linear-Slide/Application/app_motor.c

#include "app_motor.h"

/* 当前位置相关：用于CiA402位置反馈 */
float current_absolute_pos_mm = 0.0f;
float last_move_start_pos_mm = 0.0f;

/* 电机内部状态机 */
Motor_State_t internal_state = STATE_SWITCH_ON_DISABLED;
Homing_State_t homing_state = HOMING_IDLE;

/* 兼容旧调试变量：值由StepLossMonitor同步更新 */
float error = 0.0f;
float distance = 0.0f;
float encoder_distance = 0.0f;
uint32_t steps = 0;

#define STEPLOSS_SETTLE_MS 200U
#define STEPLOSS_THRESHOLD_MM_DEFAULT 0.1f

/* 丢步检测运行态：集中管理，避免状态分散在多个全局变量 */
typedef struct
{
    /* 实时观测量 */
    float abs_error_mm;
    float cmd_distance_mm;
    float enc_distance_mm;
    uint32_t cmd_steps;

    /* 编码器16位计数扩展 */
    int32_t accum_pulses;
    uint16_t prev_raw_cnt;
    uint8_t prev_raw_valid;
    uint8_t motion_active;
    uint32_t prev_cmd_steps;

    /* 停止后延时上报 */
    uint8_t wait_stop_settle;
    uint32_t stop_tick_ms;
    uint8_t report_ready;
    float report_error_mm;
    float threshold_mm;
    Stepper_state_t prev_state;
} StepLossMonitor_t;

static StepLossMonitor_t s_step_loss = {
    .threshold_mm = STEPLOSS_THRESHOLD_MM_DEFAULT,
    .prev_state = STOP,
    .prev_cmd_steps = 0U,
};

static float Normalize_FollowingErrorThreshold(float threshold_mm, float fallback_mm)
{
    if (!(threshold_mm == threshold_mm))
    {
        return fallback_mm;
    }

    if (threshold_mm <= 0.0f)
    {
        return fallback_mm;
    }

    if (threshold_mm > SOFT_LIMIT_MAX_MM)
    {
        return SOFT_LIMIT_MAX_MM;
    }

    return threshold_mm;
}

static void Sync_FollowingErrorThreshold_From_OD(void)
{
    OD_entry_t *entry_ferr = OD_find(OD, CIA402_INDEX_FOLLOWING_ERROR_WINDOW);

    if (entry_ferr == NULL)
    {
        return;
    }

    float32_t threshold_mm = 0.0f;
    if (OD_get_f32(entry_ferr, 0, &threshold_mm, true) == ODR_OK)
    {
        s_step_loss.threshold_mm =
            Normalize_FollowingErrorThreshold((float)threshold_mm, s_step_loss.threshold_mm);
    }
}

static void Update_PP_FollowingError_StatusBit(float stop_error_mm)
{
    OD_entry_t *entry_mode = OD_find(OD, CIA402_INDEX_OP_MODE);
    OD_entry_t *entry_sw = OD_find(OD, CIA402_INDEX_STATUSWORD);

    if (entry_mode == NULL || entry_sw == NULL)
    {
        return;
    }

    int8_t mode = 0;
    OD_get_i8(entry_mode, 0, &mode, true);
    if (mode != 1)
    {
        return;
    }

    CO_LOCK_OD(CO->CANmodule);
    uint16_t sw = 0;
    OD_get_u16(entry_sw, 0, &sw, true);

    if (stop_error_mm > s_step_loss.threshold_mm)
    {
        sw |= CIA402_STATUS_OMS_13;
    }
    else
    {
        sw &= (uint16_t)(~CIA402_STATUS_OMS_13);
    }

    OD_set_u16(entry_sw, 0, sw, true);
    CO_UNLOCK_OD(CO->CANmodule);
}

static void Update_FollowingErrorActual_To_OD(float abs_error_mm)
{
    OD_entry_t *entry_ferr_actual = OD_find(OD, CIA402_INDEX_FOLLOWING_ERROR_ACTUAL);
    float32_t ferr_mm = (float32_t)abs_error_mm;

    if (entry_ferr_actual == NULL)
    {
        return;
    }

    if (CO != NULL)
    {
        CO_LOCK_OD(CO->CANmodule);
        (void)OD_set_f32(entry_ferr_actual, 0, ferr_mm, true);
        CO_UNLOCK_OD(CO->CANmodule);
    }
    else
    {
        (void)OD_set_f32(entry_ferr_actual, 0, ferr_mm, true);
    }
}

/* 核心运动分发：先做安全判断，再按模式进入回零/位置模式处理 */
static void Process_Motion_Logic(void)
{
    /* 未使能运行时，强制停机并维持状态反馈 */
    if ((internal_state != STATE_OPERATION_ENABLED) && (stepper_1.run_flag == 0u))
    {
        if (stepper_1.state != STOP)
        {
            Int_TMC2209_stop();
            stepper_1.state = STOP;
        }
        homing_state = HOMING_IDLE;
        Update_Motion_State_To_OD();
        return;
    }

    Update_Motion_State_To_OD();

