pin configuration
const MotorPins MOTOR2_PINS = {
RPWM2_PIN, LPWM2_PIN, R_IS2_PIN, L_IS2_PIN, PWM_CHANNEL_R2, PWM_CHANNEL_L2
};
// Current Sense Configuration
// BTS7960 current sense ratio: 8500:1 (kilo-amps)
// With 1kΩ resistor on IS pin: V = I_motor / 8500

17
include/motor.h
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@@ -9,6 +9,9 @@ typedef void (*StallCallback)();
class MotorController {
public:
// Constructor with pin configuration and motor name
MotorController(const MotorPins& pins, const char* name);
void begin();
void setSpeed(int speed); // 0-100 percentage
void setDirection(int dir); // -1=reverse, 0=stop, 1=forward
@@ -20,6 +23,7 @@ public:
float getCurrentRight(); // Current in amps (forward direction)
float getCurrentLeft(); // Current in amps (reverse direction)
float getCurrentActive(); // Current from active direction
const char* getName(); // Get motor name for logging
// Stall detection
bool isStalled();
@@ -27,6 +31,9 @@ public:
void resetStallDetection();
private:
MotorPins _pins;
const char* _name;
int _speed = 0;
int _direction = 0;
float _currentRight = 0;
@@ -42,12 +49,20 @@ private:
StallCallback _stallCallback = nullptr;
unsigned long _lastDirectionChangeTime = 0;
// Static flag to track if enable pins are already configured
static bool _enablePinsConfigured;
void applyMotorState();
float readCurrentSense(int pin);
void calibrateCurrentOffset();
void checkStall();
};
extern MotorController motor;
// Two motor controller instances
extern MotorController motor1;
extern MotorController motor2;
// Legacy alias for backwards compatibility
#define motor motor1
#endif

118
plans/dual-motor-driver.md Normal file
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@@ -0,0 +1,118 @@
# Dual BTS7960 Motor Driver Integration Plan
## Overview
Add a second BTS7960 motor driver for differential drive robot, sharing enable pins between both drivers.
## Hardware Configuration
### Pin Assignments
| Function | Motor 1 | Motor 2 | Notes |
|----------|---------|---------|-------|
| **R_EN** | GPIO 27 | GPIO 27 (shared) | Both drivers enable together |
| **L_EN** | GPIO 14 | GPIO 14 (shared) | Both drivers enable together |
| **RPWM** | GPIO 25 | GPIO 32 | Forward PWM |
| **LPWM** | GPIO 26 | GPIO 33 | Reverse PWM |
| **R_IS** | GPIO 34 | GPIO 36 (VP) | Current sense - input only |
| **L_IS** | GPIO 35 | GPIO 39 (VN) | Current sense - input only |
### Wiring Diagram
```
ESP32 LOLIN32 BTS7960 #1 BTS7960 #2
-------------- ---------- ----------
GPIO 27 (R_EN) ------> R_EN -----------> R_EN
GPIO 14 (L_EN) ------> L_EN -----------> L_EN
GPIO 25 (RPWM) ------> RPWM
GPIO 26 (LPWM) ------> LPWM
GPIO 34 (R_IS) <------ R_IS
GPIO 35 (L_IS) <------ L_IS
GPIO 32 (RPWM2) --------------------> RPWM
GPIO 33 (LPWM2) --------------------> LPWM
GPIO 36 (R_IS2) <-------------------- R_IS
GPIO 39 (L_IS2) <-------------------- L_IS
```
## Code Changes
### 1. config.h - Add Motor 2 pin definitions
```cpp
// Motor 2 BTS7960 Pin Definitions
#define RPWM2_PIN 32 // Right PWM Motor 2
#define LPWM2_PIN 33 // Left PWM Motor 2
#define R_IS2_PIN 36 // Right Current Sense Motor 2
#define L_IS2_PIN 39 // Left Current Sense Motor 2
// Motor 2 PWM Channels
#define PWM_CHANNEL_R2 2
#define PWM_CHANNEL_L2 3
```
### 2. motor.h - Parameterized MotorController
```cpp
struct MotorPins {
uint8_t rpwm;
uint8_t lpwm;
uint8_t r_is;
uint8_t l_is;
uint8_t pwm_channel_r;
uint8_t pwm_channel_l;
};
class MotorController {
public:
MotorController(const MotorPins& pins, const char* name);
void begin();
// ... existing methods unchanged
private:
MotorPins _pins;
const char* _name;
// ... existing members
};
extern MotorController motor1;
extern MotorController motor2;
```
### 3. motor.cpp - Use parameterized pins
- Constructor stores pin config
- `begin()` uses `_pins.rpwm` instead of `RPWM_PIN`, etc.
- Serial output includes motor name for debugging
### 4. webserver.cpp - Dual motor API
New endpoints:
- `/motor1/speed`, `/motor1/direction`, `/motor1/stop`
- `/motor2/speed`, `/motor2/direction`, `/motor2/stop`
- `/status` - returns both motors data
Keep legacy endpoints mapping to motor1 for backwards compatibility.
