A method for motor protection by battery voltage detection and a system thereof

Abstract

The application provides a method and system for motor protection by battery voltage detection. In one aspect, the application provides a method for motor protection by battery voltage detection, which comprises the following processing steps: step 1: during operation, the voltage across the battery is detected in real time, and the voltage value is collected and sent to a control device at a set interval; step 2: when the voltage across the battery is reduced by more than a set value at the start, and the voltage does not recover to the normal operating voltage of the motor within a set time, the control device controls protection; step 3: when the received voltage value signal across the battery is reduced by more than a set value compared with the previous received voltage value signal across the battery during normal start of the motor, the control device controls protection. In another aspect, the application provides a system for motor protection by battery voltage detection. The application can effectively save cost and reduce the use volume.

Description

Technical Field

[0001] This invention belongs to the field of motor protection, and particularly relates to a method for motor protection by battery voltage detection, and also relates to a system for motor protection by battery voltage detection. Background Technology

[0002] Motor stall occurs when a motor continues to output torque even at zero revolutions per minute (0 RPM), typically due to mechanical or human error. It's caused by excessive motor load, mechanical failure in the driven component, or bearing damage leading to rotor rubbing, resulting in the motor failing to start or stop. Motor overload refers to a situation where a motor has a fixed operating power, called its rated power (measured in watts, W). If, under certain conditions, the actual power used by the motor exceeds its rated power, this is called motor overload. Currently, existing equipment and methods primarily use resistance methods to detect motor stall or overload. This method is costly and bulky. Therefore, a more cost-effective and functional motor protection method and system are needed. Summary of the Invention

[0003] The first objective of this invention is to provide a method for motor protection through battery voltage detection, which can effectively save costs and reduce the size of the device.

[0004] The second objective of this invention is to provide a system for implementing the above-described method.

[0005] To achieve objective one, the present invention provides a method for motor protection by battery voltage detection, the method comprising the following processing steps.

[0006] Step 1: During operation, the voltage across the battery terminals is monitored in real time, and the voltage values ​​are collected and sent to the control device at set intervals.

[0007] Step 2: The control device controls the operation based on the collected voltage signal across the battery terminals. If the voltage drop across the battery terminals exceeds the set value and fails to recover to the normal operating voltage of the motor within the set time during startup, the control device will disconnect the power supply to the motor for protection. Otherwise, the motor will start normally.

[0008] Step 3: When the motor starts working normally, the control device compares the received voltage signal across the battery terminals with the previously received voltage signal across the battery terminals in real time. If the decrease in the received voltage signal across the battery terminals exceeds a set value, the control device will disconnect the power supply to the motor for protection. If the decrease in the received voltage signal across the battery terminals does not exceed the set value, normal operation will continue.

[0009] Preferably, the control device displays the battery level in real time to provide reminders.

[0010] Preferably, in step 2, the voltage drop across the battery terminals during startup is set according to the voltage drop when the selected motor is stalled.

[0011] Preferably, in step 3, when the control device compares the received voltage value signal at both ends of the battery with the previously received voltage value signal at both ends of the battery, the set value of the reduction value is determined by actually measuring several sets of voltage reduction values ​​when the selected motor is overloaded and calculating the average value.

[0012] Preferably, the control device is a microcontroller.

[0013] To achieve the second objective, this invention provides a system for motor protection through battery voltage detection, comprising an input connector for connection to an external power source, a battery connector for connection to a battery, a battery charging management module for battery charging control connected to both the input connector and the battery connector, a stall and overload protection circuit for motor power supply control and stall or overload protection connected to the battery connector, and a power detection module for battery level detection connected to the battery connector. The battery charging management module, stall and overload protection circuit, and power detection module are each signal-connected to a control device for control. The battery connector and the input connector are respectively connected to the control device through a control power supply circuit for powering the control device. The control device is equipped with control buttons for controlling the motor to start and stop, and a power indicator module for indicating battery level.

[0014] Preferably, the battery charging management module is provided with a battery charging management chip that is connected to the battery connector, the control device and the input connector respectively, and the power detection module is provided with a second resistor with one end connected to the positive terminal of the battery connector, the other end of the second resistor being connected to the control device and connected to the ground wire through a third resistor and an eighth capacitor respectively.

[0015] Preferably, the control power supply circuit includes a first diode, a seventh diode, and a three-terminal Zener diode. The positive terminal of the first diode is connected to the positive terminal of the input connector, the positive terminal of the seventh diode is connected to the positive terminal of the battery connector, the negative terminals of the first diode and the seventh diode are connected, the negative terminal of the first diode is connected to the input terminal of the three-terminal Zener diode through an eleventh resistor, the input terminal of the three-terminal Zener diode is connected to ground through a third capacitor, and the output terminal of the three-terminal Zener diode is connected to ground through an output capacitor and is also connected to the control device and the power indicator module.

