Solar tracking control system and control method based on Hall sensor

Abstract

The present invention discloses a solar tracking control system based on a Hall sensor, including a housing, a control unit, a drive motor, a reducer, a motor drive board, a power board and a rotary motor. The outer wall of the housing is provided with a wireless communication antenna interface, a power input interface and a position calibration interface. The wireless communication antenna interface and the position calibration interface are connected to the control unit, the power input interface is connected to the power board, the motor drive board and the power board are both connected to the control unit, the motor drive board and the reducer are both connected to the drive motor, a wireless communication antenna is provided on the rotary motor, and the wireless communication antenna is connected to the wireless communication antenna interface; a Hall sensor is provided inside the drive motor. The present invention has an integrated design, and the Hall sensor is arranged inside the drive motor, which reduces the installation cost of the auxiliary parts and labor of the electrical box, reduces the failure point and improves the stability of the system operation.

Description

Technical Field

[0001] The present invention relates to the field of automatic tracking technology, and in particular to a solar tracking control system and a control method based on a Hall sensor. Background Art

[0002] At present, in order to improve the utilization rate of solar energy, a solar energy automatic tracking system is designed. This tracking control system adopts a method that combines software calculation control and sensor precision control, designs a reasonable mechanical structure, and realizes high-precision solar tracking through a hardware control system.

[0003] However, the existing solutions have the following risks:

[0004] There are two ways to fix the tracker control box in the mainstream market. One is to fix it on the column and connect the motor wire and angle sensor wire externally. The other is to fix it on the main beam and also need to connect the motor wire and angle sensor wire externally. Moreover, the angle sensor is prone to poor contact when the component board is twisted for a long time, and it requires more labor installation costs. Summary of the invention

[0005] In order to overcome the deficiencies of the prior art, one of the objects of the present invention is to provide a solar tracking control system based on Hall sensors, which can solve the technical problems of the prior art such as high labor costs, exposed motor wires, and the need for angle sensors.

[0006] A second object of the present invention is to provide an electronic device that can solve the technical problems of the prior art, such as high labor costs, exposed motor wires, and the need for angle sensors.

[0007] One of the purposes of the present invention is achieved by the following technical solution:

[0008] A solar tracking control system based on Hall sensors comprises a shell, a control unit, a drive motor, a reducer, a motor drive board, a power board and a rotary motor, wherein the control unit, the drive motor, the reducer, the motor drive board and the power board are all arranged in the shell, and a wireless communication antenna interface, a power input interface and a position calibration interface are arranged on the outer wall of the shell, the wireless communication antenna interface and the position calibration interface are connected to the control unit, the power input interface is connected to the power board, the motor drive board and the power board are both connected to the control unit, the motor drive board and the reducer are both connected to the drive motor, a wireless communication antenna is arranged on the rotary motor, and the wireless communication antenna is connected to the wireless communication antenna interface; a Hall sensor is arranged in the drive motor.

[0009] Furthermore, a heat-insulating layer is provided in the shell, and the heat-insulating layer is located between the motor drive board and the drive motor.

[0010] Furthermore, the control unit and the power board are both located on a side of the motor drive board away from the drive motor.

[0011] Furthermore, the number of the Hall sensors is 2.

[0012] Furthermore, it also includes a wire, and the rotary motor is also provided with a position calibration component, and the position calibration component is connected to the position calibration interface through a wire.

[0013] The second object of the present invention is achieved by adopting the following technical solution:

[0014] The solar tracking control method based on the Hall sensor is applied to the solar tracking control system based on the Hall sensor, the solar tracking control system includes a control unit, a drive motor, a reducer, a motor drive board, a power board and a rotary motor, and is characterized in that the solar tracking control method includes the steps of:

[0015] Angle detection step: the Hall sensor detects the number of rotations of the driving motor, and outputs a pulse signal to the control unit when it detects that the driving motor rotates one circle;

[0016] The first calculation step: the control unit calculates the number of rotations of the driving motor according to the pulse signal output by the Hall sensor;

[0017] The second calculation step: the control unit calculates the actual angle change value of the drive motor per rotation according to the known reduction ratio of the drive motor and the known transmission ratio of the worm gear in the rotary machine;

[0018] Position adjustment steps: The control unit calculates the angle deviation required for adjusting the drive motor according to the target angle value and the actual angle value, and drives the drive motor to rotate a corresponding number of times in combination with the actual angle change value per rotation of the drive motor.