### 5. main.cpp - Initialize both controllers
```cpp
void setup() {
motor1.begin();
motor1.setStallCallback(onMotor1Stall);
motor2.begin();
motor2.setStallCallback(onMotor2Stall);
// ...
}
void loop() {
handleWebServer();
motor1.update();
motor2.update();
delay(1);
}
```
## Notes
- Enable pins are set HIGH once in motor1.begin - both drivers share them
- GPIO 36 and 39 are valid for ADC input - they are input-only pins
- GPIO 32 and 33 support both PWM and ADC, using them for PWM only
- Web UI will need expansion to show both motors - consider tabbed interface or side-by-side layout

133
readme.md
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@@ -1,15 +1,16 @@
# BTS7960 Motor Controller
# Dual BTS7960 Motor Controller
ESP32-based DC motor controller with web interface, using BTS7960 dual H-bridge driver with current sensing and stall protection.
ESP32-based differential drive robot controller with web interface, using two BTS7960 dual H-bridge drivers with current sensing and stall protection.
## Features
- Web-based control panel with real-time current monitoring
- Forward/Reverse/Stop motor control with speed slider (20-100%)
- Current sensing on both H-bridge sides (R_IS and L_IS)
- Sample-based stall detection with automatic motor shutoff
- Web-based dual motor control panel with real-time current monitoring
- Independent Forward/Reverse/Stop control for each motor with speed sliders (20-100%)
- Current sensing on both H-bridge sides for each motor
- Sample-based stall detection with automatic motor shutoff (per motor)
- ADC offset calibration at startup for accurate current readings
- Stall warning displayed on web interface
- Stall warning displayed on web interface per motor
- Emergency stop for both motors
## Hardware
@@ -18,9 +19,9 @@ ESP32-based DC motor controller with web interface, using BTS7960 dual H-bridge
| Component | Model/Specification |
|-----------|---------------------|
| Microcontroller | ESP32 LOLIN32 Rev1 |
| Motor Driver | BTS7960 Dual H-Bridge Module |
| Motor Drivers | 2× BTS7960 Dual H-Bridge Module |
| Power Supply | 12V DC |
| Sense Resistors | 2× 1kΩ (for current sensing) |
| Sense Resistors | 4× 1kΩ (for current sensing) |
### BTS7960 Module Reference
@@ -29,16 +30,37 @@ ESP32-based DC motor controller with web interface, using BTS7960 dual H-bridge
## Wiring
### Motor Control Pins
### Pin Assignments
| BTS7960 Pin | ESP32 GPIO | Function |
|-------------|------------|----------|
| RPWM | GPIO25 | Forward PWM |
| LPWM | GPIO26 | Reverse PWM |
| R_EN | GPIO27 | Right Enable |
| L_EN | GPIO14 | Left Enable |
| VCC | 3.3V | Logic Power |
| GND | GND | Ground |
Both drivers share enable pins (they enable/disable together).
| Function | Motor 1 | Motor 2 | Notes |
|----------|---------|---------|-------|
| **R_EN** | GPIO 27 | GPIO 27 (shared) | Both drivers enable together |
| **L_EN** | GPIO 14 | GPIO 14 (shared) | Both drivers enable together |
| **RPWM** | GPIO 25 | GPIO 32 | Forward PWM |
| **LPWM** | GPIO 26 | GPIO 33 | Reverse PWM |
| **R_IS** | GPIO 34 | GPIO 36 (VP) | Current sense - input only |
| **L_IS** | GPIO 35 | GPIO 39 (VN) | Current sense - input only |
### Wiring Diagram
```
ESP32 LOLIN32 BTS7960 #1 BTS7960 #2
-------------- ---------- ----------
GPIO 27 (R_EN) ------> R_EN -----------> R_EN
GPIO 14 (L_EN) ------> L_EN -----------> L_EN
GPIO 25 (RPWM) ------> RPWM
GPIO 26 (LPWM) ------> LPWM
GPIO 34 (R_IS) <------ R_IS
GPIO 35 (L_IS) <------ L_IS
GPIO 32 (RPWM) --------------------> RPWM
GPIO 33 (LPWM) --------------------> LPWM
GPIO 36 (R_IS) <-------------------- R_IS
GPIO 39 (L_IS) <-------------------- L_IS
```
### Current Sensing Circuit
@@ -47,29 +69,19 @@ The BTS7960 has IS (Current Sense) pins that output current proportional to moto
```
BTS7960 Module ESP32
┌─────────────────┐ ┌──────┐
│ │ │ │
│ R_IS (pin 7) ─┼──────┬───────┤GPIO34│
│ │ │ │ │
│ │ [R1] │ │
│ R_IS (pin 7) ─┼──────┬───────┤GPIOxx│ (34 for M1, 36 for M2)
│ │ [R] │ │
│ │ 1kΩ │ │
│ │ │ │ │
│ GND ─┼──────┴───────┤GND │
│ │ │ │
│ L_IS (pin 8) ─┼──────┬───────┤GPIO35│
│ │ │ │ │
│ │ [R2] │ │
│ L_IS (pin 8) ─┼──────┬───────┤GPIOxx│ (35 for M1, 39 for M2)
