A multifunctional controller for a rotary guide actuator and a control method thereof

Abstract

The present disclosure discloses a multifunctional controller for a rotary steerable actuator and a control method thereof, wherein the control method comprises: selecting a control mode; obtaining operating parameters during the operation of a brushless DC motor; a signal detection module detecting whether the received sensor signal is normal; a digital signal processing module receiving the target pressure of the actuator; performing PI calculation based on the operating parameters and the target pressure, and outputting a PWM wave; and a motor drive module driving the brushless DC motor to operate according to a given target pressure according to the PWM wave. The multifunctional controller comprises a signal detection module, an acquisition circuit module, a digital signal processing module, and a motor drive module. The present disclosure can switch control modes according to the type of actuator and is compatible with three mainstream actuators on the market. When a sensor fails, the sensor failure can be detected by the signal detection module, and the actuator can continue to work by switching the control mode without leaving the well for maintenance.

Description

Technical Field

[0001] The present disclosure relates to the field of control of a rotary steerable actuator, and in particular to a multifunctional controller of a rotary steerable actuator and a control method thereof. Background Art

[0002] Rotary steerable actuators are a core component of oil drilling systems. Currently, rotary steerable actuators typically consist of three main components: a brushless DC motor, a pressure sensor, and a hydraulic system. The brushless DC motor incorporates a Hall effect sensor. The controller uses this Hall effect sensor to obtain rotor position information and drive the brushless DC motor. Simultaneously, the controller obtains pressure information from the pressure sensor, creating a closed-loop pressure control system.

[0003] However, the operating environment of downhole oil equipment is characterized by high temperatures and strong vibrations. Hall effect sensors have poor resistance to high temperatures and vibrations, and may fail in such working environments, causing the brushless DC motor to malfunction and reducing system reliability.

[0004] Currently, there are three main types of mainstream actuators: motor with Hall sensor + pressure sensor, motor without Hall sensor + pressure sensor, and motor without Hall sensor + no pressure sensor.

[0005] Different types of actuators require different controllers, and these controllers are incompatible with each other, resulting in a large number of controller models and poor interchangeability, which is not conducive to future repair and replacement. Furthermore, current controllers have a single control mode. If a Hall effect sensor or pressure sensor fails during operation, the controller cannot switch control modes and the well must be removed for maintenance, resulting in a waste of resources. Summary of the Invention

[0006] In response to the above-mentioned problems, the purpose of the present disclosure is to provide a multifunctional controller for a rotary guide actuator and a control method thereof, which has three switchable modes and is compatible with the three currently mainstream actuators, thereby improving the compatibility of the controller and increasing the flexibility of the control method.

[0007] To achieve the above objectives, the present disclosure provides, in a first aspect, a control method for a rotary steering actuator, which is applied to a rotary steering actuator having a brushless DC motor and an output mechanism, wherein the brushless DC motor is drivingly connected to the output mechanism. The control method comprises the following steps:

[0008] Select the control mode;

[0009] Obtain the operating parameters of the brushless DC motor during operation;

[0010] The signal detection module detects whether the received sensor signal is normal.

[0011] The digital signal processing module receives the target pressure of the actuator;

[0012] Perform PI calculation based on operating parameters and target pressure and output PWM wave;

[0013] The motor drive module drives the brushless DC motor to operate according to the given target pressure based on the PWM wave;

[0014] The operating parameters include Hall sensor signal, current pressure signal, phase current, phase voltage, bus current and bus voltage;

[0015] The control modes include a first mode, a second mode and a third mode;

[0016] The first mode is based on an actuator with a Hall sensor and a pressure sensor;

[0017] The second mode is based on an actuator without a Hall sensor but with a pressure sensor;

[0018] The third mode is based on an actuator without Hall sensors and pressure sensors.

[0019] Optionally, the control method further includes: when the actuator has a Hall sensor, the control mode selects the first mode, and the signal detection module detects whether the Hall sensor signal during the operation of the motor is normal;

[0020] When a Hall sensor signal failure is detected, the control mode is reselected.

