diff --git a/include/config.h b/include/config.h
index 845c534..f166813 100644
--- a/include/config.h
+++ b/include/config.h
@@ -37,22 +37,8 @@
#define ADC_VREF 3.3f // ADC reference voltage
#define CURRENT_CALIBRATION 1.0f // Calibration factor (measured current / reported current)
-// Stall Detection Configuration (delta-based)
-// Detects sudden current spikes above the rolling average
-#define STALL_DELTA_THRESHOLD 1.2f // Current spike above average that indicates stall (amps)
-#define STALL_EMA_ALPHA 0.1f // EMA smoothing factor (0.1 = slow, 0.5 = fast response)
-#define STALL_EMA_BASELINE 2.0f // Expected running current baseline for EMA seeding (amps)
-#define STALL_STABILIZE_MS 300 // Ignore stalls for this long after motor starts/changes
-#define STALL_CONFIRM_MS 50 // Current must exceed threshold for this long to confirm stall
-#define DISABLE_STALL_DETECT false // Set to true to disable stall detection
-
-// Under-current stall detection: motor commanded but drawing no current
-#define STALL_UNDERCURRENT_THRESHOLD 0.5f // If current below this for too long = stall (amps)
-#define STALL_UNDERCURRENT_MS 1000 // Under-current must persist this long to confirm stall
-
-// Repeated spike stall detection: catches oscillating stall (driver protection cycling)
-#define STALL_CANDIDATE_COUNT 5 // Number of stall candidates in window to confirm stall
-#define STALL_CANDIDATE_WINDOW_MS 2000 // Time window for counting stall candidates
+// Current logging interval for data collection
+#define CURRENT_LOG_INTERVAL_MS 100 // Log current readings every 100ms
// Web Server
#define HTTP_PORT 80
diff --git a/include/motor.h b/include/motor.h
index 4b4ae58..891e9f3 100644
--- a/include/motor.h
+++ b/include/motor.h
@@ -10,53 +10,33 @@ public:
void setSpeed(int speed); // 0-100 percentage
void setDirection(int dir); // -1=reverse, 0=stop, 1=forward
void stop();
- void update(); // Call in loop() for stall detection
+ void update(); // Call in loop() for current monitoring
int getSpeed();
int getDirection();
float getCurrentRight(); // Current in amps (forward direction)
float getCurrentLeft(); // Current in amps (reverse direction)
float getCurrentActive(); // Current from active direction
- bool isStalled(); // True if stall detected
- // Callback for stall events
- void setStallCallback(void (*callback)(float current));
-
- // Pingpong mode
- void startPingpong(int speed, int timeMs, int speedRandomPercent, int timeRandomPercent, bool useStallReturn);
+ // Pingpong mode (time-based only)
+ void startPingpong(int speed, int timeMs, int speedRandomPercent, int timeRandomPercent);
void stopPingpong();
bool isPingpongActive();
int getPingpongSpeed();
int getPingpongTime();
int getPingpongSpeedRandom();
int getPingpongTimeRandom();
- bool getPingpongStallReturn();
private:
int _speed = 0;
int _direction = 0;
float _currentRight = 0;
float _currentLeft = 0;
- bool _stalled = false;
- unsigned long _stallStartTime = 0;
- void (*_stallCallback)(float current) = nullptr;
// ADC zero-current offset (calibrated at startup)
int _adcOffsetRight = 0;
int _adcOffsetLeft = 0;
- // Delta-based stall detection (rolling average tracking)
- float _currentEMA = 0; // Exponential moving average of current
- unsigned long _motorStartTime = 0; // When motor started (for stabilization period)
