The below script can be used to test the functionality of the Hall and Encoder sensors of a motor. To run it, the motor together with its sensors must be connected to the controller.
Steps
1. Copy - paste the below script in the script tab
'Disclaimer:
'----------
'The script is tested and validated by Roboteq and is believed to be fault-free.
'The possibility always exists, however, that the particular configuration and/or use
'condition uncovers a fault that escaped our validation test coverage. Always
'extensively test the script under your use conditions prior to deploying it in the field.
option explicit
'************************************************************
' ADD BELOW THE
' ENCODER PPR
'************************************************************
#define PPR 4096 '<--- Encoder pulses per revolution
'************************************************************
' ADD BELOW THE
' MPOTOR NOMINAL CURRENT
'************************************************************
#define REFERENCE_POWER 70 '< --- Amps used during calibration.
' Must be equal to nominal current.
' Value in amps*10
'************************************************************
' ADD BELOW THE
' MPOTOR POLE PAIRS
'************************************************************
#define POLE_PAIRS 5 '< --- Pole pairs of the motor.
' Value is pole number divided by 2
'************************************************************
' Script starts here. DON'T MODIFY BELOW
#define CHANNELS 2 'Number of channels to be tested
#define HALL_UP_LIMIT 90 'Maximum allowed electrical angle between two Hall transitions. Nominal is 85. Value in degrees*512/360
#define HALL_DOWN_LIMIT 80 'Minimum allowed electrical angle between two Hall transitions. Nominal is 85. Value in degrees*512/360
#define HALL_ZERO_MARGIN 14 'The acceptable error for the HALL_ZERO value. Default value is 14 that corresponds to 10 degrees. Value in degrees*512/360
#define ENCODER_MIN 15768 'Minumum allowed encoder counts per one rotation. Nominal is 16384
#define HALL_ERROR 2 'Maximum allowed Hall error counts in one rotation
'Script parameters. Do not modify
dim channel as integer
dim timeout as integer
dim power as integer
dim command as integer
dim encoderError as integer
dim hStatus as integer
dim statusCounter as integer
dim encoderCounter as integer
dim hallCounter as integer
dim motorConnected as boolean
dim sensorsOk as boolean
dim setupOk as boolean
motorConnected = false
sensorsOk = false
setupOk = false
'check sensors vars
dim isOneOnce as boolean
isOneOnce = false
'Check alignment vars
dim positive[6] as integer
dim negative[6] as integer
dim isAligned as boolean
isAligned = false
'Open Loop vars
dim motorRotates as boolean
dim swapHall as boolean
dim swapEnc as boolean
dim isOpenLoopOk as boolean
dim maxCurrentFw as integer
dim maxTorqueFw as integer
dim maxFluxFw as integer
dim maxEncSpeedFw as integer
dim maxHallSpeedFw as integer
dim minEncSpeedFw as integer
dim minHallSpeedFw as integer
dim maxCurrentRv as integer
dim maxTorqueRv as integer
dim maxFluxRv as integer
dim maxEncSpeedRv as integer
dim maxHallSpeedRv as integer
dim minEncSpeedRv as integer
dim minHallSpeedRv as integer
isOpenLoopOk = false
motorRotates = false
swapHall = false
swapEnc = false
maxCurrentFw = 0
maxTorqueFw = 0
maxFluxFw = 0
maxCurrentRv = 0
maxTorqueRv = 0
maxFluxRv = 0
maxHallSpeedFw = 0
maxEncSpeedFw = 0
minEncSpeedFw = 5000
minHallSpeedFw = 5000
maxHallSpeedRv = 0
maxEncSpeedRv = 0
minEncSpeedRv = 5000
minHallSpeedRv = 5000
encoderError = 4*PPR/30
' closed Loop vars
dim isClosedLoopOk as boolean
isclosedLoopOk = false
