A direct-current brushless motor flow action configurable controller

Abstract

The application relates to the technical field of direct-current brushless motor control, in particular to a controller with configurable flow action of a direct-current brushless motor, which comprises a main control unit, a power supply system, a driving output system, a sampling system, a communication system and a control signal system; the main control unit is electrically connected with the power supply system, the driving output system, the sampling system, the communication system and the control signal system; the power supply system comprises TVS tubes D4 and D5 which are connected in parallel and constitute an anti-surge circuit, further comprises voltage stabilizing chips U2 and U3 and a voltage boosting circuit; the driving output system comprises core power devices for motor UVW three-phase driving, a reverse electromotive force suppression circuit and a half-bridge driving chip set; the sampling system comprises a first-order filter circuit, an operational amplifier, an AD acquisition interface of the main control unit and a Hall sampling circuit; the application can improve the convenience of direct-current brushless motor control.

Description

Technical Field

[0001] This application relates to the field of DC brushless motor control technology, and in particular to a controller with configurable process actions for a DC brushless motor. Background Technology

[0002] DC brushless motors, with their advantages of high efficiency, long lifespan, low noise, and high reliability, have been widely used in various fields such as industry, medical, and home. In practical applications, in most scenarios, the motor needs to operate in a fixed logical cycle, such as forward rotation to the limit switch - reverse rotation to the limit switch; forward rotation timing - stop - reverse rotation timing, etc. The core control requirement is to achieve the execution of fixed logical actions without complex programming.

[0003] Traditional brushless DC motor control schemes require three parts: an independent control unit, a drive unit, and the motor itself. This presents the following problems: The drive unit is only responsible for converting control signals into motor drive current. The logic control of motor start / stop, forward / reverse rotation, speed regulation, and limit protection requires additional control units, such as PLCs, MCUs, or microcontrollers. The functions of these control units often far exceed the requirements of fixed logic control, increasing hardware procurement costs and leading to complex system wiring and a large installation space requirement. Users need professional programming skills to write custom control programs for the control unit. For different application scenarios, such as limit control of the lifting platform or cyclic start / stop of the conveyor belt, programs need to be redeveloped or modified, with adaptation cycles typically taking several hours to several days, which cannot meet the needs of rapid deployment. Signal transmission between the control unit and the drive unit is susceptible to electromagnetic interference in industrial environments, which can cause control commands to be delayed, lost, or falsely triggered, leading to motor malfunctions. Traditional drive units only support a single control method, such as accepting only pulse signals or analog signals, and cannot be compatible with diverse needs such as external switch control, remote configuration by host computer, and multi-protocol communication. Utility Model Content

[0004] To improve the ease of control of brushless DC motors, this application provides a controller with configurable process actions for brushless DC motors.