- bool _emaInitialized = false; // EMA needs seeding on first reading
-
- // Under-current stall detection
- unsigned long _undercurrentStartTime = 0; // When under-current condition started
-
- // Repeated spike detection (oscillating stall pattern)
- int _stallCandidateCount = 0; // Number of stall candidates in current window
- unsigned long _stallCandidateWindowStart = 0; // When current counting window started
-
// Pingpong state
bool _pingpongActive = false;
int _pingpongBaseSpeed = 50;
@@ -67,13 +47,10 @@ private:
int _pingpongCurrentTime = 2000;
unsigned long _pingpongLastSwitch = 0;
int _pingpongDirection = 1;
- bool _pingpongUseStallReturn = false; // Return only after stall detection
void applyMotorState();
float readCurrentSense(int pin);
void calibrateCurrentOffset();
- void checkStall();
- void resetStallDetection();
void updatePingpong();
int applyRandomness(int baseValue, int randomPercent);
};
diff --git a/src/main.cpp b/src/main.cpp
index 8b1f95b..b6d6d40 100644
--- a/src/main.cpp
+++ b/src/main.cpp
@@ -33,32 +33,18 @@ void setupWiFi() {
}
}
-// Stall protection callback - stops motor immediately when stall detected
-// (unless pingpong with stallReturn is active - it handles stall by switching direction)
-void onMotorStall(float current) {
- if (motor.isPingpongActive() && motor.getPingpongStallReturn()) {
- // Pingpong will handle stall by switching direction
- Serial.printf("STALL DETECTED: Pingpong will switch direction (current: %.2fA)\n", current);
- return;
- }
- Serial.printf("STALL PROTECTION: Stopping motor (current: %.2fA)\n", current);
- motor.stop();
-}
-
void setup() {
Serial.begin(115200);
delay(1000);
Serial.println("\n=============================");
Serial.println(" BTS7960 Motor Controller");
+ Serial.println(" (Stall Detection Removed)");
Serial.println("=============================\n");
// Initialize motor controller
motor.begin();
- // Register stall protection callback
- motor.setStallCallback(onMotorStall);
-
// Connect to WiFi
setupWiFi();
@@ -72,6 +58,6 @@ void setup() {
void loop() {
handleWebServer();
- motor.update(); // Update current sensing and stall detection
+ motor.update(); // Update current sensing and logging
delay(1);
}
diff --git a/src/motor.cpp b/src/motor.cpp
index 921f4f0..d6fc3a9 100644
--- a/src/motor.cpp
+++ b/src/motor.cpp
@@ -45,34 +45,21 @@ void MotorController::begin() {
void MotorController::setSpeed(int speed) {
_speed = constrain(speed, 0, 100);
- resetStallDetection();
applyMotorState();
}
void MotorController::setDirection(int dir) {
_direction = constrain(dir, -1, 1);
- resetStallDetection();
applyMotorState();
}
void MotorController::stop() {
// Don't reset _speed - keep last speed setting
_direction = 0;
- resetStallDetection();
ledcWrite(PWM_CHANNEL_R, 0);
ledcWrite(PWM_CHANNEL_L, 0);
}
-void MotorController::resetStallDetection() {
- _stalled = false;
- _stallStartTime = 0;
- _undercurrentStartTime = 0;
- _stallCandidateCount = 0;
- _stallCandidateWindowStart = 0;
- _emaInitialized = false; // Re-seed EMA on motor state change
- _motorStartTime = millis();
-}
-
void MotorController::update() {
#if CURRENT_SENSING_ENABLED
static unsigned long lastPrintTime = 0;
@@ -81,17 +68,13 @@ void MotorController::update() {
_currentRight = readCurrentSense(R_IS_PIN);