│ │ [R] │ │
│ │ 1kΩ │ │
│ │ │ │ │
│ GND ─┼──────┴───────┤GND │
└─────────────────┘ └──────┘
```
| Connection | Details |
|------------|---------|
| R_IS → GPIO34 | Through 1kΩ resistor to GND |
| L_IS → GPIO35 | Through 1kΩ resistor to GND |
**Note:** GPIO34 and GPIO35 are input-only pins on ESP32, ideal for ADC readings.
**Note:** GPIO34, 35, 36, 39 are input-only pins on ESP32, ideal for ADC readings.
### Current Sensing Math
@@ -116,32 +128,61 @@ Access the control panel at `http://10.81.2.185` (or the IP shown on serial moni
### Features
- **Current Display**: Real-time left (L) and right (R) current readings in amps
- **Direction Status**: Shows FORWARD, REVERSE, or STOPPED
- **Speed Slider**: Adjustable from 20% to 100% (minimum PWM prevents motor stalling at low speeds)
- **Stall Warning**: Red banner appears when stall is detected
- **Dual Motor Panels**: Side-by-side controls for Motor 1 (Left) and Motor 2 (Right)
- **Current Display**: Real-time forward (FWD) and reverse (REV) current readings per motor
- **Direction Status**: Shows FORWARD, REVERSE, or STOPPED per motor
- **Speed Sliders**: Adjustable from 20% to 100% per motor
- **Stall Warning**: Red banner per motor when stall is detected
- **Emergency Stop**: Global button to stop both motors immediately
### API Endpoints
| Endpoint | Method | Parameters | Description |
|----------|--------|------------|-------------|
| `/` | GET | - | Control panel HTML page |
| `/status` | GET | - | JSON: `{speed, direction, currentR, currentL, stalled}` |
| `/speed` | POST | `value` (0-100) | Set motor speed percentage |
| `/direction` | POST | `value` (-1, 0, 1) | Set direction (reverse/stop/forward) |
| `/stop` | POST | - | Emergency stop |
| `/status` | GET | - | JSON with both motors' status |
| `/motor1/speed` | GET | `value` (0-100) | Set motor 1 speed percentage |
| `/motor1/direction` | GET | `value` (-1, 0, 1) | Set motor 1 direction |
| `/motor1/stop` | GET | - | Stop motor 1 |
| `/motor2/speed` | GET | `value` (0-100) | Set motor 2 speed percentage |
| `/motor2/direction` | GET | `value` (-1, 0, 1) | Set motor 2 direction |
| `/motor2/stop` | GET | - | Stop motor 2 |
| `/stop` | GET | - | Emergency stop (both motors) |
| `/speed` | GET | `value` | Legacy: maps to motor1 |
| `/direction` | GET | `value` | Legacy: maps to motor1 |
### Status JSON Format
```json
{
"motor1": {
"speed": 50,
"direction": 1,
"currentR": 2.35,
"currentL": 0.00,
"stalled": false
},
"motor2": {
"speed": 50,
"direction": -1,
"currentR": 0.00,
"currentL": 1.87,
"stalled": false
}
}
```
## Stall Protection
The stall detection uses a sample-based approach for reliability:
The stall detection uses a sample-based approach for reliability (independent per motor):
1. **Threshold**: Current above 8.0A indicates potential stall (based on observed ~2A running vs ~17A stalled)
2. **Debounce**: 3 consecutive samples above threshold confirms stall (~300ms at 100ms intervals)
3. **Stabilization**: Ignores current spikes for 500ms after direction changes
When stall is confirmed:
1. Motor stops immediately
2. Serial log: `STALL PROTECTION: Stopping motor (current: X.XXA)`
3. Web interface shows red "STALL DETECTED" warning
When stall is confirmed on a motor:
1. That motor stops immediately
2. Serial log: `MotorX STALL DETECTED! Current=X.XXA (threshold=8.0A)`
3. Web interface shows red "STALL!" warning on that motor's panel
To resume operation, send a new direction command via the web interface.

