feat: add anti-cogging calibration with heap memory management

Author: manoukianv

Firmware/FFBoard/Inc/flash_helpers.h

@@ -32,6 +32,11 @@ bool Flash_ReadWriteDefault(uint16_t adr,uint16_t *buf,uint16_t def); // returns
 void Flash_Dump(std::vector<std::tuple<uint16_t,uint16_t>> *result,bool includeAll = false);
 bool Flash_Format();
 
+#ifdef COGGING_TABLE_FLASH_START_ADDRESS
+bool Flash_WriteCoggingTable(uint8_t table_idx, int16_t* data);
+bool Flash_ReadCoggingTable(uint8_t table_idx, int16_t* data);
+#endif
+
 bool OTP_Write(uint16_t adroffset,uint64_t dat);
 bool OTP_Read(uint16_t adroffset,uint64_t* dat);
 

Firmware/FFBoard/Src/flash_helpers.cpp

@@ -153,7 +153,7 @@ bool I2C_EEPROM_Write16(uint16_t devAdr,uint16_t adr, uint16_t dat){
 /**
  * Helper function to read 16b data from i2c eeproms with different block sizes
  */
-bool I2C_EEPROM_Read16(uint16_t devAdr,uint16_t adr, uint16_t *buf, bool checkempty){
+bool I2C_EEPROM_Read16(uint16_t devAdr,uint16_t adr,uint16_t *buf, bool checkempty){
 	uint32_t adrAbs = (adr * sizeof(*buf)/I2C_EEPROM_DATA_SIZE);
 	assert(adrAbs < I2C_EEPROM_SIZE);
 	while(!i2cport_int.isDeviceReady(&i2cdeveeprom, devAdr, 100, I2C_EEPROM_TIMEOUT,false)){
@@ -245,7 +245,75 @@ __weak bool Flash_Init(){
 }
 
 #endif
+#if defined(COGGING_TABLE_FLASH_START_ADDRESS)
 
+// Statically allocated buffer to prevent heap allocation errors on memory constrained devices.
+static uint8_t cogging_flash_buffer[32 * 1024];
+
+/**
+ * @brief Writes a single cogging table to flash using a safe read-modify-write procedure.
+ * @param table_idx Index of the table to write (0 to MAX_COGGING_TABLES-1).
+ * @param data Pointer to the table data to be written.
+ * @return true on success, false on failure.
+ */
+bool Flash_WriteCoggingTable(uint8_t table_idx, int16_t* data) {
+    if (table_idx >= MAX_COGGING_TABLES) {
+        return false;
+    }
+
+    // Use a statically allocated buffer to avoid stack overflow and heap allocation errors.
+    const uint32_t region_size = sizeof(cogging_flash_buffer);
+    uint8_t* temp_buffer = cogging_flash_buffer;
+
+    // 1. Read the entire existing region from flash into the buffer
+    memcpy(temp_buffer, (void*)COGGING_TABLE_FLASH_START_ADDRESS, region_size);
+
+    // 2. Copy the new table data into the buffer at the correct offset
+    uint32_t offset = table_idx * COGGING_TABLE_SIZE;
+    memcpy(temp_buffer + offset, data, COGGING_TABLE_SIZE);
+
+    // 3. Erase the flash sector
+    HAL_FLASH_Unlock();
+    FLASH_EraseInitTypeDef pEraseInit;
+    pEraseInit.TypeErase = FLASH_TYPEERASE_SECTORS;
+    pEraseInit.Sector = FLASH_SECTOR_11; // The reserved 32k region is within this sector
+    pEraseInit.NbSectors = 1;
+    pEraseInit.VoltageRange = VOLTAGE_RANGE_3;
+    uint32_t SectorError = 0;
+    if (HAL_FLASHEx_Erase(&pEraseInit, &SectorError) != HAL_OK) {
+        HAL_FLASH_Lock();
+        return false;
+    }
+
+    // 4. Write the entire modified buffer back to flash, word by word for efficiency
+    for (uint32_t i = 0; i < region_size / sizeof(uint32_t); ++i) {
+        uint32_t write_address = COGGING_TABLE_FLASH_START_ADDRESS + i * sizeof(uint32_t);
+        uint32_t word_to_write = ((uint32_t*)temp_buffer)[i];
+        if (HAL_FLASH_Program(FLASH_TYPEPROGRAM_WORD, write_address, word_to_write) != HAL_OK) {
+            HAL_FLASH_Lock();
+            return false;
+        }
+    }
+
+    HAL_FLASH_Lock();
+    return true;
+}
+
+/**
+ * @brief Reads a single cogging table from its dedicated flash area.
+ * @param table_idx Index of the table to read (0 to MAX_COGGING_TABLES-1).
+ * @param data Pointer to a buffer where the table data will be stored.
+ * @return true on success, false on failure.
+ */
+bool Flash_ReadCoggingTable(uint8_t table_idx, int16_t* data) {
+    if (table_idx >= MAX_COGGING_TABLES) {
+        return false;
+    }
+    uint32_t address = COGGING_TABLE_FLASH_START_ADDRESS + (table_idx * COGGING_TABLE_SIZE);
+    memcpy(data, (void*)address, COGGING_TABLE_SIZE);
+    return true;
+}
+#endif
 /*
  * Dumps all set variables from flash to a vector
  * does by default not include certain calibration constants that could break something if imported on a different board