[0021] Optionally, the control method further includes: when the actuator has a pressure sensor, the control mode selects the first mode or the second mode, and the signal detection module detects whether the pressure sensor signal is normal,

[0022] When a pressure sensor failure is detected, the control mode is reselected.

[0023] Optionally, when the first mode is selected, the control method includes the following steps: receiving a target pressure of the actuator;

[0024] Get the current pressure of the actuator;

[0025] The signal detection module detects whether the received sensor signal is normal. If normal, continue; otherwise, reselect the control mode;

[0026] Perform pressure loop PI calculation according to target pressure and output pressure to obtain pressure loop PI calculation result;

[0027] Acquire Hall sensor signals and obtain electronic commutation and speed of the motor according to the Hall sensor signals;

[0028] Perform speed loop PI calculation based on the pressure loop PI calculation result and the obtained speed, and output PWM wave;

[0029] After receiving the PWM wave, the motor drive module controls the DC brushless motor to operate according to the given target pressure.

[0030] Optionally, when the second mode is selected, the control method includes the following steps:

[0031] Receive target pressure of the actuator;

[0032] Get the current pressure signal of the actuator;

[0033] The signal detection module detects whether the received sensor signal is normal. If normal, continue; otherwise, reselect the control mode;

[0034] Perform pressure loop PI calculation according to the target pressure and the current pressure signal to obtain the pressure loop PI calculation result;

[0035] Get phase voltage and phase current;

[0036] The current rotor electrical angular velocity and Iq current value are estimated based on the phase voltage and phase current;

[0037] Perform speed loop PI calculation based on the electrical angular velocity and pressure loop PI calculation results to obtain the speed loop PI calculation results;

[0038] Perform current loop PI calculation based on the speed loop PI calculation result and Iq current value, and output PWM wave;

[0039] After receiving the PWM wave, the motor drive module controls the DC brushless motor to operate according to the given target pressure.

[0040] Optionally, when the third mode is selected, the control method includes the following steps:

[0041] Receive target pressure of the actuator;

[0042] Read bus voltage signal and bus current;

[0043] According to the bus voltage signal and bus current signal, the output pressure of the brushless DC motor is estimated based on the pressure-free algorithm.

[0044] According to the target pressure and output pressure, the pressure loop PI operation is performed to obtain the pressure loop PI operation result;

[0045] Read phase voltage and phase current;

[0046] Estimate the current rotor electrical angle value and Iq current value based on the phase voltage and phase current;

[0047] Perform differential operation on the estimated electrical angle value to obtain the current electrical angular velocity of the rotor;

[0048] According to the electrical angular velocity and pressure loop PI calculation results, the speed loop PI calculation is performed to obtain the speed loop PI calculation results;

[0049] According to the speed loop PI calculation result and Iq current value, the current loop PI calculation is performed to output PWM wave;

[0050] The motor drive module controls the brushless DC motor to operate according to the given target pressure based on the PWM wave.

[0051] Optionally, the pressure-free algorithm includes the following steps:

[0052] Calculate the instantaneous power of the brushless DC motor based on the bus voltage and bus current;

[0053] Perform low-pass filtering on the instantaneous power to obtain the operating power of the brushless DC motor;

[0054] The output pressure is calculated based on the operating power.

[0055] Optionally, the instantaneous power is calculated as:

[0056] P = V × I;

[0057] The calculation formula for operating power is:

[0058] P′=PF(V×I);

[0059] The formula for calculating the output pressure is:

[0060] F=a×P′ 2 +b×P′+c;

[0061] in:

[0062] P is the instantaneous power of the motor,

[0063] V is the bus voltage,

[0064] I is the bus current,

[0065] F is the output pressure,

[0066] P' is the operating power of the motor,

[0067] a, b, and c are the calibration parameters of the actuator.