[0005] This application provides a configurable controller for the flow action of a brushless DC motor, which adopts the following technical solution: including a main control unit, a power supply system, a drive output system, a sampling system, a communication system, and a control signal system; The main control unit is electrically connected to the power supply system, drive output system, sampling system, communication system and control signal system respectively; The power supply system includes TVS diodes D4 and D5 connected in parallel to form a surge protection circuit, as well as voltage regulator chips U2 and U3 and a boost circuit. The input terminal of voltage regulator chip U2 is connected to the power supply VCC and the output terminal outputs a 5V voltage. The input terminal of voltage regulator chip U3 is connected to a 5V voltage and the output terminal outputs a 3.3V voltage. The input terminal of the boost circuit is connected to a 5V voltage and the output terminal outputs a 12V voltage. The drive output system includes core power devices for three-phase drive of the motor (UVW), a back EMF suppression circuit, and a half-bridge drive chipset. The half-bridge drive chipset includes half-bridge drive chips U5, U8, U13, and U19. The core power devices are MOSFETs Q5, Q6, Q7, Q8, Q9, and Q10. The back EMF suppression circuit includes components for receiving control signals output from the main control unit and is electrically connected to the main control unit. The MOSFET Q2, power resistors R41, R42, and R43 are connected to the main circuit terminal of MOSFET Q2, which is connected to power resistors R41, R42, and R43, and the motor output terminal, respectively. The half-bridge driver chip U8 is electrically connected to MOSFETs Q5 and Q6, the half-bridge driver chip U13 is electrically connected to MOSFETs Q7 and Q8, and the half-bridge driver chip U19 is electrically connected to MOSFETs Q9 and Q10. All half-bridge driver chips are electrically connected to MOSFET Q2. The sampling system includes a first-order filter circuit, an operational amplifier, an AD acquisition interface of the main control unit, and a Hall sampling circuit. The input of the first-order filter circuit is connected to the output of each phase of the motor, and the output of the first-order filter circuit is connected to the input of the operational amplifier. The output of the operational amplifier is connected to the AD acquisition interface. The operational amplifier is a high-precision rail-to-rail input / output operational amplifier. The Hall sampling circuit is used to acquire the Hall signal of the motor. When the main control unit determines that the received current reaches the maximum current that the controller can withstand, the motor overload protection will be triggered and an alarm message will be output. The communication system includes an RS485 interface, a CAN communication interface, and an interface protection circuit. The interface protection circuit includes a resettable fuse, a TVS diode, and a resistor. The communication system follows the Modbus-RTU protocol (RS485 interface) and the CAN-Open protocol (CAN communication interface). The control signal system includes digital input terminals, analog 0-10V input terminals, pulse signal input terminals, PWM input terminals, and frequency signal input terminals. Each of the digital input terminals, analog 0-10V input terminals, pulse signal input terminals, PWM input terminals, and frequency signal input terminals is equipped with a protection network. The protection network includes a Zener diode, a resistor-capacitor device, and an operational amplifier. The digital input terminals support dry contact signals and 0-24V level signal inputs. The digital input terminals include R / S-COM terminals, P1-COM terminals, and N1-COM terminals.

[0006] Optionally, the 3.3V voltage output by the power supply system supplies the main control unit, the 12V voltage supplies the drive output system, and the 5V voltage provides the input voltage for the voltage regulator chip U3 and the boost circuit.

[0007] Optionally, the half-bridge driver chipset of the drive output system is electrically connected to the main control unit. When the main control unit outputs a unipolar PWM signal, the half-bridge driver chipset will control the corresponding core power device to turn on or off according to the PWM signal. The MOSFET Q2 is electrically connected to the main control unit. When the motor stops suddenly or decelerates rapidly and the main control unit detects an abnormal increase in voltage, the main control unit will control the MOSFET Q2 to turn on, and the power resistors R41, R42, and R43 will consume the reverse electromotive force of the motor.

[0008] Optionally, the communication system can set the controller's fixed operating mode via RS485 commands or CAN communication commands, and can read the motor's real-time operating parameters; the fixed operating mode is achieved through external components of the control signal system, specifically including: Mode 1: Connect an external jog button to the R / S-COM terminal, a normally open forward limit switch to the P1-COM terminal, and a normally open reverse limit switch to the N1-COM terminal; when the jog button is triggered, the motor rotates forward, and when it is triggered again, the motor brakes; when the motor rotates forward, triggering P1 will cause the motor to rotate in reverse, and when the motor rotates in reverse, triggering N1 will cause the motor to rotate forward. Mode 2: Connect an external self-locking switch to the R / S-COM terminal, a dry contact forward limit switch to the P1-COM terminal, and a dry contact reverse limit switch to the N1-COM terminal; when the self-locking switch is on, the motor runs; when it is off, the motor brakes. When P1 is on, the motor rotates forward; when P1 is off during forward rotation, the motor brakes. When N1 is on, the motor reverses; when N1 is off during reverse rotation, the motor brakes. Mode 3: The R / S-COM terminal is connected to an external self-locking switch, and the P1-COM and N1-COM terminals are connected to normally closed dry contact limit switches; the motor runs when the self-locking switch is on and brakes when it is off; the motor rotates forward when P1 is on and reverses when P1 is off; the motor brakes when both P1 and N1 are off or both are on.

