BOOSTXL-DRV8323RS: 28069M DRV Fries and Shunt Resister Explodes Under Semi Hard Load

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//! \file   solutions/instaspin_foc/src/proj_lab04a.c
//! \brief  Using InstaSPIN�FOC only as a torque controller FPU32
//!
//! (C) Copyright 2011, Texas Instruments, Inc.

//! \defgroup PROJ_LAB04A PROJ_LAB04A
//@{

//! \defgroup PROJ_LAB04A_OVERVIEW Project Overview
//!
//! Running InstaSPIN�FOC only as a Torque controller FPU32
//!

// **************************************************************************
// the includes

// system includes
#include <math.h>
#include "main.h"

#ifdef FLASH
#pragma CODE_SECTION(mainISR,"ramfuncs");
#endif

// Include header files used in the main function


// **************************************************************************
// the defines

#define LED_BLINK_FREQ_Hz   5


// **************************************************************************
// the globals

uint_least16_t gCounter_updateGlobals = 0;

bool Flag_Latch_softwareUpdate = true;

CTRL_Handle ctrlHandle;

#ifdef CSM_ENABLE
#pragma DATA_SECTION(halHandle,"rom_accessed_data");
#endif

HAL_Handle halHandle;

#ifdef CSM_ENABLE
#pragma DATA_SECTION(gUserParams,"rom_accessed_data");
#endif

USER_Params gUserParams;

HAL_PwmData_t gPwmData = {_IQ(0.0), _IQ(0.0), _IQ(0.0)};

HAL_AdcData_t gAdcData;

_iq gMaxCurrentSlope = _IQ(0.0);

#ifdef FAST_ROM_V1p6
CTRL_Obj *controller_obj;
#else
#ifdef CSM_ENABLE
#pragma DATA_SECTION(ctrl,"rom_accessed_data");
#endif
CTRL_Obj ctrl;				//v1p7 format
#endif

uint16_t gLEDcnt = 0;

volatile MOTOR_Vars_t gMotorVars = MOTOR_Vars_INIT;

#ifdef FLASH
// Used for running BackGround in flash, and ISR in RAM
extern uint16_t *RamfuncsLoadStart, *RamfuncsLoadEnd, *RamfuncsRunStart;

#ifdef CSM_ENABLE
extern uint16_t *econst_start, *econst_end, *econst_ram_load;
extern uint16_t *switch_start, *switch_end, *switch_ram_load;
#endif
#endif


#ifdef DRV8301_SPI
// Watch window interface to the 8301 SPI
DRV_SPI_8301_Vars_t gDrvSpi8301Vars;
#endif
#ifdef DRV8305_SPI
// Watch window interface to the 8305 SPI
DRV_SPI_8305_Vars_t gDrvSpi8305Vars;
#endif

#ifdef DRV8323_SPI
// Watch window interface to the 8301 SPI
DRV_SPI_8323_Vars_t gDrvSpi8323Vars;
#endif

_iq gFlux_pu_to_Wb_sf;

_iq gFlux_pu_to_VpHz_sf;

_iq gTorque_Ls_Id_Iq_pu_to_Nm_sf;

_iq gTorque_Flux_Iq_pu_to_Nm_sf;

// **************************************************************************
// the functions

void main(void)
{
  uint_least8_t estNumber = 0;

#ifdef FAST_ROM_V1p6
  uint_least8_t ctrlNumber = 0;
#endif

  // Only used if running from FLASH
  // Note that the variable FLASH is defined by the project
  #ifdef FLASH
  // Copy time critical code and Flash setup code to RAM
  // The RamfuncsLoadStart, RamfuncsLoadEnd, and RamfuncsRunStart
  // symbols are created by the linker. Refer to the linker files
  memCopy((uint16_t *)&RamfuncsLoadStart,(uint16_t *)&RamfuncsLoadEnd,(uint16_t *)&RamfuncsRunStart);

  #ifdef CSM_ENABLE
  //copy .econst to unsecure RAM
  if(*econst_end - *econst_start)
  {
     memCopy((uint16_t *)&econst_start,(uint16_t *)&econst_end,(uint16_t *)&econst_ram_load);
  }

