Motor integrated control protection device

Abstract

The application discloses a motor integrated control protection device, which comprises a sampling board, a control board and a main control board.The sampling board comprises a current sampling circuit, a voltage sampling circuit and a metering chip, and the current sampling circuit, the voltage sampling circuit and the metering chip are connected through a first connector.The control board comprises a motor execution circuit and a current conversion circuit, and the motor execution circuit and the current conversion circuit are connected through a second connector.The main control board comprises an incoming circuit, a communication circuit, a button circuit and a digital signal processing circuit, and the incoming circuit, the communication circuit, the button circuit and the digital signal processing circuit are connected through a third connector.The sampling board is connected with the main control board through the first connector, and the control board is connected with the main control board through the second connector.The device can be easily replaced by non-technical workers when a fault occurs, and the time and cost of after-sales service are greatly reduced.

Description

Technical Field

[0001] This application relates to an integrated motor control and protection device, belonging to the field of controller technology. Background Technology

[0002] Traditional control of motors, pumps, and electrical outputs relies on a complex array of components, including intermediate relays, time relays, changeover switches, various normally open and normally closed contacts, indicator lights, and buttons, all connected by a series of secondary wires. This method suffers from complex wiring, and the various interlocking, chaining, and sealing connections are easily confused, leading to incorrect wiring. Its drawbacks are obvious: a single incorrectly connected or loose wire, or a component failure in any part of the system, can paralyze the entire system, making repair extremely difficult and requiring specialized personnel. Therefore, an integrated motor control and protection device is designed. Utility Model Content

[0003] According to one aspect of this application, an integrated motor control and protection device is provided, which allows non-technical workers to easily complete the replacement operation when a fault occurs, greatly reducing the time and cost of after-sales service.

[0004] An integrated motor control and protection device, characterized in that it includes: The sampling board circuit includes a current sampling circuit, a voltage sampling circuit, and a metering chip, wherein the current sampling circuit, the voltage sampling circuit, and the metering chip are connected through a first connector; The control board circuit includes a motor execution circuit and a current conversion circuit, which are connected via a second connector. The main control board circuit includes an input circuit, a communication circuit, a key circuit, and a digital signal processing circuit, wherein the input circuit, the communication circuit, the key circuit, and the digital signal processing circuit are connected through a third connector. The sampling board circuit is connected to the main control board circuit via a first connector, and the control board circuit is connected to the main control board circuit via a second connector.

[0005] Furthermore, the first connector includes a first output terminal and a first connection pin, one end of the voltage sampling circuit and the current sampling circuit are connected to the pin of the first output terminal, and the other end of the current sampling circuit and the voltage sampling circuit are connected to the metering chip; The metering chip is connected to the first connection pin, and the first connection pin is connected to the digital signal processing circuit.

[0006] Furthermore, the second connector includes a second connecting pin, a third connecting pin, and a second output terminal. One end of the motor execution circuit and the current conversion circuit is connected to the pin of the second output terminal, and the motor execution circuit realizes different execution functions of the motor by connecting different pins of the second output terminal. The other end of the motor actuation circuit is connected to the digital signal processing circuit via a second connection pin, and the other end of the current conversion circuit is connected to the third connection pin.

[0007] Furthermore, the third connector includes a fourth connecting pin, a fifth connecting pin, and a third output terminal. One end of the input circuit is connected to the third output terminal, and the other end of the input circuit is connected to the digital signal processing circuit. One end of the button circuit is connected to the fourth connecting pin, and the other end of the button circuit is connected to the digital signal processing circuit. The communication circuit is connected to the digital signal processing circuit.

[0008] Furthermore, the implementation of the motor execution circuit includes at least the forward rotation of the motor, the reverse rotation of the motor, the controller alarm, and the controller power failure alarm.