' wait until released vars
dim isreleased as boolean
isreleased = false
'Load test vars
dim isLoadOk as boolean
dim pha[2] as integer
isLoadOk= false
pha[0] = 0
pha[1] = 0
'general vars
dim temp as integer
dim i as integer
dim j as integer
dim speed[2] as integer
dim steps[2] as integer
dim error[60] as integer
dim warnings[20] as integer
dim current as integer
temp = i = j = 0
current = 0
speed[0] = 0
speed[1] = 0
steps[0] = 0
steps[1] = 0
timeout = 0
command = 0
channel = 1
power = 0
hStatus = 0
statusCounter = 0
encoderCounter = 0
hallCounter = 0
wait(2000) ' Add 2 second wait, in case of script crash
setcommand(_G,1,0) 'Make command to both motors zero, in case that previous command is running with RWD 0
setcommand(_G,2,0)
'*********************************************
' MAIN PROGRAM
'*********************************************
wait(1000)
print("This script is used to test the motors having Hall sensors and ", PPR," resolution encoder\n \n")
wait(4000)
print("STARTING\n")
print("--------\n \n")
wait(2000)
print("1. Initializing profile... \n \n")
gosub initialize_profile
print("-Profile loaded! \n \n")
for channel = 1 andwhile (channel < (CHANNELS+1))
gosub initialize_parameters
wait(2000)
print("2. Checking if motor ", channel," is connected... \n \n")
wait(2000)
gosub is_motor_connected
if motorConnected
wait(2000)
steps[channel-1]++ 'step = 1
print("3. Checking if sensors are present... \n \n")
gosub check_sensors
end if
if sensorsOk
wait(1000)
steps[channel-1]++ 'step = 2
print("4. Performing motor/sensor setup... \n \n")
gosub motor_setup
end if
if setupOk
wait(1000)
steps[channel-1]++ 'step = 3
print("5. Checking Hall sensors alignment... \n \n \n")
wait(3000)
gosub check_alignment
end if
if (channel = 1)
print("\n \nproceeding to channel 2\n \n")
wait(2000)
end if
next
wait(3000)
print("\n\nTest finished \n \n")
terminate
'*************************************************
' SUBS
'*************************************************
'*************************************************
' 0. Initialize profile
'-------------------------------------------------
' Initialize the controller's profile. I will
' configure sinusoidal for both motors, configure
' the reference seek power, disable sensor error
' protection, reset the Hall angle table
'*************************************************
initialize_profile:
for channel = 1 andwhile channel < 3
setconfig(_MMOD,channel,0)
wait(1)
setconfig(_SED,channel,0)
wait(1)
setconfig(_BZPW,channel,REFERENCE_POWER)
wait(1)
setconfig(_BMOD,channel,1)
wait(1)
setconfig(_BPOL,channel,POLE_PAIRS)
wait(1)
setconfig(_EPPR,channel,PPR)
wait(1)
setconfig(_BFBK,channel,2)
wait(1)
setconfig(_BLFB,channel,0)
wait(1)
setconfig(_BLSTD,channel,0)
setconfig(_ALIM,channel,200)
wait(1)
next
setconfig(_RWD,0)
wait(1)
setconfig(_EMOD,1,18)
wait(1)
setconfig(_EMOD,2,34)
wait(1)
for i = 1 andwhile i <25
setconfig(_HSAT,i,0)
wait(1)
next
wait(250)
if((getvalue(_FF,1) and 16))
setcommand(_MG,1)
end if
wait(50)
channel = 1
return
'*************************************************
' 1. Initialize parameters
'-------------------------------------------------
' Checks if at least two of the motor phases are
' connected by giving a PWM voltage to the motor
' and measuring the motor current
'*************************************************
initialize_parameters:
maxCurrentFw = 0
maxTorqueFw = 0
maxFluxFw = 0
maxCurrentRv = 0
maxTorqueRv = 0
maxFluxRv = 0
maxHallSpeedFw = 0
maxEncSpeedFw = 0
minEncSpeedFw = 5000
minHallSpeedFw = 5000
maxHallSpeedRv = 0
maxEncSpeedRv = 0
minEncSpeedRv = 5000
minHallSpeedRv = 5000
timeout = 0
command = 0
power = 0
