ESP-32 BLDC Robot Actuator Controller

Description

Based on my previous design replacing PSOC4 with an ESP-32 WROOM-32D Module.

On-board SPI absolute magnetic encoder (for joint position) and an external SPI absolute magnetic encoder for BLDC motor communication.
DRV8305 Smart MOSFET Driver with 3x Current sensors.

6x FETs
3x 2mOhms Shunt Resistors
3V3 @ 600mA SM Regulator
MOSFET Temperature Monitor
External Temperature Sensor Connector
Voltage Monitor
USB for Programming

Communications
Wifi
Bluetooth
CAN 2.0B
I2C Qwiic (For OLED Display)

Files

Brushless ESP-32 REV0.pdf

Schematic

Adobe Portable Document Format - 1009.53 kB - 03/31/2020 at 08:01

Preview

Project Logs

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Teddy-Way / Hover-Teddy
Paul Gould • 05/10/2021 at 16:47 • 0 comments

New Project with the controller here.
https://hackaday.io/project/179695-teddy-way-hover-teddy
Revision 4_1
Paul Gould • 11/08/2020 at 13:52 • 0 comments
Now with onboard USB for Arduino Programming and diagnostics. 30A @ 30V (~1kW)
- Made for JLCPCB SMT assembly (minus WROOM, Tact switches and connectors)
- switched to mostly 0402 components to save space
- Can fit either the ESP32-WROOM-32U (U.FL antenna Connector) and 32D (PCB antenna)
- CAN connectors on the same side
- Better/centre location for MOSFET temp sensor
- Two 2.54 top mount connectors for Servos, FANs or limit switches (2 IO pins)
- Fixed power supply switch over (Can be powered and programmed via USB)
- Fixed missing test to 0V connection on MA730/MA702 encoder
- Added Pull down for IO12
- Added Tactile Switches for Boot and RST/Enable

MCPWM with deadband

Paul Gould • 10/04/2020 at 06:23 • 0 comments

Still helping u/_jeem_

Syncronising the start pulses

Half bridge MOSFET control and avoiding shoot through

PWMxA is the highside FET

PWMxB is the lowside FET

High = FET on

#include "driver/mcpwm.h"
#include "soc/mcpwm_reg.h"
#include "soc/mcpwm_struct.h"
#include "wiring_private.h" // pinPeripheral() function
 
// MCPWM Pins
#define GPIO_PWM0A_OUT 15   //Set GPIO 15 as PWM0A
#define GPIO_PWM0B_OUT 02   //Set GPIO 02 as PWM0B
#define GPIO_PWM1A_OUT 0   //Set GPIO 00 as PWM1A
#define GPIO_PWM1B_OUT 04   //Set GPIO 04 as PWM1B
#define GPIO_PWM2A_OUT 16   //Set GPIO 16 as PWM2A
#define GPIO_PWM2B_OUT 17   //Set GPIO 17 as PWM2B

static void setup_mcpwm_pins()
{
    Serial.println("initializing mcpwm control gpio...n");
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM0A, GPIO_PWM0A_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM0B, GPIO_PWM0B_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM1A, GPIO_PWM1A_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM1B, GPIO_PWM1B_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM2A, GPIO_PWM2A_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM2B, GPIO_PWM2B_OUT);  
} // setup_pins()

static void setup_mcpwm()
{
   setup_mcpwm_pins();

   mcpwm_config_t pwm_config;
   pwm_config.frequency = 4000;  //frequency = 20000Hz
   pwm_config.cmpr_a = 50.0;      //duty cycle of PWMxA = 50.0%
   pwm_config.cmpr_b = 50.0;      //duty cycle of PWMxB = 50.0%
   pwm_config.counter_mode = MCPWM_UP_COUNTER; //MCPWM_UP_DOWN_COUNTER; // Up-down counter (triangle wave)
   pwm_config.duty_mode = MCPWM_DUTY_MODE_0; // Active HIGH
   mcpwm_init(MCPWM_UNIT_0, MCPWM_TIMER_0, &pwm_config);    //Configure PWM0A & PWM0B with above settings
   mcpwm_init(MCPWM_UNIT_0, MCPWM_TIMER_1, &pwm_config);    //Configure PWM0A & PWM0B with above settings
   mcpwm_init(MCPWM_UNIT_0, MCPWM_TIMER_2, &pwm_config);    //Configure PWM0A & PWM0B with above settings
   mcpwm_deadtime_enable(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_ACTIVE_HIGH_COMPLIMENT_MODE, 40, 40); 
   mcpwm_deadtime_enable(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_ACTIVE_HIGH_COMPLIMENT_MODE, 40, 40);   
   mcpwm_deadtime_enable(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_ACTIVE_HIGH_COMPLIMENT_MODE, 40, 40);

