Merge pull request #35 from emmanuelsrlok/rdavis/PHX3_VFD_ABB_ACH580_RTU

Rdavis/phx3 vfd abb ach580 rtu
This commit is contained in:
Emmanuel HC
2025-10-23 22:06:37 -05:00
committed by GitHub
9 changed files with 563 additions and 6 deletions

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@@ -43,7 +43,7 @@ float SingleValueStrategy::execute(float currentValue) {
}
int noiseInt = rand() % 201;
noiseInt -= 100;
float noise = (static_cast<float>(noiseInt) / 100) * _noiseMagnitude;
float noise = (static_cast<float>(noiseInt) / 100.0f) * _noiseMagnitude;
Serial.printf("Single value strategy with noise. %f \n", noise);
return _setpoint + noise;
}

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@@ -11,7 +11,7 @@
[platformio]
default_envs = PDU_Maverick_Power_TCP ; Select here the name of the configuration you want to download
default_envs = PHX3_VFD_ABB_ACH580_RTU ; Select here the name of the configuration you want to download
[env]
upload_port = COM50
@@ -200,3 +200,9 @@ platform = espressif32
board = dfrobot_firebeetle2_esp32e
extends = common_env_options
build_src_filter = -<*> +<BMS/CHILLER/CH_York_YVAA_RTU>
[env:PHX3_VFD_ABB_ACH580_RTU]
platform = espressif32
board = dfrobot_firebeetle2_esp32e
extends = common_env_options
build_src_filter = -<*> +<BMS/VFD/PHX3_VFD_ABB_ACH580_RTU>

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@@ -0,0 +1,40 @@
# VFD ABB ACH580 RTU
## Brief Introduction
This is based on a 50hp motor, 480V, 65 FLA, 60Hz, 1800 rpm (PHX3 DC1/2)
## List of Equipment
This configuration has been used for these models:
* **ACH580**: 10-23-2025
* **Model**: 09-15-23
* **Model**: 09-15-25
## Hardware Prerequisites
The code is written for an ESP8266/ESP32-style microcontroller with WiFi capabilities and at least one hardware serial port for RS485 communication.
* **Microcontroller**: [Firebeetle 2 ESP32.](https://www.dfrobot.com/product-2231.html)
* **RS485 Transceiver**: [RS485 Shield for Arduino.](https://www.dfrobot.com/product-1024.html)
---
## States and Strategies
The hardwire IO signals to/from VFD/PLC are Start Cmd, Stop Cmd, Speed Command, Speed Feedback, VFD Run Status, VFD Fault.
User needs to set the speed command (HR 150) in RPM from the PLC
User needs to set the Start command (HR 151) from the PLC
It appears these registers were arbitrarily chosen for the purpose of this Arduino simulation.
The registers selected are based on FS Config file from CDR project.
Currently there is no connection on Speed Feedback, Run Status, or Fault from Arduino to PICS
### Standby State
* **Equipment**: Equipment parameters go back to 0
### Running State
* **Ramp Strategy**: The following regisers will dynamically ramp based upon the Speed Cmd:
* Motor Speed Used, Motor Speed estimated, Output Frequency, Motor Current, Motor Torque, DC Voltage, Output Voltage, Output Power
* The logic is based on Affinity laws and nominal motor values stated in the Introduction section.
* **Square Strategy**: Inverter Temperature switches between 40 and 80 based on inherited code.
* **Totalizers Strategy**: Inverter kWh cnt, Hours Run
### Fail State
* Not used

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@@ -0,0 +1,77 @@
/**
* @file State_Fail.cpp
* @brief Implementation of the FailState class.
* @author Emmanuel Hernandez Cruz
* @date 2025-09-05
*
* This file contains the implementation for the FailState, which defines
* the behavior of the equipment when it has entered a fault condition.
*/
#include "States/State_Standby.h"
#include "States/State_Fail.h"
#include "ModbusPoints/Modbus_Point.h"
#include "Equipment/Equipment.h"
#include "Strategies/Strategy_SingleValue.h"
#include "Strategies/Strategy_PID.h"
#include <vector>
#include <string>
#if defined(USE_MODBUS_IP)
#include <ModbusIP_ESP8266.h>
#else
#include <ModbusRTU.h>
#endif
/**
* @brief Constructs a new FailState object.
