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Finalise automated motor control

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Blizzard Finnegan 2023-03-08 14:32:59 -05:00
parent dae70b168f
commit 1ef2fecb57
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GPG key ID: DE547EDF547DDA49
2 changed files with 190 additions and 142 deletions
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125
src/main/java/org/baxter/disco/ocr/Cli.java
View file

@ -81,75 +81,80 @@ public class Cli
ErrorLogging.logError("Version: " + version); ErrorLogging.logError("Version: " + version);
ErrorLogging.logError("========================"); ErrorLogging.logError("========================");
try{ try{
inputScanner = new Scanner(System.in); //inputScanner = new Scanner(System.in);
ConfigFacade.init(); //ConfigFacade.init();
int userInput = 0; //int userInput = 0;
ErrorLogging.logError("Calibrating motor movement. This may take several minutes..."); ErrorLogging.logError("Calibrating motor movement. This may take several minutes...");
MovementFacade.calibrate(); ErrorLogging.logError("The piston will fire momentarily when the motor calibration is complete.");
MovementFacade.pressButton();
do ErrorLogging.logError("Testing config.");
{ MovementFacade.goDown();
printMainMenu(); MovementFacade.goUp();
userInput = (int)inputFiltering(inputScanner.nextLine());
switch (userInput) //do
{ //{
case 1: // printMainMenu();
println("Setting up cameras..."); // userInput = (int)inputFiltering(inputScanner.nextLine());
println("This may take a moment...");
configureCameras();
camerasConfigured = true;
break;
case 2:
setDUTSerials();
break;
case 3:
setIterationCount();
break;
case 4:
setActiveCameras();
break;
case 5:
if(!camerasConfigured)
{
prompt("You have not configured the cameras yet! Are you sure you would like to continue? (y/N): ");
String input = inputScanner.nextLine().toLowerCase().trim();
if( input.isBlank() || input.charAt(0) != 'y' ) break;
else
ErrorLogging.logError("DEBUG: Potential for error: Un-initialised cameras.");
}
serialsSet = true; // switch (userInput)
for(String cameraName : OpenCVFacade.getCameraNames()) // {
{ // case 1:
if(ConfigFacade.getValue(cameraName,ConfigProperties.ACTIVE) != 0 && // println("Setting up cameras...");
ConfigFacade.getSerial(cameraName) == null ) // println("This may take a moment...");
serialsSet = false; // configureCameras();
} // camerasConfigured = true;
if(!serialsSet) // break;
{ // case 2:
prompt("You have not set the serial numbers for your DUTs yet! Are you sure you would like to continue? (y/N): "); // setDUTSerials();
String input = inputScanner.nextLine().toLowerCase().trim(); // break;
if( input.isBlank() || input.charAt(0) != 'y' ) break; // case 3:
else // setIterationCount();
ErrorLogging.logError("DEBUG: Potential for error: Un-initialised DUT Serial numbers."); // break;
} // case 4:
// setActiveCameras();
// break;
// case 5:
// if(!camerasConfigured)
// {
// prompt("You have not configured the cameras yet! Are you sure you would like to continue? (y/N): ");
// String input = inputScanner.nextLine().toLowerCase().trim();
// if( input.isBlank() || input.charAt(0) != 'y' ) break;
// else
// ErrorLogging.logError("DEBUG: Potential for error: Un-initialised cameras.");
// }
runTests(); // serialsSet = true;
break; // for(String cameraName : OpenCVFacade.getCameraNames())
case 6: // {
printHelp(); // if(ConfigFacade.getValue(cameraName,ConfigProperties.ACTIVE) != 0 &&
break; // ConfigFacade.getSerial(cameraName) == null )
case 8: // serialsSet = false;
break; // }
default: // if(!serialsSet)
//Input handling already done by inputFiltering() // {
} // prompt("You have not set the serial numbers for your DUTs yet! Are you sure you would like to continue? (y/N): ");
// String input = inputScanner.nextLine().toLowerCase().trim();
// if( input.isBlank() || input.charAt(0) != 'y' ) break;
// else
// ErrorLogging.logError("DEBUG: Potential for error: Un-initialised DUT Serial numbers.");
// }
} while (userInput != mainMenuOptionCount); // runTests();
// break;
// case 6:
// printHelp();
// break;
// case 8:
// break;
// default:
// //Input handling already done by inputFiltering()
// }
//} while (userInput != mainMenuOptionCount);
} }
//If anything ever goes wrong, catch the error and exit //If anything ever goes wrong, catch the error and exit

199
src/main/java/org/baxter/disco/ocr/MovementFacade.java
View file

@ -35,19 +35,6 @@ public class MovementFacade
*/ */
private static Thread runSwitchThread; private static Thread runSwitchThread;
/**
* Conversion factor from cm/s to PWM frequency.