30
src/main.cpp
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@@ -4,10 +4,16 @@
#include "motor.h"
#include "webserver.h"
// Called when motor stall is detected
void onMotorStall() {
Serial.println("Stall callback triggered - stopping motor!");
motor.stop();
// Called when motor 1 stall is detected
void onMotor1Stall() {
Serial.println("Motor1 stall callback triggered - stopping motor!");
motor1.stop();
}
// Called when motor 2 stall is detected
void onMotor2Stall() {
Serial.println("Motor2 stall callback triggered - stopping motor!");
motor2.stop();
}
void setupWiFi() {
@@ -44,13 +50,16 @@ void setup() {
delay(1000);
Serial.println("\n=============================");
Serial.println(" BTS7960 Motor Controller");
Serial.println(" Simple Stall Detection");
Serial.println(" Dual BTS7960 Motor Controller");
Serial.println(" Differential Drive Robot");
Serial.println("=============================\n");
// Initialize motor controller
motor.begin();
motor.setStallCallback(onMotorStall);
// Initialize motor controllers
motor1.begin();
motor1.setStallCallback(onMotor1Stall);
motor2.begin();
motor2.setStallCallback(onMotor2Stall);
// Connect to WiFi
setupWiFi();
@@ -65,6 +74,7 @@ void setup() {
void loop() {
handleWebServer();
motor.update(); // Update current sensing and logging
motor1.update(); // Update current sensing and logging for motor 1
motor2.update(); // Update current sensing and logging for motor 2
delay(1);
}

104
src/motor.cpp
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@@ -6,41 +6,57 @@
// Number of samples for offset calibration
#define OFFSET_CALIBRATION_SAMPLES 16
MotorController motor;
// Static member initialization
bool MotorController::_enablePinsConfigured = false;
// Create two motor controller instances
MotorController motor1(MOTOR1_PINS, "Motor1");
MotorController motor2(MOTOR2_PINS, "Motor2");
// Constructor
MotorController::MotorController(const MotorPins& pins, const char* name)
: _pins(pins), _name(name) {
}
void MotorController::begin() {
// Configure enable pins as outputs
pinMode(R_EN_PIN, OUTPUT);
pinMode(L_EN_PIN, OUTPUT);
// Configure shared enable pins only once (first motor to initialize does this)
if (!_enablePinsConfigured) {
pinMode(R_EN_PIN, OUTPUT);
pinMode(L_EN_PIN, OUTPUT);
// Enable the H-bridge (shared by both drivers)
digitalWrite(R_EN_PIN, HIGH);
digitalWrite(L_EN_PIN, HIGH);
_enablePinsConfigured = true;
Serial.println("Shared enable pins configured (HIGH)");
}
// Enable the H-bridge
digitalWrite(R_EN_PIN, HIGH);
digitalWrite(L_EN_PIN, HIGH);
// Configure LEDC PWM channels for ESP32
ledcSetup(PWM_CHANNEL_R, PWM_FREQ, PWM_RESOLUTION);
ledcSetup(PWM_CHANNEL_L, PWM_FREQ, PWM_RESOLUTION);
// Configure LEDC PWM channels for this motor
ledcSetup(_pins.pwm_channel_r, PWM_FREQ, PWM_RESOLUTION);
ledcSetup(_pins.pwm_channel_l, PWM_FREQ, PWM_RESOLUTION);
// Attach PWM channels to GPIO pins
ledcAttachPin(RPWM_PIN, PWM_CHANNEL_R);
ledcAttachPin(LPWM_PIN, PWM_CHANNEL_L);
ledcAttachPin(_pins.rpwm, _pins.pwm_channel_r);
ledcAttachPin(_pins.lpwm, _pins.pwm_channel_l);
#if CURRENT_SENSING_ENABLED
// Configure current sense pins as analog inputs
// GPIO34 and GPIO35 are input-only pins, perfect for ADC
// GPIO34, 35, 36, 39 are input-only pins, perfect for ADC
analogSetAttenuation(ADC_11db); // Full range 0-3.3V
pinMode(R_IS_PIN, INPUT);
pinMode(L_IS_PIN, INPUT);
pinMode(_pins.r_is, INPUT);
pinMode(_pins.l_is, INPUT);
// Calibrate zero-current offset (ESP32 ADC has inherent offset)
calibrateCurrentOffset();
Serial.println("Current sensing enabled");
Serial.printf("%s: Current sensing enabled\n", _name);
#endif
// Start stopped
stop();
Serial.println("Motor controller initialized");
Serial.printf("%s: Controller initialized (RPWM=%d, LPWM=%d)\n",
_name, _pins.rpwm, _pins.lpwm);
}
void MotorController::setSpeed(int speed) {
@@ -61,10 +77,10 @@ void MotorController::setDirection(int dir) {
void MotorController::stop() {
// Don't reset _speed - keep last speed setting
_direction = 0;
ledcWrite(PWM_CHANNEL_R, 0);
ledcWrite(PWM_CHANNEL_L, 0);
ledcWrite(_pins.pwm_channel_r, 0);
ledcWrite(_pins.pwm_channel_l, 0);
resetStallDetection();
Serial.println("Motor: STOPPED (manual)");
Serial.printf("%s: STOPPED (manual)\n", _name);
}
void MotorController::update() {
@@ -76,8 +92,8 @@ void MotorController::update() {