*
* This constructor receives a list of alarm descriptions and creates strategies
* to set the corresponding Modbus points to a value of 1, indicating an
* active alarm. It also initializes a PID strategy for the valve position.
*/
template<>
FailState<ModbusRTU>::FailState(const std::vector<std::string>& activeAlarms) {
// Simulate a failure: set common alarm and a specific fan alarm.
}
/**
* @brief Executes the fail state's logic for one update cycle.
*
* This method checks the "Clear Alm" Modbus point for a command to transition
* back to Standby, which would typically happen after a fault is cleared by a
* user. If no transition is requested, it continues to apply the failure strategies.
*
* @param equipment Pointer to the Equipment instance.
* @return A pointer to a new State if a transition should occur, otherwise nullptr.
*/
template<>
State<ModbusRTU>* FailState<ModbusRTU>::update(Equipment<ModbusRTU>* equipment) {
// STATE control, add conditions if change to a different state is needed
Serial.println("Fail update function");
_applyStrategies(equipment);
return nullptr;
}
/**
* @brief Logic to execute once when entering the fail state. Sets the main alarm bit.
* @param equipment Pointer to the Equipment instance.
*/
template<>
void FailState<ModbusRTU>::enterState(Equipment<ModbusRTU>* equipment) {
// Logic to run when the equipment enters this state
Serial.println("Enter Fail State...");
}
/**
* @brief Logic to execute once when exiting the fail state. Clears the main alarm bit.
* @param equipment Pointer to the Equipment instance.
*/
template<>
void FailState<ModbusRTU>::exitState(Equipment<ModbusRTU>* equipment) {
// Cleanup logic to run when the equipment leaves this state
Serial.println("Exit Fail State...");
}

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@@ -0,0 +1,163 @@
/**
* @file State_Running.cpp
* @brief Implementation of the RunningState class.
* @author Emmanuel Hernandez Cruz, Robert J Davis
* @date 2025-10-22
*
* This file contains the implementation for the RunningState, which defines
* the behavior of the equipment when it is actively running.
*/
#include "States/State_Standby.h"
#include "States/State_Running.h"
#include "States/State_Fail.h"
#include "Strategies/Strategy_Behavior.h"
#include "Strategies/Strategy_PID.h"
#include "Strategies/Strategy_Ramp.h"
#include "Strategies/Strategy_Totalizer.h"
#include "Strategies/Strategy_Random.h"
#include "Strategies/Strategy_SingleValue.h"
#include "Strategies/Strategy_Saw.h"
#include "Strategies/Strategy_Square.h"
#include "Equipment/Equipment.h"
#include "ModbusPoints/Modbus_Point.h"
#include "ModbusPoints/Modbus_FloatDecorator.h"
#include <vector>
#include <string>
#if defined(USE_MODBUS_IP)
#include <ModbusIP_ESP8266.h>
#else
#include <ModbusRTU.h>
#endif
/**
* @brief Constructs a new RunningState object.
*
* This constructor initializes behavior strategies active during the running
* state, such as a PID controller for the 'CW Valve Position' and totalizers
* for the run-hours of each EC fan.
*/
template<>
RunningState<ModbusRTU>::RunningState() {
addStrategy("Motor Speed Used", new RampStrategy(1800.0f, 100.0f, 1000));
addStrategy("Motor Speed estimated", new RampStrategy(1800.0f, 100.0f, 1000));
addStrategy("Motor Current", new RampStrategy(65.0f, 7.0f, 1000));
addStrategy("Motor Torque", new RampStrategy(90.0f, 10.0f, 1000));
addStrategy("Inverter Temperature", new SquareStrategy(40.0f, 80.0f, 1000));
addStrategy("Output Frequency", new RampStrategy(60.0f, 3.0f, 1000 ));
addStrategy("Output Voltage", new RampStrategy(480.0f, 15.0f, 1000 ));
addStrategy("DC Voltage", new RampStrategy(678.0f, 20.0f, 1000 ));
addStrategy("Output Power", new RampStrategy(36.7f, 2.0f, 1000 ));
addStrategy("Inverter kWh cnt", new TotalizerStrategy(1000));
addStrategy("Hours Run", new TotalizerStrategy(1000));
}
/**
* @brief Executes the running state's logic for one update cycle.