   mcpwm_sync_enable(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_SELECT_SYNC_INT0, 0);
   mcpwm_sync_enable(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_SELECT_SYNC_INT0, 0);
   mcpwm_sync_enable(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_SELECT_SYNC_INT0, 0);
  
   MCPWM0.timer[0].sync.out_sel = 1;
   delayMicroseconds(1000);
   MCPWM0.timer[0].sync.out_sel = 0;

   int pwm0 = 50;
   int pwm1 = 30;
   int pwm2 = 10;
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_OPR_A, pwm0);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_OPR_B, pwm0);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_OPR_A, pwm1);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_OPR_B, pwm1);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_OPR_A, pwm2);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_OPR_B, pwm2);
} // setup_mcpwm

void setup() {
  setup_mcpwm();
}
 
void loop() {
}

This is not ideal as I still have to set the duty cycle for both PWMxA and PWMxB and this could be prone to errors.

I would like to use PWMxA only

I thought that

MCPWM_ACTIVE_RED_FED_FROM_PWMXA

MCPWM_ACTIVE_RED_FED_FROM_PWMXB

would work correctly but it does not.

Reddit Help u/_jeem_

Paul Gould • 10/02/2020 at 13:30 • 0 comments

https://www.reddit.com/r/esp32/comments/j0lbrl/update_how_to_remove_delay_between_pwm_signals/

#include "driver/mcpwm.h"
#include "soc/mcpwm_reg.h"
#include "soc/mcpwm_struct.h"
#include "wiring_private.h" // pinPeripheral() function
 
// MCPWM Pins
#define GPIO_PWM0A_OUT 15   //Set GPIO 15 as PWM0A
#define GPIO_PWM0B_OUT 02   //Set GPIO 02 as PWM0B
#define GPIO_PWM1A_OUT 0   //Set GPIO 00 as PWM1A
#define GPIO_PWM1B_OUT 04   //Set GPIO 04 as PWM1B
#define GPIO_PWM2A_OUT 16   //Set GPIO 16 as PWM2A
#define GPIO_PWM2B_OUT 17   //Set GPIO 17 as PWM2B

static void setup_mcpwm_pins()
{
    Serial.println("initializing mcpwm control gpio...n");
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM0A, GPIO_PWM0A_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM0B, GPIO_PWM0B_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM1A, GPIO_PWM1A_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM1B, GPIO_PWM1B_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM2A, GPIO_PWM2A_OUT);
    mcpwm_gpio_init(MCPWM_UNIT_0, MCPWM2B, GPIO_PWM2B_OUT);  
} // setup_pins()

static void setup_mcpwm()
{
   setup_mcpwm_pins();

   mcpwm_config_t pwm_config;
   pwm_config.frequency = 40000;  //frequency = 20000Hz
   pwm_config.cmpr_a = 50.0;      //duty cycle of PWMxA = 50.0%
   pwm_config.cmpr_b = 50.0;      //duty cycle of PWMxB = 50.0%
   pwm_config.counter_mode = MCPWM_UP_COUNTER; //MCPWM_UP_DOWN_COUNTER; // Up-down counter (triangle wave)
   pwm_config.duty_mode = MCPWM_DUTY_MODE_0; // Active HIGH
   mcpwm_init(MCPWM_UNIT_0, MCPWM_TIMER_0, &pwm_config);    //Configure PWM0A & PWM0B with above settings
   mcpwm_init(MCPWM_UNIT_0, MCPWM_TIMER_1, &pwm_config);    //Configure PWM0A & PWM0B with above settings
   mcpwm_init(MCPWM_UNIT_0, MCPWM_TIMER_2, &pwm_config);    //Configure PWM0A & PWM0B with above settings

   mcpwm_sync_enable(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_SELECT_SYNC_INT0, 0);
   mcpwm_sync_enable(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_SELECT_SYNC_INT0, 0);
   mcpwm_sync_enable(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_SELECT_SYNC_INT0, 0);
  