[0068] In a second aspect, the present disclosure provides a multifunctional controller for a rotary steering actuator, configured to execute the above-mentioned control method, comprising:

[0069] A signal detection module is used to detect whether the received sensor signal is normal;

[0070] The acquisition circuit module is used to collect the operating parameters of the motor of the actuator during operation;

[0071] The digital signal processing module receives the target pressure of the actuator through the communication circuit, performs calculations based on the operating parameters and the target pressure, and outputs a PWM wave;

[0072] The motor drive module drives the DC brushless motor to operate according to the target pressure through the received PWM wave

[0073] Optionally, the acquisition circuit module includes:

[0074] A three-phase current acquisition circuit module for obtaining the phase current of the DC brushless motor during operation;

[0075] A three-phase voltage acquisition circuit module for obtaining the phase voltage of the brushless DC motor during operation;

[0076] A Hall signal acquisition circuit module for acquiring Hall sensor signals;

[0077] A pressure signal acquisition circuit module for acquiring a current pressure signal of the actuator;

[0078] Bus voltage and current acquisition circuit module for obtaining bus voltage and bus current.

[0079] The present disclosure has the following beneficial effects:

[0080] (1) The multifunctional controller provided by the present disclosure is compatible with different types of rotary guide actuators. By switching different control modes, it can meet different usage requirements and facilitate subsequent maintenance and replacement;

[0081] (2) The multifunctional controller provided by the present disclosure can detect whether the sensor signal is normal through the signal detection module, thereby determining whether the sensor is working properly, facilitating timely detection of sensor failure and switching the control mode, thereby ensuring the normal operation of the multifunctional controller;

[0082] (3) The control method provided by the present disclosure can quickly switch the control mode to continue working when the Hall sensor or pressure sensor fails, thereby realizing the diversity of control methods, improving the reliability and redundancy of the system, and making it unnecessary for the actuator to be taken out of the well for maintenance, thus saving resources;

[0083] (4) The control method provided by the present disclosure is targeted at different types of actuators and is compatible with various types of actuators available on the market. The steps are reasonable and the measurement results are accurate. BRIEF DESCRIPTION OF THE DRAWINGS

[0084] The accompanying drawings illustrate exemplary embodiments of the present disclosure and together with the description serve to explain the principles of the present disclosure. These drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification.

[0085] Figure 1 It is a schematic diagram of the main structure of the multifunctional controller of the rotary guide actuator disclosed in the present invention;

[0086] Figure 2 is a detailed structural diagram of a multifunctional controller of a rotary steering actuator disclosed in the present invention;

[0087] Figure 3 is a logic diagram of the control method in the first mode of the present disclosure;

[0088] Figure 4 is a logic diagram of the control method in the second mode of the present disclosure;

[0089] Figure 5 is a logic diagram of the control method under the third mode of the present disclosure;

[0090] Figure 6 It is a schematic diagram of the main steps of the control method of the transfer guide actuator disclosed in the present invention;

[0091] Figure 7 is a schematic diagram of the steps of the control method in the first mode of the present disclosure;

[0092] Figure 8 is a schematic diagram of the steps of the control method in the second mode of the present disclosure;

[0093] Figure 9 It is a schematic diagram of the steps of the control method under the third mode in the present disclosure.

[0094] In the figure: 1. Digital signal processing module; 2. Acquisition circuit module; 21. Three-phase voltage acquisition circuit module; 22. Three-phase current acquisition circuit module; 23. Hall signal acquisition circuit module; 24. Pressure signal acquisition circuit module; 25. Bus voltage / current acquisition circuit module; 3. Motor drive module; 4. Secondary power supply; 5. Communication circuit; 6. Signal detection module. DETAILED DESCRIPTION

[0095] The present disclosure will be further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are intended only to illustrate the relevant content and are not intended to limit the present disclosure. It should also be noted that, for ease of description, only the portions relevant to the present disclosure are shown in the accompanying drawings.

[0096] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in the present disclosure can be combined with each other. The present disclosure will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0097] Example 1

[0098] For the actuator with Hall sensor motor + pressure sensor type, this embodiment provides a multifunctional controller for a rotary steering actuator, see Figure 1 The system comprises a digital signal processing module 1, an acquisition circuit module 2, a signal detection module 6, and a motor drive module 3. The functional controller in this embodiment controls a rotary steerable actuator equipped with a Hall effect sensor and a pressure sensor. Both the multifunctional controller and the rotary steerable actuator are powered by the power supply system.

