Motor controller with Hall assembly and Hall coefficient adjusting system and method

Abstract

The invention discloses a motor controller with a Hall assembly and a Hall coefficient adjusting system and method.According to the motor controller with the Hall assembly, the outer side of a magnetic sensitive chip is sleeved with a magnetic sensitive chip sheath, and the top end of the magnetic sensitive chip sheath is clamped with a notch of a Hall magnetic ring; and the bottom end of the magnetic sensitive chip sheath is clamped with the bayonet of the integrated circuit board through the clamping jaw, so that the magnetic sensitive chip is ensured to be erected in the notch, the magnetic sensitive chip can be prevented from being collided and toppled over, and the acquisition precision of the Hall assembly is improved. According to the Hall coefficient adjustment system and the Hall coefficient adjustment method, the Hall adjustment coefficient can be automatically calculated, so that the sampling precision of the Hall assembly of each electrode controller is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicles, and more specifically, to a motor controller with a Hall assembly, a Hall coefficient adjustment system and a method. Background Art

[0002] The electric vehicle motor controller needs to accurately collect three-phase current in real time to precisely control the torque or speed of the drive motor. Therefore, the accuracy of current collection will be directly reflected in the torque or speed control accuracy of the motor controller, which has a huge impact on the output performance of the electric vehicle. The current acquisition system is usually composed of acquisition circuits, magnetic sensitive chips, Hall magnetic rings and other main components. The acquisition circuits are basically the same, and the matching of magnetic sensitive chips and Hall magnetic rings will affect the acquisition accuracy, such as the individual differences in the materials and performance of the magnetic sensitive chips and Hall magnetic rings themselves, as well as the assembly positions between them.

[0003] In the existing technology, the cost of the entire integrated Hall current acquisition system is relatively high, so usually choose to develop Hall sensors by yourself, which can greatly reduce costs on the one hand, and can also be designed according to the structural characteristics of your own electronic control products on the other hand. However, the self-made Hall sensors are affected by the individual differences of the magnetic sensitive chip and the Hall magnetic ring and their assembly size tolerances, and the output Hall sampling accuracy varies.

[0004] Therefore, it is urgent to design a Hall sensor with reliable relative position. After each prototype is assembled, an efficient Hall coefficient adjustment method is used to correct the Hall coefficient of each motor controller to ensure that the current sampling accuracy meets certain requirements. Summary of the invention

[0005] In view of this, the present invention provides a motor controller with a Hall assembly, and a Hall coefficient adjustment system and method.

[0006] In one aspect, the present invention provides a motor controller with a Hall assembly, wherein the motor controller includes an integrated circuit board and a Hall assembly, wherein the Hall assembly includes a three-phase copper bus, a Hall magnetic ring, a magnetic sensitive chip, and a magnetic sensitive chip sheath.

[0007] The integrated circuit board includes an acquisition circuit;

[0008] A three-phase copper bar is fixed on one side of the integrated circuit board, and the three-phase copper bar includes a U-phase copper bar, a V-phase copper bar and a W-phase copper bar;

[0009] The outer sides of the three-phase copper bars are all sleeved with Hall magnetic rings, which have gaps;

[0010] The magnetic sensing chip is at least partially disposed in the notch, and the magnetic sensing chip includes pins, and the pins are electrically connected to the acquisition circuit;

[0011] The magnetic chip sheath is arranged on the outside of the Hall magnetic ring, the integrated circuit board includes a bayonet, and the side of the magnetic chip sheath close to the integrated circuit board has a claw, which is engaged with the bayonet.

[0012] On the other hand, the present invention also provides a Hall coefficient adjustment system, comprising:

[0013] The motor controller, constant current source, control circuit and host computer with Hall assembly, wherein:

[0014] The motor controller with the Hall assembly is electrically connected to the host computer and the control circuit respectively;

[0015] The constant current source is electrically connected to the control circuit and the host computer respectively;

[0016] The control circuit includes a U-phase control circuit, a V-phase control circuit, a W-phase control circuit and a relay group, wherein:

[0017] The relay group includes a first relay, a second relay, a third relay and a fourth relay;

[0018] The positive electrode of the constant current source is connected to the first relay and the third relay, and the negative electrode of the constant current source is connected to the second relay and the fourth relay;

[0019] The U-phase control circuit includes a U-phase upper bridge tube, a U-phase lower bridge tube, and a first Hall magnetic ring, wherein one end of the U-phase upper bridge tube is electrically connected to the first relay, the second end of the U-phase upper bridge tube is electrically connected to the first Hall magnetic ring, the first section of the U-phase lower bridge tube is electrically connected to the fourth relay, the second end of the U-phase lower bridge tube is electrically connected to the first Hall magnetic ring, and the other end of the first Hall magnetic ring is electrically connected to the third relay and the second relay respectively;

[0020] The V-phase control circuit includes a V-phase upper bridge tube, a V-phase lower bridge tube, and a second Hall magnetic ring, wherein one end of the V-phase upper bridge tube is electrically connected to the first relay, the second end of the V-phase upper bridge tube is electrically connected to the second Hall magnetic ring, the first section of the V-phase lower bridge tube is electrically connected to the fourth relay, the second end of the V-phase lower bridge tube is electrically connected to the second Hall magnetic ring, and the other end of the second Hall magnetic ring is electrically connected to the third relay and the second relay respectively;

[0021] The W-phase control circuit includes a W-phase upper bridge tube, a W-phase lower bridge tube, and a third Hall magnetic ring. One end of the W-phase upper bridge tube is electrically connected to the first relay, the second end of the W-phase upper bridge tube is electrically connected to the third Hall magnetic ring, the first section of the W-phase lower bridge tube is electrically connected to the fourth relay, the second end of the W-phase lower bridge tube is electrically connected to the third Hall magnetic ring, and the other end of the third Hall magnetic ring is electrically connected to the third relay and the second relay respectively.

