docs motor burnout

docs/final_project/final_project.md

@@ -346,6 +346,7 @@ From this tab I can edit the body with all the references in place. So I could u
 
 
 ## Burnout!
+### Part 1
 One of my motors during testing burned out completely when it was attached to the printed arm. I think the cause for this is overheating due to a propellor that's too big.
 
 ![alt text](image-27.jpg)
@@ -359,6 +360,12 @@ Another thing that also could be the issue is that my ESC was surging above 40 A
 
 I think the main reason was heat and the coating on the motors evaporating causing a chain reaction.
 
+### Part 2
+This time it was completely my fault for not paying attention to the wires when connecting them to the right terminals. I had all other motors taped off like this but I forgot to do that for one motor I was testing.
+
+![alt text](imag1.jpg)
+
+<video controls src="../final_project/PXL_20250528_093723437(1)(1).mp4" title="Title"></video>
 ## Cables
 The drone needs lots of cables to get power to the places where they need to be. I first started out by laying out everything that needed to be connected.
 

src/controller/drone controller/src/main.cpp

@@ -77,7 +77,7 @@ void loop()
 
 int mapPot(int normalizedValue)
 {
-  return map(normalizedValue, 400, 2500, MINPWMVALUE, MAXPWMVALUE); // map the normalized value to the PWM range
+  return map(normalizedValue, 400, 4095, MINPWMVALUE, MAXPWMVALUE); // map the normalized value to the PWM range
 }
 
 // legacy stuff for original potsliders

src/drone/src/main.cpp

@@ -175,9 +175,9 @@ unsigned long channel_5_fs = 2000; // gear, greater than 1500 = throttle cut
 unsigned long channel_6_fs = 2000; // aux1
 
 // Filter parameters - Defaults tuned for 2kHz loop rate; Do not touch unless you know what you are doing:
-float B_madgwick = 0.04; // Madgwick filter parameter
-float B_accel = 0.14;    // Accelerometer LP filter paramter, (MPU6050 default: 0.14. MPU9250 default: 0.2)
-float B_gyro = 0.1;      // Gyro LP filter paramter, (MPU6050 default: 0.1. MPU9250 default: 0.17)
+float B_madgwick = 0.00001; // Madgwick filter parameter
+float B_accel = 0.00001;    // Accelerometer LP filter paramter, (MPU6050 default: 0.14. MPU9250 default: 0.2)
+float B_gyro = 0.0001;      // Gyro LP filter paramter, (MPU6050 default: 0.1. MPU9250 default: 0.17)
 float B_mag = 1.0;       // Magnetometer LP filter parameter
 
 // Magnetometer calibration parameters - if using MPU9250, uncomment calibrateMagnetometer() in void setup() to get these values, else just ignore these
@@ -189,33 +189,33 @@ float MagScaleY = 1.0;
 float MagScaleZ = 1.0;
 
 // IMU calibration parameters - calibrate IMU using calculate_IMU_error() in the void setup() to get these values, then comment out calculate_IMU_error()
-float AccErrorX = 0.0;
-float AccErrorY = 0.0;
-float AccErrorZ = 0.0;
-float GyroErrorX = 0.0;
-float GyroErrorY = 0.0;
-float GyroErrorZ = 0.0;
+float AccErrorX = 0.05;
+float AccErrorY = 0.01;
+float AccErrorZ = -0.01;
+float GyroErrorX = 0.00;
+float GyroErrorY = 0.00;
+float GyroErrorZ = 0.00;
 
 // Controller parameters (take note of defaults before modifying!):
 float i_limit = 25.0;  // Integrator saturation level, mostly for safety (default 25.0)
-float maxRoll = 30.0;  // Max roll angle in degrees for angle mode (maximum ~70 degrees), deg/sec for rate mode
-float maxPitch = 30.0; // Max pitch angle in degrees for angle mode (maximum ~70 degrees), deg/sec for rate mode
+float maxRoll = 15.0;  // Max roll angle in degrees for angle mode (maximum ~70 degrees), deg/sec for rate mode
+float maxPitch = 15.0; // Max pitch angle in degrees for angle mode (maximum ~70 degrees), deg/sec for rate mode
 float maxYaw = 160.0;  // Max yaw rate in deg/sec
 
-float Kp_roll_angle = 0.2;   // Roll P-gain - angle mode
-float Ki_roll_angle = 0.3;   // Roll I-gain - angle mode
-float Kd_roll_angle = 0.05;  // Roll D-gain - angle mode (has no effect on controlANGLE2)
+float Kp_roll_angle = 2.0;   // Roll P-gain - angle mode
+float Ki_roll_angle = 0.5;   // Roll I-gain - angle mode
+float Kd_roll_angle = 0.1;  // Roll D-gain - angle mode (has no effect on controlANGLE2)
 float B_loop_roll = 0.9;     // Roll damping term for controlANGLE2(), lower is more damping (must be between 0 to 1)
-float Kp_pitch_angle = 0.2;  // Pitch P-gain - angle mode
-float Ki_pitch_angle = 0.3;  // Pitch I-gain - angle mode
-float Kd_pitch_angle = 0.05; // Pitch D-gain - angle mode (has no effect on controlANGLE2)
+float Kp_pitch_angle = 2.0;  // Pitch P-gain - angle mode
+float Ki_pitch_angle = 0.5;  // Pitch I-gain - angle mode
+float Kd_pitch_angle = 0.1; // Pitch D-gain - angle mode (has no effect on controlANGLE2)
 float B_loop_pitch = 0.9;    // Pitch damping term for controlANGLE2(), lower is more damping (must be between 0 to 1)
 