[0099] For details, see Figure 1 、 Figure 2 The digital signal processing module 1 includes a digital signal processor (DSP). The digital signal processing module 1 is provided with multiple connection ports. The multiple connection ports facilitate the connection of various sensors according to installation requirements, which greatly improves the compatibility of the digital signal processing module 1 with different types of sensors. The digital signal processing module 1 is electrically connected to a communication circuit 5. The digital signal processing module 1 can receive a target pressure sent through the communication circuit 5. The target pressure is the numerical value of the target pressure to be achieved by the actuator. The digital signal processing module 1 is also electrically connected to a secondary power supply 4 for maintaining the stability of the controller's operating voltage. In this embodiment, the secondary power supply 4 is a secondary power supply 4 circuit that is electrically connected to the digital signal processing module 1 at one end and connected to the power supply system at the other end. The secondary power supply 4 can keep the controller's operating voltage stable at three operating voltages: 5V, 3.3V, or 1.8V. In addition, the digital signal processing module 1 is also electrically connected to a motor drive module 3 for driving the motor to operate according to a given target pressure. The motor drive module 3 is electrically connected to the power supply system, and the motor drive module 3 is electrically connected to the DC brushless motor. The digital signal processing module 1 transmits the PWM wave to the motor drive module 3, and the motor drive module 3 drives the motor to operate in a corresponding state according to the given target pressure based on the PWM wave. The motor drive module 3 includes a three-phase inverter.

[0100] See also Figure 1 、 Figure 2Acquisition circuit module 2 is used to collect operating parameters of the actuator's motor during operation. These operating parameters include phase current, phase voltage, Hall sensor signals, bus current, bus voltage, and current pressure signals. Acquisition circuit module 2 includes a three-phase current acquisition circuit module 22 for acquiring phase currents during motor operation; a three-phase voltage acquisition circuit module 21 for acquiring phase voltages during motor operation; a Hall signal acquisition circuit module 23 for acquiring Hall sensor signals; a pressure signal acquisition circuit module 24 for acquiring the actuator's current pressure; and a bus voltage / current acquisition circuit module 2 for acquiring bus voltage and bus current.

[0101] Among them, the three-phase voltage acquisition circuit module 21 and the three-phase current acquisition circuit module 22 are respectively used to acquire the phase voltage and phase current of the brushless DC motor. The phase current and phase voltage are the numerical values ​​of the phase current and phase voltage of the DC brushless motor when the DC brushless motor is running, which can reflect the operating status of the DC brushless motor. One end of the three-phase voltage acquisition circuit module 21 is electrically connected to the corresponding connection port of the digital signal processing module 1, and the other end is electrically connected to the three-phase voltage terminal of the motor. It can accurately acquire the phase voltage value of the motor and transmit it to the digital signal processing module 1. One end of the three-phase current acquisition circuit module 22 is electrically connected to the corresponding connection port of the digital signal processing module 1, and the other end is electrically connected to the motor drive module 3. It can accurately acquire the phase current value of the motor and transmit it to the digital signal processing module 1.

[0102] See also Figure 1 、 Figure 2 The bus voltage / current acquisition circuit module 2 is used to collect the bus voltage and bus current of the power supply system. The bus voltage and bus current represent the voltage and current values ​​of the working circuit of the brushless DC motor, respectively. One end of the bus voltage / current acquisition circuit module 2 is electrically connected to the power supply system, and the other end is electrically connected to the digital signal processing module 11.

[0103] See also Figure 1 、 Figure 2 The Hall signal acquisition circuit module 23 can acquire Hall sensor signals from the Hall sensor. When the actuator uses a brushless DC motor with a Hall sensor, one end of the Hall signal acquisition circuit module 23 is electrically connected to the Hall sensor, and the other end is electrically connected to the corresponding connection port of the digital signal processing module 1. When the actuator uses a brushless DC motor without a Hall sensor, the Hall signal acquisition circuit module 23 is not installed. The Hall signal acquisition circuit module 23 can accurately acquire the Hall sensor signals from the Hall sensor and transmit them to the digital signal processing module 1.