*
* This method first checks for state transition commands:
* 1. It reads the "ON/OFF Command By BMS" point. If it's 0, it transitions to StandbyState.
* 2. It reads the "Fault Code" point. If it's non-zero, it transitions to FailState,
* passing the corresponding alarm description.
*
* If no transition occurs, it applies the strategies defined for the running state.
*
* @param equipment Pointer to the Equipment instance.
* @return A pointer to a new State if a transition should occur, otherwise nullptr.
*/
template<>
State<ModbusRTU>* RunningState<ModbusRTU>::update(Equipment<ModbusRTU>* equipment) {
// STATE control, add conditions if change to a different state is needed
Serial.println("Running update function");
float speed_pct = getPointValue(equipment, "Speed Cmd") / 1800.0f;
// Based on Affinity Laws. Motor: 65 FLA, 480V, 60Hz, 1800 rpm, 50hp
float voltage_update = speed_pct * 480;
float dc_voltage_update = speed_pct * 678;
float current_update = speed_pct * speed_pct * 65;
float torque_update = speed_pct * speed_pct * 100; // This is a % of nominal motor torque
float freq_update = speed_pct * 60;
float power_update = speed_pct * speed_pct * speed_pct * 36.77f; // 50 hp ~ 36.77kW
int VFD_Start_Stop = getPointValue(equipment, "Start/Stop");
if (VFD_Start_Stop == 0){
return new StandbyState<ModbusRTU>();
}
float currentSP = getPointValue(equipment, "Speed Cmd");
Strategy_Behavior* motorSpeedUsed = getStrategy("Motor Speed Used");
// 2. Check if the strategy exists
if (motorSpeedUsed) {
// 3. Cast it to a RampStrategy pointer and call setSetpoint.
static_cast<RampStrategy*>(motorSpeedUsed)->setTarget(currentSP);
}
// To have Motor Speed estimated slightly different - for purposes of differentiating in Ignition
float rpm_est = currentSP * 0.98f;
Strategy_Behavior* motorSpeedEst = getStrategy("Motor Speed estimated");
if (motorSpeedEst) {
static_cast<RampStrategy*>(motorSpeedEst)->setTarget(rpm_est);
}
Strategy_Behavior* frequencystrategy = getStrategy("Output Frequency");
if (frequencystrategy) {
static_cast<RampStrategy*>(frequencystrategy)->setTarget(freq_update);
}
Strategy_Behavior* currentstrategy = getStrategy("Motor Current");
if (currentstrategy) {
static_cast<RampStrategy*>(currentstrategy)->setTarget(current_update);
}
Strategy_Behavior* torquestrategy = getStrategy("Motor Torque");
if (torquestrategy) {
static_cast<RampStrategy*>(torquestrategy)->setTarget(torque_update);
}
Strategy_Behavior* dcvoltagestrategy = getStrategy("DC Voltage");
if (dcvoltagestrategy) {
static_cast<RampStrategy*>(dcvoltagestrategy)->setTarget(dc_voltage_update);
}
Strategy_Behavior* voltagestrategy = getStrategy("Output Voltage");
if (voltagestrategy) {
static_cast<RampStrategy*>(voltagestrategy)->setTarget(voltage_update);
}
Strategy_Behavior* powerstrategy = getStrategy("Output Power");
if (powerstrategy) {
static_cast<RampStrategy*>(powerstrategy)->setTarget(power_update);
}
// Apply any strategies defined for the standby state
_applyStrategies(equipment);
return nullptr;
}
/**
* @brief Logic to execute once when entering the running state.
* Sets the "Chiller Sts" point to indicate the unit is running.
* @param equipment Pointer to the Equipment instance.
*/
template<>
void RunningState<ModbusRTU>::enterState(Equipment<ModbusRTU>* equipment) {
// Logic to run when the equipment enters this state
Serial.println("Enter Running State...");
}
/**
* @brief Logic to execute once when exiting the running state.
