Project Status: Active Development 🚧
Currently iterating through hardware and software implementations. While the core design is complete, we're rigorously testing and refining the control systems.
== Versions ==
Currently developing 4 variants:
[HIGH POWER - 10A]
• Board-mounted encoder version
• External encoder version (FFC connection)
[STANDARD - 4.1A]
• Board-mounted encoder version
• External encoder version (FFC connection)
== Technical Deep-Dive ==
[Motor Requirements]
• Extended/through shaft or secondary shaft (e.g., gear systems)
• Magnet mounting capability
• 6mm spacing requirement between magnet and encoder
[Control System]
The heart of DCServo AE is its sophisticated PID controller with several advanced features:
• Fixed 1ms discrete time steps
• Trapezoidal integration
• Back-calculation anti-windup system
• Derivative on measurement (prevents derivative kick)
• Low-pass filtered derivative term
• Deadband management
• Disturbance detection and automatic reset
• Real-time parameter tuning via CAN
[Real-Time Configuration]
ALL parameters are configurable via CAN during operation:
• PID gains (Kp, Ki, Kd)
• Maximum speed
• Error thresholds
• Anti-windup gains
• Low-pass filter time constant
• Disturbance thresholds
• Integration limits
[Hardware Specifications]
• Input Voltage: 6-36V (38V absolute maximum)
• Current Rating: 4.1A/10A depending on version
• Communication: CAN bus only
• Theoretical Resolution: 0.025 degrees
• Practical Resolution: 0.05 degrees
• Board Cost: ~$10 (components only)
== Implementation Details ==
The control loop implements several crucial features:
1. Trapezoidal integration for improved accuracy
2. Back-calculation anti-windup using adjustable gain
3. Derivative on measurement instead of error
4. Low-pass filtering on derivative term
5. Automatic reset on large disturbances
6. Output limiting with proper saturation handling
== Next Steps ==
[Immediate Focus]
• Software refinement
• Performance testing and validation
• Documentation development
• Creation of basic usage examples
[Future Plans]
• Mechanical design for enclosures
• Performance characterization under various loads
• Example applications and integration guides
== Get Involved ==
Current priorities for contribution:
1. Testing with different motor types
2. Mechanical design for mounting solutions
3. Documentation improvement
4. Use case validation
All design files will be open-source:
• Hardware: PCB designs (KiCAD)
• Software: STM32 firmware (C)
• Documentation: Assembly and usage guides
Stay tuned for:
• Prototype demonstrations
• Performance metrics
• Assembly guides
• Configuration tools
Want to contribute? The project especially needs help with mechanical design for different motor mounting solutions!
== Why DCServo AE? ==
• Complete solution: controller + driver + encoder
• Highly configurable via CAN
• Advanced control algorithms
• Open source hardware and software
• Affordable (~$10 board cost)
• Compact form factor
• Real-time parameter adjustment
Remember: This is an active development project. While the core design is complete, we're continuously improving and validating the implementation. Contributors and testers welcome!