_currentLeft = readCurrentSense(L_IS_PIN);
- // Log current readings every 500ms when motor is running
- if ((_direction != 0 || _speed != 0) && (millis() - lastPrintTime > 500)) {
- lastPrintTime = millis();
- float activeCurrent = getCurrentActive();
- float delta = activeCurrent - _currentEMA;
- Serial.printf("Current: R=%.2fA L=%.2fA Active=%.2fA (avg=%.2fA, delta=%.2fA, thresh=%.1fA)\n",
- _currentRight, _currentLeft, activeCurrent, _currentEMA, delta, STALL_DELTA_THRESHOLD);
+ // Log current readings frequently for data collection
+ unsigned long now = millis();
+ if (now - lastPrintTime >= CURRENT_LOG_INTERVAL_MS) {
+ lastPrintTime = now;
+ Serial.printf("CURRENT: R=%.2fA L=%.2fA dir=%d spd=%d\n",
+ _currentRight, _currentLeft, _direction, _speed);
}
-
- // Check for stall condition
- checkStall();
#endif
// Update pingpong mode
@@ -123,14 +106,6 @@ float MotorController::getCurrentActive() {
return 0.0f;
}
-bool MotorController::isStalled() {
- return _stalled;
-}
-
-void MotorController::setStallCallback(void (*callback)(float current)) {
- _stallCallback = callback;
-}
-
void MotorController::applyMotorState() {
// Apply minimum PWM when motor is running
int effectiveSpeed = _speed;
@@ -206,32 +181,27 @@ void MotorController::calibrateCurrentOffset() {
#endif
}
-// Pingpong mode implementation
-void MotorController::startPingpong(int speed, int timeMs, int speedRandomPercent, int timeRandomPercent, bool useStallReturn) {
+// Pingpong mode implementation (time-based only)
+void MotorController::startPingpong(int speed, int timeMs, int speedRandomPercent, int timeRandomPercent) {
_pingpongBaseSpeed = constrain(speed, 0, 100);
_pingpongBaseTime = constrain(timeMs, 100, 30000);
_pingpongSpeedRandomPercent = constrain(speedRandomPercent, 0, 100);
_pingpongTimeRandomPercent = constrain(timeRandomPercent, 0, 100);
- _pingpongUseStallReturn = useStallReturn;
_pingpongDirection = 1;
_pingpongCurrentSpeed = applyRandomness(_pingpongBaseSpeed, _pingpongSpeedRandomPercent);
- // Time randomness disabled when using stall return
- _pingpongCurrentTime = _pingpongUseStallReturn ? _pingpongBaseTime : applyRandomness(_pingpongBaseTime, _pingpongTimeRandomPercent);
+ _pingpongCurrentTime = applyRandomness(_pingpongBaseTime, _pingpongTimeRandomPercent);
_pingpongLastSwitch = millis();
_pingpongActive = true;
- _stalled = false; // Reset stall state when starting pingpong
- _stallStartTime = 0;
// Apply initial state
_speed = _pingpongCurrentSpeed;
_direction = _pingpongDirection;
applyMotorState();
- Serial.printf("Pingpong started: speed=%d%% (base=%d, rand=%d%%), time=%dms (base=%d, rand=%d%%), stallReturn=%s\n",
+ Serial.printf("Pingpong started: speed=%d%% (base=%d, rand=%d%%), time=%dms (base=%d, rand=%d%%)\n",
_pingpongCurrentSpeed, _pingpongBaseSpeed, _pingpongSpeedRandomPercent,
- _pingpongCurrentTime, _pingpongBaseTime, _pingpongTimeRandomPercent,
- _pingpongUseStallReturn ? "true" : "false");
+ _pingpongCurrentTime, _pingpongBaseTime, _pingpongTimeRandomPercent);
}
void MotorController::stopPingpong() {
@@ -260,41 +230,19 @@ int MotorController::getPingpongTimeRandom() {
return _pingpongTimeRandomPercent;
}
-bool MotorController::getPingpongStallReturn() {
- return _pingpongUseStallReturn;
-}
-
void MotorController::updatePingpong() {