[0022] In a third aspect, the present invention further provides a method for adjusting the Hall coefficient, using the above-mentioned Hall coefficient adjustment system, comprising:

[0023] The steps of controlling the current output are as follows: the upper bridge instruction is sent to the motor controller through the upper computer, the current flows into the positive electrode of the constant current source, the current passes through the control circuit and the Hall assembly in sequence, and returns to the negative electrode of the constant current source, and the positive current of the U phase, the positive current of the V phase, and the positive current of the W phase are collected; the lower bridge instruction is sent to the motor controller through the upper computer, the current flows into the positive electrode of the constant current source, the current passes through the Hall assembly and the control circuit in sequence, and returns to the negative electrode of the constant current source, and the negative current of the U phase, the negative current of the V phase, and the negative current of the W phase are collected;

[0024] The step of adjusting the current is to set positive currents from small to large to the constant current source, and use the method of controlling current output to respectively collect the positive currents fed back by the motor controller; set negative currents from large to small to the constant current source, and use the method of controlling current output to respectively collect the negative currents fed back by the motor controller;

[0025] The steps for calculating the current coefficient are as follows: according to the positive current given by the constant current source and the positive current fed back by the motor controller, the positive current coefficient is calculated at each current, and the average value of the positive current coefficient is calculated; according to the negative current given by the constant current source and the negative current fed back by the motor controller, the negative current coefficient is calculated at each current, and the average value of the negative current coefficient is calculated; and then the average value of the positive current coefficient and the average value of the negative current coefficient are averaged to obtain the Hall adjustment coefficient.

[0026] On the other hand, the present invention further provides a computer-readable storage medium, comprising computer instructions, which, when executed on the Hall coefficient calibration system, enable the Hall coefficient calibration system to execute the Hall coefficient calibration method as described above.

[0027] Compared with the prior art, the motor controller with a Hall assembly, the Hall coefficient adjustment system and method provided by the present invention achieve at least the following beneficial effects:

[0028] The motor controller with Hall assembly provided by the present invention has the following advantages: on one hand, AC current passes through the three-phase copper busbar, and a changing magnetic field is induced under the action of the Hall magnetic ring. The magnetic sensitive chip senses the change in the magnetic field and outputs an induced voltage. The acquisition circuit in the integrated circuit board acquires the induced voltage and then transmits it to the central processing unit MCU. The MCU feeds back the current size flowing through the copper busbar; on the other hand, the Hall magnetic ring in the present invention has a notch, and a magnetic sensitive chip sheath is provided on the outer side of the magnetic sensitive chip. The top end of the magnetic sensitive chip sheath is engaged with the notch of the Hall magnetic ring, and the bottom end of the magnetic sensitive chip sheath is engaged with the bayonet of the integrated circuit board through a claw, thereby ensuring that the magnetic sensitive chip stands upright in the notch, and preventing the magnetic sensitive chip from colliding and falling, thereby improving the acquisition accuracy of the Hall assembly.

[0029] In the Hall coefficient calibration system provided by the present invention, the host computer is responsible for command input and controlling the automatic operation of the entire system, the motor controller containing the Hall assembly is responsible for current acquisition and signal feedback, the control circuit is responsible for executing the on-off of the current loop, and the constant current source is responsible for outputting currents in different ranges. The host computer interacts with the control circuit and the constant current source by signal to control the input and return of the current, and the host computer interacts with the motor controller containing the Hall assembly by signal to obtain the collected current and calculate the calibration coefficient, and at the same time writes the calibration coefficient into the motor controller, and the entire system is completed automatically with one click.

[0030] The Hall coefficient adjustment method of the present invention includes controlling current output, adjusting current and calculating current coefficient, and can realize automatic calculation of Hall adjustment coefficient, thereby ensuring the sampling accuracy of the Hall assembly of each electrode controller.

[0031] The beneficial effects of the computer-readable storage medium in the present invention can be referred to the beneficial effects analysis of the Hall coefficient adjustment system and the Hall coefficient adjustment method, which will not be repeated here.

[0032] Of course, any product implementing the present invention does not necessarily need to achieve all of the technical effects described above at the same time.

[0033] Further features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments of the present invention with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0035] Figure 1 is a partial stereoscopic diagram of a motor controller with a Hall assembly provided by an embodiment of the present invention;

[0036] Figure 2 is a partial front view of a motor controller with a Hall assembly provided by an embodiment of the present invention;

[0037] Figure 3 yes Figure 2 A cross-section in the A-A' direction;

[0038] Figure 4 is a top view of a magnetic sensitive chip sheath provided by an embodiment of the present invention;

[0039] Figure 5 is a structural diagram of a Hall coefficient calibration system provided by an embodiment of the present invention;

[0040] Figure 6 is a three-phase control circuit diagram provided by an embodiment of the present invention;

[0041] Figure 7 This is a flow chart of a method for adjusting the Hall coefficient provided by the present invention.

[0042] Figure 8 is a three-phase positive current adjustment path diagram provided by an embodiment of the present invention;

[0043] Fig. 9 is a three-phase negative current adjustment path diagram provided by an embodiment of the present invention;

[0044] Fig.10 It is a schematic diagram of the upper computer interface;

[0045] Among them, 100-motor controller, 1-integrated circuit board, 2-three-phase copper busbar, 21-U phase copper busbar, 22-V phase copper busbar, 23-W phase copper busbar, 3-Hall magnetic ring, 31-first Hall magnetic ring, 32-second Hall magnetic ring, 33-third Hall magnetic ring, 4-gap, 5-magnetic sensitive chip, 5a-pin, 6-magnetic sensitive chip sheath, 7-bayonet, 8-claw, 9-first side, 200-constant current source, 300-control circuit, 400-upper Position machine, 2001-first relay, 2002-second relay, 2003-third relay, 2004-fourth relay, 2005-U phase control circuit, 20051-U phase upper bridge tube, 20052-U phase lower bridge tube, 2006-V phase control circuit, 20061-V phase upper bridge tube, 20062-V phase lower bridge tube, 2007-W phase control circuit, 20071-W phase upper bridge tube, 20072-W phase lower bridge tube. DETAILED DESCRIPTION

[0046] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0047] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

[0048] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0049] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0050] It should be noted that like reference numerals and letters refer to similar items in the following figures, and therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0051] Reference Figures 1 to 4 , Figure 1 is a partial stereogram of a motor controller with a Hall assembly provided by an embodiment of the present invention, Figure 2 is a partial front view of a motor controller with a Hall assembly provided by an embodiment of the present invention, Figure 3 yes Figure 2 A cross-section along the A-A' direction, Figure 4 is a top view of a magnetic sensitive chip sheath provided by an embodiment of the present invention. This embodiment provides a motor controller with a Hall assembly. Figure 1 and Figure 2 is the local structure of the motor controller, Figure 1 and Figure 2 Only the integrated circuit board and Hall assembly in the motor controller are shown.