-float Kp_roll_rate = 0.15;    // Roll P-gain - rate mode
-float Ki_roll_rate = 0.2;     // Roll I-gain - rate mode
+float Kp_roll_rate = 0.015;    // Roll P-gain - rate mode
+float Ki_roll_rate = 0.02;     // Roll I-gain - rate mode
 float Kd_roll_rate = 0.0002;  // Roll D-gain - rate mode (be careful when increasing too high, motors will begin to overheat!)
-float Kp_pitch_rate = 0.15;   // Pitch P-gain - rate mode
-float Ki_pitch_rate = 0.2;    // Pitch I-gain - rate mode
+float Kp_pitch_rate = 0.015;   // Pitch P-gain - rate mode
+float Ki_pitch_rate = 0.02;    // Pitch I-gain - rate mode
 float Kd_pitch_rate = 0.0002; // Pitch D-gain - rate mode (be careful when increasing too high, motors will begin to overheat!)
 
 float Kp_yaw = 0.3;     // Yaw P-gain
@@ -358,6 +358,7 @@ void printDebugInfo();
 void setupMotorPWM();
 int pulseWidthToDutyCycle(int pulseWidth);
 void setupMatrixSerial();
+void printPitchInfo();
 //========================================================================================================================//
 //                                                      VOID SETUP                                                        //
 //========================================================================================================================//
@@ -445,15 +446,16 @@ void loop()
 
   // Print data at 100hz (uncomment one at a time for troubleshooting) - SELECT ONE:
   // printRadioData();     //Prints radio pwm values (expected: 1000 to 2000)
-  printDesiredState();  //Prints desired vehicle state commanded in either degrees or deg/sec (expected: +/- maxAXIS for roll, pitch, yaw; 0 to 1 for throttle)
+  // printDesiredState();  //Prints desired vehicle state commanded in either degrees or deg/sec (expected: +/- maxAXIS for roll, pitch, yaw; 0 to 1 for throttle)
   // printGyroData();      //Prints filtered gyro data direct from IMU (expected: ~ -250 to 250, 0 at rest)
   // printAccelData(); // Prints filtered accelerometer data direct from IMU (expected: ~ -2 to 2; x,y 0 when level, z 1 when level)
   // printMagData();       //Prints filtered magnetometer data direct from IMU (expected: ~ -300 to 300)
   // printRollPitchYaw();  //Prints roll, pitch, and yaw angles in degrees from Madgwick filter (expected: degrees, 0 when level)
   // printPIDoutput();     //Prints computed stabilized PID variables from controller and desired setpoint (expected: ~ -1 to 1)
-  // printMotorCommands(); //Prints the values being written to the motors (expected: 120 to 250)
+  printMotorCommands(); //Prints the values being written to the motors (expected: 120 to 250)
   // printLoopRate();      //Prints the time between loops in microseconds (expected: microseconds between loop iterations)
-  // printDebugInfo(); //PWM 1 and 5 + Armed condition
+  // printDebugInfo(); //PWM 1 and 5 + Armed conditio
+  // printPitchInfo();
 
   // Get arming status
   armedStatus(); // Check if the throttle cut is off and throttle is low.
@@ -507,15 +509,14 @@ void controlMixer()
    *channel_6_pwm - free auxillary channel, can be used to toggle things with an 'if' statement
    */
 
-  // Quad mixing - EXAMPLE
-  m1_command_scaled = thro_des - pitch_PID + roll_PID + yaw_PID; // Front Left (CW) Check
-  m2_command_scaled = thro_des - pitch_PID - roll_PID - yaw_PID; // Front Right (CCW) check
-  m3_command_scaled = thro_des + pitch_PID - roll_PID + yaw_PID; // Back Right (CW) check
-  m4_command_scaled = thro_des + pitch_PID + roll_PID - yaw_PID; // Back Left (CCW)
+  // Quad mixer with pitch bias because the sensor isnt flat on the board
+  m1_command_scaled = thro_des - pitch_PID + roll_PID - yaw_PID; // Front Left CCW
+  m2_command_scaled = thro_des - pitch_PID - roll_PID + yaw_PID; // Front Right CW
+  m3_command_scaled = thro_des + pitch_PID - roll_PID - yaw_PID; // Back Right CCW
+  m4_command_scaled = thro_des + pitch_PID + roll_PID + yaw_PID; // Back Left CW
   m5_command_scaled = 0;
   m6_command_scaled = 0;
   
