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Add STM32 tuning integration and rewrite README with step-by-step guide

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- stm32_link.py: synchronous serial interface to STM32 debug protocol
  (ping, telemetry read/avg, param read/write, frame parser)
- tuner.py: automated tuning combining HIOKI + STM32 measurements
  (param sweep, deadtime optimization, multi-point sweep, CSV/plot output)
- CLI commands: stm32-read, stm32-write, tune-param, tune-deadtime
- README: complete step-by-step guide covering setup, sweeps, analysis,
  tuning, shade profiles, debug console, and parameter reference

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
This commit is contained in:
Alexander Grabowski
2026-03-12 16:52:09 +07:00
parent e7a23a3c7e
commit 1c41910c1e
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README.md
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@@ -1,127 +1,247 @@
# MPPT Testbench
Unified CLI tool for testing MPPT (Maximum Power Point Tracking) converters using three coordinated instruments:
Unified tool for testing and tuning MPPT (Maximum Power Point Tracking) converters. Combines three bench instruments with direct STM32 firmware access for closed-loop parameter optimization.
| Instrument | Role | Interface |
|---|---|---|
| **ITECH IT6500D** | DC power supply (solar panel simulator) | USB-TMC / SCPI via PyVISA |
| **ITECH IT6537D** | DC power supply (solar panel simulator, 80V/120A/6kW) | USB-TMC / SCPI via PyVISA |
| **Prodigit 3366G** | DC electronic load (600V/420A/6kW) | RS-232 (115200 8N1 RTS/CTS) |
| **HIOKI 3193-10** | Power analyzer (efficiency measurement) | GPIB via UsbGpib / PyVISA |
| **STM32G474** | Converter firmware (LVSolarBuck64) | Serial 460800 baud (debug protocol) |
## Wiring
```
┌──────────────────┐
IT6500D ──(+/-)──> │ MPPT Tracker │ ──(+/-)──> Prodigit 3366G
│ (DUT) │
HIOKI Ch5 ──(sense)── │ Input Output │ ──(sense)── HIOKI Ch6
└──────────────────┘
+------------------+
IT6500D --(+/-)--> | MPPT Tracker | --(+/-)--> Prodigit 3366G
| (DUT) |
HIOKI Ch5 --(sense)-- | Input Output | --(sense)-- HIOKI Ch6
+------------------+
|
STM32 debug
serial (COM28)
HIOKI EFF1 = P6 / P5 x 100% (output power / input power)
```
## Installation
Requires Python 3.12+, NI-VISA runtime, and `uv`.
Requires Python 3.12+, NI-VISA runtime, and [uv](https://docs.astral.sh/uv/).
```bash
git clone --recurse-submodules https://git.b4l.co.th/B4L/mppt-testbench.git
cd mppt-testbench
uv venv
uv pip install -e .
uv sync
```
## Quick Start
The debug console (inside `code64/`) has its own environment:
```bash
# 1. Check all instruments are connected
mppt identify
# 2. Configure everything for MPPT testing
# (sets wiring, coupling, auto-range, efficiency formula, display)
mppt setup
# 3. Take a single reading from all instruments
mppt measure
# 4. Continuous monitoring with CSV export
mppt monitor --interval 1.0 --output data.csv
# 5. Live real-time graph (Power, Efficiency, Voltage, Current)
mppt live --interval 0.5
cd code64
uv sync
```
## Sweep Commands
## Step-by-Step Guide
### Voltage Sweep
Sweep supply voltage across a range while the load is held constant. Records efficiency at each point.
### 1. Connect and verify instruments
```bash
mppt sweep \
# Check all bench instruments respond
uv run mppt identify
# Check STM32 responds (reads params + telemetry)
uv run mppt stm32-read --stm32-port COM28
```
### 2. Configure instruments for MPPT testing
```bash
uv run mppt setup
```
This sets wiring mode (1P2W), DC coupling, auto-ranging, efficiency formula (EFF1 = P6/P5), and display layout on the HIOKI.