* Sets the "Chiller Sts" point to indicate the unit is no longer running.
* @param equipment Pointer to the Equipment instance.
*/
template<>
void RunningState<ModbusRTU>::exitState(Equipment<ModbusRTU>* equipment) {
// Cleanup logic to run when the equipment leaves this state
Serial.println("Exit Running State...");
setPointValue(equipment, "Output Frequency", 0.0f);
}

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@@ -0,0 +1,90 @@
/**
* @file State_Standby.cpp
* @brief Implementation of the StandbyState class.
* @author Emmanuel Hernandez Cruz, Robert J Davis
* @date 2025-10-23
*
* This file contains the implementation for the StandbyState, which defines
* the behavior of the equipment when it is in an idle or standby mode.
*/
#include "States/State_Running.h"
#include "States/State_Fail.h"
#include "ModbusPoints/Modbus_Point.h"
#include "ModbusPoints/Modbus_FloatDecorator.h"
#include "Equipment/Equipment.h"
#include "Strategies/Strategy_Ramp.h"
#include "Strategies/Strategy_SingleValue.h"
#include <vector>
#include <string>
#if defined(USE_MODBUS_IP)
#include <ModbusIP_ESP8266.h>
#else
#include <ModbusRTU.h>
#endif
/**
* @brief Constructs a new StandbyState object.
*
* In this state, the equipment is idle. This constructor initializes several
* strategies to generate random values for various status points, simulating
* a live but non-operational unit.
*/
template<>
StandbyState<ModbusRTU>::StandbyState() {
addStrategy("Output Frequency", new SingleValueStrategy(0.1f, 0.2f, 1000 ));
addStrategy("Output Voltage", new SingleValueStrategy(0.1f, 0.1f, 1000 ));
addStrategy("DC Voltage", new SingleValueStrategy(0.1f, 0.1f, 1000 ));
addStrategy("Output Power", new SingleValueStrategy(0.1f, 0.1f, 1000 ));
addStrategy("Motor Speed Used", new RampStrategy(0.0f, 200.0f, 1000 ));
addStrategy("Motor Speed estimated", new RampStrategy(0.0f, 200.0f, 1000 ));
addStrategy("Motor Current", new RampStrategy(0.0f, 20.0f, 1000 ));
addStrategy("Motor Torque", new RampStrategy(0.0f, 20.0f, 1000 ));
addStrategy("Inverter Temperature", new RampStrategy(0.0f, 1.0f, 1000 ));
}
/**
* @brief Executes the standby state's logic for one update cycle.
*
* This method checks the "Chiller On-Off" Modbus point for a command to
* transition to the Running state. If no transition is requested, it applies
* the strategies defined for the standby state.
*
* @param equipment Pointer to the Equipment instance.
* @return A pointer to a new State if a transition should occur, otherwise nullptr.
*/
template<>
State<ModbusRTU>* StandbyState<ModbusRTU>::update(Equipment<ModbusRTU>* equipment) {
// STATE control, add conditions if change to a different state is needed
Serial.println("Standby update function");
int VFD_Start_Stop = getPointValue(equipment, "Start/Stop");
if (VFD_Start_Stop == 1){
return new RunningState<ModbusRTU>();
}
// Apply any strategies defined for the standby state
_applyStrategies(equipment);
return nullptr;
}
/**
* @brief Logic to execute once when entering the standby state.
* Sets the "Chiller Sts" point to indicate the unit is not running.
* @param equipment Pointer to the Equipment instance.
*/
template<>
void StandbyState<ModbusRTU>::enterState(Equipment<ModbusRTU>* equipment) {
// Logic to run when the equipment enters this state
Serial.println("Enter Standby State...");
}
/**
* @brief Logic to execute once when exiting the standby state.
* @param equipment Pointer to the Equipment instance.
*/
template<>
void StandbyState<ModbusRTU>::exitState(Equipment<ModbusRTU>* equipment) {
// Cleanup logic to run when the equipment leaves this state
}

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@@ -0,0 +1,100 @@
/**
* @file config.h
* @brief Main configuration file for the ABB ACH580 (VFD) emulator.