hStatus = 0
statusCounter = 0
encoderCounter = 0
hallCounter = 0
isAligned = false
isOpenLoopOk = false
motorRotates = false
swapHall = false
swapEnc = false
isclosedLoopOk = false
isreleased = false
motorConnected = false
sensorsOk = false
setupOk = false
isOneOnce = false
isLoadOk = false
return
'*************************************************
' 2. Is motor Connected
'-------------------------------------------------
' Checks if at least two of the motor phases are
' connected by giving a PWM voltage to the motor
' and measuring the motor current
'*************************************************
is_motor_connected:
motorConnected = false
timeout = 0
command = 0
while timeout < 5000
command ++
timeout ++
setcommand(_G,channel, command/4)
current= abs(getvalue(_A,channel))
if (current > 10)
setcommand(_G,channel,0)
motorConnected = true
print("-motor ", channel," is connected!\n \n")
return
end if
wait(1)
end while
setcommand(_G,channel,0)
print("-motor ",channel," is not connected!\n \n")
error[(channel-1)*30+1]=1
return
'*************************************************
' 3. Check sensors
'-------------------------------------------------
' Checks if at least two of the motor phases are
' connected by giving a PWM voltage to the motor
' and measuring the motor current
'*************************************************
check_sensors:
timeout = 0
sensorsOk = false
isOneOnce = false
statusCounter = 0
setcommand(_C,channel,0)
wait(250)
setcommand(_CB,channel,0)
wait(250)
setcommand(_VPM,channel,POLE_PAIRS)
while (timeout<1000)
if (getvalue(_A,channel)>REFERENCE_POWER*2/3)
setcommand(_C,channel,0)
wait(1)
setcommand(_CB,channel,0)
wait(1)
exit while
end if
timeout++
wait(1)
end while
timeout = 0
while timeout < 10000
power = getvalue(_P,channel)
timeout++
if ((timeout < 1000) and (power = 0))
print("\n \n-VPM Error. Motor power is zero! \n")
error[(channel-1)*30+2]=1
setcommand(_VPM,channel,0)
return
end if
if ((timeout > 2000) and (power = 0))
exit while
end if
if (timeout > 9000)
print("\n \n-VPM Error. Rotation did not finish on time! \n")
setcommand(_VPM,channel,0)
error[(channel-1)*30+3]=1
return
end if
hStatus = getvalue(_HS,channel)
if ((hStatus = 1) and (statusCounter = 0))
statusCounter++
elseif ((hStatus = 2) and (statusCounter = 1))
statusCounter++
elseif ((hStatus = 3) and (statusCounter = 2))
statusCounter++
elseif ((hStatus = 4) and (statusCounter = 3))
statusCounter++
elseif ((hStatus = 5) and (statusCounter = 4))
statusCounter++
elseif ((hStatus = 6) and (statusCounter = 5))
statusCounter++
end if
if(getvalue(_C,channel) = 1)
isOneOnce = true
end if
wait(1)
end while
setcommand(_VPM,channel,0)
encoderCounter = abs(getvalue(_C,channel))
hallCounter = abs(getvalue(_CB,channel))
if (encodercounter >= 4*PPR-encoderError) and (encodercounter <= 4*PPR+encoderError) and (hallCounter >= 6*POLE_PAIRS-HALL_ERROR) and (hallCounter <= 6*POLE_PAIRS+HALL_ERROR) and (statusCounter = 6)
sensorsOk = true
print ("-sensors ok!\n \n")
else
if (encoderCounter = 0) and (not isOneOnce)
print("\n \n-Encoder not present! \n")
error[(channel-1)*30+4]=1
elseif (encoderCounter < 10) and isOneOnce
print("\n \n-One of the Encoder signals not present! \n")
error[(channel-1)*30+5]=1
elseif ((encoderCounter < 4*PPR-encoderError) or (encoderCounter > 4*PPR+encoderError))
print ("\n \n-Encoder is malfunctioning. Encoder counts are ",encoderCounter," instead of ", 4*PPR,"! \n")
error[(channel-1)*30+6]=1
end if
if (getvalue(_HS,channel) = 7)
print("\n \n-Hall is not present! \n")
error[(channel-1)*30+7]=1
else
if ((hallCounter < 6*POLE_PAIRS-HALL_ERROR) or (hallCounter > 6*POLE_PAIRS+HALL_ERROR))