   MCPWM0.timer[0].sync.out_sel = 1;
   delayMicroseconds(100);
   MCPWM0.timer[0].sync.out_sel = 0;

   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_OPR_A, 70);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_0, MCPWM_OPR_B, 60);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_OPR_A, 50);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_1, MCPWM_OPR_B, 40);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_OPR_A, 30);
   mcpwm_set_duty(MCPWM_UNIT_0, MCPWM_TIMER_2, MCPWM_OPR_B, 20);
} // setup_mcpwm

void setup() {
  setup_mcpwm();
}
 
void loop() {
}

Joint Control - Cycloidal Brushless Actuator
Paul Gould • 09/04/2020 at 15:19 • 0 comments
Haptic Control using ESP-Now
Paul Gould • 08/16/2020 at 16:51 • 0 comments
Prototype is controlling a BLDC motor
Paul Gould • 07/29/2020 at 16:18 • 0 comments
Boards can in from JLC PCB, components can in from LCSC and Mouser.
Hand populated the first one, testing as I went. I have a stencil for the next few.
A few little mistakes.
- Auto Power switch over between USB 5V and Battery Voltage had a high forward voltage and had to be replaced.
- Needed a pull down on ESP-32 IO12
- Had to Parallel Caps for the Charge Pump because I ordered the wrong one.
Programs via Arduino IDE using USB-TTL-3V3
I can control a motor and a joint's position via bluetooth and display into on the I2C OLED (FET Temp, Battery Voltage, Joint Position, Motor current).
Has two absolute magnetic encoders, for for motor position and one for joint position
I do not recommend Bluetooth/wifi for joint control.
CAN is also up and running.
10 boards on order at JLC
Paul Gould • 06/14/2020 at 16:30 • 0 comments
Connectors clockwise from the top
- BLDC motor connectors & Power In/Out
- CAN in/out
- qwiic
- ESP-32 Prog
- Encoder SPI
- Fan or Servo CTRL
- CAN out/in
Connectors on the back
- FAN or Servo
- ESP-32 Prog
- Pot
ESP-32 and DRV8305N Schematic
Paul Gould • 03/31/2020 at 08:00 • 0 comments

PDF in files
SPI in an IRQ
Paul Gould • 02/27/2020 at 16:39 • 0 comments
The standard SPI Transfer code does tot work well in an IRQ mainly becaise it is run out of FLASH. Uese the IRAM_ATTR to put it in RAM.
Other digitalWrte() is slow and should not be uses in the IRQ.
Use GPIO.out_w1ts = ((uint32_t)1 << IO_PIN_Number); to set the pin high
Use GPIO.out_w1ts = ((uint32_t)1 << IO_PIN_Number); to set the pin low
This can only be used when the IO_PIN_Number is 0-31
There is other code for 32-39 pins.
SPI Set-up
#include "driver/periph_ctrl.h"
#include "driver/spi_master.h"
#include "soc/gpio_sig_map.h"
#include "soc/spi_reg.h"
#include "soc/dport_reg.h"
#include "soc/spi_struct.h"
static const int spiClk = 4000000; // 1 MHz
SPIClass * hspi = NULL;
```
void IRAM_ATTR SPIInit(void)
{
  hspi = new SPIClass(HSPI);
  hspi->begin(); 
  pinMode(INT_ENC_nCS, OUTPUT);
  pinMode(EXT_ENC_nCS, OUTPUT);
  pinMode(DRV_nSCS, OUTPUT);
  GPIO.out_w1ts = ((uint32_t)1 << INT_ENC_nCS);
  GPIO.out_w1ts = ((uint32_t)1 << EXT_ENC_nCS);
  GPIO.out_w1ts = ((uint32_t)1 << DRV_nSCS);
  hspi->beginTransaction(SPISettings(spiClk, MSBFIRST, SPI_MODE1));
  SPI2.mosi_dlen.usr_mosi_dbitlen = (1 * 16) - 1;
  SPI2.miso_dlen.usr_miso_dbitlen = (1 * 16) - 1;
}
```
void IRAM_ATTR SPI_Read_Encoder(){ GPIO.out_w1tc = ((uint32_t)1 << INT_ENC_nCS); SPI2.data_buf[0] = 0xFFFF; SPI2.cmd.usr = 1; while(SPI2.cmd.usr); GPIO.out_w1ts = ((uint32_t)1 << INT_ENC_nCS); encoder_int = SPI2.data_buf[0] & 0xFFFF; if(!SPI2.ctrl.rd_bit_order){ encoder_int = (encoder_int >> 8) | (encoder_int << 8); } encoder_int = encoder_int & 0x3FFF ; }

