EVPSIN32G4_DUAL triggers immediate overcurrent on startup (Closed-loop + Encoder)

[hayden1013]

Hello:

Currently, I am using the EVPSIN32G4_DUAL board, generating the code with MotorControl Workbench, and monitoring the system via Motor Pilot.

I am encountering an issue where an overcurrent fault is triggered immediately upon startup when using a closed-loop + Encoder configuration.

I can confirm that the motor hardware is fine, because it runs perfectly when driven using the PLL configuration. However, if I disable the overcurrent protection (OCP), the system just triggers other errors, such as driver protection or a startup failure.

Here are the troubleshooting steps I have already tried without success:

1. Reduced the Max. application Current from 13.6A to 5A.

2. Adjusted the Start-up parameters (duration: 500 ms / Alignment electrical angle of Id: 0 deg / Final current ramp value: 0.3A). Note: The motor still exhibits holding torque (shaft locks properly) during the open-loop test.

3. Decreased the Speed loop PI gains (both P and I) by a factor of 10.

4. Adjusted the Current Sensing parameters (T_rise from 300 ns to 600 ns / T_noise from 500 ns to 800 ns).

My troubleshooting approach so far has been focused on reducing the startup current and lowering the current sensing sensitivity. Could you please point me in the right direction or suggest what might be causing this issue? Any insights would be greatly appreciated.

Thank you!

[GMA]

Hello @hayden1013,

Verify that the U, V, and W motor phases are correctly associated with the U, V, and W pins on the CON3 and CON4 connectors. Verify that the EncA and EncB signals are correctly associated with the H1 and H2 inputs on the J5 and J6 connectors.

Use the main speed sensor as the STO-PLL and the auxiliary speed sensor as the quadrature encoder. Display the STOPLL_EL_ANGLE and ENCODER_EL_ANGLE signals, and verify that both signals are aligned.

[hayden1013]

Hello:

Here is my test plot with the PLL as the Main Sensor and the Encoder as the Auxiliary Sensor. The motor spun up normally and is running at around 1600 RPM.

Although the encoder signal climbs steadily, it appears to be updating far too slowly. Conversely, the PLL graph looks more normal, likely just limited by a low telemetry/transmission frequency. Is my understanding correct here? If so, what could be the potential causes for this behavior? I have verified that the PPR (Pulses Per Revolution) value is configured correctly, while other parameters like Counter Period and Filter remain at their default settings.

Additionally, I have encountered another issue: once the speed exceeds 1600 RPM, the encoder angle value completely freezes and stops updating, acting as if the sensor is no longer detecting anything. What could be causing this root issue?

Any insights or suggestions on where to look would be greatly appreciated!

[GMA]

Hello @hayden1013,

Use the MC Pilot high-frequency plot to verify electrical angle alignment.