*
* PWM to linear speed conversion:
* Motor controller should be set to 6400 pulses / revolution
* (See motor controller documentation)
* Fixture corkscrew has a lead of 3 revolutions / cm
* (Lead = thread pitch * # of thread starts)
*
* Frequency (Hz) = Speed (cm/s) * (pulses/rev) * (lead)
*/
private static final double PWM_FREQ_CONVERT = 19200;
/** /**
* Max allowed speed by current fixture design. * Max allowed speed by current fixture design.
* Motor appears to start acting erratically over 192kHz. * Motor appears to start acting erratically over 192kHz.
@ -65,26 +52,21 @@ public class MovementFacade
private static final int MIN_FREQUENCY = 10000; private static final int MIN_FREQUENCY = 10000;
/** /**
* Distance in cm the fixture needs to travel. * Fraction of the total travel time at speed to start slowing down.
*
* Distance between limit switches: ~80cm.
* Thickness of fixture arm: ~50cm.
* *** ABOVE MATH IS WRONG ***
* I don't know what I did wrong, but this value doesn't work
* properly if straight calculated.
* I will look into this more at some point.
*/ */
private static final int TRAVEL_DIST = 12; private static final double SLOW_POLL_FACTOR = 3.0 / 4.0;
/** /**
* What percentage of the travel to slow down the motor. * Amount to slow down the speed by.
*/ */
private static final double STEP_1 = 2.0/3.0; private static final int SPEED_DOWN_FACTOR = 2;
/** /**
* What percentage of the travel to slow down the motor farther. * Amount of distance to travel.
* Measured in... seemingly arbitrary units? Not sure on the math here.
* Set in {@link #findDistance()}
*/ */
private static final double STEP_2 = 5.0/6.0; private static double TRAVEL_DIST;
/** /**
* Frequency fed to the PWM pin, which the motor controller converts into movement speed. * Frequency fed to the PWM pin, which the motor controller converts into movement speed.
@ -231,7 +213,6 @@ public class MovementFacade
} }
}, "Run switch monitor."); }, "Run switch monitor.");
runSwitchThread.start(); runSwitchThread.start();
//ErrorLogging.logError("DEBUG: Lock thread started!");
//Initialise Pi4J //Initialise Pi4J
pi4j = Pi4J.newAutoContext(); pi4j = Pi4J.newAutoContext();
@ -249,6 +230,9 @@ public class MovementFacade
//Initialise PWM object. //Initialise PWM object.
pwm = pwmBuilder("pwm","PWM Pin",PWM_PIN_ADDR); pwm = pwmBuilder("pwm","PWM Pin",PWM_PIN_ADDR);
pwm.on(DUTY_CYCLE, FREQUENCY); pwm.on(DUTY_CYCLE, FREQUENCY);
//Find Distance and max speeds
calibrate();
} }
/** /**
@ -351,7 +335,7 @@ public class MovementFacade
public static int resetArm() public static int resetArm()
{ {
ErrorLogging.logError("DEBUG: --------------------------------------"); ErrorLogging.logError("DEBUG: --------------------------------------");
int counter = 0; int counter;
ErrorLogging.logError("DEBUG: Setting minimum frequency of PWM..."); ErrorLogging.logError("DEBUG: Setting minimum frequency of PWM...");
pwm.on(DUTY_CYCLE, MIN_FREQUENCY); pwm.on(DUTY_CYCLE, MIN_FREQUENCY);
if(upperLimit.isHigh()) if(upperLimit.isHigh())
@ -372,24 +356,29 @@ public class MovementFacade
motorEnable.on(); motorEnable.on();
ErrorLogging.logError("DEBUG: Is the upper limit switch reached? " + upperLimit.isHigh()); ErrorLogging.logError("DEBUG: Is the upper limit switch reached? " + upperLimit.isHigh());
while(!upperLimit.isHigh()) for(counter = 0; counter < Integer.MAX_VALUE; counter++)
{ {
try{ Thread.sleep(100); } try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
catch (Exception e) { ErrorLogging.logError(e); } if(upperLimit.isOn())
counter++; {
try{ Thread.sleep(1); } catch(Exception e){ErrorLogging.logError(e); }
if(upperLimit.isOn()) break;
}
} }
motorEnable.off(); motorEnable.off();
ErrorLogging.logError("DEBUG: Motor returned after " + counter + " polls."); ErrorLogging.logError("Motor returned after " + counter + " polls.");
ErrorLogging.logError("DEBUG: --------------------------------------"); ErrorLogging.logError("DEBUG: --------------------------------------");
return counter; return counter;
} }
/** /**
* Used to set the motor's max speed. * Used to programmatically determine the motor's max speed.