[0009] The beneficial effects that this application can produce include: The integrated motor control and protection device provided in this application rationally designs and connects a sampling board, a control board, and a main control board. The sampling board accurately collects data using current and voltage sampling circuits and metering chips. The control board realizes motor execution and current conversion functions. The main control board integrates various circuits such as input and communication for comprehensive processing. The boards are efficiently interconnected through connectors, realizing fast and accurate data transmission and collaborative operation. It can accurately monitor and protect motor operation, improve motor control efficiency and stability, reduce the failure rate, and allow non-technical workers to easily complete the replacement operation in case of failure, greatly reducing the time and cost of after-sales service. Attached Figure Description

[0010] Figure 1 This is a voltage sampling circuit diagram according to one embodiment of this application; Figure 2 This is a schematic diagram of a current sampling circuit in one embodiment of this application; Figure 3 This is a schematic diagram of a metering chip circuit in one embodiment of this application; Figure 4 This is a schematic diagram of the first output terminal in one embodiment of this application; Figure 5 This is a schematic diagram of the first connecting pin in one embodiment of this application; Figure 6This is a schematic diagram showing the connection of the motor execution circuit under different states in one embodiment of this application; Figure 7 This is a schematic diagram of the current conversion circuit connection in one embodiment of this application; Figure 8 This is a schematic diagram of the second output terminal in one embodiment of this application; Figure 9 This is a schematic diagram of the second and third connecting pins in one embodiment of this application; Figure 10 This is a schematic diagram of an input circuit in one embodiment of this application; Figure 11 This is a schematic diagram of a communication circuit in one embodiment of this application; Figure 12 This is a schematic diagram of a button circuit in one embodiment of this application; Figure 13 This is a schematic diagram of a digital signal processing circuit in one embodiment of this application; Figure 14 This is a schematic diagram of the third output terminal in one embodiment of this application; Figure 15 This is a schematic diagram of the fourth and fifth connecting pins in one embodiment of this application. Detailed Implementation

[0011] The present application is described in detail below with reference to the embodiments, but the present application is not limited to these embodiments.

[0012] See Figure 1-15 An integrated motor control and protection device, characterized in that it includes: The sampling board circuit includes a current sampling circuit, a voltage sampling circuit, and a metering chip, wherein the current sampling circuit, the voltage sampling circuit, and the metering chip are connected through a first connector; The control board circuit includes a motor execution circuit and a current conversion circuit, which are connected via a second connector. The main control board circuit includes an input circuit, a communication circuit, a key circuit, and a digital signal processing circuit, wherein the input circuit, the communication circuit, the key circuit, and the digital signal processing circuit are connected through a third connector. The sampling board circuit is connected to the main control board circuit via a first connector, and the control board circuit is connected to the main control board circuit via a second connector.