print ("\n \n- Hall is malfunctioning. Hall counts are ",hallCounter," instead of ", 6*POLE_PAIRS,"! \n")
error[(channel-1)*30+8]=1
end if
if (statusCounter <> 6)
print("- At least one of the Hall signals is missing! \n")
error[(channel-1)*30+9]=1
end if
end if
end if
return
'*************************************************
' 4. Motor/Sensor setup
'-------------------------------------------------
' Checks if at least two of the motor phases are
' connected by giving a PWM voltage to the motor
' and measuring the motor current
'*************************************************
motor_setup:
setupOk = false
timeout = 0
setcommand(_MSS,channel)
while(timeout < 4000)
timeout++
wait(1)
if (getvalue(_P,channel)>50)
exit while
end if
end while
if (timeout = 4000)
print("\n \n-Motor/Sensor setup timeout! \n")
error[(channel-1)*30+10]=1
return
end if
timeout = 0
print("HS \t A \t P \n")
while (timeout<2000)
timeout++
power= getvalue(_P,channel)
if (power = 0)
print("\n \n-Motor/Sensor setup ok!\n \n")
setupOk = true
return
end if
wait(10)
print(getvalue(_HS,channel),"\t",getvalue(_A,channel),"\t",getvalue(_P,channel),"\n")
end while
print("\n \n-Motor/Sensor setup timeout! \n")
error[(channel-1)*30+10]=1
return
'*************************************************
' 5. Check Hall Alignment
'-------------------------------------------------
' Checks if at least two of the motor phases are
' connected by giving a PWM voltage to the motor
' and measuring the motor current
'*************************************************
check_alignment:
isAligned = true
' Read the HSAT
for i = 0 andwhile i < 6
negative[i] = getconfig(_HSAT,((channel-1)*12)+i+1)
positive[i] = getconfig(_HSAT,((channel-1)*12)+i+7)
next
'Sort the HSAT
for i = 0 andwhile i < 6
for j = 0 andwhile j < (6 - i -1 )
if negative[j]>negative[j+1]
temp = negative[j]
negative[j] = negative[j+1]
negative[j+1] = temp
end if
if positive[j]>positive[j+1]
temp = positive[j]
positive[j] = positive[j+1]
positive[j+1] = temp
end if
next
next
Print("Hall sensors negative direction:\n \n")
for i = 0 andwhile i < 6
print(negative[i],"\t")
next
wait(250)
Print("\n \nNegative direction angle difference:\n \n")
for i = 0 andwhile i < 5
print(abs(negative[i]-negative[i+1]),"\t")
if ((abs(negative[i]-negative[i+1])> HALL_UP_LIMIT) or (abs(negative[i]-negative[i+1]) < HALL_DOWN_LIMIT))
isAligned = false
end if
next
wait(250)
print("\n \n")
Print("Hall sensors positive direction:\n \n")
for i = 0 andwhile i < 6
print(positive[i],"\t")
next
print("\n")
wait(250)
Print("\n \nPositive direction angle difference:\n \n")
for i = 0 andwhile i < 5
print(abs(positive[i]-positive[i+1]),"\t")
if ((abs(positive[i]-positive[i+1])> HALL_UP_LIMIT) or (abs(positive[i]-positive[i+1]) < HALL_DOWN_LIMIT))
isAligned = false
end if
next
wait(250)
print("\n")
if (isAligned = false)
print("\n \n \n-Hall sensors not well aligned!\n \n")
error[(channel-1)*30+11]=1
warnings[(channel-1)*10+0] = 1 'Update the first elemnt of the warnings array.
else
print ("\n \n \n-Hall sensors are well aligned! \n \n")
end if
isAligned = true 'Made the flag again true so the motor test does not finish if the sensors are misaligned
return
2. Go at line 8 of the script and configure the encoder resolution (PPR), the motor nominal current and pole pairs. Note that the nominal current should be added in A/10, so 10 A for example should be written as 100.
3. Click "to device" to download the script on the controller
4. Go at the console tab and clear the logs
5. Run script
6. Once the test is finished copy the logs and send them for evaluation
