Motor Profiler Stuck at 28% with custom motors

[pdiefend_GLO]

[PN]: NUCLEO-G431RB with EVLDRIVE102BH and custom motor

[VERSION]: Version: 6.4.1 Build: 250722.104358
[TOOL]: MC PROFILER
[DETAILS]:

I am attempting to build a new motor controller that runs sensorless FOC instead of 6-step and my first step was to use the profiler to verify some of the figures on the motor's datasheet. Specifically the friction and inertia values on the datasheet seemed suspect and didn't have the right units for the motor controller workbench. Furthermore I'm assuming the gearbox included on the motor doesn't take these values into consideration. When attempting to run the profiler I seem to get stuck at 28%, which seems to be a common issue and it sounds like the issue is the motor not reaching a stable speed per the forum posts I've already read. From what I can tell it seems like the motor is physically spinning at a stable speed and I don't know why the profiler is struggling to read the speed. I have been banging my head on the wall for weeks now and have tried other similar motors from other vendors and a completely different motor with a different operating voltage but nothing seems to work. The only motor I can get to work with the profiler is the one that came in the P-NUCLEO-IHM03 pack.

I want to switch off of TI and over to ST to use the new smaller SoCs, can anyone please help me to get a motor spinning as a proof of concept?

I attached screen shots of the 2 datasheets of the custom motors I tried.

Questions:

Is there are way to determine if the motor controller is indeed struggling to reach a stable speed? And if this is true how do I go about fixing that? I tried the open-loop tuning mentioned in other posts, but the documentation on how to actually do that isn't super clear and I don't see where to incorporate those values into the profiler. 

Some of the earlier motors models I have do have a hall sensor, can I or the profiler use that to get to a stable operating speed so the mechanical model can be completed?

Ultimately I want to figure out the control loop parameters before moving to the STSPIN32F0 family of controllers on a custom PCB. Does attempting to profile and tune on the hardware I'm using even make sense? I understand the parameters will have to change slightly due to differences in hardware. It doesn't seem like the STSPIN32F0 is friendly to tuning rather than already having a good starting point ready.

[GMA]

Hello @pdiefend_GLO,

Did you check the Motor Profiler Application Note available through "Workbench tool">About>Documentations>Documentation>"User manual" tab? 
There is a chapter about the Profiler remaining at 28% (decreasing Max Current or Max speed is also mentioned) with a link to Open Loop full description.
Is it possible to profile the motor without the gearbox?

[pdiefend_GLO]

Hi @GMA, Thank you for your reply.

To answer your basic troubleshooting steps,
Yes, I have read through the manual, application note, and all the forum posts I could find with similar issues but am still stuck with my troubleshooting.

I have tried varying the max current and max speed, I don't know how much more feasible it is to tune these values. The motor does spin while stuck at 28%, ramping up successfully at the ever decreasing accelerations until eventually I have to abort because the motor starts to heat up too much. I have tried the motor both with and without the gearbox.

When you (and all the others) have said to switch to open loop, where are the voltage reference and other values incorporated into the profiler project?

[pdiefend_GLO]

I worked on trying to get the profiler to work, I can only get open loop to run at low speed, it seems like trying to go over 500rpm causes the motor to start to shake violently in open-loop mode with and without the gearbox. I loaded the ramp rate I was testing, 500rpm and 1000ms which was working in open loop, into the profiler project in the sensorless startup parameters and changed the startup exit condition to 500rpm as well.

I tried this in the profiler and the profiler still got stuck at 28%. I think because my Ke is so low the low speed isn't fast enough for the profiler to detect the back emf.

I know the profiler is capable of spinning the motor faster, so something else must be going on under the hood that allows it to get over the 500rpm I can get in open-loop before the motor shakes.

I don't know where to go from here, motor tuning isn't my expertise and I'm learning as I go.

At this point I'm willing to ditch the profiler altogether if I had some good resources on how to tune the FOC algorithm with this motor manually within the motor pilot program. Does anyone (or @GMA) have any good resources if I need to do this the manual way assuming I can't get the profiler to work? 

[GMA]

Hello @pdiefend_GLO,

You mentioned that you are using a "custom board".
Can you drive a known motor in field-oriented control (FOC) sensorless mode with your hardware setup?