[0009] Optionally, the RS485 interface and CAN communication interface of the communication system are both connected to the host computer. When the motor process step parameters configured by the host computer are transmitted to the main control unit through the RS485 interface or CAN communication interface, the main control unit will store the motor process step parameters. The switch input terminal of the control signal system is electrically connected to an external start / stop switch. When the external start / stop switch transmits start / stop commands to the main control unit through the control signal system, the main control unit will start or stop the motor according to the commands.

[0010] Optionally, the main control unit is an ARM core processor. After the main control unit receives the current signal and Hall signal from the sampling system, the configuration parameters of the communication system and the input signal from the control signal system, the main control unit will generate a control signal and transmit it to the half-bridge driver chipset of the drive output system to control the motor to run.

[0011] In summary, this application includes the following beneficial technical effects: 1. Integrated ARM core main control unit, eliminating the need for additional PLC, MCU and other control units; integrated design of power system, drive output system, sampling system, etc., reducing external wiring, lowering hardware costs, simplifying installation and maintenance, and reducing space occupation; 2. The communication system supports host computer parameter configuration, and the control signal system supports hardware mode switching, eliminating the need for coding; 3. TVS diodes D4 and D4D5 provide surge protection, and multi-stage voltage regulation ensures stable voltage; MOSFET Q2, power resistors R41, R42, and R43 suppress reverse electromotive force; the sampling system features high-precision rail-to-rail operational amplifier sampling and automatic overload protection, with Zener diodes, resistors, capacitors, and operational amplifiers forming a protection network. Attached Figure Description

[0012] Figure 1 This is a system block diagram of a configurable controller for the flow action of a brushless DC motor according to this application; Figure 2 This is an action programming configuration diagram of a controller with configurable process actions for a DC brushless motor according to this application; Figure 3 This is a schematic diagram of the power circuit of a controller for a configurable DC brushless motor flow action according to this application. Figure 4 This is the first part of the schematic diagram of the drive output system of a configurable controller for the process action of a brushless DC motor according to this application; Figure 5 This is the first part of the schematic diagram of the drive output system of a configurable controller for the process action of a brushless DC motor according to this application; Figure 6 This is a schematic diagram of the sampling system of a configurable controller for the flow action of a brushless DC motor according to this application; Figure 7 This is a Hall sampling schematic diagram of a controller with configurable flow action for a brushless DC motor according to this application; Figure 8 This is a schematic diagram of the communication system of a controller with configurable flow action for a brushless DC motor according to this application; Figure 9 This is a schematic diagram of the control signal input of a controller for a configurable DC brushless motor flow action according to this application; Figure 10 This is a schematic diagram of the main control unit of a controller for a configurable DC brushless motor process operation according to this application. Detailed Implementation

[0013] The following is in conjunction with the appendix Figure 1-10 This application will be described in further detail.

[0014] This application discloses a configurable controller for the process of a brushless DC motor. It includes a main control unit, a power supply system, a drive output system, a sampling system, a communication system, and a control signal system. These systems are electrically connected to form a collaborative control architecture. The specific structure and functions are as follows: Main control unit: Employing an ARM core processor, this unit serves as the core computing and control module of the controller, electrically connected to the power supply system, drive output system, sampling system, communication system, and control signal system. Its core functions are: receiving current and Hall signals from the sampling system, configuration parameters from the communication system, and external input signals from the control signal system; processing these signals to generate a unipolar PWM control signal; and transmitting this signal to the half-bridge driver chipset of the drive output system to achieve logic control such as motor start / stop, forward / reverse rotation, speed regulation, and overload protection.