[0104] See also Figure 1 、 Figure 2The pressure signal acquisition circuit module 24 can collect the current pressure signal from the pressure sensor, reflecting the numerical value of the actuator's output pressure. When the actuator is equipped with a pressure sensor, one end of the pressure signal acquisition circuit is electrically connected to the pressure sensor, and the other end is electrically connected to the corresponding connection port of the pressure signal acquisition circuit. When the actuator is not equipped with a pressure sensor, the pressure signal acquisition circuit module 24 does not need to be installed. The pressure signal acquisition circuit module 24 can accurately collect the actuator's current pressure signal and transmit it to the digital signal processing module 1.

[0105] See also Figure 1 、 Figure 2 The signal detection module 6 can detect whether the received sensor signals are normal and transmit the detection results to the digital signal processing module 1. In this embodiment, the sensor signals received by the signal detection module 6 are Hall sensor signals and pressure sensor signals. One end of the signal detection module 6 is electrically connected to the digital signal processing module 1, and the other end is electrically connected to the Hall signal acquisition circuit module 23 and the pressure signal acquisition circuit module 24.

[0106] In some embodiments, each of the above modules is installed on a circuit board serving as a carrier, and the wide side of the circuit board is provided with reinforcing ribs for enhancing the anti-vibration performance. The circuit board is installed on the assembled PCB board by screws, which greatly improves the anti-vibration performance of the multi-function controller, enables the multi-function controller to cope with strong vibrations in the working environment, and reduces the chance of damage to the multi-function controller.

[0107] In some embodiments, the electronic components and connectors used in the above modules are all high-temperature resistant devices, which can effectively withstand the high-temperature environment underground, greatly improving the high-temperature resistance of the controller and meeting the needs of the high-temperature environment underground.

[0108] According to the multifunctional controller described above, this embodiment further provides a control method for a rotary guide actuator, which is used to control an actuator of the Hall sensor motor + pressure sensor type, see Figure 6 , including the following steps:

[0109] S001: Select control mode.

[0110] S002: The signal acquisition circuit module obtains the operating parameters of the brushless DC motor during operation.

[0111] S003: The signal detection module 6 detects whether the received sensor signal is normal.

[0112] S004: The digital signal processing module 1 receives the target pressure of the actuator.

[0113] S005: Perform PI calculation based on operating parameters and target pressure, and output PWM wave.

[0114] S006: The motor driving module 3 drives the brushless DC motor to operate according to the given target pressure according to the PWM wave.

[0115] Wherein, the control mode includes a first mode, a second mode and a third mode;

[0116] The first mode is based on an actuator with a Hall sensor and a pressure sensor;

[0117] The second mode is based on an actuator without a Hall sensor but with a pressure sensor;

[0118] The third mode is based on an actuator without Hall sensors and pressure sensors.

[0119] Specifically in this embodiment 1, see Figure 3 、 Figure 7 The specific steps of the control method are as follows: S101: Selecting the control mode as the first mode. Specifically in this embodiment 1, the control mode of the digital signal processing module 1 is selected as the first mode.

[0120] S102: Collecting the current pressure signal and Hall sensor signal. Specifically, the Hall signal acquisition circuit module 23 collects the Hall sensor signal, and the pressure signal acquisition circuit module 24 collects the current pressure signal.

[0121] S103: Detect whether the current pressure signal and the Hall sensor signal are normal. Specifically, the signal detection module 6 detects whether the Hall sensor signal and the current pressure signal are normal.

[0122] The method for detecting whether the Hall sensor signal and the current pressure signal are normal is as follows:

[0123] 1. Fault detection method of Hall sensor.

[0124] In the first embodiment, during the operation of the brushless DC motor, the Hall sensor signal fed back by the Hall sensor has the following six states.

[0125] H3 H2 H1 Control Word 1 0 1 5 0 0 1 1 0 1 1 3 0 1 0 2 1 1 0 6 1 0 0 4

[0126] During motor operation, the Hall sensor signal received by the signal detection module 6 may have two control words: 5 → 1 → 3 → 2 → 4 → 6 or 5 → 6 → 4 → 2 → 3 → 1, depending on the direction of operation. The signal detection module 6 determines the current control word based on the previous control word. If an abnormal sequence is detected, or if the Hall signal is 0 or 8, the Hall sensor signal is considered abnormal and the sensor is faulty.