[0052] The Hall assembly includes a three-phase copper busbar 2, a Hall magnetic ring 3, a magnetic sensitive chip 5 and a magnetic sensitive chip sheath 6, and the integrated circuit board 1 includes an acquisition circuit (not shown in the figure); a three-phase copper busbar 2 is fixed to one side of the integrated circuit board 1, and the three-phase copper busbar 2 includes a U-phase copper busbar 21, a V-phase copper busbar 22 and a W-phase copper busbar 23; the outer sides of the three-phase copper busbar 2 are sleeved with a Hall magnetic ring 3, and the Hall magnetic ring 3 has a notch 4; the magnetic sensitive chip 5 is at least partially arranged in the notch 4, and the magnetic sensitive chip 5 includes a pin 5a, and the pin 5a is electrically connected to the acquisition circuit; the magnetic sensitive chip sheath 6 is sleeved on the outer side of the Hall magnetic ring 3, the integrated circuit board 1 includes a bayonet 7, and the magnetic sensitive chip sheath 6 has a claw 8 on the side close to the integrated circuit board 1, and the claw 8 is engaged with the bayonet 7.

[0053] Specifically, the Hall assembly is a device that integrates multiple components and is used to detect changes in the magnetic field and convert them into electrical signals for output.

[0054] The three-phase copper bar 2 includes a U-phase copper bar 21, a V-phase copper bar 22 and a W-phase copper bar 23, and is used to transmit three-phase power or signals.

[0055] The Hall magnetic ring 3 is a component that generates a magnetic field. It is a permanent magnet. The strength and direction of the magnetic field change with the rotation or position of the magnetic ring. The Hall assembly works by detecting the change of the magnetic field. The outer sides of the U-phase copper bar 21, the V-phase copper bar 22 and the W-phase copper bar 23 are respectively sleeved with Hall magnetic rings 3. The first Hall magnetic ring 31 is sleeved on the outer side of the U-phase copper bar 21, the second Hall magnetic ring 32 is sleeved on the outer side of the V-phase copper bar 22, and the third Hall magnetic ring 33 is sleeved on the outer side of the W-phase copper bar 23.

[0056] In some optional embodiments, the three-phase copper busbar 2 and the Hall magnetic ring 3 are fixed together by plastic coating to form insulation. Of course, the shapes of the three-phase copper busbar 2 and the Hall magnetic ring 3 can be adapted and designed according to the electric control structure, and are not specifically limited here.

[0057] The magnetic sensitive chip 5 is the core part of the Hall assembly, also known as the Hall element. It is a semiconductor device based on the Hall effect. When placed in a magnetic field, an electric potential difference (Hall voltage) will be generated on both sides of the chip. The electric potential difference is proportional to the strength of the magnetic field. The magnetic sensitive chip 5 can detect and respond to changes in the magnetic field, and then convert it into an electrical signal output.

[0058] The acquisition circuit is responsible for amplifying, filtering, shaping and other processing of the weak electrical signals output by the magnetic sensitive chip 5 so that the subsequent circuit or microprocessor can accurately read and analyze these signals.

[0059] The Hall magnetic ring 3 has a gap 4, and the magnetic sensitive chip 5 stands in the middle of the gap 4. The pin 5a of the magnetic sensitive chip 5 is welded on the integrated circuit board 1. The acquisition circuit is a part of the integrated circuit board 1. The acquisition circuit in the present invention can adopt the circuit of the prior art, and no improvement is made to the acquisition circuit here.

[0060] In the prior art, due to the influence of the size tolerance of the magnetic chip 5 and the assembly size of the Hall magnetic ring 3, the magnetic chip 5 may fall over, resulting in different output Hall sampling accuracy. In order to solve this problem, the present invention provides a magnetic chip sheath 6 on the outer side of the magnetic chip 5 to ensure that the magnetic chip 5 can stand upright in the notch 4, to ensure that the magnetic chip 5 is not crushed by collision, and to improve the Hall sampling accuracy.

[0061] The magnetic chip sheath 6 is sleeved on the outside of the Hall magnetic ring 3, the integrated circuit board 1 includes a bayonet 7, and the magnetic chip sheath 6 has a claw 8 on the side close to the integrated circuit board 1, and the claw 8 is engaged with the bayonet 7, so that the magnetic chip sheath 6 and the integrated circuit board 1 can be fixed more stably, thereby ensuring the stability of the magnetic chip 5, protecting the magnetic chip 5 from being crushed by collision, and improving the Hall sampling accuracy.

[0062] In some optional embodiments, referring to Figure 3 and Figure 4 The magnetically sensitive chip sheath 6 includes an upper end, a middle end and a lower end connected in sequence, wherein:

[0063] The magnetic sensitive chip 5 is fixed in the internal cavity of the upper end, and the upper end is engaged with the inner wall of the notch 4;

[0064] The middle end includes side walls, which extend to the bayonet 7;

[0065] Along the arrangement direction of the three-phase copper busbar 2, the lower end includes a claw 8 protruding toward the side away from the internal cavity. The claw 8 passes through the bayonet 7 and fits against the first side 9 of the integrated circuit board 1. The first side 9 is the side of the integrated circuit board 1 away from the three-phase copper busbar 2.

[0066] Specifically, the shape of the magnetic chip sheath 6 is not specifically limited here, as long as it has an internal cavity that can fix the magnetic chip 5 and can be engaged with the notch 4 of the Hall magnetic ring 3. Of course, the shape of the claw 8 is not specifically limited here, as long as it can be engaged with the bayonet 7 of the integrated chip. In this embodiment, only the triangular cone shape of the claw 8 is used as an example for schematic description.