### 3. Basic measurements
```bash
# Single reading from all instruments
uv run mppt measure
# Continuous text monitoring with CSV export
uv run mppt monitor --interval 1.0 --output data.csv
```
### 4. Launch the GUI
```bash
uv run mppt-gui
```
The GUI provides:
- Real-time readouts from all three instruments
- Supply voltage/current control with ON/OFF indicators
- Load mode (CC/CR/CV/CP) and setpoint control
- HIOKI channel range selectors + degauss buttons
- Meter format selector (scientific/normal)
- 2D sweep panel with time estimate
- Live-updating power, efficiency, voltage, and current plots
- Console log panel
### 5. Run efficiency sweeps
#### Voltage sweep (1D)
```bash
uv run mppt sweep \
--v-start 30 --v-stop 100 --v-step 5 \
--current-limit 10 \
--load-mode CC --load-value 3.0 \
--settle 2.0 \
-o voltage_sweep.csv
--current-limit 20 \
--load-mode CP --load-value 200 \
--settle 2.0 -o voltage_sweep.csv
```
After the sweep, the supply returns to 75V and stays ON.
### Load Current Sweep
Sweep load current (CC mode) at a fixed supply voltage.
#### Load sweep at fixed voltage (1D)
```bash
mppt sweep-load \
--voltage 75 --current-limit 10 \
--i-start 0.5 --i-stop 8 --i-step 0.5 \
--settle 2.0 \
-o load_sweep.csv
uv run mppt sweep-load \
--voltage 60 --current-limit 20 \
--i-start 0.5 --i-stop 15 --i-step 0.5 \
--settle 2.0 -o load_sweep.csv
```
After the sweep, the load turns OFF and the supply returns to 75V (stays ON).
#### 2D voltage x load sweep (efficiency map)
### Auto-Range Handling
```bash
# Constant Power mode
uv run mppt sweep-vi \
--v-start 60 --v-stop 100 --v-step 5 \
--l-start 50 --l-stop 500 --l-step 50 \
--load-mode CP --current-limit 20 \
--settle 2.0 -o map_cp.csv
The HIOKI 3193-10 returns special error values (`+9999.9E+99`) while auto-ranging. The testbench automatically waits for all measurement channels to settle before recording each sweep point. The supply is kept alive with periodic queries during the wait to prevent USB-TMC timeouts.
# Constant Current mode
uv run mppt sweep-vi \
--v-start 35 --v-stop 100 --v-step 5 \
--l-start 0.5 --l-stop 15 --l-step 0.5 \
--load-mode CC --current-limit 20 \
--settle 2.0 -o map_cc.csv
```
## Direct Instrument Control
### 6. Analyze sweep results
```bash
# Generate efficiency overlay, heatmap, and power loss plots (no instruments needed)
uv run mppt plot-sweep map_cp.csv
# Save plots without displaying
uv run mppt plot-sweep map_cp.csv --no-show -o plots/
```
Produces three PNG files:
- `*_efficiency.png` -- efficiency vs load, one line per voltage, best point marked
- `*_heatmap.png` -- 2D efficiency surface (voltage x load)
- `*_loss.png` -- power loss vs load, all voltages overlaid
### 7. Tune converter parameters
The tuning commands combine the testbench instruments (ground truth efficiency from HIOKI) with direct STM32 parameter writes to find optimal settings.
#### Read current STM32 state
```bash
uv run mppt stm32-read
```
#### Write a single parameter
```bash
uv run mppt stm32-write --param dt_10_20A --value 20
```
#### Sweep a parameter to find the optimum
Sweeps a parameter from start to stop, measuring HIOKI efficiency + STM32 telemetry at each step. Plots the result.
```bash
# Optimize deadtime for the 10-20A bracket at 300W
uv run mppt tune-param \
--param dt_10_20A --start 14 --stop 40 --step 1 \
--voltage 60 --current-limit 20 \
--load-mode CP --load-value 300 \
--settle 3.0 -o dt_tune.csv
# Tune Vfly proportional gain
uv run mppt tune-param \
--param vfly_kp --start -2 --stop 2 --step 0.1 \
--voltage 60 --current-limit 20 \
--load-mode CP --load-value 200 \
--settle 3.0
```
#### Auto-optimize all deadtime brackets
Automatically sweeps deadtime for each of the 6 current brackets (0-3A, 3-5A, 5-10A, 10-20A, 20-30A, 30-45A), setting an appropriate load for each bracket.