[0015] Power supply system: Provides a stable and adaptable operating voltage for the entire controller, specifically including: Surge protection module: Composed of TVS diodes D4 and D5 connected in parallel, it can absorb instantaneous surge voltages in the power supply line, such as overvoltages caused by lightning strikes or power switch switching, protecting the subsequent voltage regulation circuit and core components from damage, and improving the reliability of the system in complex power supply environments. Multi-stage voltage regulation and boost module: The power supply VCC is connected to the input of the voltage regulator chip U2, and U2 outputs a 5V voltage. The 5V voltage is divided into two paths: one path is connected to the input of the voltage regulator chip U3, and U3 outputs a 3.3V voltage to supply the main control unit, meeting the low-voltage power supply requirements of the ARM core processor; the other path is connected to the input of the boost circuit, and the boost circuit outputs a 12V voltage to supply the drive output system, meeting the high-voltage drive requirements of the half-bridge driver chip and MOSFET. Through multi-stage voltage conversion, it ensures that each system obtains a precise and stable operating voltage, avoiding control errors or device burnout caused by voltage fluctuations.

[0016] Drive output system: Enables three-phase drive and reverse electromotive force protection for the UVW brushless DC motor, specifically including: Core power devices include MOSFETs Q5, Q6, Q7, Q8, Q9, and Q10, which drive the three-phase windings UVW of the motor. The forward and reverse rotation and speed regulation of the motor are achieved by the combination of turning the MOSFETs on and off. The half-bridge driver chipset includes half-bridge driver chips U5, U8, U13, and U19. All five chips are electrically connected to the MOSFET Q2 in the reverse electromotive force suppression circuit. The core function of the half-bridge driver chipset is to amplify the weak PWM signal output from the main control unit into a strong drive signal, controlling the on / off state of the corresponding core power devices. Simultaneously, it isolates the main control unit from the high-voltage drive circuit, preventing high-voltage signal interference to the main control unit. The reverse electromotive force (EMF) suppression circuit consists of a MOSFET Q2, power resistors R41, R42, and R43. The control terminal of MOSFET Q2 is electrically connected to the main control unit, and the main circuit terminals are connected to power resistors R41, R42, R43, and the motor output terminal, respectively. When the motor stops abruptly or decelerates rapidly, the reverse EMF generated by the inductor coil inside the motor causes an abnormal increase in the motor terminal voltage. Upon detecting this abnormality, the main control unit immediately outputs a control signal to turn on MOSFET Q2. The reverse EMF flows through MOSFET Q2 and then through power resistors R41, R42, and R43. The energy dissipation of these resistors quickly suppresses the reverse EMF, preventing it from accumulating on the power supply network and damaging the power supply or core components.

[0017] Sampling system: Enables motor current acquisition, overload protection, and rotor position detection, specifically including: The current sampling module consists of a first-order filter circuit, an operational amplifier, and an AD acquisition interface for the main control unit. The output current of each phase of the motor is fed into the first-order filter circuit to filter out high-frequency noise in the current signal before entering the rail-to-rail high-precision operational amplifier. The amplification factor can be set according to actual needs, typically 10-20 times, amplifying the weak current signal to a range recognizable by the main control unit's AD acquisition interface, such as 0-3.3V. The amplified current signal is transmitted to the AD acquisition interface, where the main control unit analyzes the current data in real time. When the current reaches the controller's maximum withstand current, it immediately triggers the motor overload protection, controlling the drive output system to stop output and outputting alarm information to prevent motor stalling and burnout caused by overload. Hall effect sampling circuit: Connected to the motor Hall sensor, it is used to collect the motor rotor position signal and transmit it to the main control unit. The main control unit determines the motor rotor position based on the Hall signal and adjusts the output timing of the PWM signal to ensure that the motor's UVW three-phase windings are energized in the correct order, achieving smooth motor start-up and operation and avoiding faults such as phase loss and stall.