[0019] Furthermore, the number of the Hall sensors is 2.

[0020] Furthermore, in the second calculation step, the angle change value of the drive motor per rotation is calculated according to the formula: 360° / (a*b), wherein a is the reduction ratio of the motor, and b is the transmission ratio of the worm gear in the rotary machine.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] The present invention has an integrated design and arranges the Hall sensor inside the drive motor, thereby eliminating the installation costs of auxiliary parts and manual installation of the electrical box, reducing the number of failure points and providing stability in system operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 The structure diagram of the solar tracking control system based on the Hall sensor of the present invention is

[0024] Figure 2 It is a principle module diagram of the solar tracking control system based on the Hall sensor of the present invention;

[0025] Figure 3 It is a diagram of two road impact signals output by the Hall sensor of the present invention;

[0026] Figure 4 The figure is a flow chart of the solar tracking control method based on Hall sensor of the present invention.

[0027] In the figure: 1. Shell; 2. Control unit; 3. Drive motor; 4. Reducer; 5. Motor drive board; 6. Power board; 7. Rotary motor; 8. Wireless communication antenna interface; 9. Power input interface; 10. Position calibration interface; 11. Wireless communication antenna; 12. Thermal insulation layer; 13. Position calibration part. DETAILED DESCRIPTION

[0028] The present invention is further described below in conjunction with the accompanying drawings and specific implementation methods. It should be noted that, under the premise of no conflict, the various embodiments or technical features described below can be arbitrarily combined to form a new embodiment.

[0029] Embodiment 1

[0030] like Figures 1 to 3 As shown, the present invention provides a solar tracking control system based on a Hall sensor, comprising a shell 1, a control unit 2, a drive motor 3, a reducer 4, a motor drive board 5, a power board 6 and a rotary motor 7. The control unit 2, the drive motor 3, the reducer 4, the motor drive board 5 and the power board 6 are all arranged in the shell 1, and the outer wall of the shell 1 is provided with a wireless communication antenna interface 8, a power input interface 9 and a position calibration interface 10, the wireless communication antenna interface 8 and the position calibration interface 10 are connected to the control unit 2, the power input interface 9 is connected to the power board 6, the motor drive board 5 and the power board 6 are both connected to the control unit 2, the motor drive board 5 and the reducer 4 are both connected to the drive motor 3, and a wireless communication antenna 11 is provided on the rotary motor 7, and the wireless communication antenna 11 is connected to the wireless communication antenna interface 8; a Hall sensor is provided in the drive motor 3.

[0031] The present invention integrates the control unit 2, the reducer 4, the power board 6 and the like into a housing 1 shared with the drive motor 3, thereby enhancing integrity and occupying less space.

[0032] The control unit 2 in the present invention includes an MCU and a current detection module, which detects the current of the drive motor 3 and feeds back the detection signal to the MCU. The Hall sensor detects the rotation angle of the drive motor 3 and outputs a pulse signal to the MCU.

[0033] In the present invention, a heat-insulating layer 12 is further provided in the housing 1, and the heat-insulating layer 12 is located between the motor drive board 5 and the drive motor 3. The present invention fixes the circuit boards between layers by fixing copper pillars, and the power supply and signal transmission between the circuit boards are connected by pin headers to ensure that they will not fall off during long-term operation.

[0034] Preferably, the control unit 2 and the power board 6 of the present invention are both located on the side of the motor drive board 5 away from the drive motor 3. The power protection, tracking control, and motor drive are all placed at the tail of the drive motor 3 and are integrated with the drive motor 3.