```bash
# Sweep and report best values
uv run mppt tune-deadtime \
--voltage 60 --current-limit 20 --load-mode CP \
--dt-start 14 --dt-stop 50 --dt-step 1 \
-o deadtime_results.csv
# Sweep, report, and apply best values to STM32
uv run mppt tune-deadtime \
--voltage 60 --current-limit 20 --load-mode CP \
--load-values 20,50,100,250,400,600 \
--apply
```
### 8. Shade / irradiance profile simulation
Simulate cloud passing or partial shading with a CSV-driven sequence:
```bash
uv run mppt shade-profile \
--profile samples/cloud_pass.csv \
--settle 2.0 -o shade_results.csv
```
Profile CSV format: `time,voltage,current_limit,load_mode,load_value`
### 9. Real-time debug console (TUI)
For live monitoring and parameter tuning via the Textual terminal UI:
```bash
cd code64
uv run debug-console COM28
```
Keybindings: `p` ping, `r` read params, `f` toggle EMA filter, `l` show log path, `q` quit.
### 10. Direct instrument control
```bash
# Supply
mppt supply set --voltage 48 --current 10
mppt supply on
mppt supply off
uv run mppt supply set --voltage 48 --current 10
uv run mppt supply on
uv run mppt supply off
# Load
mppt load set --mode CC --value 5.0
mppt load set --mode CR --value 10.0
mppt load on
mppt load off
uv run mppt load set --mode CP --value 200
uv run mppt load on
uv run mppt load off
# Emergency shutdown (load first, then supply)
mppt safe-off
```
## Efficiency Measurement
Measure averaged efficiency at a fixed operating point:
```bash
mppt efficiency \
--voltage 75 --current-limit 10 \
--load-mode CC --load-value 3.0 \
--samples 10 --settle 3.0
uv run mppt safe-off
```
## CLI Reference
```
mppt [-h] [--supply-address ADDR] [--load-port PORT] [--load-baud BAUD]
[--meter-address ADDR] [--timeout MS]
{identify,setup,measure,monitor,live,sweep,sweep-load,efficiency,
supply,load,safe-off}
uv run mppt [-h] [--supply-address ADDR] [--load-port PORT] [--load-baud BAUD]
[--meter-address ADDR] [--timeout MS]
[--stm32-port PORT] [--stm32-baud BAUD]
{command}
```
| Command | Description |
@@ -133,7 +253,14 @@ mppt [-h] [--supply-address ADDR] [--load-port PORT] [--load-baud BAUD]
| `live` | Real-time 4-panel matplotlib graph |
| `sweep` | Voltage sweep with efficiency recording |
| `sweep-load` | Load current sweep at fixed voltage |
| `sweep-vi` | 2D voltage x load sweep (efficiency map) |
| `efficiency` | Averaged efficiency at a fixed operating point |
| `shade-profile` | Run shade/irradiance profile from CSV |
| `plot-sweep` | Generate analysis plots from sweep CSV (offline) |
| `stm32-read` | Read all STM32 parameters and telemetry |
| `stm32-write` | Write a parameter to the STM32 |
| `tune-param` | Sweep an STM32 parameter while measuring efficiency |
| `tune-deadtime` | Auto-optimize deadtime for each current bracket |
| `supply` | Direct IT6500D control (on/off/set) |
| `load` | Direct Prodigit 3366G control (on/off/set) |
| `safe-off` | Emergency shutdown (load first, then supply) |
@@ -147,48 +274,70 @@ mppt [-h] [--supply-address ADDR] [--load-port PORT] [--load-baud BAUD]
| `--load-baud` | `115200` | Prodigit 3366G baud rate |
| `--meter-address` | auto-detect | HIOKI 3193-10 VISA address |
| `--timeout` | `5000` | VISA timeout in milliseconds |
| `--stm32-port` | `COM28` | STM32 debug serial port |
| `--stm32-baud` | `460800` | STM32 debug baud rate |
## Tunable STM32 Parameters
| Parameter | Type | Range | Description |
|---|---|---|---|
| `VREF` | uint16 | 3100-3700 | ADC reference voltage |
| `vfly_kp` | float | -10 to 10 | Vfly proportional gain |
| `vfly_ki` | float | -10 to 10 | Vfly integral gain |
| `vfly_clamp` | uint16 | 0-10000 | Vfly integrator clamp |