[0018] Communication system: Enables host computer configuration, remote control, and data interaction, specifically including: Dual communication interfaces: Supports RS485 interface and CAN communication interface. The RS485 interface follows the Modbus-RTU protocol, and the CAN communication interface follows the CAN-Open protocol. It supports multi-node networking and is suitable for industrial bus scenarios. Users can choose the appropriate interface according to their on-site communication needs. Interface protection circuit: Composed of a resettable fuse, a TVS diode, and a resistor. The resettable fuse prevents overcurrent damage to the interface chip in the communication line; the TVS diode suppresses instantaneous overvoltage in the communication line; the resistor suppresses signal reflection and improves communication stability. Core functions: Connecting to the host computer software via the communication interface, it can configure motor process steps, such as action type, speed, target pulse count, and waiting time; set fixed working mode, and switch between modes 1-3 via RS485 / CAN commands; read real-time running parameters, such as motor current, speed, and running steps; receive alarm information, such as overload alarm and limit trigger alarm, and complete control logic configuration without on-site programming.

[0019] Control signal system: Enables external hardware control and signal protection, specifically including: Multiple input types: including digital inputs such as R / S-COM, P1-COM, N1-COM, analog 0-10V inputs (which can be connected to potentiometers to adjust speed); pulse signal inputs (which can receive external pulses to control speed); PWM inputs (which can receive external PWM signals to control motor operation); and frequency signal inputs (which can receive external frequency signals to achieve synchronous control), meeting diverse external control needs. Comprehensive protection network: All input terminals are equipped with a protection network consisting of Zener diodes, resistors, capacitors, and operational amplifiers. Zener diodes suppress overvoltage signals from external inputs, such as a 24V signal abnormally rising to 30V; the filter circuit composed of resistors and capacitors filters out high-frequency noise, such as electromagnetic interference in industrial environments; the operational amplifiers condition the input signal, such as linearly converting analog 0-10V signals to 0-3.3V signals to match the main control unit's input range, improving signal stability and system compatibility. Digital input function: The digital input terminal supports dry contact signals and 0-24V level signals. It can be connected to an external jog button to control start and stop; a self-locking switch to control running or braking; and a limit switch to control direction switching, realizing manual control on site and adapting to simple scenarios without a host computer.

[0020] The following is in conjunction with the appendix Figure 1-9 The document describes three fixed operating modes and details the specific implementation of this controller. The selection of components for each system can be adjusted according to actual needs. For example, voltage regulator chip U2 can be LM1117-5.0, voltage regulator chip U3 can be AMS1117-3.3, MOSFET can be IRF3205, operational amplifier can be AD8605, and ARM processor can be STM32F103C8T6. I. System Initialization Power supply startup: Connect the DC power supply to the power input terminal of the controller, and the power system starts: TVS diodes D4 and D5 enter the surge protection standby state; the voltage regulator chip U2 converts VCC to 5V voltage, one path is regulated to 3.3V by the voltage regulator chip U3 to supply the main control unit, and the other path is converted to 12V by the boost circuit to supply the drive output system. Self-test and default mode: After the main control unit is powered on, it performs a self-test to check whether each system, namely the communication system, sampling system and control signal system, is normal. If no communication command or external mode setting is detected, it will enter the configuration mode by default and can be configured through the host computer. Parameter loading: If the main control unit stores historical configuration parameters, such as the process steps used last time, the parameters are automatically loaded into the running memory, waiting for external start / stop commands.