View all 14 project logs

Discussions

Pierre Schippers wrote 11/06/2021 at 18:48

Hello, look great but i can not compile the code for the esp32. Is there a source for mcpwm.h file I got these error:

MCPWM_SELECT_SYNC_INT0' was not declared in this scope

Are there any sugestions ?

Are you sure? yes | no

Scrungo-Beepis wrote 04/27/2021 at 18:24

These look so cool! Thank you for just giving us the schematics for free!

Are you sure? yes | no

Alex wrote 03/29/2021 at 17:08

Hi Paul, looks great! I love that low cost WiFi enabled controllers plus solid state encoders and low cost out runners are finally intersecting. Exciting time for medium performance smallish robotics.

I'd love to build one of these for an application I'm working on, are you still planning to release the PCBA files?

Are you sure? yes | no

scott nellis wrote 03/26/2021 at 05:29

How close is you're current design to the PDF you have uploaded?

Are you sure? yes | no

John Lauer wrote 11/13/2020 at 17:43

You're using DRV8305 in your design. The MIT Mini Cheetah uses the DRV8323. They seem to have very similar specs other than the voltage ranges, which don't really matter much. Are these basically almost the same chip thus it doesn't matter much? The price seems to be around $5 on Digikey for DRV8305 and $4 for DRV8323, so just based on price seems like DRV8305 has more features/is newer?

Are you sure? yes | no

Paul Gould wrote 11/13/2020 at 18:25

DRV8305 is available on JLCPCB assembly service. DRV8323RH is a better Chip. Less external components with integrated Buck and less/better connections and routing to FETs. 8323 uses less PCB area. I have been designing a mini 10-20A ESP-32 WROOM controller about the 8323RH. Will also make a prototype soonish.

Are you sure? yes | no

John Lauer wrote 12/08/2020 at 07:36

Looks like JLCPCB now has DRV8323 listed in their SMT parts library. I don't recall seeing it listed there before.

https://jlcpcb.com/parts/componentSearch?searchTxt=drv8323

Are you sure? yes | no

gumush wrote 11/12/2020 at 14:13

ordering assembled from JLCPCB will be great. Thanks

Are you sure? yes | no

John Lauer wrote 11/08/2020 at 04:12

Any chance you might be up for releasing the board files for this? I'm really interested in it.

Are you sure? yes | no

Paul Gould wrote 11/08/2020 at 14:19

Good timing. I have been working on fixing/improving this design for the past week. Check out the latest update. Once do a new prototype and get it working, I'll release the files. I'm hoping you can just order them directly from JLCPCB.

Are you sure? yes | no

John Lauer wrote 11/09/2020 at 01:23

Sweet! The update looks awesome. Can't wait to order my own from JLCPCB since I've been wanting to use their SMT assembly service.

Are you sure? yes | no

John Lauer wrote 11/09/2020 at 02:05

BTW, just bought a couple of low KV 50mm diameter brushless motors https://www.aliexpress.com/item/4000734710615.html to test with. They're pretty cheap at $17 with shipping, but seem to have similar kv and size to your Multistar 5010 motors. If your latest design is 30A at 30V then these seem to have the right specs.