[0067] The magnetic chip sheath 6 includes an upper end, a middle end and a lower end connected in sequence, the lower end is close to the integrated circuit board 1, and the upper end is far away from the integrated circuit board 1. Of course, each copper bar corresponds to a magnetic chip 5, and a magnetic chip sheath 6 is also provided accordingly. The magnetic chip 5 is fixed in the internal cavity of the upper end, and the upper end is engaged with the inner wall of the notch 4 to ensure the stability of the connection between the magnetic chip 5 and the magnetic chip sheath 6. At the same time, the upper end is engaged with the inner wall of the notch 4 to ensure the stability of the connection between the magnetic chip sheath 6 and the Hall magnetic ring 3. The lower end includes a claw 8 protruding to the side away from the internal cavity. The claw 8 penetrates the bayonet 7 and fits the first surface 9 of the integrated circuit board 1. In this way, the connection between the magnetic chip sheath 6 and the integrated circuit board 1 is stable, thereby ensuring the stability of the magnetic chip 5, protecting the magnetic chip 5 from being crushed by collision, and improving the Hall sampling accuracy.

[0068] Embodiment 2:

[0069] Combination Figure 5 and Figure 6 , Figure 5 This is a structural diagram of a Hall coefficient adjustment system provided by the present invention. Figure 6 It is a three-phase control circuit diagram provided in an embodiment of the present invention. The Hall coefficient adjustment system in this embodiment includes the motor controller 100 with the Hall assembly in Example 1, and also includes a constant current source 200, a control circuit 300 and a host computer 400.

[0070] like Figure 5 As shown, the motor controller 100 with the Hall assembly is electrically connected to the host computer 400 and the control circuit 300 respectively;

[0071] The constant current source 200 is electrically connected to the control circuit 300 and the host computer 400 respectively;

[0072] The control circuit 300 includes a U-phase control circuit 2005, a V-phase control circuit 2006, a W-phase control circuit 2007 and a relay group, wherein:

[0073] The relay group includes a first relay 2001, a second relay 2002, a third relay 2003 and a fourth relay 2004;

[0074] The positive electrode of the constant current source 200 is connected to the first relay 2001 and the third relay 2003, and the negative electrode of the constant current source 200 is connected to the second relay 2002 and the fourth relay 2004;

[0075] The U-phase control circuit 2005 includes a U-phase upper bridge tube 20051 and a U-phase lower bridge tube 20052, one end of the U-phase upper bridge tube 20051 is electrically connected to the first relay 2001, the second end of the U-phase upper bridge tube 20051 is electrically connected to the first Hall magnetic ring 31, the first section of the U-phase lower bridge tube 20052 is electrically connected to the fourth relay 2004, the second end of the U-phase lower bridge tube 20052 is electrically connected to the first Hall magnetic ring 31, and the other end of the first Hall magnetic ring 31 is electrically connected to the third relay 2003 and the second relay 2002 respectively;

[0076] The V-phase control circuit 2006 comprises a V-phase upper bridge tube 20061 and a V-phase lower bridge tube 20062, wherein one end of the V-phase upper bridge tube 20061 is electrically connected to the first relay 2001, the second end of the V-phase upper bridge tube 20061 is electrically connected to the second Hall magnetic ring 32, the first section of the V-phase lower bridge tube 20062 is electrically connected to the fourth relay 2004, the second end of the V-phase lower bridge tube 20062 is electrically connected to the second Hall magnetic ring 32, and the other end of the second Hall magnetic ring 32 is electrically connected to the third relay 2003 and the second relay 2002 respectively;

[0077] The W-phase control circuit 2007 includes a W-phase upper bridge tube 20071 and a W-phase lower bridge tube 20072, one end of the W-phase upper bridge tube 20071 is electrically connected to the first relay 2001, the second end of the W-phase upper bridge tube 20071 is electrically connected to the third Hall magnetic ring 33, the first section of the W-phase lower bridge tube 20072 is electrically connected to the fourth relay 2004, the second end of the W-phase lower bridge tube 20072 is electrically connected to the third Hall magnetic ring 33, and the other end of the third Hall magnetic ring 33 is electrically connected to the third relay 2003 and the second relay 2002 respectively.

[0078] Specifically, the motor controller 100 with a Hall assembly is electrically connected to the host computer 400 and the control circuit 300, respectively. As mentioned above, the motor controller 100 is a key component for controlling the operation of the motor in an electric vehicle or industrial equipment. It receives instructions from the host computer 400 (such as the dashboard of the electric vehicle, the controller or the PLC of the industrial equipment, etc.) and combines the feedback signal of the control circuit 300 to achieve precise control of the motor. The motor controller 100 and the host computer 400 transmit data through a specific communication protocol. The control circuit 300 can provide a stable power supply for the motor controller 100 to ensure that the controller can work normally. The motor controller 100 drives the motor to operate through the power devices (such as IGBT, MOSFET, etc.) in the control circuit 300 according to the output results of the control algorithm. The motor controller 100 in the present invention has a Hall assembly, such as Figures 1 to 4 ,have Figures 1 to 4 The beneficial effects of any embodiment will not be described in detail here. The control circuit 300 in the present invention can control the current according to the upper bridge instruction or the lower bridge instruction of the host computer 400.

[0079] The constant current source 200 is electrically connected to the control circuit 300 and the host computer 400, respectively. The constant current source 200 provides a stable current output for the control circuit 300. The host computer 400 sends a control instruction to the constant current source 200 through a communication interface (such as CAN bus, RS-485, etc.), such as setting current value, start / stop control, etc. After receiving the instruction, the constant current source 200 will adjust its output current to meet the requirements of the host computer 400. This instruction transmission method realizes the remote control and monitoring of the motor control system by the host computer 400. In addition to receiving instructions, the constant current source 200 can also feed back its own state information (such as output current value, fault state, etc.) to the host computer 400. The host computer 400 can understand the working state of the constant current source 200 in real time according to these feedback information, and perform corresponding processing or adjustment.

[0080] The control circuit 300 in the present invention is composed of three independent control circuits of U phase, V phase and W phase, and each phase control circuit 300 includes an upper bridge tube, a lower bridge tube and a Hall magnetic ring 3. In addition, it also includes a relay group (composed of a first relay 2001, a second relay 2002, a third relay 2003 and a fourth relay 2004).