[0035] In order to prevent the entire detection system from malfunctioning or not working when one Hall sensor fails, the present invention adopts a redundant design and sets two Hall sensors. Both of the two Hall sensors are located in the drive motor 3 and detect the number of rotations of the drive motor 3 at the same time. The two Hall sensors of the present invention replace the external inclination sensor of the prior art, and the control unit 2 controls the running position of the motor by obtaining the Hall signal calculation. The Hall sensor can actually output two pulse signals, and there is an angle difference of 45 degrees between the two pulse signals. For example, the first pulse signal is high at 0 degrees, low at 90 degrees, and high at 180 degrees. The second pulse signal is low at 0 degrees, high at 45 degrees, and low at 135 degrees. The difference is 45 degrees, which can be referred to. Figure 3 , Figure 3 Signal 1 is the first pulse signal, signal 2 is the second pulse signal, high represents high level, and low represents low level.

[0036] The present invention can independently calculate the pulse signals output by two Hall sensors, and compare the pulse signals of the Hall sensors, thereby improving the reliability of the calculated data and preventing the failure of one Hall sensor from causing the entire detection system to not work. In the present invention, for example, the reduction ratio of the drive motor 3 is 575:1, and the transmission ratio of the worm gear of the rotary motor 7 is 60:1. By calculation in the MCU, it can be concluded that the angle change of the rotary side of the drive motor 3 after one rotation is: θ=360° / (60*575)≈0.01°, and the above reduction ratio and transmission ratio are both known parameters.

[0037] For example, the accuracy of the tilt sensor used by the mainstream industry is ±0.5°, and the precision of the precision tilt sensor can reach ±0.1°, but the price is relatively expensive. The present invention can obtain a more accurate angle value at a low cost, so that the tracking angle accuracy of the tracker is further improved.

[0038] The rotary motor 7 also includes a wire, and a position calibration member 13 is provided on the rotary motor 7, and the position calibration member 13 is connected to the position calibration interface 10 through a wire. The position calibration member 13 installed on the external rotary motor 7 is used to calibrate the position once a day to reduce the cumulative error generated when the motor rotates.

[0039] The total running time of the tracker in a day does not exceed 30 minutes, and each movement lasts for more than ten seconds and then runs for more than ten minutes. The driving motor 3 is in a stopped state at other times, so the heat generated by the driving motor 3 is very small. In addition, the circuit board uses high and low temperature resistant electronic components to ensure the stability of the system operation. The present invention is applicable to single-axis and dual-axis tracking systems of solar trackers; and is applicable to brushed and brushless DC motors or AC motors.

[0040] Embodiment 2

[0041] like Figure 4 As shown, the second embodiment discloses a solar tracking control method based on a Hall sensor, which is applied to a solar tracking control system based on a Hall sensor. The solar tracking control system includes a control unit, a drive motor, a reducer, a motor drive board, a power board and a rotary motor. The connection relationship between the above devices is the same as that of the solar tracking control system in the first embodiment. The solar tracking control method in this embodiment includes the following steps:

[0042] S1: The Hall sensor detects the number of rotations of the drive motor, and outputs a pulse signal to the control unit after detecting that the drive motor has rotated one circle; in this step, the Hall sensor can actually output two pulse signals to the control unit, and the two pulse signals are 45 degrees apart. The first pulse signal is high at 0 degrees, low at 90 degrees, and high at 180 degrees. The second pulse signal is low at 0 degrees, high at 45 degrees, and low at 135 degrees, thus differing by 45 degrees.

[0043] S2: The control unit calculates the number of rotations of the driving motor according to the pulse signal output by the Hall sensor;

[0044] S3: The control unit calculates the actual angle change value of the drive motor per rotation according to the known reduction ratio of the drive motor and the known transmission ratio of the worm gear in the rotary machine;

[0045] S4: The control unit calculates the angle deviation required for adjusting the driving motor according to the target angle value and the actual angle value, and drives the driving motor to rotate a corresponding number of cycles in combination with the actual angle change value per rotation of the driving motor.

[0046] The above-mentioned Hall sensor is two-way. In S3, the angle change value of the drive motor per rotation is calculated according to the formula: 360° / (a*b), where a is the reduction ratio of the motor and b is the transmission ratio of the worm gear in the rotary machine.