[0013] Specifically, such as Figure 1-5As shown, the current sampling circuit acquires three-phase current signals (IA1P, IA1N, IB1P, IB1N, IC1P, IC1N) through a resistor divider and differential amplifier (e.g., R50R, C33nF), and inputs them to the metering chip. The voltage sampling circuit acquires three-phase voltage signals (Ua, Ub, Uc, Un) through a resistor divider network (e.g., R750R, C133nF), and inputs them to the metering chip. The metering chip processes the sampled signals and outputs digital values ​​to the main control board (via SPI interfaces such as DSP_MOSI and DSP_MISO). The external output terminals in the first connector include pins such as P1 and P2, used to connect to the main control board. Signal transmission DSP_CLK (clock), DSP_CS1 (chip select), DSP_MOSI (master output, slave input), etc., communicate with the DSP on the main control board through pins. Power distribution DVCC (digital power) and DGND (digital ground) are supplied through pins. The sampling board's metering chip communicates with the main control board's DSP processor via the SPI interface (DSP_MOSI, DSP_MISO) through the first connector. DVCC and DGND provide stable power to the main control board via pins. Figure 6-9 As shown, the motor execution circuit includes relays (such as K1_1 and K1_2) and a drive circuit to control the motor's forward / reverse rotation. The relays control signals DSP_CT RL_ALARM1 to DSP_CT RL_ALARM7, which drive the relay coil through pins. The current conversion circuit converts the control signals output from the main control board (such as PWM or 0-10V) into current signals suitable for the motor. The second connector includes output terminals such as P1 and P2 pins for connecting to the main control board. Forward and reverse control signals are transmitted to the motor through pins, and the motor's forward and reverse states are fed back to the main control board through pins. The main control board outputs control signals via GPIO or PWM, which are transmitted to the relay drive circuit on the control board via the second connector. The main control board's +5V1 and DGND pins supply power to the control board. Figure 10-15As shown, the input circuit receives remote control signals (such as remote forward control input and remote reverse control input), and inputs them to the DSP after optocoupler isolation. The communication circuit includes RS485 interfaces (DSP_485_Rxd, DSP_485_Txd) to realize data interaction with the host computer or other devices. The button circuit inputs user commands through buttons KEY_1 to KEY_4, which are connected to the DSP via pins. The digital signal processing circuit, with the DSP as its core, processes sampled data, executes control algorithms, and outputs control signals. The third connector includes on-board pins such as PZ254R-12-12P and PZ254R-12-16P, used to connect the sampling board and the control board. The sampling board interface SPI signals such as DSP_MOSI and DSP_MISO communicate with the sampling board through pins. The control board interface forward control output and reverse control output signals interact with the control board through pins. The DSP reads sampled data through the SPI interface via the third connector. The main control board's DVCC and DGND supply power to the sampling board through pins. The DSP outputs control signals via GPIO or PWM, which are transmitted to the control board through a third connector. The control board feeds back the motor's forward and reverse rotation status to the DSP via pins.

[0014] It is worth noting that traditional water pump motor control cabinets (boxes) typically use buttons, indicator lights, selector switches, intermediate relays, time relays, and terminal blocks. However, this application revolutionizes the traditional control methods for motors and water pumps used in highways, buildings, and industrial enterprises, while integrating all the functions of traditional motor control: manual / automatic selection, fire protection interface, building intelligence interface, remote control interface, remote communication interface, and PLC terminal functions.

[0015] Furthermore, this application employs plug-in connectors to connect with various actuators, resulting in exceptionally low maintenance and after-sales costs. Even non-technical personnel can perform repairs themselves, eliminating the need for complex secondary wiring and testing of individual connection points. If a problem arises, the replacement method can be used directly, simply replacing the corresponding component.

[0016] The first connector includes a first output terminal and a first connection pin. One end of the voltage sampling circuit and the current sampling circuit are connected to the pin of the first output terminal, and the other end of the current sampling circuit and the voltage sampling circuit are connected to the metering chip. The metering chip is connected to the first connection pin, and the first connection pin is connected to the digital signal processing circuit.