if (!_pingpongActive) return;
- bool shouldSwitch = false;
unsigned long now = millis();
- if (_pingpongUseStallReturn) {
- // Switch direction only when stall is detected
- if (_stalled) {
- shouldSwitch = true;
- Serial.println("Pingpong: stall detected, switching direction");
- }
- } else {
- // Time-based switching
- if ((now - _pingpongLastSwitch) >= (unsigned long)_pingpongCurrentTime) {
- shouldSwitch = true;
- }
- }
-
- if (shouldSwitch) {
+ // Time-based switching
+ if ((now - _pingpongLastSwitch) >= (unsigned long)_pingpongCurrentTime) {
// Switch direction
_pingpongDirection = -_pingpongDirection;
- // Full stall detection reset for new direction
- // This triggers STALL_STABILIZE_MS grace period to ignore motor inrush current
- resetStallDetection();
-
// Apply randomness for next cycle
_pingpongCurrentSpeed = applyRandomness(_pingpongBaseSpeed, _pingpongSpeedRandomPercent);
- // Time randomness disabled when using stall return
- _pingpongCurrentTime = _pingpongUseStallReturn ? _pingpongBaseTime : applyRandomness(_pingpongBaseTime, _pingpongTimeRandomPercent);
+ _pingpongCurrentTime = applyRandomness(_pingpongBaseTime, _pingpongTimeRandomPercent);
_pingpongLastSwitch = now;
// Apply new state
@@ -302,9 +250,8 @@ void MotorController::updatePingpong() {
_direction = _pingpongDirection;
applyMotorState();
- Serial.printf("Pingpong switch: dir=%d, speed=%d%%, next_time=%dms, stallReturn=%s\n",
- _pingpongDirection, _pingpongCurrentSpeed, _pingpongCurrentTime,
- _pingpongUseStallReturn ? "true" : "false");
+ Serial.printf("Pingpong switch: dir=%d, speed=%d%%, next_time=%dms\n",
+ _pingpongDirection, _pingpongCurrentSpeed, _pingpongCurrentTime);
}
}
@@ -318,120 +265,3 @@ int MotorController::applyRandomness(int baseValue, int randomPercent) {
// Ensure result stays positive and reasonable
return max(1, result);
}
-
-void MotorController::checkStall() {
-#if CURRENT_SENSING_ENABLED
- if (DISABLE_STALL_DETECT) return;
-
- // Only check stall when motor should be running
- if (_direction == 0 || _speed == 0) {
- _stalled = false;
- _stallStartTime = 0;
- _undercurrentStartTime = 0;
- _emaInitialized = false;
- return;
- }
-
- unsigned long now = millis();
- float activeCurrent = getCurrentActive();
-
- // Initialize EMA at expected baseline (prevents inrush from looking like stall)
- if (!_emaInitialized) {
- _currentEMA = STALL_EMA_BASELINE;
- _emaInitialized = true;
- }
-
- // During stabilization: DON'T update EMA - keep baseline to avoid drift toward 0
- // This lets stall detection work correctly even if starting from stalled position
- if ((now - _motorStartTime) < STALL_STABILIZE_MS) {
- return;
- }
-
- // Calculate delta from average
- float delta = activeCurrent - _currentEMA;
-
- // Check if current spike exceeds delta threshold
- bool spikeDetected = (delta > STALL_DELTA_THRESHOLD);
-
- // Update EMA only when no spike is being investigated
- // This prevents EMA from "chasing" up to the spike during detection window
- if (!spikeDetected && !_stalled) {
- _currentEMA = (STALL_EMA_ALPHA * activeCurrent) + ((1.0f - STALL_EMA_ALPHA) * _currentEMA);
- }
-
- if (spikeDetected) {
- if (_stallStartTime == 0) {
- // Start timing potential stall
- _stallStartTime = now;
-
- // Count this as a stall candidate for repeated-spike detection