  //copy .switch ot unsecure RAM
  if(*switch_end - *switch_start)
  {
    memCopy((uint16_t *)&switch_start,(uint16_t *)&switch_end,(uint16_t *)&switch_ram_load);
  }
  #endif
  #endif

  // initialize the hardware abstraction layer
  halHandle = HAL_init(&hal,sizeof(hal));


  // check for errors in user parameters
  USER_checkForErrors(&gUserParams);


  // store user parameter error in global variable
  gMotorVars.UserErrorCode = USER_getErrorCode(&gUserParams);


  // do not allow code execution if there is a user parameter error
  if(gMotorVars.UserErrorCode != USER_ErrorCode_NoError)
    {
      for(;;)
        {
          gMotorVars.Flag_enableSys = false;
        }
    }


  // initialize the user parameters
  USER_setParams(&gUserParams);


  // set the hardware abstraction layer parameters
  HAL_setParams(halHandle,&gUserParams);


  // initialize the controller
#ifdef FAST_ROM_V1p6
  ctrlHandle = CTRL_initCtrl(ctrlNumber, estNumber);  		//v1p6 format (06xF and 06xM devices)
  controller_obj = (CTRL_Obj *)ctrlHandle;
#else
  ctrlHandle = CTRL_initCtrl(estNumber,&ctrl,sizeof(ctrl));	//v1p7 format default
#endif


  {
    CTRL_Version version;

    // get the version number
    CTRL_getVersion(ctrlHandle,&version);

    gMotorVars.CtrlVersion = version;
  }


  // set the default controller parameters
  CTRL_setParams(ctrlHandle,&gUserParams);


  // setup faults
  HAL_setupFaults(halHandle);


  // initialize the interrupt vector table
  HAL_initIntVectorTable(halHandle);


  // enable the ADC interrupts
  HAL_enableAdcInts(halHandle);


  // enable global interrupts
  HAL_enableGlobalInts(halHandle);


  // enable debug interrupts
  HAL_enableDebugInt(halHandle);


  // disable the PWM
  HAL_disablePwm(halHandle);


#ifdef DRV8301_SPI
  // turn on the DRV8301 if present
  HAL_enableDrv(halHandle);
  // initialize the DRV8301 interface
  HAL_setupDrvSpi(halHandle,&gDrvSpi8301Vars);
#endif

#ifdef DRV8305_SPI
  // turn on the DRV8305 if present
  HAL_enableDrv(halHandle);
  // initialize the DRV8305 interface
  HAL_setupDrvSpi(halHandle,&gDrvSpi8305Vars);
#endif

#ifdef DRV8323_SPI
  // turn on the DRV8305 if present
  HAL_enableDrv(halHandle);
  // initialize the DRV8305 interface
  HAL_setupDrvSpi(halHandle,&gDrvSpi8323Vars);
#endif

  // enable DC bus compensation
  CTRL_setFlag_enableDcBusComp(ctrlHandle, true);


  // compute scaling factors for flux and torque calculations
  gFlux_pu_to_Wb_sf = USER_computeFlux_pu_to_Wb_sf();
  gFlux_pu_to_VpHz_sf = USER_computeFlux_pu_to_VpHz_sf();
  gTorque_Ls_Id_Iq_pu_to_Nm_sf = USER_computeTorque_Ls_Id_Iq_pu_to_Nm_sf();
  gTorque_Flux_Iq_pu_to_Nm_sf = USER_computeTorque_Flux_Iq_pu_to_Nm_sf();


  for(;;)
  {
    // Waiting for enable system flag to be set
    while(!(gMotorVars.Flag_enableSys));

    // Dis-able the Library internal PI.  Iq has no reference now
    CTRL_setFlag_enableSpeedCtrl(ctrlHandle, false);

    // loop while the enable system flag is true
    while(gMotorVars.Flag_enableSys)
      {
        CTRL_Obj *obj = (CTRL_Obj *)ctrlHandle;

        // increment counters
        gCounter_updateGlobals++;

        // enable/disable the use of motor parameters being loaded from user.h
        CTRL_setFlag_enableUserMotorParams(ctrlHandle,gMotorVars.Flag_enableUserParams);