const int dotInterval = 5; // Print dot every N idle readings
// Read current sensors
_currentRight = readCurrentSense(R_IS_PIN);
_currentLeft = readCurrentSense(L_IS_PIN);
_currentRight = readCurrentSense(_pins.r_is);
_currentLeft = readCurrentSense(_pins.l_is);
// Log current readings frequently for data collection
unsigned long now = millis();
@@ -90,8 +106,8 @@ void MotorController::update() {
if (isIdle) {
if (!lastWasIdle) {
// First idle after non-idle: print full line once
Serial.printf("CURRENT: R=%.2fA L=%.2fA dir=%d spd=%d\n",
_currentRight, _currentLeft, _direction, _speed);
Serial.printf("%s CURRENT: R=%.2fA L=%.2fA dir=%d spd=%d\n",
_name, _currentRight, _currentLeft, _direction, _speed);
idleDotCount = 0;
} else {
// Subsequent idle: print dot every N readings
@@ -109,8 +125,8 @@ void MotorController::update() {
if (lastWasIdle && idleDotCount > 0) {
Serial.println(); // Newline after dots before full reading
}
Serial.printf("CURRENT: R=%.2fA L=%.2fA dir=%d spd=%d\n",
_currentRight, _currentLeft, _direction, _speed);
Serial.printf("%s CURRENT: R=%.2fA L=%.2fA dir=%d spd=%d\n",
_name, _currentRight, _currentLeft, _direction, _speed);
lastWasIdle = false;
idleDotCount = 0;
}
@@ -146,6 +162,10 @@ float MotorController::getCurrentActive() {
return 0.0f;
}
const char* MotorController::getName() {
return _name;
}
// Stall detection
bool MotorController::isStalled() {
return _stalled;
@@ -181,8 +201,8 @@ void MotorController::checkStall() {
if (_stallConfirmCount >= STALL_CONFIRM_SAMPLES && !_stalled) {
_stalled = true;
Serial.printf("STALL DETECTED! Current=%.2fA (threshold=%.1fA)\n",
activeCurrent, STALL_THRESHOLD);
Serial.printf("%s STALL DETECTED! Current=%.2fA (threshold=%.1fA)\n",
_name, activeCurrent, STALL_THRESHOLD);
// Call stall callback if registered
if (_stallCallback != nullptr) {
@@ -196,7 +216,7 @@ void MotorController::checkStall() {
// Clear stall flag if current returns to normal
if (_stalled) {
_stalled = false;
Serial.println("Stall condition cleared");
Serial.printf("%s: Stall condition cleared\n", _name);
}
}
}
@@ -213,19 +233,19 @@ void MotorController::applyMotorState() {
if (_direction == 0 || _speed == 0) {
// Stop - both PWM outputs off
ledcWrite(PWM_CHANNEL_R, 0);
ledcWrite(PWM_CHANNEL_L, 0);
ledcWrite(_pins.pwm_channel_r, 0);
ledcWrite(_pins.pwm_channel_l, 0);
} else if (_direction > 0) {
// Forward - RPWM active, LPWM off
ledcWrite(PWM_CHANNEL_R, pwmValue);
ledcWrite(PWM_CHANNEL_L, 0);
ledcWrite(_pins.pwm_channel_r, pwmValue);
ledcWrite(_pins.pwm_channel_l, 0);
} else {
// Reverse - LPWM active, RPWM off
ledcWrite(PWM_CHANNEL_R, 0);
ledcWrite(PWM_CHANNEL_L, pwmValue);
ledcWrite(_pins.pwm_channel_r, 0);
ledcWrite(_pins.pwm_channel_l, pwmValue);
}
Serial.printf("Motor: dir=%d, speed=%d%%, pwm=%d\n", _direction, _speed, pwmValue);
Serial.printf("%s: dir=%d, speed=%d%%, pwm=%d\n", _name, _direction, _speed, pwmValue);
}
float MotorController::readCurrentSense(int pin) {
@@ -234,7 +254,7 @@ float MotorController::readCurrentSense(int pin) {
int adcValue = analogRead(pin);
// Subtract zero-current offset (calibrated at startup)
int offset = (pin == R_IS_PIN) ? _adcOffsetRight : _adcOffsetLeft;
int offset = (pin == _pins.r_is) ? _adcOffsetRight : _adcOffsetLeft;
adcValue = adcValue - offset;
if (adcValue < 0) adcValue = 0; // Clamp to zero
@@ -263,15 +283,15 @@ void MotorController::calibrateCurrentOffset() {
long sumLeft = 0;
for (int i = 0; i < OFFSET_CALIBRATION_SAMPLES; i++) {
sumRight += analogRead(R_IS_PIN);
sumLeft += analogRead(L_IS_PIN);
sumRight += analogRead(_pins.r_is);
sumLeft += analogRead(_pins.l_is);
delay(5); // Small delay between samples
}
_adcOffsetRight = sumRight / OFFSET_CALIBRATION_SAMPLES;
_adcOffsetLeft = sumLeft / OFFSET_CALIBRATION_SAMPLES;
Serial.printf("Current sense offset calibrated: R=%d L=%d (ADC counts)\n",
_adcOffsetRight, _adcOffsetLeft);
Serial.printf("%s: Current sense offset calibrated: R=%d L=%d (ADC counts)\n",
_name, _adcOffsetRight, _adcOffsetLeft);
#endif
}

376
src/webserver.cpp
View File

@@ -5,13 +5,13 @@
WebServer server(HTTP_PORT);
// HTML page for motor control
// HTML page for dual motor control
const char index_html[] PROGMEM = R"rawliteral(
<!DOCTYPE html>
<html>
<head>
<meta name="viewport" content="width=device-width, initial-scale=1">