- if (_stallCandidateWindowStart == 0) {
- _stallCandidateWindowStart = now;
- _stallCandidateCount = 1;
- } else if ((now - _stallCandidateWindowStart) > STALL_CANDIDATE_WINDOW_MS) {
- // Window expired, start new window
- _stallCandidateWindowStart = now;
- _stallCandidateCount = 1;
- } else {
- _stallCandidateCount++;
- }
-
- Serial.printf("Stall candidate #%d: current=%.2fA, avg=%.2fA, delta=%.2fA\n",
- _stallCandidateCount, activeCurrent, _currentEMA, delta);
-
- // Check if enough candidates to confirm stall (oscillating pattern)
- if (_stallCandidateCount >= STALL_CANDIDATE_COUNT && !_stalled) {
- _stalled = true;
- Serial.printf("STALL DETECTED (repeated spikes)! %d candidates in %lums\n",
- _stallCandidateCount, now - _stallCandidateWindowStart);
-
- if (_stallCallback != nullptr) {
- _stallCallback(activeCurrent);
- }
- }
- } else if ((now - _stallStartTime) > STALL_CONFIRM_MS) {
- // Sustained spike - stall confirmed
- if (!_stalled) {
- _stalled = true;
- Serial.printf("STALL DETECTED! Current: %.2fA (avg: %.2fA, delta: %.2fA)\n",
- activeCurrent, _currentEMA, delta);
-
- // Call callback if registered
- if (_stallCallback != nullptr) {
- _stallCallback(activeCurrent);
- }
- }
- }
- } else {
- // Current normal, reset spike stall timing (but keep EMA updating)
- if (_stallStartTime != 0) {
- Serial.printf("Stall candidate cleared: current=%.2fA, avg=%.2fA\n",
- activeCurrent, _currentEMA);
- }
- _stallStartTime = 0;
- // Don't clear _stalled here - under-current/repeated-spike detection may have set it
- }
-
- // Under-current stall detection: motor commanded but not drawing current
- // This catches stalls where the motor can't even start (e.g., already at end stop)
- if (!_stalled && activeCurrent < STALL_UNDERCURRENT_THRESHOLD) {
- if (_undercurrentStartTime == 0) {
- _undercurrentStartTime = now;
- } else if ((now - _undercurrentStartTime) > STALL_UNDERCURRENT_MS) {
- _stalled = true;
- Serial.printf("STALL DETECTED (under-current)! Current: %.2fA (threshold: %.2fA)\n",
- activeCurrent, STALL_UNDERCURRENT_THRESHOLD);
-
- if (_stallCallback != nullptr) {
- _stallCallback(activeCurrent);
- }
- }
- } else if (activeCurrent >= STALL_UNDERCURRENT_THRESHOLD) {
- // Current is normal, reset under-current timer and clear stall
- _undercurrentStartTime = 0;
- if (!spikeDetected) {
- _stalled = false;
- }
- }
-#endif
-}
diff --git a/src/webserver.cpp b/src/webserver.cpp
index 9370251..d195aab 100644
--- a/src/webserver.cpp
+++ b/src/webserver.cpp
@@ -58,15 +58,6 @@ const char index_html[] PROGMEM = R"rawliteral(
font-size: 12px;
color: #888;
}
- .stall-warning {
- background: #ff5252;
- color: white;
- padding: 10px;
- border-radius: 5px;
- margin-bottom: 20px;
- display: none;
- }
- .stall-warning.active { display: block; }
.slider-container {
background: #16213e;
padding: 20px;
@@ -178,18 +169,14 @@ const char index_html[] PROGMEM = R"rawliteral(
Motor Control
-
- ⚠️ STALL DETECTED - Motor Stopped
-
-
-
CURRENT (Active)
-
0.00A
+
CURRENT R
+
0.00A
-
THRESHOLD
-
4.0A
+
CURRENT L
+
0.00A
@@ -239,12 +226,6 @@ const char index_html[] PROGMEM = R"rawliteral(
0%
-
-
-
-
-
- When enabled, direction switches only after stall detection (time randomness disabled)
@@ -269,16 +250,6 @@ const char index_html[] PROGMEM = R"rawliteral(