* @author Emmanuel Hernandez Cruz, Robert J Davis
* @date 2025-10-22
*
* This file contains important configurations for the Modbus RTU communication
* and the specific register map for the emulated device.
*/
#ifndef CONFIG_H
#define CONFIG_H
#include <ModbusRTU.h>
#include "core.h"
#include "Equipment/Equipment.h"
#if defined(USE_MODBUS_IP)
/**
* @defgroup ModbusTCPConfig Modbus IP Configuration
* @brief Parameters for Modbus TCP communication.
* @{
*/
#include <ModbusIP_ESP8266.h>
const char *ssid = "wifi_name"; /**< @brief The SSID of the WiFi network. */
const char *password = "wifi_password"; /**< @brief The password for the WiFi network. */
IPAddress local_IP(192, 168, 1, 234); /**< @brief The static IP address for the device. */
IPAddress gateway(192, 168, 1, 1); /**< @brief The gateway IP address. */
IPAddress subnet(255, 255, 255, 0); /**< @brief The subnet mask. */
ModbusIP mb;
#else
/**
* @defgroup ModbusRTUConfig Modbus RTU Configuration
* @brief Parameters for serial Modbus RTU communication.
* @{
*/
#include <ModbusRTU.h>
const int BAUDRATE = 19200; /**< @brief The serial communication speed in bits per second. */
const int RX_PIN = 17; /**< @brief The GPIO pin used for receiving data (RX). */
const int TX_PIN = 16; /**< @brief The GPIO pin used for transmitting data (TX). */
const int RST_PIN = 4; /**< @brief The GPIO pin connected to the RS485 driver's DE/RE pins for direction control. */
const int MODBUS_ID = 1; /**< @brief The unique slave ID for this device on the Modbus bus. */
/** @} */
/** @brief Global instance of the Modbus RTU server. */
ModbusRTU mb;
#endif
/**
* @brief The Modbus map for the Equipment device.
* This array defines all the Modbus points available on the emulated device.
* The `description` field is crucial as it's used to look up points within the application logic.
*/
modbusMap mb_map[] =
{
{HR, 149, 0, "Speed Cmd"}, // expecting rpm (1800 rpm max)
{HR, 151, 0, "Start/Stop"},
{HR, 152, 0, "HOA Command"},
{HR, 100, 0, "Motor Speed Used"}, // RJD: 1800 rpm max
{HR, 101, 0, "Motor Speed estimated"}, // RJD: 1800 rpm max
{HR_10x, 105, 0, "Output Frequency"}, // 60 Hz @100% speed
{HR, 106, 0, "Motor Current"}, // RJD: Changed from HR_10x to HR, 65 FLA
{HR_10x, 109, 0, "Motor Torque"}, // % of nominal torque
{HR_10x, 110, 0, "DC Voltage"}, // approx 678 VDC @100% speed
{HR, 112, 0, "Output Voltage"}, // RJD: 480 VAC
{HR, 113, 0, "Output Power"}, //max 372580 // RJD: Changed from HR_10x to HR, 50 hp ~ 36.77 kW
{HR_10x, 119, 0, "Inverter kWh cnt"},
{HR, 502, 0, "Hours Run"},
{HR, 510, 0, "Inverter Temperature"}, // RJD: Changed from HR_10x to HR, % of fault limit
{HR, 521, 0, "HOA Status Word"},
{HR, 410, 0, "Last Fault"},
{HR, 411, 0, "2nd to last Fault"},
{HR, 412, 0, "3rd to last Fault"},
{HR, 439, 0, "Event Word Param"},
{HR, 610, 0, "Status Word 1"},
{HR, 615, 0, "Status Word 2"},
{HR, 616, 0, "Status Word 3"},
{HR, 617, 0, "Status Word 4"},
{HR, 618, 0, "Status Word 5"},
{HR, 619, 0, "Status Word 6"},
{HR, 620, 0, "Status Word 7"},
{HR, 621, 0, "Status Word 8"},
};
//Size of modbus map used in FOR cycles, automatically calculated.
/**
* @brief The total number of entries in the `mb_map` array.
* This is calculated at compile time and used for iterating over the map.
*/
const int map_size = sizeof(mb_map) / sizeof(mb_map[0]);
/**
* @brief The main loop update interval in milliseconds.