[0017] Specifically, the first output terminal serves as the physical interface for the sampling board's external output, used to connect to external devices or as a signal relay within the board. The pins include analog signal pins such as IA1P, IA1N (A-phase current sampling input), Ua, and Ub (voltage sampling input), which directly connect to the output of the current / voltage sampling circuit. It also includes auxiliary pins such as DVCC (digital power supply) and DGND (digital ground) for power supply or reference ground. The first connection pin serves as the signal transmission channel between the sampling board and the main control board, employing a standardized pin design (e.g., 2.54mm pitch) for easy and quick insertion and removal. The pins include digital signal pins such as DSP_MOSI, DSP_MISO (SPI communication signal), and DSP_CS1 (chip select signal), which directly connect to the output of the metering chip and the main control board's DSP processor. It also includes power supply pins such as DVCC and DGND, sharing the power supply channel with the first output terminal. Analog signals (current / voltage sampling) are output through the first output terminal to avoid mixing with digital signals (SPI) and reduce interference. Digital signals are transmitted through the first connection pin, employing a high-speed differential signal or shielded wire design to ensure data integrity. Both the first output terminal and the first connection pin include DVCC and DGND pins, forming a dual power supply path to improve power supply reliability. The input of the current / voltage sampling circuit is connected to the secondary side outputs of the motor's three-phase current transformer (CT) and voltage transformer (PT). After filtering by components such as R50R and C33nF, the signals are output to the IA1P and IA1N pins of the first output terminal. The metering chip acquires the analog signals (such as IA1P and Ua) from the first output terminal via its internal ADC. The processed digital signals (such as RMS current and RMS voltage) are output to the first connection pin via the SPI interface (DSP_MOSI, DSP_MISO). The IA1P and Ua pins of the first output terminal are connected to external test points (optional) via ribbon cables or PCB traces. The DSP_MOSI and DSP_CS1 pins of the first connection pin are directly inserted into the corresponding sockets on the main control board (such as PZ254R-12-12P) to achieve communication. From the sampling board to the main control board, the metering chip transmits the current values ​​(IA, IB, IC) and voltage values ​​(Ua, Ub, Uc) to the main control board's DSP in real time via SPI for overcurrent / overvoltage protection, power calculation, and other logic. Optical or magnetic coupling isolation is used between the current / voltage sampling circuit and the first output terminal to block common-mode interference. Example: A 10kΩ resistor and a 0.1μF capacitor are added between IA1P and IA1N to form a low-pass filter and suppress high-frequency noise. The signal lines of the first connection pin use twisted-pair or coaxial cable, with the outer shielding layer grounded to reduce electromagnetic interference (EMI). Critical signal pins (such as DVCC and DGND) of the first output terminal and the first connection pin employ a dual-backup design; a single pin failure will not affect system operation.The main control board's DSP periodically polls the metering chip's status via SPI. If no response is received within a timeout period, a system reset is triggered to prevent crashes. If the sampling board fails, the first connection pin can be directly disconnected and a new board replaced without needing to readjust the SPI communication parameters. The main control board can read the metering chip's internal registers (such as STATUS_REG) via SPI to monitor the sampling circuit for open / short circuits in real time.

[0018] The second connector includes a second connecting pin, a third connecting pin, and a second output terminal. One end of the motor execution circuit and the current conversion circuit is connected to the pin of the second output terminal, and the motor execution circuit realizes different execution functions of the motor by connecting different pins of the second output terminal. The other end of the motor actuation circuit is connected to the digital signal processing circuit via a second connection pin, and the other end of the current conversion circuit is connected to the third connection pin.

[0019] Specifically, the second connector is a 2×6-pin (12-pin) header with a 2.54mm spacing, transmitting digital control signals (such as PWM and direction commands) and connecting the motor execution circuit to the digital signal processing circuit (DSP). The third connector is a 1×4-pin (4-pin) header with a 2.0mm spacing, transmitting current feedback signals (such as Hall sensor output) and connecting the current conversion circuit to the DSP's ADC input channel. The second output terminal is a 3×5-pin Phoenix terminal (15-pin) with a locking screw, providing the power interface (such as three-phase drive signals and braking signals) and function selection pins for the motor execution circuit. The power signal (motor drive current) is transmitted through the second output terminal, using thickened wire (such as AWG18) and gold-plated contacts to reduce contact resistance and heat generation. The control signals (PWM, direction) are transmitted through the second connector, using high-speed optocoupler isolation (such as TLP521) to block electrical noise. The feedback signal (current sampling) is transmitted through the third connector, using shielded twisted-pair cable to reduce electromagnetic interference (EMI). Some pins of the second output terminal (such as PIN3 and PIN7) can be configured via jumper caps or DIP switches to switch between motor forward / reverse and soft-start modes. Motor execution circuit control logic: The DSP outputs pulse width modulation signals and direction commands through the PWM_OUT and DIR_CTRL pins of the second connection pin. The U, V, and W pins of the second output terminal are connected to the gate drive circuit of the three-phase IGBT module, providing ±15V drive voltage. By adjusting the duty cycle (0%~100%) of PWM_OUT, linear adjustment of the motor speed (e.g., 500~3000rpm) is achieved. The commutation logic of the IGBT module is controlled by the DIR_CTRL pin level (high / low) to achieve forward / reverse rotation. The BRAKE pin of the second output terminal is connected to a braking resistor; when the DSP detects overspeed, it triggers regenerative braking. Current conversion circuit feedback mechanism: A Hall sensor (such as LA55-P) detects the three-phase current of the motor and outputs a 0~5V analog signal to the current conversion circuit. The current conversion circuit uses an RC low-pass filter (R=1kΩ, C=0.1μF) to suppress high-frequency noise. Electrical isolation is achieved using linear optocouplers (such as HCNR201) to avoid ground loop interference. The 0~5V signal is converted to 0~3.3V to match the DSP's ADC input range (0~VREF). The processed current signal is transmitted to the DSP's ADC channel via the I_A, I_B, and I_C pins of the third connector for overcurrent protection (e.g., triggering a fault shutdown when I>2A).