| `vfly_active` | uint8 | 0-1 | Vfly loop enable |
| `cc_target` | float | 0-60000 | CC target (mA) |
| `cc_gain` | float | -1 to 1 | CC proportional gain |
| `cc_active` | int32 | 0-1 | CC loop enable |
| `mppt_step` | float | 0-10000 | MPPT P&O step size (mA) |
| `mppt_deadband` | float | 0-1 | MPPT deadband |
| `mppt_active` | int32 | 0-1 | MPPT loop enable |
| `dt_0_3A` | uint8 | 14-200 | Deadtime 0-3A (HRTIM ticks) |
| `dt_3_5A` | uint8 | 14-200 | Deadtime 3-5A |
| `dt_5_10A` | uint8 | 14-200 | Deadtime 5-10A |
| `dt_10_20A` | uint8 | 14-200 | Deadtime 10-20A |
| `dt_20_30A` | uint8 | 14-200 | Deadtime 20-30A |
| `dt_30_45A` | uint8 | 14-200 | Deadtime 30-45A |
## CSV Output Format
Sweep CSV files contain the following columns:
Sweep CSV files contain:
| Column | Description |
|---|---|
| `voltage_set` | Supply voltage setpoint (V) |
| `current_limit` | Supply current limit (A) |
| `load_setpoint` | Load setpoint value (A for CC mode) |
| `load_setpoint` | Load setpoint value (A for CC, W for CP) |
| `supply_V/I/P` | Supply measured voltage, current, power |
| `load_V/I/P` | Load measured voltage, current, power |
| `input_power` | HIOKI P5 -- power into MPPT tracker (W) |
| `output_power` | HIOKI P6 -- power out of MPPT tracker (W) |
| `efficiency` | HIOKI EFF1 -- P6/P5 x 100 (%) |
## Setup Details
`mppt setup` configures the instruments as follows:
- **Supply**: Remote control mode
- **Load**: Remote control mode
- **Meter**:
- Wiring: 1P2W
- Ch5 (solar input): DC coupling, voltage and current auto-range
- Ch6 (MPPT output): DC coupling, voltage and current auto-range
- Response speed: SLOW (best accuracy)
- EFF1 = P6 / P5 (output / input)
- Display: 16-item SELECT view -- U5, I5, P5, EFF1 (left) | U6, I6, P6 (right)
Tuning CSV files additionally contain `param_name`, `param_value`, and STM32 telemetry columns (`stm_vin`, `stm_vout`, `stm_iin`, `stm_iout`, `stm_eff`, `stm_vfly`, `stm_etemp`).
## Project Structure
```
mppt-testbench/
├── IT6500D/ git submodule - DC power supply driver
├── PRODIGIT-3366G/ git submodule - electronic load driver
├── HIOKI-3193-10/ git submodule - power analyzer driver
├── testbench/
│ ├── __init__.py exports MPPTTestbench
│ ├── bench.py orchestrator (sweeps, measurement, auto-range wait)
│ └── cli.py unified CLI entry point
└── pyproject.toml package config, entry point: mppt
+-- IT6500D/ git submodule -- DC power supply driver
+-- PRODIGIT-3366G/ git submodule -- electronic load driver
+-- HIOKI-3193-10/ git submodule -- power analyzer driver
+-- testbench/
| +-- __init__.py exports MPPTTestbench
| +-- bench.py orchestrator (sweeps, measurement, auto-range wait)
| +-- cli.py unified CLI entry point
| +-- gui.py tkinter GUI with live plots
| +-- gui_workers.py background instrument I/O thread
| +-- stm32_link.py synchronous STM32 debug protocol interface
| +-- tuner.py automated tuning routines (param sweep, deadtime opt)
+-- code64/
| +-- Core/ STM32G474 firmware (C)
| +-- Drivers/ HAL drivers
| +-- debug_console/ Textual TUI for live debugging
| +-- pyproject.toml uv-compatible package config
+-- samples/ shade profile CSV examples
+-- pyproject.toml package config, entry points: mppt, mppt-gui
```
## Dependencies
@@ -197,4 +346,6 @@ mppt-testbench/
- [PyVISA](https://pyvisa.readthedocs.io/) + [pyvisa-py](https://pyvisa.readthedocs.io/projects/pyvisa-py/)
- [pyserial](https://pyserial.readthedocs.io/)
- [matplotlib](https://matplotlib.org/)
- [numpy](https://numpy.org/)
- NI-VISA runtime (for GPIB/USB-TMC communication)
- [Textual](https://textual.textualize.io/) (debug console only, in code64/)