[0081] The relay group plays a key role in the control circuit 300. They indirectly control the on and off of the three-phase circuit by controlling the current flow direction of the constant current source 200. When the first relay 2001 and the third relay 2003 are closed, the positive current of the constant current source 200 is allowed to pass through, which may activate the upper bridge tubes of the U phase, V phase, and W phase. When the second relay 2002 and the fourth relay 2004 are closed, the negative current of the constant current source 200 is allowed to pass through, which may activate the lower bridge tubes of the U phase, V phase, and W phase.

[0082] Specifically, the positive electrode of the constant current source 200 is connected to the first relay 2001 and the third relay 2003, and the negative electrode of the constant current source 200 is connected to the second relay 2002 and the fourth relay 2004; the U-phase control circuit 2005 includes a U-phase upper bridge tube 20051, a U-phase lower bridge tube 20052, and a first Hall magnetic ring 31, one end of the U-phase upper bridge tube 20051 is electrically connected to the first relay 2001, and the second end of the U-phase upper bridge tube 20051 is electrically connected to the first Hall magnetic ring 31. The first section of the U-phase lower bridge tube 20052 is electrically connected to the fourth relay 2004, the second end of the U-phase lower bridge tube 20052 is electrically connected to the first Hall magnetic ring 31, and the other end of the first Hall magnetic ring 31 is electrically connected to the third relay 2003 and the second relay 2002 respectively; the V-phase control circuit 2006 includes a V-phase upper bridge tube 20061 and a V-phase lower bridge tube 20062, one end of the V-phase upper bridge tube 20061 is electrically connected to the first relay 2001 is electrically connected, the second end of the V-phase upper bridge tube 20061 is electrically connected to the second Hall magnetic ring 32, the first section of the V-phase lower bridge tube 20062 is electrically connected to the fourth relay 2004, the second end of the V-phase lower bridge tube 20062 is electrically connected to the second Hall magnetic ring 32, and the other end of the second Hall magnetic ring 32 is electrically connected to the third relay 2003 and the second relay 2002 respectively; the W-phase control circuit 2007 includes a W-phase upper bridge tube 20071 and a W-phase lower bridge tube 20072, one end of the W-phase upper bridge tube 20071 is electrically connected to the first relay 2001, the second end of the W-phase upper bridge tube 20071 is electrically connected to the third Hall magnetic ring 33, the first section of the W-phase lower bridge tube 20072 is electrically connected to the fourth relay 2004, the second end of the W-phase lower bridge tube 20072 is electrically connected to the third Hall magnetic ring 33, and the other end of the third Hall magnetic ring 33 is electrically connected to the third relay 2003 and the second relay 2002 respectively.

[0083] The constant current source 200 provides a certain range of current output, the relay control circuit 300 is responsible for executing the on-off of the loop, and the host computer 400 controls the four relays to be turned on and off in sequence so that the U phase flows through the current in different directions. Here, the current direction from the electric control to the motor is defined as the positive direction of the current, and the current from the motor to the electric control is defined as the negative direction of the current. The host computer 400 controls the first relay 2001 and the second relay 2002 to close, so that the current can enter from the U phase upper bridge tube 20051 and come out from the first Hall magnetic ring 31, that is, the motor flows into a positive current; the host computer 400 controls the third relay 2003 and the fourth relay 2004 to close, so that the current can enter from the first Hall magnetic ring 31 and come out from the U phase lower bridge tube 20052, that is, the motor flows into a negative current, and the other V phase and W phase control circuits 2007 are similar, and will not be repeated.

[0084] In the Hall coefficient calibration system provided by the present invention, the host computer 400 is responsible for command input and controlling the automatic operation of the entire system, the motor controller 100 containing the Hall assembly is responsible for current acquisition and signal feedback, the control circuit 300 is responsible for executing the current loop on and off, and the constant current source 200 is responsible for outputting currents in different ranges. The host computer 400 interacts with the control circuit 300 and the constant current source 200 through signals to control the input and return of the current. The host computer 400 interacts with the motor controller 100 containing the Hall assembly through signals to obtain the collected current and calculate the calibration coefficient, and at the same time writes the calibration coefficient into the motor controller 100, and the entire system is completed automatically with one click.

[0085] In some optional embodiments, continue to refer to Figure 5 The communication between the host computer 400 and the motor controller 100 includes one of the CAN bus, LIN bus or FlexRay bus.

[0086] CAN bus is a serial communication protocol bus for real-time applications. It is suitable for high-speed, real-time communication between various electronic control units in automobiles and has a wide range of applications. CAN bus has the advantages of high real-time performance, high speed and high reliability.

[0087] LIN bus is a low-cost serial communication network protocol with the characteristics of low cost, single-line transmission, master-slave structure, and auxiliary communication. As a low-cost alternative to low-speed CAN, it is suitable for low-speed data transmission scenarios such as sensor / actuator control.

[0088] FlexRay is a high-speed, deterministic, fault-tolerant bus technology for automobiles, with the advantages of high bandwidth, time determinism, strong fault tolerance and flexibility.

[0089] In the present invention, the communication between the host computer 400 and the motor controller 100 may adopt any of the above-mentioned methods.

[0090] Example 3

[0091] This embodiment provides a method for adjusting the Hall coefficient. Figure 7 , Figure 7 This is a flow chart of a method for adjusting the Hall coefficient provided by the present invention, combined with Figure 8 and Fig. 9 , Figure 8 is a three-phase positive current adjustment path diagram provided by an embodiment of the present invention, Fig. 9 : is a three-phase negative current adjustment path diagram provided by an embodiment of the present invention, and the Hall coefficient adjustment system of the above embodiment 2 is applied, including:

[0092] S301, a step of controlling current output, wherein the upper bridge instruction is sent to the motor controller 100 through the host computer 400, the current flows into the positive electrode of the constant current source 200, and the current passes through the control circuit 300 and the Hall assembly in sequence, and returns to the negative electrode of the constant current source 200, and the positive current of the U phase, the positive current of the V phase, and the positive current of the W phase are collected; the lower bridge instruction is sent to the motor controller 100 through the host computer 400, the current flows into the positive electrode of the constant current source 200, and the current passes through the Hall assembly and the control circuit 300 in sequence, and returns to the negative electrode of the constant current source 200, and the negative current of the U phase, the negative current of the V phase, and the negative current of the W phase are collected;