[0020] At time t0, the DSP outputs PWM_OUT=50%, DIR_CTRL=high, the IGBT module is turned on, the motor starts rotating forward, the Hall sensor detects the current, and outputs I_A=1.2A; at time t1, the DSP detects I_A>1.5A (overload), triggers the braking resistor to engage via the BRAKE pin, the current drops to I_A=0.5A, and feedback is sent to the DSP; at time t2, the DSP outputs PWM_OUT=0, the IGBT module is turned off, the motor stops, the current returns to zero, and feedback is sent to the DSP to confirm the shutdown state. The PWM_OUT and DIR_CTRL pins of the second connection terminal adopt a dual backup design (e.g., PWM_OUT1, PWM_OUT2), automatically switching to the backup pin when a single pin fails. The DSP monitors the current feedback signal of the third connection pin through a timer; if no valid data is received within 200ms, a system reset is triggered. The U, V, and W pins of the second output terminal are interlocked with the BRAKE pin through hardware circuitry to ensure that the IGBT module is completely turned off during braking, avoiding shoot-through short circuits.

[0021] It is worth noting that the digital control signal (second connection pin) and the power drive signal (second output terminal) are physically isolated, with an isolation voltage of 2500VAC, meeting the IEC 61850 standard. The current feedback signal of the third connection pin uses differential transmission (such as RS-485 protocol), achieving a common-mode rejection ratio (CMRR) of 80dB, effectively suppressing power frequency interference. If the motor execution circuit fails, the drive module connected to the second output terminal can be replaced independently without reconfiguring the DSP parameters. The DSP reads the fault code (such as over-temperature or over-voltage) of the motor execution circuit through the FAULT_PIN pin of the second connection pin and uploads it to the monitoring system via the CAN bus. The second output terminal can be configured with different voltage levels (such as 24VDC and 48VDC) via jumper caps, supporting various power motors. SPI pins (such as MOSI and MISO) are reserved for the second connection pin, allowing for future expansion to connect intelligent sensors (such as vibration and temperature sensors) for predictive maintenance.

[0022] The third connector includes a fourth connecting pin, a fifth connecting pin, and a third output terminal. One end of the input circuit is connected to the third output terminal, and the other end of the input circuit is connected to the digital signal processing circuit. One end of the button circuit is connected to the fourth connecting pin, and the other end of the button circuit is connected to the digital signal processing circuit. The communication circuit is connected to the digital signal processing circuit.

[0023] Specifically, the fourth connection pin is a 2×4 row of 8 pins with a spacing of 2.54mm, transmitting the switch signals of the button circuit (such as start / stop, emergency stop, mode switching), and connecting the button panel to the digital signal processing circuit (DSP); the fifth connection pin is a 1×6 row of 6 pins with a spacing of 2.0mm, reserving an expansion interface (such as analog input, encoder feedback) to support future function upgrades (such as vibration monitoring, position control); the third output terminal is a 2×5 Phoenix terminal (10 pins) with a locking screw, connecting the dry contact signals of the input circuit (such as motor running status, fault alarm, remote control commands), providing 24VDC power and signal isolation.