*/
int interval = 250;
#endif // CONFIG_H

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/**
* @file main.cpp
* @brief Main execution program for the Daikin Chiller (RTU) Emulator.
* @author Emmanuel Hernandez Cruz
* @date 2025-09-02
*
* @details This file contains the main execution program for an Arduino-based
* emulator of a Daikin Chiller unit. The program communicates via the
* Modbus RTU protocol over a serial connection.
*
* The setup() function initializes the following:
* - Serial communication for debugging.
* - A Modbus RTU server with parameters from config.h.
* - Modbus points (Coils, Holding Registers, etc.) based on a predefined map in config.h.
*
* The loop() function continuously:
* - Services the Modbus RTU server to handle incoming requests.
* - Periodically calls the main update loop for the emulated equipment, which
* manages state transitions and behavior strategies.
*
* @see config.h for Modbus RTU and register map configuration.
* @see Equipment.h for the main equipment logic.
* @see State.h for different equipment states.
* @see Strategies/Strategy_Behavior.h for value generation strategies.
* @see Modbus_Point.h for the base class for all Modbus points.
*/
//=================================================================================================================================
//Libraries and declaration of variables.
#include <Arduino.h>
#include "config.h"
#include "ModbusPoints/Modbus_PointFactory.h"
//=================================================================================================================================
/**
* @brief Initializes the application.
* @details This function runs once at startup. It configures the serial communication
* for debugging and the Modbus RTU server. It then creates and initializes all
* the Modbus points based on the `mb_map` array in `config.h`.
*/
const int rtsPin = 4;
void setup() {
Serial.begin(115200);
Serial.println("Setup function started");
Serial2.begin(BAUDRATE, SERIAL_8N1, RX_PIN, TX_PIN);
mb.begin(&Serial2, RST_PIN); // Start the server
mb.slave(MODBUS_ID); // Set the slave ID
for(int i = 0; i < map_size; i++){
Modbus_Point<ModbusRTU>* point = createModbus_Point(&mb, mb_map[i].category, mb_map[i].address, mb_map[i].value, mb_map[i].description);
if (point) {
point->addToModbusServer();
EquipmentInstance.addModbus_Point(mb_map[i].description, point);
}
}
Serial.println("Setup function ended");
}
//=================================================================================================================================
/**
* @brief The main application loop.
* @details This function runs repeatedly after setup() has completed. It performs two main actions:
* 1. It continuously services the Modbus server by calling `mb.task()` to handle
* incoming requests from a Modbus master.
* 2. At a fixed interval (defined in `config.h`), it calls `EquipmentInstance.update()`
* to run the emulator's internal state machine and behavior logic.
*/
void loop() {
mb.task();
unsigned long currentMillis = millis();
if (currentMillis - previousMillis >= interval) {
previousMillis = currentMillis;
unsigned long startTime = millis();
EquipmentInstance.update();
unsigned long endTime = millis();
unsigned long elapsedTime = endTime - startTime;
Serial.printf("Control Execution time: %d ms\n", elapsedTime);
}
}

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@@ -1,8 +1,8 @@
/**
* @file State_Running.cpp
* @brief Implementation of the RunningState class.
* @author Emmanuel Hernandez Cruz
* @date 2025-09-05
* @author Emmanuel Hernandez Cruz, Robert J Davis
* @date 2025-10-22
*
* This file contains the implementation for the RunningState, which defines
* the behavior of the equipment when it is actively running.
@@ -41,8 +41,11 @@
*/
template<>
RunningState<ModbusRTU>::RunningState() {
addStrategy("Inverter Temperature", new SquareStrategy(40.0f, 80.0f,1000));
addStrategy("Inverter Temperature", new SquareStrategy(40.0f, 80.0f, 1000));
addStrategy("Motor Speed Used", new RampStrategy(100.0f, 10.0f, 1000));
addStrategy("Motor Speed Estimated", new RampStrategy(80.0f, 10.0f, 1000));
addStrategy("Motor Current", new RampStrategy(65.0f, 2.0f, 1000));
addStrategy("Motor Torque", new RampStrategy(200.0f, 10.0f, 1000));
}
/**