[0016] Preferably, the stall and overload protection circuit includes a first transistor, a second MOSFET, and a third MOSFET. The base of the first transistor is connected to the first control terminal of the control device via a sixth resistor, and the connection between the sixth resistor and the first control terminal is connected to ground via a fifth resistor. The collector of the first transistor is connected to the gate of the third MOSFET, and the emitter of the first transistor is connected to ground. The gate of the third MOSFET is connected to the positive terminal of the battery connector via a fourth resistor. The source of the third MOSFET is connected to the positive terminal of the battery connector and the positive terminal of the motor. The drain of the third MOSFET is connected to the drain of the second MOSFET and the negative terminal of the motor. A fourth capacitor and a second diode are connected in parallel between the source and drain of the third MOSFET. The anode of the second diode is connected to the drain of the third MOSFET. The gate of the second MOSFET is connected to the second control terminal of the control device. The source of the second MOSFET is connected to ground, and the drain of the second MOSFET is also connected to ground via a third capacitor.

[0017] Compared with the prior art, the advantages of this invention are as follows:

[0018] This invention utilizes a control device to perform stall or overload protection based on the detected voltage signals at both ends of the battery, effectively saving costs and reducing the size of the PCB board. The invention also employs a microcontroller for protection control, resulting in a smaller overall structure. A controlled power supply circuit ensures stable power supply, and a power indicator module allows for real-time monitoring of the battery level during operation, facilitating timely charging and ensuring stable operation. Furthermore, the control device manages the stall and overload protection circuits, enabling rapid power cut-off and effective motor protection. Attached Figure Description

[0019] Figure 1 This is a flowchart of the method in this invention;

[0020] Figure 2 This is a structural block diagram of the system in this invention;

[0021] Figure 3 This is a schematic diagram of the circuit structure of the battery charging management module, the power detection module, and the control power supply circuit in this invention;

[0022] Figure 4 This is a schematic diagram of the circuit structure of the control device in this invention;

[0023] Figure 5 This is a schematic diagram of the circuit structure of the power indicator module in this invention;

[0024] Figure 6 This is a schematic diagram of the circuit structure of the stall and overload protection circuit in this invention. Detailed Implementation

[0025] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to the following description.

[0026] like Figure 1 As shown, the present invention provides a method for motor protection by battery voltage detection, which includes the following processing steps.

[0027] Step 1: During operation, the voltage across the battery terminals is monitored in real time, and the voltage values ​​are collected and sent to the control device 1 at set intervals.

[0028] Step 2: Control device 1 controls the operation based on the collected voltage signal across the battery terminals. If the voltage drop across the battery terminals exceeds the set value and fails to recover to the normal operating voltage of the motor within the set time during startup, control device 1 will disconnect the power supply to the motor for protection. Otherwise, the operation will start normally.

[0029] Step 3: When the motor starts working normally, the control device 1 compares the received voltage signal at both ends of the battery with the previously received voltage signal at both ends of the battery in real time. If the decrease in the voltage signal at both ends of the battery received this time exceeds the set value, the control device 1 will disconnect the power supply to the motor for protection. If the decrease in the voltage signal at both ends of the battery received this time does not exceed the set value, normal operation will continue.

[0030] Control device 1 displays the battery level in real time to provide reminders, facilitating timely charging and ensuring stable power supply. The use of a microcontroller in control device 1 reduces the overall size of the structure while ensuring stable control.

[0031] In step 2, the set value for the voltage drop across the battery terminals during startup is set based on the voltage drop value when the selected motor is stalled. In step 3, when the control device 1 compares the received battery terminal voltage signal with the previously received battery terminal voltage signal, the set value for the voltage drop is determined by actually measuring several sets of voltage drop values ​​when the selected motor is overloaded and calculating the average value. In this embodiment, different motor models can be selected, and the settings can be adjusted according to the characteristics of the motor to improve the protection effect.

[0032] like Figure 2-6As shown, this invention also provides a system for motor protection through battery voltage detection, including an input connector DC_IN for connection to an external power source, a battery connector BAT1 for connection to a battery, a battery charging management module 2 connected to both the input connector DC_IN and the battery connector BAT1 for battery charging control, a stall and overload protection circuit 5 connected to the battery connector BAT1 for motor power supply control and stall or overload protection, and a power detection module 3 connected to the battery connector BAT1 for battery power detection. The battery charging management module 2, the stall and overload protection circuit 5, and the power detection module 3 are all signal-connected to a control device 1 for control. The battery connector BAT1 and the input connector DC_IN are connected to the control device 1 via a control power supply circuit 4 for powering the control device 1. The control device 1 has a control button S1 for controlling the motor's on / off state and a power indicator module 6 for indicating battery power. The power indicator module 6 has three LEDs to indicate different battery levels for easy viewing. The stall and overload protection circuit 5 disconnects upon receiving a protection signal to provide motor braking protection.