<title>Motor Control</title>
<title>Dual Motor Control</title>
<style>
* { box-sizing: border-box; }
body {
@@ -23,34 +23,40 @@ const char index_html[] PROGMEM = R"rawliteral(
min-height: 100vh;
}
.container {
max-width: 400px;
max-width: 800px;
margin: 0 auto;
text-align: center;
}
h1 { color: #00d9ff; margin-bottom: 30px; }
h2 { color: #00d9ff; margin: 20px 0 15px 0; font-size: 20px; }
.status {
h2 { color: #00d9ff; margin: 10px 0; font-size: 20px; }
.motors-container {
display: grid;
grid-template-columns: 1fr 1fr;
gap: 20px;
}
@media (max-width: 600px) {
.motors-container {
grid-template-columns: 1fr;
}
}
.motor-panel {
background: #16213e;
padding: 15px;
border-radius: 10px;
margin-bottom: 20px;
padding: 20px;
border-radius: 15px;
}
.status span {
font-size: 24px;
font-size: 20px;
font-weight: bold;
color: #00d9ff;
}
.current-display {
background: #16213e;
padding: 15px;
border-radius: 10px;
margin-bottom: 20px;
display: grid;
grid-template-columns: 1fr 1fr;
gap: 10px;
margin: 15px 0;
}
.current-value {
font-size: 28px;
font-size: 24px;
font-weight: bold;
color: #00d9ff;
}
@@ -59,41 +65,38 @@ const char index_html[] PROGMEM = R"rawliteral(
color: #888;
}
.slider-container {
background: #16213e;
padding: 20px;
border-radius: 10px;
margin-bottom: 20px;
margin: 15px 0;
}
.slider {
width: 100%;
height: 25px;
height: 20px;
-webkit-appearance: none;
background: #0f3460;
border-radius: 12px;
border-radius: 10px;
outline: none;
}
.slider::-webkit-slider-thumb {
-webkit-appearance: none;
width: 35px;
height: 35px;
width: 30px;
height: 30px;
background: #00d9ff;
border-radius: 50%;
cursor: pointer;
}
.buttons {
display: flex;
gap: 10px;
gap: 8px;
justify-content: center;
flex-wrap: wrap;
}
.btn {
padding: 20px 30px;
font-size: 18px;
padding: 15px 20px;
font-size: 14px;
border: none;
border-radius: 10px;
border-radius: 8px;
cursor: pointer;
transition: transform 0.1s, background 0.2s;
min-width: 100px;
min-width: 80px;
}
.btn:active { transform: scale(0.95); }
.btn-forward { background: #00c853; color: white; }
@@ -101,124 +104,187 @@ const char index_html[] PROGMEM = R"rawliteral(
.btn-stop { background: #ff9100; color: white; flex-basis: 100%; }
.btn:hover { filter: brightness(1.1); }
.speed-value {
font-size: 48px;
font-size: 36px;
color: #00d9ff;
margin: 10px 0;
}
.section-divider {
border-top: 2px solid #0f3460;
margin: 30px 0;
margin: 5px 0;
}
.stall-warning {
background: #ff5252;
color: white;
padding: 15px;
border-radius: 10px;
margin-bottom: 20px;
padding: 10px;
border-radius: 8px;
margin-bottom: 15px;
font-weight: bold;
font-size: 18px;
display: none;
}
.stall-warning.active {
display: block;
}
.global-controls {
margin-top: 20px;
padding: 20px;
background: #0f3460;
border-radius: 15px;
}
.global-controls h2 {
margin-top: 0;
}
.btn-emergency {
background: #d50000;
color: white;
font-size: 18px;
padding: 20px 40px;
}
</style>
</head>
<body>
<div class="container">
<h1>Motor Control</h1>
<h1>Dual Motor Control</h1>
<div class="stall-warning" id="stallWarning">⚠️ STALL DETECTED!</div>
<div class="current-display">
<div>
<div class="current-label">CURRENT R</div>
<div class="current-value"><span id="currentR">0.00</span>A</div>
<div class="motors-container">
<!-- Motor 1 Panel -->
<div class="motor-panel">
<h2>Motor 1 (Left)</h2>
<div class="stall-warning" id="stallWarning1">⚠️ STALL!</div>
<div class="current-display">
<div>
<div class="current-label">FWD</div>
<div class="current-value"><span id="m1_currentR">0.00</span>A</div>
</div>
<div>
<div class="current-label">REV</div>
<div class="current-value"><span id="m1_currentL">0.00</span>A</div>
</div>
</div>
<div class="status">
<span id="m1_dirStatus">STOPPED</span>
</div>
<div class="slider-container">
<div class="speed-value"><span id="m1_speedValue">20</span>%</div>
<input type="range" class="slider" id="m1_slider" min="20" max="100" value="20">
</div>
<div class="buttons">
<button class="btn btn-forward" onclick="setDir(1, 1)">FWD</button>
<button class="btn btn-reverse" onclick="setDir(1, -1)">REV</button>
<button class="btn btn-stop" onclick="stopMotor(1)">STOP</button>
</div>
</div>
<div>
<div class="current-label">CURRENT L</div>
<div class="current-value"><span id="currentL">0.00</span>A</div>
<!-- Motor 2 Panel -->
<div class="motor-panel">
<h2>Motor 2 (Right)</h2>