[0021] Specific implementation of three fixed working modes Mode 1: Controlled by jog buttons and normally open limit switches, suitable for manual reciprocating control scenarios, such as manual lifting platforms. Mode configuration: Send RS485 or CAN commands via host computer software to set the controller to mode 1; External wiring: R / S-COM terminal: External jog button, one end connected to the R / S terminal and the other end connected to the COM terminal, used to control the start and stop of the motor; P1-COM terminal: External normally open forward rotation limit switch, one end connected to P1 terminal and the other end connected to COM terminal, installed at the motor's forward rotation limit position, such as the highest point of the lifting platform; N1-COM terminal: External normally open reverse limit switch, one end connected to N1 terminal and the other end connected to COM terminal, installed at the motor's reverse limit position, such as the lowest point of the lifting platform; Operation logic: Start-stop control: Pressing the jog button triggers the main control unit to send a PWM signal to the drive output system, controlling the motor to rotate forward; pressing the jog button again sends a brake signal, stopping the motor. Limit rotation: During the forward rotation of the motor, if the P1 limit switch is triggered and the platform reaches the highest point, the main control unit detects the P1 trigger signal through the sampling system and immediately adjusts the PWM signal timing to control the motor to switch to reverse rotation; during the reverse rotation of the motor, if the N1 limit switch is triggered and the platform reaches the lowest point, the main control unit controls the motor to switch to forward rotation. Limit switch validity: The main control unit determines the current direction of the motor based on the Hall sampling signal. P1 is only effective when the motor is rotating forward, and N1 is effective when it is rotating in reverse, to avoid the erratic operation caused by the false triggering of the reverse limit switch; Parameter reading: During operation, RS485 commands can be sent from the host computer to read parameters such as real-time motor current, speed, and limit switch trigger status, which is convenient for on-site monitoring.

[0022] Mode 2: Controlled by self-locking switches and dry contact limit switches, suitable for continuous operation and limit protection scenarios, such as conveyor belts. Mode configuration: Send RS485 or CAN commands via host computer software to set the controller to mode 2; External wiring: R / S-COM terminal: External self-locking switch, one end connected to the R / S terminal and the other end connected to the COM terminal. When the switch is on, the motor runs; when the switch is off, the motor brakes. P1-COM terminal: External dry contact forward rotation limit switch, one end connected to P1 terminal and the other end connected to COM terminal, installed at the forward rotation limit position of the conveyor belt; N1-COM terminal: External dry contact reverse limit switch, one end connected to N1 terminal and the other end connected to COM terminal, installed at the reverse limit position of the conveyor belt; Operation logic: Start-stop control: When the self-locking switch is closed, the main control unit detects a high-level signal at the R / S terminal and controls the motor to enter the standby state; when the self-locking switch is opened, the main control unit detects a low-level signal and immediately controls the motor to brake. Forward rotation control: When the self-locking switch is closed, the P1 limit switch is on. Before the conveyor belt reaches the forward rotation limit, the main control unit controls the motor to rotate forward. During forward rotation, if the P1 limit switch is off and the conveyor belt reaches the limit, the main control unit controls the motor to brake. Reverse control: When the self-locking switch is closed, the N1 limit switch is on, and the conveyor belt has not reached the reverse limit, the main control unit controls the motor to reverse; during the reverse process, if the N1 limit switch is open, the conveyor belt reaches the limit, and the main control unit controls the motor to brake. Fault protection: If P1 and N1 are disconnected simultaneously during forward rotation, the limit switch is faulty. The main control unit determines that the limit is abnormal, immediately controls the motor brake, and sends a limit abnormality alarm to the host computer through the communication system.

[0023] Mode 3: Controlled by self-locking switches and normally closed limit switches, suitable for high-safety-requirement scenarios, such as medical lifting beds. Mode configuration: Send RS485 or CAN commands via host computer software to set the controller to mode 3; External wiring: R / S-COM terminal: External self-locking switch, one end connected to the R / S terminal and the other end connected to the COM terminal. When the switch is on, the motor runs; when the switch is off, the motor brakes. P1-COM terminal: External normally closed forward limit switch, one end connected to P1 terminal and the other end connected to COM terminal, installed at the lifting limit position of the lifting bed, such as the maximum safe height; N1-COM terminal: External normally closed reverse limit switch, one end connected to N1 terminal and the other end connected to COM terminal, installed at the lowering limit position of the lifting bed, such as the minimum safe height; Motor wiring: Connect the three-phase windings of the DC brushless motor UVW of the lifting bed to the drive output terminals U / V / W of the controller, and connect the motor Hall signal to the Hall interface of the sampling system. Ensure that the motor rotation direction is consistent with the lifting direction of the bed. If the directions are opposite, the U and V phase wiring can be swapped.