Are you sure? yes | no

Paul Gould wrote 11/09/2020 at 16:13

@John Lauer Those motors aren't great (sorry). Most brushless motors state the dimensions of the stator 50mm dia and 10 mm high. Those motors state the dimensions of the bell. Also the magnets are thin and not curved. These are the same as flycat in the following link. http://build-its-inprogress.blogspot.com/2016/01/motor-characterization-for-small.html
I use https://gogo-rc.com/store/index.php?route=product/product&product_id=3493

Are you sure? yes | no

John Lauer wrote 11/10/2020 at 05:05

Ok, gotcha. That blog post was a great find. I cancelled that order and got your suggestion instead. I also ordered a couple 4112 and 3508 motors from the same brand as well because I may need to make some smaller actuators too. https://www.aliexpress.com/item/32490567876.html and https://www.aliexpress.com/item/32509216587.html

Are you sure? yes | no

LucasJ1906 wrote 10/28/2020 at 10:48

Great Project , thank you for sharing. I'm fascinating to see how technologies is just being democratize and how you realise project that seems to be unfeasible, may be 10 years ago for, by just one person! Congratulations !

Would it be possible to use digital encoder using RS485 communication protocol ?

Are you still planing to share sources (BOM, Schématics, PCB, etc...)?

Thank you again and kinds regards

Are you sure? yes | no

Adam Donovan wrote 05/10/2020 at 13:54

Great Paul, I really look forward to build one.

Are you sure? yes | no

Gilouli wrote 04/30/2020 at 07:56

Love your project., very interesting.

Are you sure? yes | no

David Gonzalez wrote 04/26/2020 at 19:01

Hey Paul, I'm trying to do something similar with an ESP32, an L293 driver, an AMT103 encoder, a tiny brushless motor and the Arduino IDE. I have successfully controlled the position of the motor with an Arduino Uno but I am having problems with the ESP, I think the problem is syncing the PWM signals with the ESP32. I saw you found a problem with the MCPWM.h file and I fixed mine but I still don't get phase-corrected PWM signals. I tried with your example codes but have had no luck. Do you have any advice or have you found anything new to do so? Thanks you!

Are you sure? yes | no

marvinhotz wrote 05/08/2020 at 07:40

I've made something similar. The ESP has normally some serious timing issues.

You should look the Video of Andreas Spiess..

Because of that I am using a Teensy 3.2 and modulating a sine wave for a asynchron motor.

200kHz interrupt routine is working fine...

Probably it works with the right code... : /

Are you sure? yes | no

Paul Gould wrote 06/14/2020 at 16:47

It took alot of work to get the code to work. The examples work fine for me. It could have been a different version of the drivers/libraries. I will try it with the new Arduino build and let you know.

Are you sure? yes | no

David Gonzalez wrote 07/21/2020 at 17:13

I got it working. I tried with a fresh install and added the lines needed in the MCPWM.h file. Thanks for your help and for sharing your findings!

Are you sure? yes | no

[deleted]

[this comment has been deleted]

Paul Gould wrote 10/04/2020 at 16:10

Nice project. What is the update rate? How are you doing back emf?

Are you sure? yes | no

zhuangfengzi wrote 04/01/2020 at 02:51

Great job!

Looking forward to your work!

Are you sure? yes | no

Lukas wrote 03/31/2020 at 06:28

Amazing work, would really like to see more! Got stuck on mine with the part selection, are you planning on sharing your PCB files and BOM?

Are you sure? yes | no

Paul Gould wrote 03/31/2020 at 08:05

I've added the Schematic as a PDF. I will open source the files after I've made a prototype and proved that it works.

Are you sure? yes | no

ESP-32 BLDC Robot Actuator Controller

Description

Files

Brushless ESP-32 REV0.pdf

Project Logs

Collapse

Teddy-Way / Hover-Teddy

Revision 4_1

MCPWM with deadband

Reddit Help u/_jeem_

Joint Control - Cycloidal Brushless Actuator

Haptic Control using ESP-Now

Prototype is controlling a BLDC motor

10 boards on order at JLC

ESP-32 and DRV8305N Schematic

SPI in an IRQ

Discussions

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ESP-32 BLDC Robot Actuator Controller

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Brushless ESP-32 REV0.pdf

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