[0033] The battery charging management module 2 is equipped with a battery charging management chip U3 connected to the battery connector BAT1, the control device 1, and the input connector DC_IN. The power detection module 3 is equipped with a second resistor R2, one end of which is connected to the positive terminal of the battery connector BAT1. The other end of the second resistor R2 is connected to the control device 1 and is connected to ground GND through a third resistor R3 and an eighth capacitor C8. The power detection module 3 obtains the real-time changes in battery voltage during operation by detecting the voltage at the positive terminal of the battery connector BAT1, which facilitates timely motor protection control and battery power calculation.

[0034] The control power supply circuit 4 includes a first diode D1, a seventh diode D7, and a three-terminal Zener diode U1. The positive terminal of the first diode D1 is connected to the positive terminal of the input connector DC_IN, and the positive terminal of the seventh diode D7 is connected to the positive terminal of the battery connector BAT1. The negative terminals of the first diode D1 and the seventh diode D7 are connected. The negative terminal of the first diode D1 is connected to the input terminal of the three-terminal Zener diode U1 through the eleventh resistor R11. The input terminal of the three-terminal Zener diode U1 is connected to ground GND through the third capacitor C3. The output terminal of the three-terminal Zener diode U1 is connected to ground GND through the output capacitor CE3 and is also connected to the control device 1 and the power indicator module 6. The control power supply circuit 4 outputs 3.3V DC.

[0035] The stall and overload protection circuit 5 includes a first transistor Q1, a second MOSFET Q2, and a third MOSFET Q3. The base of the first transistor Q1 is connected to the first control terminal R100 of the control device 1 via a sixth resistor R6, and the connection between the sixth resistor R6 and the first control terminal R100 is connected to ground GND via a fifth resistor R5. The collector of the first transistor Q1 is connected to the gate of the third MOSFET Q3, and the emitter of the first transistor Q1 is connected to ground GND. The gate of the third MOSFET Q3 is connected to the positive terminal of the battery connector BAT1 via a fourth resistor R4. The source of S-MOSFET Q3 is connected to the positive terminal of battery connector BAT1 and the positive terminal of the motor. The drain of the third MOSFET Q3 is connected to the drain of the second MOSFET Q2 and the negative terminal of the motor. A fourth capacitor C4 and a second diode D2 are connected in parallel between the source and drain of the third MOSFET Q3. The anode of the second diode D2 is connected to the drain of the third MOSFET Q3. The gate of the second MOSFET Q2 is connected to the second control terminal R200 of the control device 1. The source of the second MOSFET Q2 is connected to ground GND. The drain of the second MOSFET Q2 is also connected to ground GND through the third capacitor C3.

[0036] In this embodiment, the input connector DC_IN is connected to an external DC power supply to provide DC power for charging the battery. The battery charging management module 2 regulates the voltage before charging the battery, and simultaneously controls the power supply circuit 4 to supply power to the power indicator module 6 and the control device 1. During charging, the battery charging management module 2 sends a signal to wake up the control device 1 and display the battery level. The power detection module 3 performs real-time voltage detection and sends the data to the control device 1 for display via the power indicator module 6. During operation, the start / stop function can be controlled via the control button S1. The control device 1 controls the operation based on the battery voltage signal collected by the power detection module 3. During startup, if the battery voltage drops beyond a set value and fails to recover to the normal operating voltage for the motor within a set time, the control device 1 controls the stall and overload protection circuit 5 to disconnect the motor power supply for protection. Otherwise, normal startup occurs. During normal motor startup, the control device 1 compares the received battery voltage signal with the previously received signal. If the current voltage drop exceeds a set value, the control device 1 controls the overload protection circuit 5 to disconnect the motor power supply for protection. If the current voltage drop does not exceed a set value, normal operation continues. After operation, the machine is stopped via control button S1. This invention effectively saves costs and reduces the size of the PCB board.