    OD_entry_t *entry_mode = OD_find(OD, CIA402_INDEX_OP_MODE);
    OD_entry_t *entry_mode_disp = OD_find(OD, CIA402_INDEX_OP_MODE_DISPLAY);

    if (entry_mode != NULL)
    {
        int8_t mode = 0;
        OD_get_i8(entry_mode, 0, &mode, true);

        if (entry_mode_disp != NULL)
        {
            OD_set_i8(entry_mode_disp, 0, mode, true);
        }

        switch (mode)
        {
        case 6:
            Handle_Homing_Mode();
            break;
        case 1:
            Handle_Position_Mode();
            break;
        default:
            break;
        }
    }
}

void App_Motor_Init(void)
{
    /* 统一初始化运行态与位置基准 */
    current_absolute_pos_mm = 0.0f;
    last_move_start_pos_mm = 0.0f;
    homing_state = HOMING_IDLE;
    internal_state = STATE_SWITCH_ON_DISABLED;
    Int_Encoder_Init();
    debug_printf("App Motor Initialized.");
}

void App_Motor_Process(void)
{
    Sync_FollowingErrorThreshold_From_OD();
    Update_FollowingErrorActual_To_OD(s_step_loss.abs_error_mm);

    /* 先跑CiA402状态机，再执行业务运动逻辑 */
    Process_StateMachine();
    Process_Motion_Logic();

    float stop_error_mm = 0.0f;
    if (App_Motor_TryGetStopError(&stop_error_mm))
    {
        Update_PP_FollowingError_StatusBit(stop_error_mm);

        /* 回零流程不输出StepLoss误差日志，避免与“回零成功/失败”语义混淆 */
        if (homing_state == HOMING_IDLE)
        {
            debug_printf("[StepLoss] stop+200ms error = %.6f mm", stop_error_mm);
        }
    }
}

void App_Motor_StepLossCheck(void)
{
    /* 周期读取硬件计数与已发步数（TIM12中断调用） */
    uint16_t raw_cnt = (uint16_t)__HAL_TIM_GET_COUNTER(&htim1);
    uint8_t rebase_now = 0U;
    s_step_loss.cmd_steps = stepper_1.step_count;

    /* 新动作开始时重置累计基准，避免跨动作串扰 */
    if (stepper_1.state != STOP)
    {
        if ((!s_step_loss.motion_active) || (s_step_loss.cmd_steps < s_step_loss.prev_cmd_steps))
        {
            s_step_loss.motion_active = 1U;
            s_step_loss.accum_pulses = 0;
            s_step_loss.prev_raw_cnt = raw_cnt;
            s_step_loss.prev_raw_valid = 1U;
            rebase_now = 1U;
        }
    }
    else if (s_step_loss.motion_active)
    {
        s_step_loss.motion_active = 0U;
    }

    /* 首次采样仅建立基准，不计算位移增量 */
    if (!s_step_loss.prev_raw_valid)
    {
        s_step_loss.prev_raw_cnt = raw_cnt;
        s_step_loss.prev_raw_valid = 1U;
    }

    /* int16差分可自然处理16位计数器回绕（溢出/下溢） */
    int16_t delta = 0;
    if (rebase_now)
    {
        /* New move baseline: skip one diff sample to avoid counter-reset jump. */
    }
    else
    {
        delta = (int16_t)(raw_cnt - s_step_loss.prev_raw_cnt);
        s_step_loss.accum_pulses += (int32_t)delta;
        s_step_loss.prev_raw_cnt = raw_cnt;
    }
    s_step_loss.prev_cmd_steps = s_step_loss.cmd_steps;

    /* 输出扩展后的总脉冲给上层使用 */
    encoder_1.pulses = s_step_loss.accum_pulses;
    encoder_1.overflow = (uint16_t)(abs(encoder_1.pulses) / 65536);

    /* 统一换算为mm并计算绝对误差 */
    s_step_loss.cmd_distance_mm = (float)s_step_loss.cmd_steps / STEPS_PER_MM;
    s_step_loss.enc_distance_mm = (float)abs(encoder_1.pulses) * STICK_LEAD / (float)ENCODER_PULSES_PER_CIRCLE;
    s_step_loss.abs_error_mm = s_step_loss.enc_distance_mm - s_step_loss.cmd_distance_mm;
    if (s_step_loss.abs_error_mm < 0.0f)
    {
        s_step_loss.abs_error_mm = -s_step_loss.abs_error_mm;
    }

    /* 同步旧调试变量，便于观察窗口/旧日志继续使用 */
    steps = s_step_loss.cmd_steps;
    distance = s_step_loss.cmd_distance_mm;
    encoder_distance = s_step_loss.enc_distance_mm;
    error = s_step_loss.abs_error_mm;

    /* 运动中不出最终结论，仅标记“停稳后需要上报一次” */
    if (stepper_1.state != STOP)
    {
        s_step_loss.wait_stop_settle = 1U;
        s_step_loss.report_ready = 0U;
        s_step_loss.prev_state = stepper_1.state;
        return;
    }

    /* 从运动态切换到STOP时，开始计时稳定窗口 */
    if (s_step_loss.prev_state != STOP)
    {
        s_step_loss.prev_state = STOP;
        s_step_loss.stop_tick_ms = HAL_GetTick();
        return;
    }

    /* STOP持续到阈值后，锁存一次最终误差 */
    if (s_step_loss.wait_stop_settle &&
        ((uint32_t)(HAL_GetTick() - s_step_loss.stop_tick_ms) >= STEPLOSS_SETTLE_MS))
    {
        s_step_loss.report_error_mm = s_step_loss.abs_error_mm;
        s_step_loss.report_ready = 1U;
        s_step_loss.wait_stop_settle = 0U;
    }
}

/* 一次性读取“停止后最终误差”；读取成功后自动清ready标志 */
bool App_Motor_TryGetStopError(float *err_mm)
{
    if (!s_step_loss.report_ready)
    {
        return false;
    }

    if (err_mm != NULL)
    {
        *err_mm = s_step_loss.report_error_mm;
    }

    s_step_loss.report_ready = 0U;
    return true;
}