[0047] In S4, the target angle value and the actual angle value are both known. The angle deviation that needs to be adjusted for the drive motor can be calculated based on the target angle value and the actual angle value. The number of rotations of the drive motor is then detected by the Hall sensor, so that the number of rotations of the drive motor can be known. The Hall sensor can detect when the drive motor rotates to the appropriate number of rotations, and the control unit can control the drive motor to stop rotating, thereby adjusting the angle deviation of the drive motor.

[0048] The above-mentioned embodiments are only preferred embodiments of the present invention and cannot be used to limit the scope of protection of the present invention. Any non-substantial changes and substitutions made by technicians in this field on the basis of the present invention shall fall within the scope of protection required by the present invention.

Claims

1. A solar tracking control system based on Hall sensor, characterized in that: It includes a shell, a control unit, a drive motor, a reducer, a motor drive board, a power board and a rotary motor. The control unit, the drive motor, the reducer, the motor drive board and the power board are all arranged in the shell. The outer wall of the shell is provided with a wireless communication antenna interface, a power input interface and a position calibration interface. The wireless communication antenna interface and the position calibration interface are connected to the control unit, the power input interface is connected to the power board, the motor drive board and the power board are both connected to the control unit, the motor drive board and the reducer are both connected to the drive motor, the rotary motor is provided with a wireless communication antenna, and the wireless communication antenna is connected to the wireless communication antenna interface; a Hall sensor is provided in the drive motor; The Hall sensor is used to detect the number of rotations of the drive motor, and output a pulse signal to the control unit after detecting that the drive motor has rotated one circle; the control unit is used to calculate the number of rotations of the drive motor according to the pulse signal output by the Hall sensor, and calculate the actual angle change value of the drive motor per rotation of one circle according to the known reduction ratio of the drive motor and the known transmission ratio of the worm gear in the rotary machine, and calculate the angle deviation that needs to be adjusted for the drive motor according to the target angle value and the actual angle value, and drive the drive motor to rotate the corresponding number of circles in combination with the actual angle change value of each rotation of the drive motor.

2. The solar tracking control system according to claim 1, characterized in that: A heat-insulating layer is also provided in the shell, and the heat-insulating layer is located between the motor drive plate and the drive motor.

3. The solar tracking control system according to claim 2, characterized in that: The control unit and the power board are both located on a side of the motor drive board away from the drive motor.

4. The solar tracking control system according to claim 1, characterized in that: The number of the Hall sensors is 2.

5. The solar tracking control system according to claim 1, characterized in that: It also includes a wire, and the rotary motor is also provided with a position calibration component, and the position calibration component is connected to the position calibration interface through a wire.

6. A solar tracking control method based on a Hall sensor, applied to a solar tracking control system based on a Hall sensor, wherein the solar tracking control system comprises a control unit, a drive motor, a reducer, a motor drive board, a power board and a rotary motor, characterized in that: The solar tracking control method comprises the steps of: Angle detection step: the Hall sensor detects the number of rotations of the driving motor, and outputs a pulse signal to the control unit when it detects that the driving motor rotates one circle; The first calculation step: the control unit calculates the number of rotations of the driving motor according to the pulse signal output by the Hall sensor; The second calculation step is a control unit: the control unit calculates the actual angle change value of the drive motor per rotation according to the known reduction ratio of the drive motor and the known transmission ratio of the worm gear in the rotary machine; Position adjustment step: the control unit calculates the angle deviation required for adjusting the drive motor according to the target angle value and the actual angle value, and drives the drive motor to rotate a corresponding number of cycles in combination with the actual angle change value per rotation of the drive motor.

7. The solar tracking control method according to claim 6, characterized in that: The number of the Hall sensors is 2.

8. The solar tracking control method according to claim 6, characterized in that: In the second calculation step, the angle change value of the drive motor per rotation is calculated according to the formula: 360° / (a*b), wherein a is the reduction ratio of the motor, and b is the transmission ratio of the worm gear in the rotary machine.

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