        // enable/disable Rs recalibration during motor startup
        EST_setFlag_enableRsRecalc(obj->estHandle,gMotorVars.Flag_enableRsRecalc);

        // enable/disable automatic calculation of bias values
        CTRL_setFlag_enableOffset(ctrlHandle,gMotorVars.Flag_enableOffsetcalc);


        if(CTRL_isError(ctrlHandle))
          {
            // set the enable controller flag to false
            CTRL_setFlag_enableCtrl(ctrlHandle,false);

            // set the enable system flag to false
            gMotorVars.Flag_enableSys = false;

            // disable the PWM
            HAL_disablePwm(halHandle);
          }
        else
          {
            // update the controller state
            bool flag_ctrlStateChanged = CTRL_updateState(ctrlHandle);

            // enable or disable the control
            CTRL_setFlag_enableCtrl(ctrlHandle, gMotorVars.Flag_Run_Identify);

            if(flag_ctrlStateChanged)
              {
                CTRL_State_e ctrlState = CTRL_getState(ctrlHandle);

                if(ctrlState == CTRL_State_OffLine)
                  {
                    // enable the PWM
                    HAL_enablePwm(halHandle);
                  }
                else if(ctrlState == CTRL_State_OnLine)
                  {
                    if(gMotorVars.Flag_enableOffsetcalc == true)
                    {
                      // update the ADC bias values
                      HAL_updateAdcBias(halHandle);
                    }
                    else
                    {
                      // set the current bias
                      HAL_setBias(halHandle,HAL_SensorType_Current,0,_IQ(I_A_offset));
                      HAL_setBias(halHandle,HAL_SensorType_Current,1,_IQ(I_B_offset));
                      HAL_setBias(halHandle,HAL_SensorType_Current,2,_IQ(I_C_offset));

                      // set the voltage bias
                      HAL_setBias(halHandle,HAL_SensorType_Voltage,0,_IQ(V_A_offset));
                      HAL_setBias(halHandle,HAL_SensorType_Voltage,1,_IQ(V_B_offset));
                      HAL_setBias(halHandle,HAL_SensorType_Voltage,2,_IQ(V_C_offset));
                    }

                    // Return the bias value for currents
                    gMotorVars.I_bias.value[0] = HAL_getBias(halHandle,HAL_SensorType_Current,0);
                    gMotorVars.I_bias.value[1] = HAL_getBias(halHandle,HAL_SensorType_Current,1);
                    gMotorVars.I_bias.value[2] = HAL_getBias(halHandle,HAL_SensorType_Current,2);

                    // Return the bias value for voltages
                    gMotorVars.V_bias.value[0] = HAL_getBias(halHandle,HAL_SensorType_Voltage,0);
                    gMotorVars.V_bias.value[1] = HAL_getBias(halHandle,HAL_SensorType_Voltage,1);
                    gMotorVars.V_bias.value[2] = HAL_getBias(halHandle,HAL_SensorType_Voltage,2);

                    // enable the PWM
                    HAL_enablePwm(halHandle);
                  }
                else if(ctrlState == CTRL_State_Idle)
                  {
                    // disable the PWM
                    HAL_disablePwm(halHandle);
                    gMotorVars.Flag_Run_Identify = false;
                  }

                if((CTRL_getFlag_enableUserMotorParams(ctrlHandle) == true) &&
                  (ctrlState > CTRL_State_Idle) &&
                  (gMotorVars.CtrlVersion.minor == 6))
                  {
                    // call this function to fix 1p6
                    USER_softwareUpdate1p6(ctrlHandle);
                  }

              }
          }


        if(EST_isMotorIdentified(obj->estHandle))
          {
            // set the current ramp
            EST_setMaxCurrentSlope_pu(obj->estHandle,gMaxCurrentSlope);
            gMotorVars.Flag_MotorIdentified = true;


            if(Flag_Latch_softwareUpdate)
            {
              Flag_Latch_softwareUpdate = false;

              USER_calcPIgains(ctrlHandle);
            }

          }
        else
          {
            Flag_Latch_softwareUpdate = true;