-  // 0.5 is centered servo, 0.0 is zero throttle if connecting to ESC for conventional PWM, 1.0 is max throttle
   s1_command_scaled = 0;
   s2_command_scaled = 0;
   s3_command_scaled = 0;
@@ -743,6 +744,7 @@ void calculate_IMU_error()
    * measurement.
    */
   int16_t AcX, AcY, AcZ, GyX, GyY, GyZ, MgX, MgY, MgZ;
+ // DESCRIPTION: Computes IMU accelerometer and gyro error on startup
  AccErrorX = 0.0;
  AccErrorY = 0.0;
  AccErrorZ = 0.0;
@@ -750,38 +752,46 @@ void calculate_IMU_error()
  GyroErrorY = 0.0;
  GyroErrorZ = 0.0;
 
-  // Read IMU values 12000 times
+ Serial.println("Starting IMU calibration...");
+ 
+ // Read IMU values 2000 times (reduced from 12000 for faster calibration)
  int c = 0;
-  while (c < 12000)
+ while (c < 2000)
  {
-#if defined USE_MPU6050_I2C
+#if defined USE_BNO085_I2C
+   unsigned long startTime = millis();
+   while (!myIMU.dataAvailable())
+   {
+     delay(1);
+     if (millis() - startTime > 100) // Reduced timeout
+     {
+       Serial.print("BNO085 timeout at iteration: ");
+       Serial.println(c);
+       return; // Exit if timeout
+     }
+   }
+
+   // Get raw sensor data - BNO085 already gives calibrated values
+   float tempGyroX = myIMU.getGyroX() * 57.29577951f; // Convert rad/s to deg/s
+   float tempGyroY = myIMU.getGyroY() * 57.29577951f;
+   float tempGyroZ = myIMU.getGyroZ() * 57.29577951f;
+   
+   float tempAccX = myIMU.getAccelX() / 9.80665f; // Convert m/s² to g
+   float tempAccY = myIMU.getAccelY() / 9.80665f;
+   float tempAccZ = myIMU.getAccelZ() / 9.80665f;
+
+   // Sum all readings
+   AccErrorX += tempAccX;
+   AccErrorY += tempAccY;
+   AccErrorZ += tempAccZ;
+   GyroErrorX += tempGyroX;
+   GyroErrorY += tempGyroY;
+   GyroErrorZ += tempGyroZ;
+
+#elif defined USE_MPU6050_I2C
     mpu6050.getMotion6(&AcX, &AcY, &AcZ, &GyX, &GyY, &GyZ);
 #elif defined USE_MPU9250_SPI
     mpu9250.getMotion9(&AcX, &AcY, &AcZ, &GyX, &GyY, &GyZ, &MgX, &MgY, &MgZ);
-#elif defined USE_BNO085_I2C
-
-    while (!myIMU.dataAvailable())
-    {
-      delay(1); // Small delay to avoid hammering the I2C bus too hard
-    }
-
-    // bno magnetometer
-    MgX = myIMU.getMagX();
-    MgY = myIMU.getMagY();
-    MgZ = myIMU.getMagZ();
-
-    // convert radians to degrees
-    GyX = myIMU.getGyroX() * 180 / PI;
-    GyY = myIMU.getGyroY() * 180 / PI;
-    GyZ = myIMU.getGyroZ() * 180 / PI;
-
-    // Acelleration (dont know if I need linear or normal. One way to find out)
-    AcX = myIMU.getAccelX() / 9.80665; // m/s² to g
-    AcY = myIMU.getAccelY() / 9.80665; // m/s² to g
-    AcZ = myIMU.getAccelZ() / 9.80665; // m/s² to g
-
-
-
 #endif
 
     AccX = AcX / ACCEL_SCALE_FACTOR;
@@ -1365,7 +1375,7 @@ void getCommands()
 #endif
 
   // Low-pass the critical commands and update previous values
-  float b = 0.7; // Lower=slower, higher=noiser
+  float b = 0.5; // Lower=slower, higher=noiser
   channel_1_pwm = (1.0 - b) * channel_1_pwm_prev + b * channel_1_pwm;
   channel_2_pwm = (1.0 - b) * channel_2_pwm_prev + b * channel_2_pwm;
   channel_3_pwm = (1.0 - b) * channel_3_pwm_prev + b * channel_3_pwm;
@@ -1891,6 +1901,20 @@ void printDebugInfo() {
   }
 }
 
+void printPitchInfo() {
+  if (current_time - print_counter > 10000) {
+    print_counter = micros();
+    Serial.print("pitch_IMU:");
+    Serial.print(pitch_IMU);
+    Serial.print(" pitch_PID:");
+    Serial.print(pitch_PID);
+    Serial.print(" pitch_des:");
+    Serial.print(pitch_des);
+    Serial.print(" error_pitch:");
+    Serial.println(error_pitch);
+  }
+}
+
 //=========================================================================================//
 
 // HELPER FUNCTIONS