[0024] The input circuit is optically isolated via a third output terminal (e.g., TLP181) to block external electrical noise, achieving an isolation voltage of 3750VAC (compliant with IEC 60664-1). The key input (fourth connector pin) uses RC filtering (R=10kΩ, C=0.1μF) to eliminate key bounce, with a filtering time constant τ=1ms to ensure signal stability. The expansion interface (fifth connector pin) reserves SPI, I2C, and ADC channels, supporting connection to smart sensors (such as temperature and vibration sensors) for predictive maintenance. Pins 1 and 5 of the fourth connector pin are critical signals (e.g., emergency stop), employing a foolproof keyway design to prevent incorrect insertion and malfunction. The pins of the third output terminal are grouped by function (e.g., PINs 1-3 for status input, PINs 4-5 for power output), and color-coded (red / black) to reduce wiring error rates.

[0025] The input circuit control logic connects to the motor control cabinet's operating status, fault alarm, and other signals via pins DI1-DI3 of the third output terminal. The VCC (24VDC) and GND pins of the third output terminal provide power to the external dry contacts, with a current capacity ≥100mA. The input circuit uses a TLP181 optocoupler to electrically isolate external signals from the DSP, avoiding ground loop interference. It converts the external 24VDC signal to 3.3VDC, matching the DSP's GPIO input range (0~VREF). The DSP monitors the motor's operating status in real time by reading the levels of pins DI1-DI3 (e.g., DI1 = high indicates operation). If a fault alarm signal (low level) is detected on pin DI2, the DSP immediately triggers a shutdown protection mechanism and uploads the fault code via the CAN bus.

[0026] The button circuit control logic connects to start / stop, emergency stop, and mode switching buttons via pins KEY1-KEY3 of the fourth connector. The button circuit uses RC filtering (τ=1ms) to eliminate mechanical bounce, ensuring that each button press triggers only one signal. The KEY1 (emergency stop) pin is configured as an external interrupt; the DSP responds within 10μs and immediately cuts off the motor drive signal. The DSP switches the motor control mode (e.g., manual / automatic, constant speed / variable frequency) based on the state of the KEY2 (mode switching) pin. The DSP records button operation logs (e.g., number of emergency stops, mode switching time) via EEPROM, supporting fault tracing.

[0027] Communication circuit control logic: Receives remote control commands (such as start, stop, parameter setting) via RS-485 or CAN bus. Connects to the expansion interface (such as ADC channel) of the fifth connector pin to acquire analog signals such as motor temperature and vibration. The communication circuit converts the RS-485 differential signal to TTL level using the MAX485 chip, matching the DSP's UART interface.

[0028] The DSP uploads motor status (such as speed, current, and temperature) to the monitoring system via the CAN bus, supporting real-time curve plotting. The host computer modifies DSP parameters (such as PWM frequency and overcurrent protection threshold) via RS-485, enabling remote parameter adjustment.

[0029] It is worth noting that the third connector achieves high-reliability status monitoring, real-time human-machine interaction, and stable remote communication for motor control and protection devices through multi-interface collaborative control, hardware interlocking mechanisms, and standardized interface design.

[0030] The implementation of the motor execution circuit includes at least the forward rotation of the motor, the reverse rotation of the motor, the controller alarm, and the controller power failure alarm.