            // the estimator sets the maximum current slope during identification
            gMaxCurrentSlope = EST_getMaxCurrentSlope_pu(obj->estHandle);
          }


        // when appropriate, update the global variables
        if(gCounter_updateGlobals >= NUM_MAIN_TICKS_FOR_GLOBAL_VARIABLE_UPDATE)
          {
            // reset the counter
            gCounter_updateGlobals = 0;

            updateGlobalVariables_motor(ctrlHandle);
          }

        // update Iq reference
        updateIqRef(ctrlHandle);

        // enable/disable the forced angle
        EST_setFlag_enableForceAngle(obj->estHandle,gMotorVars.Flag_enableForceAngle);

        // enable or disable power warp
        CTRL_setFlag_enablePowerWarp(ctrlHandle,gMotorVars.Flag_enablePowerWarp);

#ifdef DRV8301_SPI
        HAL_writeDrvData(halHandle,&gDrvSpi8301Vars);

        HAL_readDrvData(halHandle,&gDrvSpi8301Vars);
#endif
#ifdef DRV8305_SPI
        HAL_writeDrvData(halHandle,&gDrvSpi8305Vars);

        HAL_readDrvData(halHandle,&gDrvSpi8305Vars);
#endif
#ifdef DRV8323_SPI
        HAL_writeDrvData(halHandle,&gDrvSpi8323Vars);

        HAL_readDrvData(halHandle,&gDrvSpi8323Vars);
#endif

      } // end of while(gFlag_enableSys) loop


    // disable the PWM
    HAL_disablePwm(halHandle);

    // set the default controller parameters (Reset the control to re-identify the motor)
    CTRL_setParams(ctrlHandle,&gUserParams);
    gMotorVars.Flag_Run_Identify = false;

  } // end of for(;;) loop

} // end of main() function

_iq gPotentiometer = _IQ(0.0);
uint32_t ringBuffer[50];
int counterr = 0;
#define LOW_BOUND ((360.0f)/(4096.0f))
#define UPPER_BOUND ((3988.0f)/(4096.0f))
#define MIDLOW_BOUND ((1460.0f)/(4096.0f))
#define MIDHigh_BOUND ((1490.0f)/(4096.0f))
#define GAS_Scale ((UPPER_BOUND - MIDHigh_BOUND))
#define BRAKE_Scale ((MIDLOW_BOUND - LOW_BOUND))
float gasvalue = 0;
#define maxAmp (15.0f)
uint32_t dutycc = 0;
uint32_t cyc = 0;

#define DUTY_MIN 58312
#define DUTY_MAX 120571
#define DUTY_MEAN 89350
uint32_t last = 0;
uint32_t min = 999999999,max = 0, mean = 0;
interrupt void mainISR(void)
{
    cyc++;
    dutycc = halHandle->capHandle->CAP2 - halHandle->capHandle->CAP1;
    if (((int32_t) dutycc) > 0 && last != halHandle->capHandle->CAP2) {
        last = halHandle->capHandle->CAP2;
        if (dutycc >= DUTY_MEAN+500) {
            gasvalue = ((float) dutycc - DUTY_MEAN) / ((float) DUTY_MAX - DUTY_MEAN) * maxAmp;
        } else if (dutycc <= DUTY_MEAN-500){
            gasvalue = ((float) dutycc - DUTY_MEAN) / ((float) DUTY_MEAN - DUTY_MIN) * maxAmp;
        } else {
            gasvalue = 0;
        }
        if (gasvalue < -0.5 & !gMotorVars.Flag_Run_Identify) {
            gMotorVars.Flag_Run_Identify = 1;
            gMotorVars.Flag_enableSys = 1;
        }
        if (abs(gasvalue) > maxAmp) {
            gasvalue = 0;
        }
        ringBuffer[counterr++] = dutycc;
        if (counterr == 50) {
            counterr = 0;
        }
        uint32_t i = 0, ccc;
        for (i = 0; i < 50; i ++) {
            ccc += ringBuffer[i];
        }
        mean = (uint32_t) ((double) ccc)/50.0;
    }
    gMotorVars.IqRef_A = _IQ(gasvalue);
  // toggle status LED
  if(++gLEDcnt >= (uint_least32_t)(USER_ISR_FREQ_Hz / LED_BLINK_FREQ_Hz))
  {
    HAL_toggleLed(halHandle,(GPIO_Number_e)HAL_Gpio_LED2);
    gLEDcnt = 0;
  }