[0024] Execution logic Start-stop control: When the self-locking switch is closed, the R / S terminal input is high level, and the main control unit controls the motor to enter the running state; when the self-locking switch is opened, the R / S terminal is low level, and the main control unit sends a brake signal, and the motor stops quickly.

[0025] Forward rotation control: When the self-locking switch is closed and the P1 limit switch is normally closed, the P1 terminal is at a high level. Before reaching the rising limit, the main control unit sends a PWM signal, and the motor rotates forward to drive the bed to rise. When the bed reaches the rising limit, the P1 switch is opened, the P1 terminal is at a low level, the main control unit adjusts the PWM timing, and the motor switches to reverse rotation to descend.

[0026] Reverse control: When the self-locking switch is closed and the N1 limit switch is normally closed, the N1 terminal is at a high level. Before the descent limit is reached, the motor reverses to drive the bed to descend. When the bed reaches the descent limit, the N1 switch opens, the N1 terminal is at a low level, the main control unit shuts off the drive output, and the motor brakes.

[0027] Safety protection: When the self-locking switch is closed, if both switches P1 and N1 are open at the same time, such as when double limit switches are triggered or there is a circuit fault, the main control unit will determine that the safety is abnormal and immediately control the motor to brake; if the limit switch is disconnected, it is equivalent to being disconnected, which will also trigger the brake to avoid safety hazards.

[0028] The implementation principle of a configurable controller for the process operation of a brushless DC motor according to an embodiment of this application is as follows: Fixed working mode, taking the medical lifting bed in mode 3 as an example 1. Hardware connection Power supply: 24VDC power supply connected to the controller, power matching a single motor, such as a 500W motor, select a power supply of ≥3A; Single motor wiring: The three-phase windings of the DC brushless motor UVW of the lifting bed are connected to the controller, that is: MOSFETs Q5, Q6, and Q7 at the motor output end, and the Hall signal is connected to the Hall 1 interface; External control: R / S-COM terminal: External self-locking switch to control the start and stop of the lifting bed; P1-COM terminal: Connect to a normally closed upper limit switch at the highest point of the bed; N1-COM terminal: Connect to a normally closed lower limit switch at the lowest point of the bed. Communication: An RS485 cable connects the controller to the computer for mode configuration and parameter monitoring.

[0029] 2. Mode Configuration and Operation Mode setting: The host computer sends an RS485 command, 0x010x060x00020x0003, to set the controller to mode 3. The software displays that mode 3 is configured successfully. Operation: When the self-locking switch is closed, the bed operates according to the logic of P1 normally closed → forward rotation and upward movement. When the upward limit is reached, P1 is opened and the bed automatically reverses and descends. During descent, the bed brakes when it reaches the N1 limit switch at its lowest point; the self-locking switch is disconnected and the bed stops immediately, meeting the safety requirements of medical scenarios. Parameter monitoring: The host computer reads the motor current in real time. If the current is 0.8A during normal operation or 2A during overload, an alarm will be triggered. Limit switch status: P1 / N1 will be closed or opened to ensure safe operation.