[0093] S302, a step of adjusting the current, respectively giving positive currents from small to large to the constant current source 200, using a method of controlling current output, respectively collecting positive currents fed back by the motor controller 100; respectively giving negative currents from large to small to the constant current source 200, using a method of controlling current output, respectively collecting negative currents fed back by the motor controller 100;

[0094] S303, the step of calculating the current coefficient, according to the positive current given by the constant current source 200 and the positive current fed back by the motor controller 100, calculate the positive current coefficient at each current, and calculate the average value of the positive current coefficient; according to the negative current given by the constant current source 200 and the negative current fed back by the motor controller 100, calculate the negative current coefficient at each current, and calculate the average value of the negative current coefficient, and then average the average value of the positive current coefficient and the average value of the negative current coefficient to obtain the Hall adjustment coefficient.

[0095] Specifically, in step S301, the host computer 400 sends an upper bridge instruction to the motor controller 100 through a communication interface (such as CAN bus, RS-485, etc.). After receiving the instruction, the motor controller 100 controls the first relay 2001 and the third relay 2003 in the relay group to close (or may be other relay combinations according to the specific design), and ensures that the second relay 2002 and the fourth relay 2004 are in a disconnected state. At this time, the positive current of the constant current source 200 flows into the upper bridge tubes of the U phase, V phase, and W phase through the closed relay. After the current passes through the upper bridge tube, it passes through the corresponding Hall magnetic ring 3 (for detecting current and magnetic field), and then flows back to the negative pole of the constant current source 200. In this process, the values ​​of the positive current of the U phase, the positive current of the V phase, and the positive current of the W phase are collected through the current detection function of the current sensor or the Hall magnetic ring 3.

[0096] The host computer 400 sends a lower bridge instruction to the motor controller 100 through the communication interface. After receiving the instruction, the motor controller 100 controls the second relay 2002 and the fourth relay 2004 in the relay group to close, and ensures that the first relay 2001 and the third relay 2003 are in the disconnected state. At this time, the positive current of the constant current source 200 flows into the Hall magnetic ring 3 through the closed relay, and then passes through the lower bridge tubes of the U phase, V phase, and W phase. After passing through the lower bridge tube, the current flows back to the common point in the control circuit 300, and finally returns to the negative pole of the constant current source 200. In this process, the values ​​of the negative current of the U phase, the negative current of the V phase, and the negative current of the W phase are also collected through the current detection function of the current sensor or the Hall magnetic ring 3.

[0097] The upper bridge instruction is an active short circuit protection (ASC) instruction in the motor controller 100, which is mainly used to protect the motor and controller system from further damage under specific fault conditions. The upper bridge instruction specifically refers to the control of the switching state of the insulated gate bipolar transistor (IGBT) in the three-phase inverter circuit of the motor to simultaneously turn off the three IGBT tubes of the upper bridge arm, thereby achieving a short circuit of the U, V, and W phases of the motor, that is, a short circuit of the upper bridge arm. The method for adjusting the given current is reflected in the action of the three-phase bridge arm of the motor controller 100, the direction of the current flow in the three-phase bridge arm of the controller, and the size of the given current. First, when the host computer 400 sends the upper bridge ASC instruction to the motor controller 100, the upper bridge of the motor controller 100 enters the ASC state (all upper bridge arms are closed and introduced). After the U-phase control circuit 2005 is activated, when the current flows into the positive electrode P of the constant current source 200, the current passes through the U-phase upper bridge tube 20051 and flows through the U-phase Hall assembly, and then flows back to the negative electrode N of the constant current source 200, thereby collecting the U-phase + current. In turn, the V-phase and W-phase control circuits 2007 are activated. When the current flows into the positive electrode P of the constant current source 200, the current passes through the upper bridge and flows through the V-phase and W-phase Hall assemblies, and then flows back to the negative electrode N of the constant current source 200, thereby collecting the V-phase + and W-phase + currents. The three-phase positive current adjustment path is as follows: Figure 8 shown.

[0098] The lower bridge instruction is a form of active short circuit protection (ASC) in the motor controller 100. It specifically refers to the control of the switch state of the insulated gate bipolar transistor (IGBT) in the three-phase inverter circuit of the motor to turn on the three IGBT tubes of the lower bridge arm at the same time (or turn off the three tubes of the upper bridge arm according to a specific strategy), thereby realizing the U, V, and W three-phase short circuit of the motor, that is, the lower bridge arm short circuit. When the host computer 400 sends the lower bridge ASC instruction to the motor controller 100, the lower bridge enters the ASC state (all lower bridge arms are closed and imported). When the U-phase control circuit 2005 is activated, when the current flows in from the positive electrode P of the constant current source 200, the current passes through the U-phase Hall assembly, then flows through the lower bridge tube, and finally flows back to the negative electrode N of the constant current source 200, thereby collecting the U-phase current. Then, the V-phase and W-phase control circuits 2007 are activated, and when the current flows in from the positive electrode P of the constant current source 200, the current passes through the V-phase and W-phase Hall assemblies, then flows through the lower bridge tube, and finally flows back to the negative electrode N of the constant current source 200, thereby collecting the V-phase and W-phase currents. The three-phase negative current adjustment path is as follows: Fig. 9 shown.

[0099] In some optional embodiments, step S301 includes:

[0100] The host computer 400 controls the first relay 2001 and the second relay 2002 to close, and the current enters from the U-phase upper bridge tube 20051 in the U-phase control circuit 2005, flows out from the first Hall magnetic ring 31, and the motor flows into a positive current; the current enters from the V-phase upper bridge tube 20061 in the V-phase control circuit 2006, flows out from the second Hall magnetic ring 32, and the motor flows into a positive current; the current enters from the W-phase upper bridge tube 20071 in the W-phase control circuit 2007, flows out from the third Hall magnetic ring 33, and the motor flows into a positive current;

[0101] The host computer 400 controls the third relay 2003 and the fourth relay 2004 to close, the current flows into the first Hall magnetic ring 31, flows out of the U-phase lower bridge tube 20052 in the U-phase control circuit 2005, and the motor flows into a negative current; the current flows into the second Hall magnetic ring 32, flows out of the V-phase lower bridge tube 20062 in the V-phase control circuit 2006, and the motor flows into a negative current; the current flows into the third Hall magnetic ring 33, flows out of the W-phase lower bridge tube 20072 in the W-phase control circuit 2007, and the motor flows into a negative current.