const ppSpeedRandVal = document.getElementById('ppSpeedRandVal');
const ppTimeRandVal = document.getElementById('ppTimeRandVal');
const ppStatus = document.getElementById('pingpongStatus');
- const ppStallReturn = document.getElementById('ppStallReturn');
-
- // Disable time randomness when stall return is checked
- ppStallReturn.onchange = function() {
- ppTimeRand.disabled = this.checked;
- if (this.checked) {
- ppTimeRand.value = 0;
- ppTimeRandVal.textContent = '0';
- }
- };
slider.oninput = function() {
speedVal.textContent = this.value;
@@ -316,8 +287,7 @@ const char index_html[] PROGMEM = R"rawliteral(
speed: ppSpeed.value,
time: ppTime.value,
speedRand: ppSpeedRand.value,
- timeRand: ppStallReturn.checked ? 0 : ppTimeRand.value,
- stallReturn: ppStallReturn.checked ? 1 : 0
+ timeRand: ppTimeRand.value
});
fetch('/pingpong/start?' + params)
.then(r => r.text())
@@ -350,17 +320,8 @@ const char index_html[] PROGMEM = R"rawliteral(
updateStatus();
// Update current display
- const active = data.direction > 0 ? data.currentR :
- data.direction < 0 ? data.currentL : 0;
- document.getElementById('currentActive').textContent = active.toFixed(2);
-
- // Show/hide stall warning
- const stallWarning = document.getElementById('stallWarning');
- if (data.stalled) {
- stallWarning.classList.add('active');
- } else {
- stallWarning.classList.remove('active');
- }
+ document.getElementById('currentR').textContent = data.currentR.toFixed(2);
+ document.getElementById('currentL').textContent = data.currentL.toFixed(2);
// Update pingpong status
if (data.pingpong) {
@@ -376,8 +337,6 @@ const char index_html[] PROGMEM = R"rawliteral(
ppSpeedRandVal.textContent = data.ppSpeedRand;
ppTimeRand.value = data.ppTimeRand;
ppTimeRandVal.textContent = data.ppTimeRand;
- ppStallReturn.checked = data.ppStallReturn;
- ppTimeRand.disabled = data.ppStallReturn;
} else {
ppStatus.textContent = 'INACTIVE';
ppStatus.classList.remove('active');
@@ -428,13 +387,11 @@ void handleStatus() {
",\"direction\":" + String(motor.getDirection()) +
",\"currentR\":" + String(motor.getCurrentRight(), 2) +
",\"currentL\":" + String(motor.getCurrentLeft(), 2) +
- ",\"stalled\":" + (motor.isStalled() ? "true" : "false") +
",\"pingpong\":" + (motor.isPingpongActive() ? "true" : "false") +
",\"ppSpeed\":" + String(motor.getPingpongSpeed()) +
",\"ppTime\":" + String(motor.getPingpongTime()) +
",\"ppSpeedRand\":" + String(motor.getPingpongSpeedRandom()) +
- ",\"ppTimeRand\":" + String(motor.getPingpongTimeRandom()) +
- ",\"ppStallReturn\":" + (motor.getPingpongStallReturn() ? "true" : "false") + "}";
+ ",\"ppTimeRand\":" + String(motor.getPingpongTimeRandom()) + "}";
server.send(200, "application/json", json);
}
@@ -443,7 +400,6 @@ void handlePingpongStart() {
int time = 2000;
int speedRand = 0;
int timeRand = 0;
- bool stallReturn = false;
if (server.hasArg("speed")) {
speed = server.arg("speed").toInt();
@@ -457,11 +413,8 @@ void handlePingpongStart() {
if (server.hasArg("timeRand")) {
timeRand = server.arg("timeRand").toInt();
}
- if (server.hasArg("stallReturn")) {
- stallReturn = server.arg("stallReturn").toInt() != 0;
- }
- motor.startPingpong(speed, time, speedRand, timeRand, stallReturn);
+ motor.startPingpong(speed, time, speedRand, timeRand);
server.send(200, "text/plain", "OK");
}