[0031] Specifically, the IGBT module FS400R12KE3 (400A / 1200V) drives the motor for forward / reverse rotation, controlling power output via PWM signals with a switching frequency of 10kHz. A freewheeling diode DSEI60-12A (60A / 1200V) provides a freewheeling path for the motor inductor, preventing back EMF damage when the IGBT is turned off. A 10Ω / 200W braking resistor (aluminum case resistor) dissipates regenerative energy during motor deceleration, preventing DC bus voltage overvoltage (triggers protection when >700V). A current sensor LA55-P (50A / ±5V output) monitors the motor current in real time, feeding back to the controller for overcurrent protection and closed-loop control (accuracy ±0.5%). The H-bridge circuit consists of four IGBTs (Q1~Q4). Forward rotation: Q1 and Q4 are on, Q2 and Q3 are off; reverse rotation: Q2 and Q3 are on, Q1 and Q4 are off. The TLP350 optocoupler (3750VAC isolation voltage) isolates the controller's output PWM signal from the IGBT drive circuit, blocking electrical noise interference. A DSP timer generates a 1μs dead time to prevent short circuits between the upper and lower transistors of the H-bridge, ensuring safe direction switching (dead time error <50ns). When the motor current exceeds 1.5 times the rated current (for 50ms), the ALARM_PIN pin is triggered (low level), and a red LED flashes as an alarm. When the DC bus voltage exceeds 700V, the IGBT drive signal is cut off, and fault code 0x01 (overvoltage) is uploaded via the CAN bus. When the controller input voltage is less than 18V (undervoltage threshold), the POWER_FAIL_PIN pin is triggered (high level), starting the UPS backup power supply (if configured). Temperature protection is implemented when the IGBT junction temperature exceeds 125℃, reducing the PWM duty cycle (current limiting mode); if the temperature continues to rise, a shutdown protection is initiated.

[0032] Motor forward / reverse control logic: Forward rotation: The controller receives a forward rotation command from the host computer via RS-485 or CAN bus (e.g., CMD=0x01). The DSP reads the current direction status (via the DIR_STATUS pin). If it is in reverse rotation, a stop procedure is executed first (see below). The DSP outputs PWM signals to the drive circuits of Q1 and Q4 (GATE_Q1 and GATE_Q4 are high), while ensuring that Q2 and Q3 are completely turned off through dead-time control. The PWM duty cycle increases linearly from 0% to the target value (e.g., 50%) to avoid motor starting inrush current (<2 times rated current). The current sensor monitors the motor current in real time. If the starting current is abnormal (>3 times rated current), overcurrent protection is immediately triggered. Reverse rotation: The controller receives a reverse rotation command (e.g., CMD=0x02). If it is currently in forward rotation, a stop procedure is executed first (PWM duty cycle drops to 0%, lasting 100ms). The DSP outputs a PWM signal to the drive circuits of Q2 and Q3 (GATE_Q2 and GATE_Q3 are high), while ensuring that Q1 and Q4 are turned off. Similar to the forward rotation process, the PWM duty cycle increases linearly to the target value. During reverse rotation, the motor phase is opposite to the forward rotation, and the DSP ensures smooth operation by adjusting the PWM phase (e.g., delaying by 180°). Upon receiving a stop command (e.g., CMD=0x00) or detecting a fault (e.g., overcurrent or overvoltage), the DSP immediately reduces the PWM duty cycle to 0%, all IGBTs are turned off, and the motor stops naturally due to frictional resistance (taking 2-5 seconds). For faster stopping, the braking resistor can be activated, and the DSP simultaneously turns on Q1 and Q3 (or Q2 and Q4), dissipating the motor's inductive energy through the braking resistor (reducing the stopping time to 0.5 seconds).