[0102] For step S302, the current is adjusted, the positive current is adjusted from small to large, and the negative current is adjusted from large to small, in order to reduce the influence of residual magnetism on the calibration accuracy. The upper limit of the current is determined according to the power range of the product, and the maximum output current value corresponding to the peak power needs to be obtained. The adjustment path refers to Figure 8 and Fig. 9 The details are shown in Table 1 below. Table 1 is a given table of phase U current.

[0103] Table 1U phase current setting table

[0104]

[0105] Of course, for different motors, the given current value is different. Table 1 is only for schematic illustration and is not used as a limit to the given current of the actual product. The given current table for V-phase and W-phase is similar to the given current table for U-phase, so it will not be repeated here.

[0106] In this embodiment, the current coefficient can be obtained by adjusting the given current.

[0107] S303, the step of calculating the current coefficient, according to the positive current given by the constant current source 200 and the positive current fed back by the motor controller 100, calculate the positive current coefficient at each current, and calculate the average value of the positive current coefficient; according to the negative current given by the constant current source 200 and the negative current fed back by the motor controller 100, calculate the negative current coefficient at each current, and calculate the average value of the negative current coefficient, and then average the average value of the positive current coefficient and the average value of the negative current coefficient to obtain the Hall adjustment coefficient.

[0108] Specifically, the average value η of the positive current coefficient of phase U is calculated according to the following method: U+ , average value of negative current coefficient of phase U η U -, U phase Hall adjustment coefficient η U ,in,

[0109]

[0110] Among them, I i’ is the U-phase current fed back by the motor controller 100, I i is the U-phase current given by the constant current source 200, n is the number of currents given by the constant current source 200, η U+ is the average value of the positive current coefficient of phase U, η U- is the average value of the negative current coefficient of phase U, η U is the U-phase Hall adjustment coefficient.

[0111] According to the average value of the positive current coefficient of phase U η U+ The same calculation method is used to calculate the average value η of the positive current coefficient of phase V V+ and the average value of the positive current coefficient of W phase η W+ ,Right now:

[0112]

[0113] According to the average value of the negative current coefficient of phase U η U- The same calculation method is used to calculate the average value η of the negative current coefficient of phase V V- and the average value of negative current coefficient of W phase η W- ,Right now

[0114]

[0115] According to the U-phase Hall adjustment coefficient η U The same calculation method is used to calculate the V phase Hall adjustment coefficient η V and W phase Hall adjustment coefficient η W ,Right now:

[0116]

[0117] This gives the three-phase adjustment coefficient.

[0118] The Hall coefficient adjustment method of the present invention includes controlling current output, adjusting current and calculating current coefficient, and can realize automatic calculation of Hall adjustment coefficient, thereby ensuring the sampling accuracy of the Hall assembly of each electrode controller.

[0119] In some optional embodiments, step S304 is also included, in which a calibration program start button is included in the host computer 400. After clicking the start button, the calibration is automatically performed, and the Hall calibration coefficient is written into the motor controller 100 and displayed in the interface of the host computer 400.

[0120] Automatic adjustment and coefficient writing can be a complete set of host computer 400 control programs. The interface diagram of host computer 400 is as follows Fig.10 As shown, click the Start Test button to perform automatic adjustment. After the adjustment test is completed, the obtained Hall adjustment coefficient value is displayed. By clicking Write K value (i.e., Hall adjustment coefficient), the Hall adjustment coefficient can be written into the motor controller 100. At the same time, the host computer 400 and the motor controller 100 will verify the written information to ensure the correctness of the writing.

[0121] Although some specific embodiments of the present invention have been described in detail by way of example, it will be appreciated by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present invention. It will be appreciated by those skilled in the art that the above embodiments may be modified without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. A motor controller with a Hall assembly, characterized in that: The motor controller includes an integrated circuit board and a Hall assembly, and the Hall assembly includes a three-phase copper bus, a Hall magnetic ring, a magnetic sensitive chip and a magnetic sensitive chip sheath. The integrated circuit board includes an acquisition circuit; The three-phase copper bar is fixed on one side of the integrated circuit board, and the three-phase copper bar includes a U-phase copper bar, a V-phase copper bar and a W-phase copper bar; The outer sides of the three-phase copper bars are sleeved with the Hall magnetic rings, and the Hall magnetic rings have gaps; The magnetic sensing chip is at least partially disposed in the notch, and the magnetic sensing chip includes a pin, and the pin is electrically connected to the acquisition circuit; The magnetically sensitive chip sheath is sleeved on the outer side of the Hall magnetic ring, the integrated circuit board comprises a bayonet, and the side of the magnetically sensitive chip sheath close to the integrated circuit board has a claw, and the claw is engaged with the bayonet.

2. The motor controller with a Hall assembly according to claim 1, characterized in that: The magnetically sensitive chip sheath comprises an upper end, a middle end and a lower end connected in sequence, wherein: The magnetic sensitive chip is fixed in the internal cavity of the upper end, and the upper end is engaged with the inner wall of the notch; The middle end includes a side wall, and the side wall extends to the bayonet; Along the arrangement direction of the three-phase copper busbar, the lower end includes the claw protruding toward the side away from the internal cavity, and the claw passes through the bayonet and fits with the first surface of the integrated circuit board, and the first surface is the side of the integrated circuit board away from the three-phase copper busbar.

3. The motor controller with a Hall assembly according to claim 1, characterized in that: The outer sides of the three-phase copper busbar and the Hall magnetic ring are both insulated by plastic wrapping.