[0127] 2. Detection method of pressure sensor failure.

[0128] Pressure sensor fault detection generally involves two types of detection before the multi-function controller performs specific control work:

[0129] (1) Power-on self-test program detection.

[0130] When the multi-function controller is powered on, the signal detection module 6 performs a power-on self-test program. If it detects that the current pressure value of the pressure sensor signal fed back by the pressure sensor is out of the normal range, it is determined that the current pressure signal is abnormal and the pressure sensor is faulty.

[0131] (2) Manual judgment and detection.

[0132] After the multi-function controller is powered on, it is manually set to several fixed speeds, such as 500 rpm, 1000 rpm, 3000 rpm, etc. The current pressure value of the pressure sensor signal fed back by the pressure sensor is manually observed. If the pressure value remains unchanged or exceeds the normal range, it is determined that the pressure sensor is faulty.

[0133] When a Hall sensor or pressure sensor fails, additional troubleshooting measures are required. The troubleshooting measures for Hall sensors and pressure sensors are as follows:

[0134] When the signal detection module 6 determines that the Hall sensor is faulty or the power-on self-test program of the signal detection module 6 reports a pressure sensor fault, the digital signal processing module sets the corresponding bit of the fault word in the program to 1 and stops the machine for investigation.

[0135] When the pressure sensor feedback fault is manually judged, the digital signal processing module sets the motor speed command to 0 and stops the machine for investigation.

[0136] When the signal detection module 6 detects that the Hall sensor or pressure sensor fails, it will stop the machine for investigation and send the fault word to the ground staff through communication. The staff will switch the control mode of the multi-function controller and restart the multi-function controller.

[0137] There are four detection results of the signal detection module 6:

[0138] The current pressure signal is normal, and the Hall sensor signal is normal;

[0139] The current pressure signal is normal, but the Hall sensor signal is abnormal;

[0140] The current pressure signal is abnormal, but the Hall sensor signal is normal;

[0141] The current pressure signal is abnormal, and the Hall sensor signal is abnormal.

[0142] According to the four different test results, the following is a detailed description of the subsequent steps of the control method under the four different test results.

[0143] (1) When the current pressure signal and the Hall sensor signal are normal, the control mode will not be changed, and the subsequent steps will be carried out according to the first mode. Figure 3 、 Figure 7 , the subsequent specific steps of the control method are as follows:

[0144] S106: Receiving the target pressure. Specifically, the digital signal processing module 1 receives the target pressure Fref transmitted via the communication circuit 5 .

[0145] S107: Perform pressure loop PI calculation based on the target pressure and the current pressure signal. Specifically, the digital signal processing module 1 performs pressure loop PI calculation based on the target pressure Fref and the current pressure signal to obtain the pressure loop PI calculation result, which serves as the target input of the speed loop.

[0146] S108: Obtaining the electronic commutation and speed of the motor according to the Hall sensor signal. Specifically, the digital signal processing module 1 obtains the electronic commutation and speed of the motor according to the Hall sensor signal.

[0147] S109: Perform speed loop PI calculation based on the pressure loop PI calculation result and the speed, and output a PWM wave. Specifically, the digital signal processing module 1 performs speed loop PI calculation based on the pressure loop PI calculation result and the obtained speed, and outputs a PWM wave.

[0148] S110: The motor drive module controls the motor to operate at a given target pressure according to the PWM wave. Specifically, the motor drive module 3 controls the brushless DC motor to operate according to the PWM wave, so that the actuator operates at a given target pressure Fref.

[0149] (2) When the current pressure signal is normal but the Hall sensor signal is abnormal, refer to Figure 6 , the subsequent specific steps of the control method are:

[0150] S104: The control mode is reselected to the second mode. Specifically, the control mode of the digital signal processing module 1 is reselected to the second mode. Subsequent control steps are performed according to the second mode. For details, see Example 2.

[0151] (3) The current pressure signal is abnormal, but the Hall sensor signal is normal. When the current pressure signal is abnormal, but the Hall sensor signal is abnormal, the subsequent steps of the control method are the same, see Figure 6 , the subsequent specific steps of the control method are:

[0152] S105: The control mode is reselected to the third mode. Specifically, the control mode of the digital signal processing module 1 is reselected to the third mode. Subsequent control steps are performed according to the third mode. For details, see Example 3.