  // acknowledge the ADC interrupt
  HAL_acqAdcInt(halHandle,ADC_IntNumber_1);


  // convert the ADC data
  HAL_readAdcData(halHandle,&gAdcData);


  // run the controller
  CTRL_run(ctrlHandle,halHandle,&gAdcData,&gPwmData);


  // write the PWM compare values
  HAL_writePwmData(halHandle,&gPwmData);


  // setup the controller
  CTRL_setup(ctrlHandle);


  return;
} // end of mainISR() function


void updateGlobalVariables_motor(CTRL_Handle handle)
{
  CTRL_Obj *obj = (CTRL_Obj *)handle;
  int32_t tmp;

  // get the speed estimate
  gMotorVars.Speed_krpm = EST_getSpeed_krpm(obj->estHandle);

  // get the torque estimate
  gMotorVars.Torque_Nm = USER_computeTorque_Nm(handle, gTorque_Flux_Iq_pu_to_Nm_sf, gTorque_Ls_Id_Iq_pu_to_Nm_sf);

  // when calling EST_ functions that return a float, and fpu32 is enabled, an integer is needed as a return
  // so that the compiler reads the returned value from the accumulator instead of fpu32 registers
  // get the magnetizing current
  tmp = EST_getIdRated(obj->estHandle);
  gMotorVars.MagnCurr_A = *((float_t *)&tmp);

  // get the rotor resistance
  tmp = EST_getRr_Ohm(obj->estHandle);
  gMotorVars.Rr_Ohm = *((float_t *)&tmp);

  // get the stator resistance
  tmp = EST_getRs_Ohm(obj->estHandle);
  gMotorVars.Rs_Ohm = *((float_t *)&tmp);

  // get the stator inductance in the direct coordinate direction
  tmp = EST_getLs_d_H(obj->estHandle);
  gMotorVars.Lsd_H = *((float_t *)&tmp);

  // get the stator inductance in the quadrature coordinate direction
  tmp = EST_getLs_q_H(obj->estHandle);
  gMotorVars.Lsq_H = *((float_t *)&tmp);

  // get the flux in V/Hz in floating point
  tmp = EST_getFlux_VpHz(obj->estHandle);
  gMotorVars.Flux_VpHz = *((float_t *)&tmp);

  // get the flux in Wb in fixed point
  gMotorVars.Flux_Wb = USER_computeFlux(handle, gFlux_pu_to_Wb_sf);

  // get the controller state
  gMotorVars.CtrlState = CTRL_getState(handle);

  // get the estimator state
  gMotorVars.EstState = EST_getState(obj->estHandle);

  // Get the DC buss voltage
  gMotorVars.VdcBus_kV = _IQmpy(gAdcData.dcBus,_IQ(USER_IQ_FULL_SCALE_VOLTAGE_V/1000.0));

  return;
} // end of updateGlobalVariables_motor() function


void updateIqRef(CTRL_Handle handle)
{
  _iq iq_ref = _IQmpy(gMotorVars.IqRef_A,_IQ(1.0/USER_IQ_FULL_SCALE_CURRENT_A));

  // set the speed reference so that the forced angle rotates in the correct direction for startup
  if(_IQabs(gMotorVars.Speed_krpm) < _IQ(0.01))
    {
      if(iq_ref < _IQ(0.0))
        {
          CTRL_setSpd_ref_krpm(handle,_IQ(-0.01));
        }
      else if(iq_ref > _IQ(0.0))
        {
          CTRL_setSpd_ref_krpm(handle,_IQ(0.01));
        }
    }

  // Set the Iq reference that use to come out of the PI speed control
  CTRL_setIq_ref_pu(handle, iq_ref);

  return;
} // end of updateIqRef() function


//@} //defgroup
// end of file