Tool/software:
Hello Team,
We are currently working on the F2800157 with two types of feedback (Hall sensor and Encoder) for the same motor specification:
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Motor Specification: 4 kW, Rated Current 110A
During vehicle-level validation, the motor with Hall feedback works as expected (both under no-load and loaded conditions) and runs smoothly in the current loop.
However, with Encoder feedback, we are facing the following issue:
1. Vehicle No-Load Condition
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Motor runs normally in the current loop.
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State transitions are correct:
Motor IDLE → Motor Seek Position → Motor Alignment → Motor OL State → Motor CL Running → Motor Control Running.
2. Vehicle Load Condition
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Motor does not start; it only vibrates.
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State transition is incorrect:
Motor IDLE → jumps directly to → Motor OL State (continuous vibration without running).
Debug Steps Tried
We increased the startup current as below, but the issue persists:
Observations
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Hall feedback: Motor runs fine under both load and no-load.
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Encoder feedback: Motor runs fine under no-load, but fails only under load.
Request
Could you please guide us on possible causes?
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Are we missing any initial setup related to encoder alignment, seek position, or index pulse usage?
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Is there any recommended tuning (flux current, alignment time, startup profile) specific to encoder feedback under load?
Your inputs will help us close this issue.
No Load Condition:
Load condition:
Thanks & Regards
C. Prabhakaran