[0153] This embodiment describes the steps of the control method in the first mode. After reselecting the second mode or the third mode, the steps to be performed refer to the subsequent embodiments 2 and 3.

[0154] Example 2

[0155] For an actuator with a motor without a Hall sensor and a pressure sensor, this embodiment provides a multifunctional controller for a rotary guide actuator. Compared with the multifunctional controller provided in Example 1, it has the following differences:

[0156] This mode is used when the Hall signal acquisition circuit module 23 is not installed in the multifunctional controller or when a Hall sensor fails.

[0157] Based on the multifunctional controller, a control method for a rotary guide actuator is provided in this embodiment. The control method is used to control an actuator of the type with a motor without a Hall sensor and a pressure sensor. Figure 4 、 Figure 8 , including the following steps:

[0158] S201: Selecting the control mode as the second mode. Specifically, selecting the control mode of the digital signal processing module 1 as the second mode.

[0159] S202: Collecting the current pressure signal. Specifically, the pressure signal collection circuit module 24 collects the current pressure signal.

[0160] S203: Detect whether the current pressure signal is normal. Specifically, the signal detection module 6 detects whether the current pressure signal is normal.

[0161] There are two detection results of the signal detection module 6 in S203. According to the two different detection results, the following is a detailed description of the subsequent steps of the control method under the two different detection results.

[0162] (1) When the current pressure signal is normal, do not change the control mode, and proceed with the subsequent steps according to the second mode. Figure 4 、 Figure 8 , the subsequent specific steps of the control method are as follows:

[0163] S204: Receiving the target pressure. Specifically, the digital signal processing module 1 receives the target pressure Fref transmitted via the communication circuit 5 .

[0164] S206: Perform a pressure loop PI calculation based on the target pressure and the current pressure signal. Specifically, digital signal processing module 1 reads the current pressure and performs a pressure loop PI calculation based on the target pressure Fref and the current pressure signal to obtain a pressure loop PI calculation result, which serves as the target input for the speed loop.

[0165] S207: Collect phase current and phase voltage. Specifically, the three-phase current collection circuit collection module collects phase current, and the three-phase voltage collection circuit module 21 collects phase voltage.

[0166] S208: Based on the phase currents and current phase voltages, the sensorless control algorithm is used to estimate the rotor's current electrical angle and Iq current values. The electrical angle values ​​are then differentiated to obtain the electrical angular velocity. Specifically, the digital signal processing module 1 uses the sensorless control algorithm to estimate the rotor's current electrical angle and Iq current values ​​based on the phase currents and phase voltages, thereby implementing Field-Oriented Control (FOC) control of the motor. The digital signal processing module 1 then differentiates the estimated electrical angle values ​​to obtain the current rotor electrical angular velocity.

[0167] S209: Perform a speed loop PI calculation based on the pressure loop PI calculation result and the electrical angular velocity. Specifically, the pressure loop PI calculation result serves as a reference value for the speed loop, and together with the estimated rotor electrical angular velocity, serves as an input parameter for the speed loop. Digital signal processing module 1 performs the speed loop PI calculation to obtain a speed loop PI calculation result.

[0168] S210: Perform a current loop PI calculation based on the speed loop PI calculation result and the Iq current value. Specifically, the speed loop PI calculation result serves as a reference input value for the current loop, and together with the calculated Iq value, serves as an input parameter for the current loop. The digital signal processing module 1 performs the current loop PI calculation to obtain a current loop PI calculation result, which is then output to the SVPWM module.

[0169] S211: Outputting a PWM wave according to the current loop PI calculation result. Specifically, the SVPWM module outputs a PWM wave to the motor drive module 3 according to the current loop PI calculation result.

[0170] S212: The motor drive module controls the motor to operate at a given target pressure according to the PWM wave. Specifically, the motor drive module 3 controls the brushless DC motor to operate according to the PWM wave, so that the actuator operates at a given target pressure Fref.