[0037] The above are merely preferred embodiments of the present invention. It should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be modified within the scope of the present invention through the above teachings or related technologies or knowledge. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A method for motor protection via battery voltage detection, characterized in that, Based on the motor protection system, the motor protection system includes an input connector (DC_IN) for connecting to an external power source, a battery connector (BAT1) for connecting to a battery, a battery charging management module (2) connected to the input connector (DC_IN) and the battery connector (BAT1) for battery charging control, a stall and overload protection circuit (5) connected to the battery connector (BAT1) for motor power supply control to perform stall or overload protection, and a power detection module (3) connected to the battery connector (BAT1) for battery power detection. The battery charging management module (2), the stall and overload protection circuit (5), and the power detection module (3) are respectively connected to a control device (1) for control. The battery connector (BAT1) and the input connector (DC_IN) are respectively connected to the control device (1) through a control power supply circuit (4) for powering the control device (1). The battery charging management module (2) is provided with a battery charging management chip (U3) that is connected to the battery connector (BAT1), the control device (1) and the input connector (DC_IN) respectively. The power detection module (3) is provided with a second resistor (R2) with one end connected to the positive terminal of the battery connector (BAT1). The other end of the second resistor (R2) is connected to the control device (1) and is connected to the ground wire (GND) through the third resistor (R3) and the eighth capacitor (C8) respectively. The method includes the following processing steps: Step 1: During operation, the voltage at both ends of the battery is detected in real time and the voltage value is collected and sent to the control device at set intervals (1). Step 2: The control device (1) controls the battery based on the collected voltage signal at both ends. If the voltage drop at both ends of the battery exceeds the set value and does not recover to the normal operating voltage of the motor within the set time during startup, the control device (1) will disconnect the power supply to the motor for protection. Otherwise, the motor will start normally. Step 3: When the motor starts working normally, the control device (1) compares the received battery voltage signal with the previously received battery voltage signal in real time. If the decrease in the received battery voltage signal exceeds the set value, the control device (1) will disconnect the motor power supply for protection. If the decrease in the received battery voltage signal does not exceed the set value, the motor will continue to work normally. In step 3, when the control device (1) compares the received voltage value signal at both ends of the battery with the previously received voltage value signal at both ends of the battery, the set value of the reduction value is determined by actually measuring several sets of voltage reduction values ​​when the selected motor is overloaded and calculating the average value.

2. The method for motor protection by battery voltage detection according to claim 1, characterized in that, The control device (1) displays the battery level in real time to provide reminders.

3. A method for motor protection by battery voltage detection according to claim 1 or 2, characterized in that, In step 2, the voltage drop across the battery terminals during startup is set according to the voltage drop when the selected motor is stalled.

4. The method for motor protection by battery voltage detection according to claim 1, characterized in that, The control device (1) is a microcontroller.

5. The method for motor protection by battery voltage detection according to claim 1, characterized in that, The control device (1) is provided with a control button (S1) for controlling the opening and closing of the motor, and the control device (1) is also provided with a power indicator module (6) for indicating the battery power.

6. A method for motor protection by battery voltage detection according to claim 5, characterized in that, The control power supply circuit (4) is equipped with a first diode (D1), a seventh diode (D7) and a three-terminal Zener diode (U1). The positive terminal of the first diode (D1) is connected to the positive terminal of the input connector (DC_IN). The positive terminal of the seventh diode (D7) is connected to the positive terminal of the battery connector (BAT1). The negative terminal of the first diode (D1) is connected to the negative terminal of the seventh diode (D7). The negative terminal of the first diode (D1) is connected to the input terminal of the three-terminal Zener diode (U1) through the eleventh resistor (R11). The input terminal of the three-terminal Zener diode (U1) is connected to the ground wire (GND) through the third capacitor (C3). The output terminal of the three-terminal Zener diode (U1) is connected to the ground wire (GND) through the output terminal capacitor (CE3) and is connected to the control device (1) and the power indicator module (6) respectively.

7. A method for motor protection by battery voltage detection according to claim 5, characterized in that, The stall and overload protection circuit (5) is equipped with a first transistor (Q1), a second MOSFET (Q2), and a third MOSFET (Q3). The base of the first transistor (Q1) is connected to the first control terminal (R100) of the control device (1) through a sixth resistor (R6), and the connection between the sixth resistor (R6) and the first control terminal (R100) is connected to ground (GND) through a fifth resistor (R5). The collector of the first transistor (Q1) is connected to the gate of the third MOSFET (Q3), and the emitter of the first transistor (Q1) is connected to ground (GND). The gate of the third MOSFET (Q3) is connected to the positive terminal of the battery connector (BAT1) through a fourth resistor (R4). The source of the MOSFET (Q3) is connected to the positive terminal of the battery connector (BAT1) and the positive terminal of the motor. The drain of the third MOSFET (Q3) is connected to the drain of the second MOSFET (Q2) and the negative terminal of the motor. A fourth capacitor (C4) and a second diode (D2) are connected in parallel between the source and drain of the third MOSFET (Q3). The positive terminal of the second diode (D2) is connected to the drain of the third MOSFET (Q3). The gate of the second MOSFET (Q2) is connected to the second control terminal (R200) ​​of the control device (1). The source of the second MOSFET (Q2) is connected to the ground line (GND). The drain of the second MOSFET (Q2) is also connected to the ground line (GND) through the third capacitor (C3).

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