Firmware/FFBoard/UserExtensions/Inc/eeprom_addresses.h

@@ -13,11 +13,11 @@
 
 #include "main.h"
 // Change this to the amount of currently registered variables
-#define NB_OF_VAR 183
+#define NB_OF_VAR 186
 extern const uint16_t VirtAddVarTab[NB_OF_VAR];
 
 // Amount of variables in exportable list
-#define NB_EXPORTABLE_ADR 168
+#define NB_EXPORTABLE_ADR 171
 extern const uint16_t exportableFlashAddresses[NB_EXPORTABLE_ADR];
 
 
@@ -125,6 +125,7 @@ uint16_t EE_ReadVariable(uint16_t VirtAddress, uint16_t* Data) will return 1 if
 #define ADR_TMC1_FLUX_I 0x32A
 #define ADR_TMC1_PHIE_OFS 0x32B
 #define ADR_TMC1_TRQ_FILT 0x32C
+#define ADR_TMC1_COGGING_CAL 0x32D
 // AXIS2
 #define ADR_AXIS2_CONFIG 0x341 // 0-2 ENC, 3-5 DRV
 #define ADR_AXIS2_POWER 0x342
@@ -157,6 +158,7 @@ uint16_t EE_ReadVariable(uint16_t VirtAddress, uint16_t* Data) will return 1 if
 #define ADR_TMC2_FLUX_I 0x36A
 #define ADR_TMC2_PHIE_OFS 0x36B
 #define ADR_TMC2_TRQ_FILT 0x36C
+#define ADR_TMC2_COGGING_CAL 0x36D
 // AXIS3
 #define ADR_AXIS3_CONFIG 0x381 // 0-2 ENC, 3-5 DRV
 #define ADR_AXIS3_POWER 0x382
@@ -189,6 +191,7 @@ uint16_t EE_ReadVariable(uint16_t VirtAddress, uint16_t* Data) will return 1 if
 #define ADR_TMC3_FLUX_I 0x3AA
 #define ADR_TMC3_PHIE_OFS 0x3AB
 #define ADR_TMC3_TRQ_FILT 0x3AC
+#define ADR_TMC3_COGGING_CAL 0x3AD
 // RMD CAN Motor
 #define ADR_RMD1_DATA1 0x3C0 //0-4 CAN ID
 #define ADR_RMD1_TORQUE 0x3C1 //Maximum current