4. A Hall coefficient calibration system, characterized in that: include: The motor controller with a Hall assembly, a constant current source, a control circuit and a host computer as described in any one of claims 1 to 3, wherein: The motor controller with the Hall assembly is electrically connected to the host computer and the control circuit respectively; The constant current source is electrically connected to the control circuit and the host computer respectively; The control circuit includes a U-phase control circuit, a V-phase control circuit, a W-phase control circuit and a relay group, wherein: The relay group includes a first relay, a second relay, a third relay and a fourth relay; The positive electrode of the constant current source is connected to the first relay and the third relay, and the negative electrode of the constant current source is connected to the second relay and the fourth relay; The U-phase control circuit comprises a U-phase upper bridge tube and a U-phase lower bridge tube, one end of the U-phase upper bridge tube is electrically connected to the first relay, the second end of the U-phase upper bridge tube is electrically connected to the first Hall magnetic ring, the first end of the U-phase lower bridge tube is electrically connected to the fourth relay, the second end of the U-phase lower bridge tube is electrically connected to the first Hall magnetic ring, and the other end of the first Hall magnetic ring is electrically connected to the third relay and the second relay respectively; The V-phase control circuit comprises a V-phase upper bridge tube and a V-phase lower bridge tube, one end of the V-phase upper bridge tube is electrically connected to the first relay, the second end of the V-phase upper bridge tube is electrically connected to the second Hall magnetic ring, the first section of the V-phase lower bridge tube is electrically connected to the fourth relay, the second end of the V-phase lower bridge tube is electrically connected to the second Hall magnetic ring, and the other end of the second Hall magnetic ring is electrically connected to the third relay and the second relay respectively; The W-phase control circuit includes a W-phase upper bridge tube and a W-phase lower bridge tube, one end of the W-phase upper bridge tube is electrically connected to the first relay, the second end of the W-phase upper bridge tube is electrically connected to the third Hall magnetic ring, the first section of the W-phase lower bridge tube is electrically connected to the fourth relay, the second end of the W-phase lower bridge tube is electrically connected to the third Hall magnetic ring, and the other end of the third Hall magnetic ring is electrically connected to the third relay and the second relay respectively.

5. The Hall coefficient calibration system according to claim 4, characterized in that: The communication between the host computer and the motor controller includes one of a CAN bus, a LIN bus or a FlexRay bus.

6. A method for adjusting the Hall coefficient, characterized in that: include: The step of controlling the current output includes: sending an upper bridge instruction to the motor controller through the host computer, the current flows into the positive electrode of the constant current source, the current passes through the control circuit and the Hall assembly in sequence, returns to the negative electrode of the constant current source, and collects the positive current of the U phase, the positive current of the V phase, and the positive current of the W phase; sending a lower bridge instruction to the motor controller through the host computer, the current flows into the positive electrode of the constant current source, the current passes through the Hall assembly and the control circuit in sequence, returns to the negative electrode of the constant current source, and collects the negative current of the U phase, the negative current of the V phase, and the negative current of the W phase; The step of adjusting the current includes: setting positive currents from small to large to the constant current source, using the method of controlling current output, and respectively collecting positive currents fed back by the motor controller; setting negative currents from large to small to the constant current source, using the method of controlling current output, and respectively collecting negative currents fed back by the motor controller; The step of calculating the current coefficient includes: calculating the positive current coefficient under each given current according to the positive current given by the constant current source and the positive current fed back by the motor controller, and calculating the average value of the positive current coefficient; calculating the negative current coefficient under each given current according to the negative current given by the constant current source and the negative current fed back by the motor controller, and calculating the average value of the negative current coefficient, and then averaging the average value of the positive current coefficient and the average value of the negative current coefficient to obtain the Hall adjustment coefficient.

7. The method for adjusting the Hall coefficient according to claim 6, characterized in that: The method also includes a step in which the host computer displays the Hall adjustment coefficient, wherein the host computer includes a calibration program start button, and after clicking the start button, the calibration is automatically performed, and the Hall adjustment coefficient is written into the motor controller and displayed in the interface of the host computer at the same time.

8. The method for adjusting the Hall coefficient according to claim 6, characterized in that: The step of controlling the current output includes: The host computer controls the first relay and the second relay to be closed, and the current enters from the U-phase upper bridge tube in the U-phase control circuit, flows out from the first Hall magnetic ring, and the motor flows into a positive current; the current enters from the V-phase upper bridge tube in the V-phase control circuit, flows out from the second Hall magnetic ring, and the motor flows into a positive current; the current enters from the W-phase upper bridge tube in the W-phase control circuit, flows out from the third Hall magnetic ring, and the motor flows into a positive current; The host computer controls the third relay and the fourth relay to be closed, and current flows into the first Hall magnetic ring, flows out of the U-phase lower bridge tube in the U-phase control circuit, and a negative current flows into the motor; current flows into the second Hall magnetic ring, flows out of the V-phase lower bridge tube in the V-phase control circuit, and a negative current flows into the motor; current flows into the third Hall magnetic ring, flows out of the W-phase lower bridge tube in the W-phase control circuit, and a negative current flows into the motor.

9. The method for adjusting the Hall coefficient according to claim 6, characterized in that: The step of calculating the current coefficient includes calculating the average value η of the positive current coefficient of the U phase according to the following method: U+ , average value of negative current coefficient of phase U η U- , U phase Hall adjustment coefficient η U ,in, Among them, I i’ is the U-phase current fed back by the motor controller, I i is the U-phase current given by the constant current source, n is the number of currents given by the constant current source, η U+ is the average value of the positive current coefficient of phase U, η U- is the average value of the negative current coefficient of phase U, η U is the U-phase Hall adjustment coefficient; According to the average value of the positive current coefficient of phase U η U+ The same calculation method is used to calculate the average value η of the positive current coefficient of phase V V+ and the average value of the positive current coefficient of W phase η W+ ; According to the average value of the negative current coefficient of phase U η U- The same calculation method is used to calculate the average value η of the negative current coefficient of phase V V- and the average value of negative current coefficient of W phase η W -; According to the U-phase Hall adjustment coefficient η U The same calculation method is used to calculate the V phase Hall adjustment coefficient η V and W phase Hall adjustment coefficient η W .

10. A computer-readable storage medium, characterized in that: The method comprises computer instructions, and when the computer instructions are executed on the Hall coefficient calibration system described in claims 4 to 5, the Hall coefficient calibration system executes the Hall coefficient calibration method described in any one of claims 6 to 9.

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