<div class="stall-warning" id="stallWarning2">⚠️ STALL!</div>
<div class="current-display">
<div>
<div class="current-label">FWD</div>
<div class="current-value"><span id="m2_currentR">0.00</span>A</div>
</div>
<div>
<div class="current-label">REV</div>
<div class="current-value"><span id="m2_currentL">0.00</span>A</div>
</div>
</div>
<div class="status">
<span id="m2_dirStatus">STOPPED</span>
</div>
<div class="slider-container">
<div class="speed-value"><span id="m2_speedValue">20</span>%</div>
<input type="range" class="slider" id="m2_slider" min="20" max="100" value="20">
</div>
<div class="buttons">
<button class="btn btn-forward" onclick="setDir(2, 1)">FWD</button>
<button class="btn btn-reverse" onclick="setDir(2, -1)">REV</button>
<button class="btn btn-stop" onclick="stopMotor(2)">STOP</button>
</div>
</div>
</div>
<div class="status">
Direction: <span id="dirStatus">STOPPED</span>
</div>
<div class="slider-container">
<label>Speed</label>
<div class="speed-value"><span id="speedValue">20</span>%</div>
<input type="range" class="slider" id="speedSlider" min="20" max="100" value="20">
</div>
<div class="buttons">
<button class="btn btn-forward" onclick="setDir(1)">FORWARD</button>
<button class="btn btn-reverse" onclick="setDir(-1)">REVERSE</button>
<button class="btn btn-stop" onclick="stopMotor()">STOP</button>
<div class="global-controls">
<h2>Global Controls</h2>
<button class="btn btn-emergency" onclick="emergencyStop()">⛔ EMERGENCY STOP</button>
</div>
</div>
<script>
const slider = document.getElementById('speedSlider');
const speedVal = document.getElementById('speedValue');
const dirStatus = document.getElementById('dirStatus');
let currentDir = 0;
slider.oninput = function() {
speedVal.textContent = this.value;
// Motor state
const motors = {
1: { slider: document.getElementById('m1_slider'), speedVal: document.getElementById('m1_speedValue'),
dirStatus: document.getElementById('m1_dirStatus'), dir: 0 },
2: { slider: document.getElementById('m2_slider'), speedVal: document.getElementById('m2_speedValue'),
dirStatus: document.getElementById('m2_dirStatus'), dir: 0 }
};
slider.onchange = function() {
fetch('/speed?value=' + this.value)
.then(r => r.text())
.then(console.log);
};
function setDir(dir) {
currentDir = dir;
fetch('/direction?value=' + dir)
.then(r => r.text())
.then(() => updateStatus());
// Slider events
for (let m of [1, 2]) {
motors[m].slider.oninput = function() {
motors[m].speedVal.textContent = this.value;
};
motors[m].slider.onchange = function() {
fetch('/motor' + m + '/speed?value=' + this.value);
};
}
function stopMotor() {
currentDir = 0;
// Don't reset slider - keep last speed
fetch('/stop')
.then(r => r.text())
.then(() => updateStatus());
function setDir(motor, dir) {
motors[motor].dir = dir;
fetch('/motor' + motor + '/direction?value=' + dir)
.then(() => updateStatus(motor));
}
function updateStatus() {
if (currentDir > 0) dirStatus.textContent = 'FORWARD';
else if (currentDir < 0) dirStatus.textContent = 'REVERSE';
else dirStatus.textContent = 'STOPPED';
function stopMotor(motor) {
motors[motor].dir = 0;
fetch('/motor' + motor + '/stop')
.then(() => updateStatus(motor));
}
function emergencyStop() {
fetch('/stop').then(() => {
motors[1].dir = 0;
motors[2].dir = 0;
updateStatus(1);
updateStatus(2);
});
}
function updateStatus(motor) {
const m = motors[motor];
if (m.dir > 0) m.dirStatus.textContent = 'FORWARD';
else if (m.dir < 0) m.dirStatus.textContent = 'REVERSE';
else m.dirStatus.textContent = 'STOPPED';
}
function pollStatus() {
fetch('/status')
.then(r => r.json())
.then(data => {
// Only update speed display if motor is running (direction != 0)
// When stopped, keep the last speed setting
if (data.direction != 0) {
slider.value = data.speed;
speedVal.textContent = data.speed;
// Update Motor 1
if (data.motor1.direction != 0) {
motors[1].slider.value = data.motor1.speed;
motors[1].speedVal.textContent = data.motor1.speed;
}
currentDir = data.direction;
updateStatus();
motors[1].dir = data.motor1.direction;
updateStatus(1);
document.getElementById('m1_currentR').textContent = data.motor1.currentR.toFixed(2);
document.getElementById('m1_currentL').textContent = data.motor1.currentL.toFixed(2);
document.getElementById('stallWarning1').classList.toggle('active', data.motor1.stalled);
// Update current display