*/ */
public static void calibrate() private static void calibrate()
{ {
ErrorLogging.logError("Initial Calibration reset."); ErrorLogging.logError("Determining distance to limit switches...");
findDistance();
ErrorLogging.logError("Resetting arm to set speed.");
resetArm(); resetArm();
ErrorLogging.logError("Coarse calibrating..."); ErrorLogging.logError("Coarse calibrating...");
FREQUENCY = calib(MIN_FREQUENCY, MAX_FREQUENCY, 10000); FREQUENCY = calib(MIN_FREQUENCY, MAX_FREQUENCY, 10000);
@ -401,10 +390,64 @@ public class MovementFacade
} }
/** /**
* Find the max speed of the fixure between two points. * Used to programmatically find the distance between the upper and lower limit switches.
*/
private static void findDistance()
{
resetArm();
int downTravelCounter = 0;
int upTravelCounter = 0;
pwm.on(DUTY_CYCLE, MIN_FREQUENCY);
motorDirection.low();
motorEnable.on();
for(downTravelCounter = 0; downTravelCounter < Integer.MAX_VALUE; downTravelCounter++)
{
try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
if(lowerLimit.isOn())
{
try{ Thread.sleep(1); } catch(Exception e){ErrorLogging.logError(e); }
if(lowerLimit.isOn()) break;
}
}
motorEnable.off();
if(lowerLimit.isOff()) ErrorLogging.logError("False positive on findDistance down!");
int downTravelDist = downTravelCounter * MIN_FREQUENCY;
ErrorLogging.logError("DEBUG: Down travel distance found to be: " + downTravelDist);
ErrorLogging.logError("Down travel count: " + downTravelCounter);
motorDirection.high();
motorEnable.on();
for(upTravelCounter = 0; upTravelCounter < Integer.MAX_VALUE; upTravelCounter++)
{
try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
if(upperLimit.isOn())
{
try{ Thread.sleep(1); } catch(Exception e){ErrorLogging.logError(e); }
if(upperLimit.isOn()) break;
}
}
motorEnable.off();
if(upperLimit.isOff()) ErrorLogging.logError("False positive on findDistance up!");
int upTravelDist = upTravelCounter * MIN_FREQUENCY;
ErrorLogging.logError("DEBUG: Up travel distance found to be: " + upTravelDist);
ErrorLogging.logError("Up travel count: " + downTravelCounter);
if(Math.abs(upTravelCounter - downTravelCounter) > 3)
{
ErrorLogging.logError("DEBUG: Values differ too far to be error. Setting to lower value.");
}
int travelCounter = Math.min(upTravelCounter, downTravelCounter);
TRAVEL_DIST = travelCounter * MIN_FREQUENCY;
}
/**
* Find the max frequency to feed to the motor.
* *
* @param start Lowest speed to check * @param start Lowest frequency to check
* @param max Highest speed to check * @param max Highest frequency to check
* @param iterate How much to iterate by * @param iterate How much to iterate by
* *
* @return The largest safe value between start and max. * @return The largest safe value between start and max.
@ -424,10 +467,10 @@ public class MovementFacade
ErrorLogging.logError("DEBUG: Motor Frequency: " + FREQUENCY); ErrorLogging.logError("DEBUG: Motor Frequency: " + FREQUENCY);
ErrorLogging.logError("DEBUG: Motor calibrate on."); ErrorLogging.logError("DEBUG: Motor calibrate on.");
motorEnable.on(); motorEnable.on();
for(int j = 0; j < 20; j++) int TWO_SECONDS = 2 * TIME_CONVERSION;
for(int j = 0; j < TWO_SECONDS; j++)
{ {
try{ Thread.sleep(100); } try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
catch (Exception e){ ErrorLogging.logError(e); }
if(lowerLimit.isHigh()) if(lowerLimit.isHigh())
{ {
ErrorLogging.logError("DEBUG: Breaking loop early!"); ErrorLogging.logError("DEBUG: Breaking loop early!");
@ -445,7 +488,7 @@ public class MovementFacade
{ {
ErrorLogging.logError("DEBUG: Motor moved at speed " + i + ". Checking for errors."); ErrorLogging.logError("DEBUG: Motor moved at speed " + i + ". Checking for errors.");
if(resetArm() < 10 && i > 3.0) if(resetArm() < 10)