[0033] During controller alarms, the controller input voltage (VIN) is monitored in real time via ADC. If VIN < 18V (undervoltage threshold), a power-down alarm is triggered. Level 1 alarm (VIN = 18V~16V): The POWER_FAIL_PIN pin outputs a high level (driving an external buzzer), and the DSP initiates the data saving process (writing key parameters to the EEPROM). Level 2 protection (VIN < 16V): The IGBT drive signal is cut off to prevent damage to the device due to low voltage. If a UPS backup power supply is configured, it automatically switches to UPS power (switching time < 10ms). The DSP records the power-down time (accuracy ± 1s) via the RTC chip and uploads it to the monitoring system via the CAN bus after power-on. A 1μs dead time is generated by the DSP timer to ensure that the upper and lower transistors of the H-bridge do not conduct simultaneously (shoot-through current > 1000A may cause device damage). The controller input uses dual power supplies (main power 24VDC + backup power 12VDC). In case of main power failure, it automatically switches to backup power (switching time < 5ms). The DSP monitors the forward / reverse control tasks (such as Task_MotorControl) via an independent timer. If a task fails to execute within 100ms, a system reset is triggered. CRC-8 checks are performed on the PWM signal and direction control signal; if the check fails, the system immediately stops and an alarm is triggered. Ferrite beads (such as BLM18PG221SN1) and Y capacitors (such as 10nF / 400V) are added to the IGBT drive circuit to suppress high-frequency noise (>1MHz). The current sensor output signal is compensated by a PT100 temperature sensor (temperature coefficient 0.4% / ℃) to ensure that the current monitoring accuracy is unaffected by ambient temperature.

[0034] It is worth noting that the motor execution circuit, through H-bridge direction control, multi-level alarm mechanisms, and power failure protection design, achieves high-reliability operation of the motor in complex industrial environments. Its design directly improves the system's stability under direction switching, fault response, and power outage scenarios, meeting the stringent requirements for motor control in fields such as wind power and HVAC.

[0035] The above description is merely a few embodiments of this application and is not intended to limit this application in any way. Although this application discloses preferred embodiments as described above, it is not intended to limit this application. Any changes or modifications made by those skilled in the art without departing from the scope of the technical solution of this application using the disclosed technical content are equivalent to equivalent implementation cases and fall within the scope of the technical solution.

Claims

1. A control and protection device for an integrated motor, characterized in that, include: The sampling board circuit includes a current sampling circuit, a voltage sampling circuit, and a metering chip, wherein the current sampling circuit, the voltage sampling circuit, and the metering chip are connected through a first connector; The control board circuit includes a motor execution circuit and a current conversion circuit, which are connected via a second connector. The main control board circuit includes an input circuit, a communication circuit, a key circuit, and a digital signal processing circuit, wherein the input circuit, the communication circuit, the key circuit, and the digital signal processing circuit are connected through a third connector. The sampling board circuit is connected to the main control board circuit via a first connector, and the control board circuit is connected to the main control board circuit via a second connector.

2. The motor integrated control protection device according to claim 1, characterized by The first connector includes a first output terminal and a first connection pin. One end of the voltage sampling circuit and the current sampling circuit are connected to the pin of the first output terminal, and the other end of the current sampling circuit and the voltage sampling circuit are connected to the metering chip. The metering chip is connected to the first connection pin, and the first connection pin is connected to the digital signal processing circuit.

3. The motor-integrated control and protection device according to claim 2, characterized by The second connector includes a second connecting pin, a third connecting pin, and a second output terminal. One end of the motor execution circuit and the current conversion circuit is connected to the pin of the second output terminal, and the motor execution circuit realizes different execution functions of the motor by connecting different pins of the second output terminal. The other end of the motor actuation circuit is connected to the digital signal processing circuit via a second connection pin, and the other end of the current conversion circuit is connected to the third connection pin.

4. The motor-integrated control and protection device according to claim 3, characterized by The third connector includes a fourth connecting pin, a fifth connecting pin, and a third output terminal. One end of the input circuit is connected to the third output terminal, and the other end of the input circuit is connected to the digital signal processing circuit. One end of the button circuit is connected to the fourth connecting pin, and the other end of the button circuit is connected to the digital signal processing circuit. The communication circuit is connected to the digital signal processing circuit.

5. The motor integrated control and protection device according to claim 1, wherein The implementation of the motor execution circuit includes at least the forward rotation of the motor, the reverse rotation of the motor, the controller alarm, and the controller power failure alarm.

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