Firmware/FFBoard/UserExtensions/Src/eeprom_addresses.c

@@ -107,6 +107,7 @@ const uint16_t VirtAddVarTab[NB_OF_VAR] =
 	ADR_TMC1_FLUX_I,
 	ADR_TMC1_PHIE_OFS,
 	ADR_TMC1_TRQ_FILT,
+	ADR_TMC1_COGGING_CAL,
 // AXIS2
 	ADR_AXIS2_CONFIG, // 0-2 ENC, 3-5 DRV
 	ADR_AXIS2_POWER,
@@ -139,6 +140,7 @@ const uint16_t VirtAddVarTab[NB_OF_VAR] =
 	ADR_TMC2_FLUX_I,
 	ADR_TMC2_PHIE_OFS,
 	ADR_TMC2_TRQ_FILT,
+	ADR_TMC2_COGGING_CAL,
 // AXIS3
 	ADR_AXIS3_CONFIG, // 0-2 ENC, 3-5 DRV
 	ADR_AXIS3_POWER,
@@ -171,6 +173,7 @@ const uint16_t VirtAddVarTab[NB_OF_VAR] =
 	ADR_TMC3_FLUX_I,
 	ADR_TMC3_PHIE_OFS,
 	ADR_TMC3_TRQ_FILT,
+	ADR_TMC3_COGGING_CAL,
 // RMD CAN Motor
 	ADR_RMD1_DATA1, //0-4 CAN ID
 	ADR_RMD1_TORQUE, //Maximum current
@@ -326,6 +329,7 @@ const uint16_t exportableFlashAddresses[NB_EXPORTABLE_ADR] =
 	ADR_TMC1_FLUX_I,
 //	ADR_TMC1_PHIE_OFS,
 	ADR_TMC1_TRQ_FILT,
+	ADR_TMC1_COGGING_CAL,
 // AXIS2
 	ADR_AXIS2_CONFIG, // 0-2 ENC, 3-5 DRV
 	ADR_AXIS2_POWER,
@@ -358,6 +362,7 @@ const uint16_t exportableFlashAddresses[NB_EXPORTABLE_ADR] =
 	ADR_TMC2_FLUX_I,
 //	ADR_TMC2_PHIE_OFS,
 	ADR_TMC2_TRQ_FILT,
+	ADR_TMC2_COGGING_CAL,
 // AXIS3
 	ADR_AXIS3_CONFIG, // 0-2 ENC, 3-5 DRV
 	ADR_AXIS3_POWER,
@@ -390,6 +395,7 @@ const uint16_t exportableFlashAddresses[NB_EXPORTABLE_ADR] =
 	ADR_TMC3_FLUX_I,
 //	ADR_TMC3_PHIE_OFS,
 	ADR_TMC3_TRQ_FILT,
+	ADR_TMC3_COGGING_CAL,
 // RMD CAN Motor
 	ADR_RMD1_DATA1, //0-4 CAN ID
 	ADR_RMD1_TORQUE, //Maximum current

Firmware/scripts/memory_map.csv

@@ -89,6 +89,7 @@ Section comment,Name,Value,Comment on key,VirtAddVarTab,exportableFlashAddresses
 ,ADR_TMC1_FLUX_I,0x32A,,1,1
 ,ADR_TMC1_PHIE_OFS,0x32B,,1,
 ,ADR_TMC1_TRQ_FILT,0x32C,,1,1
+,ADR_TMC1_COGGING_CAL,0x32D,,1,1
 // AXIS2,,,,,
 ,ADR_AXIS2_CONFIG,0x341,"// 0-2 ENC, 3-5 DRV",1,1
 ,ADR_AXIS2_POWER,0x342,,1,1
@@ -121,6 +122,7 @@ Section comment,Name,Value,Comment on key,VirtAddVarTab,exportableFlashAddresses
 ,ADR_TMC2_FLUX_I,0x36A,,1,1
 ,ADR_TMC2_PHIE_OFS,0x36B,,1,
 ,ADR_TMC2_TRQ_FILT,0x36C,,1,1
+,ADR_TMC2_COGGING_CAL,0x36D,,1,1
 // AXIS3,,,,,
 ,ADR_AXIS3_CONFIG,0x381,"// 0-2 ENC, 3-5 DRV",1,1
 ,ADR_AXIS3_POWER,0x382,,1,1
@@ -153,6 +155,7 @@ Section comment,Name,Value,Comment on key,VirtAddVarTab,exportableFlashAddresses
 ,ADR_TMC3_FLUX_I,0x3AA,,1,1
 ,ADR_TMC3_PHIE_OFS,0x3AB,,1,
 ,ADR_TMC3_TRQ_FILT,0x3AC,,1,1
+,ADR_TMC3_COGGING_CAL,0x3AD,,1,1
 // RMD CAN Motor,,,,,
 ,ADR_RMD1_DATA1,0x3C0,//0-4 CAN ID,1,1
 ,ADR_RMD1_TORQUE,0x3C1,//Maximum current,1,1