Hardware Setup Guide - Fatigue Test ESP-NOW Unit

Overview

This guide covers the hardware setup for the Fatigue Test ESP-NOW Unit, including motor connections, encoder setup, and ESP32 configuration.

Hardware Requirements

Required Components

  1. ESP32 Development Board (ESP32-C6 recommended)
  2. TMC5160 Stepper Motor Driver (SPI interface)
  3. Stepper Motor (compatible with TMC5160)
  4. ABN Encoder (optional, for encoder-based bounds detection)
  5. Reference Switches (optional, for homing)
  6. Power Supply (appropriate for motor and ESP32)

Pin Configuration

SPI Interface (TMC5160)

The TMC5160 communicates via SPI. Default pin configuration (from test config):

  • MOSI: GPIO 23
  • MISO: GPIO 19
  • SCK: GPIO 18
  • CS: GPIO 5

Note: Pin configuration is managed by tmc51x0_test_config::GetDefaultPinConfig(). Modify test config if needed.

UART Interface (Debug/Control)

  • TX: GPIO 1 (UART0)
  • RX: GPIO 3 (UART0)
  • Baud Rate: 115200

ESP-NOW

  • WiFi Channel: 1 (configured in code)
  • MAC Address: Auto-detected, can be read from serial output

Motor Configuration

Test Rig Selection

The system uses a test rig configuration system. Edit main.cpp:

1
2

static constexpr tmc51x0_test_config::TestRigType SELECTED_TEST_RIG = 
    tmc51x0_test_config::TestRigType::TEST_RIG_FATIGUE;

Motor Parameters

Motor parameters are configured via tmc51x0_test_config::ConfigureDriverFromTestRig(). Key parameters:

  • Sense Resistor: Typically 50mĪ©
  • Supply Voltage: Motor supply voltage (e.g., 24V)
  • Rated Current: Motor rated current
  • Microsteps: Typically 256 microsteps

Motor Wiring

  1. Power Supply:
    • Connect motor power supply to TMC5160 VM/GND
    • Ensure adequate current capacity
    • Use appropriate voltage for your motor
  2. Motor Phases:
    • Connect motor phases to TMC5160 motor outputs
    • Verify phase wiring (swap if motor runs backwards)
  3. TMC5160 Configuration:
    • SPI interface to ESP32
    • Enable pin (if used)
    • DIAG pin (for diagnostics)

Encoder Setup (Optional)

ABN Encoder Wiring

If using encoder-based bounds detection:

  • A Phase: Connect to encoder A input
  • B Phase: Connect to encoder B input
  • Index: Optional, for homing

Note: Encoder configuration is managed by test rig config:

  • GetTestRigEncoderConfig<SELECTED_TEST_RIG>()
  • GetTestRigEncoderPulsesPerRev<SELECTED_TEST_RIG>()
  • GetTestRigEncoderInvertDirection<SELECTED_TEST_RIG>()

Encoder Requirements

  • Resolution: Sufficient for position monitoring
  • Interface: Quadrature encoder (A/B phases)
  • Mounting: Properly aligned with motor shaft

Reference Switches (Optional)

For homing and position reference:

  • Min Switch: Physical limit switch at minimum position
  • Max Switch: Physical limit switch at maximum position

Note: Current implementation uses bounds finding (StallGuard or encoder) rather than limit switches.

Power Supply

Requirements

  1. Motor Power:
    • Voltage: As specified for your motor (typically 12V-48V)
    • Current: Sufficient for motor operation (check motor specs)
    • Regulation: Stable voltage under load
  2. ESP32 Power:
    • Voltage: 3.3V or 5V (depending on board)
    • Current: ~200-500mA typical
    • Can share supply with TMC5160 logic supply

Power Sequencing

  1. Power on motor supply first
  2. Power on ESP32
  3. Allow initialization time (~1-2 seconds)

Mechanical Setup

Motor Mounting

  • Secure motor to test fixture
  • Ensure proper alignment
  • Check for mechanical binding

Load Configuration

  • Attach test load to motor shaft
  • Verify load is within motor specifications
  • Check for excessive friction or binding

Bounds Detection

  • StallGuard Method: No additional hardware needed
  • Encoder Method: Requires encoder properly mounted

Initial Testing

1. Serial Connection

Connect to ESP32 via USB/UART:

1
2
3
4
5
6

# Find serial port
ls /dev/ttyUSB*  # Linux
ls /dev/tty.*    # macOS

# Connect with serial monitor
screen /dev/ttyUSB0 115200

2. Verify Initialization

Look for startup messages:

1
2
3

ā•”ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•—
ā•‘         Fatigue Test Unit with ESP-NOW Communication                         ā•‘
ā•šā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•ā•

3. Test UART Commands

Try basic commands:

1
2

-s          # Show status
-h          # Show help

4. Test ESP-NOW Communication

  1. Power on test unit
  2. Note MAC address from serial output
  3. Configure MAC in remote controller
  4. Power on remote controller
  5. Verify communication

Troubleshooting

Motor Not Moving

  1. Check Power Supply:
    • Verify motor power is connected
    • Check voltage levels
    • Verify current capacity
  2. Check SPI Communication:
    • Verify SPI wiring
    • Check CS pin connection
    • Verify SPI clock speed
  3. Check Motor Wiring:
    • Verify phase connections
    • Check for shorts
    • Try swapping phases
  4. Check TMC5160 Configuration:
    • Verify driver is enabled
    • Check current settings
    • Verify microstep configuration

ESP-NOW Not Working

  1. Check MAC Address:
    • Verify MAC is correct in remote controller
    • Check both devices are on same WiFi channel
  2. Check Range:
    • Ensure devices are within range (~100-200m)
    • Check for interference
  3. Check Serial Output:
    • Look for ESP-NOW initialization messages
    • Check for error messages

Bounds Finding Fails

  1. StallGuard Method:
    • Check SGT threshold setting
    • Verify motor can actually stall
    • Check for false stall detection
  2. Encoder Method:
    • Verify encoder wiring
    • Check encoder pulses per revolution setting
    • Verify encoder is properly mounted

Serial Communication Issues

  1. Check Baud Rate: Must be 115200
  2. Check Wiring: Verify TX/RX connections
  3. Check USB Driver: Ensure drivers are installed

Safety Considerations

  1. Motor Power: Use appropriate safety measures for high-voltage motor supplies
  2. Mechanical Safety: Ensure proper mechanical stops to prevent over-travel
  3. Emergency Stop: Consider adding emergency stop functionality
  4. Current Limits: Set appropriate current limits in TMC5160 configuration

Calibration

StallGuard Calibration

If using StallGuard method:

  1. Run stallguard tuning tool (separate example)
  2. Determine optimal SGT threshold
  3. Configure in test rig settings

Encoder Calibration

If using encoder method:

  1. Verify encoder pulses per revolution
  2. Check encoder direction (invert if needed)
  3. Verify encoder mounting alignment

Maintenance

  1. Regular Checks:
    • Motor connections
    • Encoder alignment (if used)
    • Power supply stability
  2. Software Updates:
    • Keep firmware updated
    • Check for configuration changes
  3. Mechanical Maintenance:
    • Lubricate moving parts
    • Check for wear
    • Verify alignment