Do note the spike around 11.5 minutes into the run, here something turned on (my guess is the freezer or refrigerator looks like what ever it is had a surge current to start and a 8-10A DC steady state draw. Sounds like the Refrigeration to me).
Because I was dumping debug data at every PWM adjustment period I could see exactingly how the system responded. Here is a snip:
Time | mS | PWM | Vbat | Amps | Watts | RPMs | :Ve | ||
11.2 | 718233 | 70 | 14.79 | 42 | 621 | 1834 | 0 | ||
11.3 | 718575 | 70 | 14.78 | 41 | 605 | 1842 | 0 | ||
11.3 | 718919 | 70 | 14.77 | 40 | 590 | 1834 | 0 | ||
11.3 | 719249 | 70 | 14.77 | 41 | 605 | 1827 | 0 | ||
11.3 | 719592 | 70 | 14.77 | 40 | 590 | 1842 | 0 | ||
11.3 | 719940 | 70 | 14.77 | 40 | 590 | 1842 | 0 | ||
11.3 | 720275 | 70 | 14.76 | 40 | 590 | 1834 | 0 | ||
11.3 | 720619 | 70 | 14.76 | 40 | 590 | 1827 | 0 | ||
11.3 | 720966 | 70 | 14.76 | 38 | 560 | 1842 | 0 | ||
11.3 | 721299 | 70 | 14.76 | 38 | 560 | 1834 | 0 | ||
11.3 | 721643 | 70 | 14.75 | 40 | 590 | 1834 | 0 | ||
11.3 | 721991 | 70 | 14.73 | 41 | 604 | 1842 | 2 | ||
11.3 | 722326 | 72 | 14.73 | 43 | 633 | 1834 | 2 | ||
11.3 | 722669 | 74 | 14.76 | 44 | 649 | 1849 | 0 | ||
11.3 | 723016 | 74 | 14.77 | 44 | 649 | 1820 | 0 | ||
11.3 | 723368 | 74 | 14.78 | 42 | 620 | 1820 | 0 | ||
11.3 | 723713 | 74 | 14.26 | 43 | 613 | 1834 | 16 | VBat declining, looks like a load was placed on. | |
11.3 | 724057 | 76 | 13.94 | 45 | 627 | 1827 | 27 | System responds by increasing PWM (PWMs are capped max 2 going UP) | |
11.3 | 724384 | 78 | 13.95 | 44 | 613 | 1834 | 27 | Still needs more PWM, but at least we have stopped the decline in VBat now. | |
11.4 | 724728 | 80 | 14.24 | 48 | 683 | 1827 | 17 | Voltage is starting to rise. | |
11.4 | 725072 | 82 | 14.28 | 52 | 742 | 1834 | 16 | However because we are still under the target voltage . . | |
11.4 | 725400 | 84 | 14.32 | 52 | 744 | 1812 | 14 | . . simple algorithm continued to increase PWM | |
11.4 | 725744 | 86 | 14.36 | 56 | 803 | 1820 | 13 | ||
11.4 | 726094 | 88 | 14.41 | 56 | 807 | 1820 | 11 | Still increasing, voltage is raising faster now. | |
11.4 | 726438 | 90 | 14.46 | 58 | 838 | 1820 | 10 | ||
11.4 | 726780 | 92 | 14.51 | 58 | 841 | 1805 | 8 | ||
11.4 | 727124 | 94 | 14.58 | 62 | 903 | 1812 | 6 | ||
11.4 | 727453 | 96 | 14.66 | 65 | 952 | 1790 | 3 | ||
11.4 | 727796 | 98 | 14.74 | 67 | 987 | 1790 | 2 | ||
11.4 | 728144 | 100 | 14.82 | 68 | 1008 | 1782 | -1 | Oh Oh, now we are over volts! Need to bring down the PWM. | |
11.4 | 728488 | 99 | 14.91 | 68 | 1013 | 1775 | -4 | But we had wound it up so much on the way up it takes time to reduce. | |
11.4 | 728833 | 95 | 14.95 | 65 | 971 | 1790 | -6 | Notice on the way down no limit how much we can change PWM in one step.. | |
11.4 | 729177 | 89 | 14.96 | 60 | 897 | 1782 | -6 | ||
11.4 | 729504 | 83 | 14.93 | 56 | 836 | 1797 | -5 | ||
11.4 | 729846 | 78 | 14.88 | 51 | 758 | 1805 | -3 | ||
11.4 | 730196 | 75 | 14.82 | 47 | 696 | 1827 | -1 | ||
11.5 | 730531 | 74 | 14.76 | 45 | 664 | 1827 | 0 | ||
11.5 | 730874 | 74 | 14.72 | 45 | 662 | 1834 | 2 | Only a little undershoot | |
11.5 | 731224 | 76 | 14.7 | 46 | 676 | 1827 | 2 | ||
11.5 | 731578 | 78 | 14.72 | 48 | 706 | 1842 | 2 | ||
11.5 | 731922 | 80 | 14.72 | 51 | 750 | 1827 | 2 | ||
11.5 | 732266 | 82 | 14.74 | 53 | 781 | 1820 | 0 | Finally, back to stable VBat. Amp draw is about 8-10A higher then before. | |
11.5 | 732621 | 82 | 14.76 | 49 | 723 | 1812 | 0 | ||
11.5 | 732965 | 82 | 14.76 | 52 | 767 | 1827 | 0 | ||
11.5 | 733318 | 82 | 14.78 | 50 | 739 | 1820 | 0 |
When I look at this, again I clearly see how adding in consideration for Trending will help. And I am likely going to make that change over the summer. But for now, I think this will work OK. I am going to try lower the cap to a max change of 1 to try and reduce overshoot. And I worry about the systems ability to respond to over-voltage, so am going to try and reduce the sampling time to 200mS and see if that still mitigates the hunting conditions. I might even be able to get away with 150mS, when combined with reducing the CAP from 2 to 1.
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