document.getElementById('currentR').textContent = data.currentR.toFixed(2);
document.getElementById('currentL').textContent = data.currentL.toFixed(2);
// Update stall warning
const stallWarning = document.getElementById('stallWarning');
if (data.stalled) {
stallWarning.classList.add('active');
} else {
stallWarning.classList.remove('active');
// Update Motor 2
if (data.motor2.direction != 0) {
motors[2].slider.value = data.motor2.speed;
motors[2].speedVal.textContent = data.motor2.speed;
}
motors[2].dir = data.motor2.direction;
updateStatus(2);
document.getElementById('m2_currentR').textContent = data.motor2.currentR.toFixed(2);
document.getElementById('m2_currentL').textContent = data.motor2.currentL.toFixed(2);
document.getElementById('stallWarning2').classList.toggle('active', data.motor2.stalled);
});
}
@@ -234,45 +300,119 @@ void handleRoot() {
server.send(200, "text/html", index_html);
}
void handleSpeed() {
// Motor 1 handlers
void handleMotor1Speed() {
if (server.hasArg("value")) {
int speed = server.arg("value").toInt();
motor.setSpeed(speed);
motor1.setSpeed(speed);
server.send(200, "text/plain", "OK");
} else {
server.send(400, "text/plain", "Missing value");
}
}
void handleDirection() {
void handleMotor1Direction() {
if (server.hasArg("value")) {
int dir = server.arg("value").toInt();
motor.setDirection(dir);
motor1.setDirection(dir);
server.send(200, "text/plain", "OK");
} else {
server.send(400, "text/plain", "Missing value");
}
}
void handleStop() {
motor.stop();
void handleMotor1Stop() {
motor1.stop();
server.send(200, "text/plain", "OK");
}
// Motor 2 handlers
void handleMotor2Speed() {
if (server.hasArg("value")) {
int speed = server.arg("value").toInt();
motor2.setSpeed(speed);
server.send(200, "text/plain", "OK");
} else {
server.send(400, "text/plain", "Missing value");
}
}
void handleMotor2Direction() {
if (server.hasArg("value")) {
int dir = server.arg("value").toInt();
motor2.setDirection(dir);
server.send(200, "text/plain", "OK");
} else {
server.send(400, "text/plain", "Missing value");
}
}
void handleMotor2Stop() {
motor2.stop();
server.send(200, "text/plain", "OK");
}
// Global stop (emergency stop both motors)
void handleStop() {
motor1.stop();
motor2.stop();
server.send(200, "text/plain", "OK");
}
// Legacy handlers (map to motor1 for backwards compatibility)
void handleSpeed() {
handleMotor1Speed();
}
void handleDirection() {
handleMotor1Direction();
}
// Status handler - returns both motors' data
void handleStatus() {
String json = "{\"speed\":" + String(motor.getSpeed()) +
",\"direction\":" + String(motor.getDirection()) +
",\"currentR\":" + String(motor.getCurrentRight(), 2) +
",\"currentL\":" + String(motor.getCurrentLeft(), 2) +
",\"stalled\":" + (motor.isStalled() ? "true" : "false") + "}";
String json = "{";
// Motor 1 status
json += "\"motor1\":{";
json += "\"speed\":" + String(motor1.getSpeed()) + ",";
json += "\"direction\":" + String(motor1.getDirection()) + ",";
json += "\"currentR\":" + String(motor1.getCurrentRight(), 2) + ",";
json += "\"currentL\":" + String(motor1.getCurrentLeft(), 2) + ",";
json += "\"stalled\":" + String(motor1.isStalled() ? "true" : "false");
json += "},";
// Motor 2 status
json += "\"motor2\":{";
json += "\"speed\":" + String(motor2.getSpeed()) + ",";
json += "\"direction\":" + String(motor2.getDirection()) + ",";
json += "\"currentR\":" + String(motor2.getCurrentRight(), 2) + ",";
json += "\"currentL\":" + String(motor2.getCurrentLeft(), 2) + ",";
json += "\"stalled\":" + String(motor2.isStalled() ? "true" : "false");
json += "}";
json += "}";
server.send(200, "application/json", json);
}
void setupWebServer() {
server.on("/", handleRoot);
// Motor 1 endpoints
server.on("/motor1/speed", handleMotor1Speed);
server.on("/motor1/direction", handleMotor1Direction);
server.on("/motor1/stop", handleMotor1Stop);
// Motor 2 endpoints
server.on("/motor2/speed", handleMotor2Speed);
server.on("/motor2/direction", handleMotor2Direction);
server.on("/motor2/stop", handleMotor2Stop);
// Legacy endpoints (backwards compatibility - map to motor1)
server.on("/speed", handleSpeed);
server.on("/direction", handleDirection);
server.on("/stop", handleStop);
// Global endpoints
server.on("/stop", handleStop); // Emergency stop both motors
server.on("/status", handleStatus);
server.begin();