[0030] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A controller with configurable flow action for a brushless DC motor, characterized in that: It includes a main control unit, power supply system, drive output system, sampling system, communication system, and control signal system; The main control unit is electrically connected to the power supply system, drive output system, sampling system, communication system and control signal system respectively; The power supply system includes TVS diodes D4 and D5 connected in parallel to form a surge protection circuit, as well as voltage regulator chips U2 and U3 and a boost circuit. The input terminal of voltage regulator chip U2 is connected to the power supply VCC and the output terminal outputs a 5V voltage. The input terminal of voltage regulator chip U3 is connected to a 5V voltage and the output terminal outputs a 3.3V voltage. The input terminal of the boost circuit is connected to a 5V voltage and the output terminal outputs a 12V voltage. The drive output system includes core power devices for three-phase drive of the motor (UVW), a back EMF suppression circuit, and a half-bridge drive chipset. The half-bridge drive chipset includes half-bridge drive chips U5, U8, U13, and U19. The core power devices are MOSFETs Q5, Q6, Q7, Q8, Q9, and Q10. The back EMF suppression circuit includes components for receiving control signals output from the main control unit and is electrically connected to the main control unit. The MOSFET Q2, power resistors R41, R42, and R43 are connected to the main circuit terminal of MOSFET Q2, which is connected to power resistors R41, R42, and R43, and the motor output terminal, respectively. The half-bridge driver chip U8 is electrically connected to MOSFETs Q5 and Q6, the half-bridge driver chip U13 is electrically connected to MOSFETs Q7 and Q8, and the half-bridge driver chip U19 is electrically connected to MOSFETs Q9 and Q10. All half-bridge driver chips are electrically connected to MOSFET Q2. The sampling system includes a first-order filter circuit, an operational amplifier, an AD acquisition interface of the main control unit, and a Hall sampling circuit. The input of the first-order filter circuit is connected to the output of each phase of the motor, and the output of the first-order filter circuit is connected to the input of the operational amplifier. The output of the operational amplifier is connected to the AD acquisition interface. The operational amplifier is a high-precision rail-to-rail input / output operational amplifier. The Hall sampling circuit is used to acquire the Hall signal of the motor. When the main control unit determines that the received current reaches the maximum current that the controller can withstand, the motor overload protection will be triggered and an alarm message will be output. The communication system includes an RS485 interface, a CAN communication interface, and an interface protection circuit. The interface protection circuit includes a resettable fuse, a TVS diode, and a resistor. The communication system follows the Modbus-RTU protocol and the CAN-Open protocol. The control signal system includes digital input terminals, analog 0-10V input terminals, pulse signal input terminals, PWM input terminals, and frequency signal input terminals. Each of the digital input terminals, analog 0-10V input terminals, pulse signal input terminals, PWM input terminals, and frequency signal input terminals is equipped with a protection network. The protection network includes a Zener diode, a resistor-capacitor device, and an operational amplifier. The digital input terminals support dry contact signals and 0-24V level signal inputs. The digital input terminals include R / S-COM terminals, P1-COM terminals, and N1-COM terminals.

2. The controller with configurable operation for a brushless DC motor according to claim 1, characterized in that, The power supply system outputs 3.3V to the main control unit, 12V to the drive output system, and 5V to provide input voltage for the voltage regulator chip U3 and the boost circuit.

3. The controller with configurable operation of a brushless DC motor according to claim 1, characterized in that, The half-bridge driver chipset of the drive output system is electrically connected to the main control unit. When the main control unit outputs a unipolar PWM signal, the half-bridge driver chipset will control the corresponding core power device to turn on or off according to the PWM signal. The MOSFET Q2 is electrically connected to the main control unit. When the motor stops suddenly or decelerates rapidly and the main control unit detects an abnormal increase in voltage, the main control unit will control the MOSFET Q2 to turn on, and the power resistors R41, R42, and R43 will consume the back electromotive force of the motor.

4. The controller with configurable operation of a brushless DC motor according to claim 1, characterized in that, The RS485 interface and CAN communication interface of the communication system are both connected to the host computer. When the motor process step parameters configured by the host computer are transmitted to the main control unit through the RS485 interface or CAN communication interface, the main control unit will store the motor process step parameters. The switch input terminal of the control signal system is electrically connected to an external start / stop switch. When the external start / stop switch transmits start / stop commands to the main control unit through the control signal system, the main control unit will start or stop the motor according to the commands.

5. The controller with configurable operation of a brushless DC motor according to claim 1, characterized in that, The main control unit is an ARM core processor. After receiving the current signal and Hall signal from the sampling system, the configuration parameters of the communication system, and the input signal from the control signal system, the main control unit will generate a control signal and transmit it to the half-bridge driver chipset of the drive output system to control the motor to run.

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