Refer to Daybreak Motor and Motor Controller for background.

During competition, the motor and Controls system ran into two major issues:

1. When max current passed to the car by pressing on pedal, the entire car and Controls system shut off.

2. The max speed of vehicle was 9 mph with 25 Amps.

In this document, we outline tests need to be done to resolve the issues and ensure overall functionality of the motor. The suggested timeline is also included.

Basic Functionality / Safety Test

Motor Characterization and Debug Timeline

State Machine Test

We need to incorporate state machine change for next-gen. Current state machine contains error. See:
https://github.com/lhr-solar/Controls/issues/418#issue-2139630420

Development Considerations

• Do we want to implement next-gen state machine on Daybreak? The only change is minor changes/debugging in SW for one pedal mode.

Test Items

• State Transition Test (Previously SendTritium.c)

  • Simulation (I/O Board)

  • Hardware

    • Q: Do we need to hook everything up to battery?

    • A: We do not, we will need to test without battery for a while.

• Cruise States Test

• One Pedal Drive (OPD) Test

Basic (Related) Functionality Test

Test Items

• Display

  • Does it display motor information (speed) properly?

Safety Critical / Intra-solar Test

Tests that ensure robust communication among the systems are needed for the motor control and power.

Test Items

• CarCAN read/send

Performance Improvement Test

Physical load (after installing motors in mechanical framework) can affect the motor’s performance. Thus we specify tests that needs to be done when physical load is present.

Physical Load Impact Test

• Simulation

  •  

• Hardware

  • With Frame

  • With Dyno [WIP] – Motor characterization

    • Inquire Jacob.

10/5/2024 Update

Conversation with Prat/Parthiv/Ishan

To test the motor, we will to repurpose the old battery pack so we have a system that can reliably supply over 1A. Emech is going to look into repairing it.

We will then need to retrofit the current test bench with much longer legs. These legs can be held down with sandbags during testing to ensure that the motor does not come off of the mount.

Ideally this test would be with a dyno or brake to reduce the speed of the motor.

We will likely run the test outside with a very long usb cable to the motor controller for safety reasons.