{ {
ErrorLogging.logError("DEBUG: Motor failed to move! Returning " + (i - iterate)); ErrorLogging.logError("DEBUG: Motor failed to move! Returning " + (i - iterate));
return i - iterate; return i - iterate;
@ -508,59 +551,59 @@ public class MovementFacade
if(limitSense.isHigh()) return FinalState.SAFE; if(limitSense.isHigh()) return FinalState.SAFE;
pwm.on(DUTY_CYCLE, FREQUENCY); pwm.on(DUTY_CYCLE, FREQUENCY);
int TRAVEL_TIME = (int)(TRAVEL_DIST / (FREQUENCY / PWM_FREQ_CONVERT)); int travelTime = (int)(TRAVEL_DIST / FREQUENCY);
int POLL_COUNT = TRAVEL_TIME * TIME_CONVERSION; int totalPollCount = travelTime * TIME_CONVERSION;
int VEL_STEP_1 = (int)(STEP_1 * POLL_COUNT); int highSpeedPolls = (int)(totalPollCount * SLOW_POLL_FACTOR);
int VEL_STEP_2 = (int)(STEP_2 * POLL_COUNT); int notHighSpeedPolls = totalPollCount - highSpeedPolls;
int medSpeedPolls = (int)(notHighSpeedPolls * SLOW_POLL_FACTOR);
ErrorLogging.logError("DEBUG: ================================="); int lowSpeedPolls = notHighSpeedPolls - medSpeedPolls;
ErrorLogging.logError("DEBUG: Total Poll count: " + POLL_COUNT);
ErrorLogging.logError("DEBUG: Transition 1: " + VEL_STEP_1);
ErrorLogging.logError("DEBUG: Transition 2: " + VEL_STEP_2);
ErrorLogging.logError("DEBUG: Travel time: " + TRAVEL_TIME);
ErrorLogging.logError("DEBUG: Travel speed: " + (FREQUENCY/PWM_FREQ_CONVERT));
ErrorLogging.logError("DEBUG: STEP_1: " + STEP_1);
ErrorLogging.logError("DEBUG: STEP_2: " + STEP_2);
ErrorLogging.logError("DEBUG: =================================");
motorEnable.on(); motorEnable.on();
for(int i = 0; i < (POLL_COUNT);i++) for(int i = 0; i < highSpeedPolls; i++)
{ {
try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); } try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
if(limitSense.isOn()) if(limitSense.isOn())
{ {
ErrorLogging.logError("DEBUG: Motor at lower limit switch early! Pre-emptively exiting loop on poll " + i); ErrorLogging.logError("DEBUG: Motor moved too fast! Stopping motor early.");
motorEnable.off();
output = FinalState.FAILED;
break; break;
} }
else if(i >= VEL_STEP_1 && i < VEL_STEP_2) }
{
if(output != FinalState.UNSAFE) if(motorEnable.isOn())
{ {
output = FinalState.UNSAFE; output = FinalState.UNSAFE;
ErrorLogging.logError("DEBUG: Slowing down."); pwm.on(DUTY_CYCLE, (FREQUENCY / SPEED_DOWN_FACTOR));
pwm.on(DUTY_CYCLE, (int)(FREQUENCY / 1.25)); for(int i = 0; i < medSpeedPolls; i++)
{
try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
if(limitSense.isOn())
{
ErrorLogging.logError("DEBUG: Motor only partially slowed down! Stopping motor early.");
motorEnable.off();
break;
} }
} }
else if(i >= VEL_STEP_2) }
if(motorEnable.isOn())
{ {
if(output != FinalState.SAFE)
{
ErrorLogging.logError("DEBUG: Slowing down more.");
pwm.on(DUTY_CYCLE, FREQUENCY / 2);
output = FinalState.SAFE; output = FinalState.SAFE;
pwm.on(DUTY_CYCLE, (FREQUENCY / SPEED_DOWN_FACTOR));
for(int i = 0; i < lowSpeedPolls; i++)
{
try{ Thread.sleep(POLL_WAIT); } catch(Exception e){ ErrorLogging.logError(e); }
if(limitSense.isOn())
{
ErrorLogging.logError("DEBUG: Motor slowed down completely, but hit limit switch early.");
motorEnable.off();
break;
} }
} }
} }
motorEnable.off(); motorEnable.off();
if(output == FinalState.FAILED)
ErrorLogging.logError("Motor moved too fast!");
else if(output == FinalState.UNSAFE)
ErrorLogging.logError("DEBUG: Motor only slowed down partially.");
else if(output == FinalState.SAFE)
{
if(limitSense.isOn()) ErrorLogging.logError("DEBUG: Motor slowed down successfully.");
else ErrorLogging.logError("DEBUG: Motor did not reach limit switch successfully.");
}
pwm.on(DUTY_CYCLE, FREQUENCY); pwm.on(DUTY_CYCLE, FREQUENCY);
return output; return output;
} }