[0171] (2) When the current pressure signal is abnormal, refer to Figure 4 、 Figure 8 , the subsequent specific steps of the control method are as follows:

[0172] S205: The control mode is reselected to the third mode. Specifically, the control mode of the digital signal processing module 1 is reselected to the second mode. Subsequent control steps are performed according to the second mode.

[0173] The control method described in this embodiment is the control method in the second mode, and the subsequent steps of step S404 in Example 1 are performed according to the control method described in this example.

[0174] Example 3

[0175] For actuators without Hall sensor motors and pressure sensors, this embodiment provides a multifunctional controller for a rotary guide actuator. Compared with the multifunctional controller provided in Example 2, it has the following differences:

[0176] The pressure signal acquisition circuit module 24 is not installed in the multifunctional controller, or the third mode is adopted when a pressure sensor fails.

[0177] Based on the multifunctional controller, a control method for a rotary guide actuator is provided in this embodiment. The control method is used to control an actuator without a Hall sensor motor and a pressure sensor. Figure 5 、 Figure 9 , including the following steps:

[0178] S301: Selecting the control mode as the third mode. Specifically, selecting the control mode of the digital signal processing module 1 as the third mode.

[0179] S302: Receiving target pressure. Specifically, the digital signal processing module 1 receives the target pressure Fref transmitted via the communication circuit 5 .

[0180] S303: Collect bus current, bus voltage, phase current, and phase voltage. Specifically, the three-phase current collection circuit collection module collects phase current, the three-phase voltage collection circuit module 212 collects phase voltage, and the bus voltage / current collection circuit module 2 collects bus voltage and bus current.

[0181] S304: Obtain output pressure based on the bus current and bus voltage using a pressure-free algorithm. Specifically, the digital signal processing module 1 reads the bus voltage and bus current and estimates the output pressure F based on the bus voltage V and bus current I using a pressure-free algorithm.

[0182] S305: Performing a pressure loop PI operation based on the target pressure and the output pressure. Specifically, the digital signal processing module 1 performs a pressure loop PI operation based on the target pressure Fref and the output pressure F to obtain a pressure loop PI operation result.

[0183] S306: Based on the phase currents and current phase voltages, the sensorless control algorithm is used to estimate the rotor's current electrical angle and Iq current values. The electrical angle values ​​are then differentiated to obtain the electrical angular velocity. Specifically, the digital signal processing module 1 uses the sensorless control algorithm to estimate the rotor's current electrical angle and Iq current values ​​based on the phase currents and phase voltages, thereby implementing Field-Oriented Control (FOC) control of the motor. The digital signal processing module 1 then differentiates the estimated electrical angle values ​​to obtain the current rotor electrical angular velocity.

[0184] S307: Perform a speed loop PI calculation based on the pressure loop PI calculation result and the electrical angular velocity. Specifically, the pressure loop PI calculation result serves as a reference value for the speed loop, and together with the estimated rotor electrical angular velocity, serves as an input parameter for the speed loop. Digital signal processing module 1 performs the speed loop PI calculation to obtain a speed loop PI calculation result.

[0185] S308: Perform a current loop PI calculation based on the speed loop PI calculation result and the Iq current value. Specifically, the speed loop PI calculation result serves as a reference input value for the current loop, and together with the calculated Iq value, serves as an input parameter for the current loop. The digital signal processing module 1 performs the current loop PI calculation to obtain a current loop PI calculation result, which is then output to the SVPWM module.

[0186] S309: Outputting a PWM wave according to the current loop PI calculation result. Specifically, the SVPWM module outputs a PWM wave to the motor drive module 3 according to the current loop PI calculation result.

[0187] S310: The motor drive module controls the motor to operate at a given target pressure according to the PWM wave. Specifically, the motor drive module 3 controls the brushless DC motor to operate according to the PWM wave, so that the actuator operates at a given target pressure Fref.

[0188] Specifically, the non-pressure-sensitive algorithm in step S112 is described as follows:

[0189] The experiments revealed a positive correlation between the operating power of the brushless DC motor and the pressure output by the actuator. The multi-function controller collects the bus voltage V and bus current I, and the instantaneous power of the motor is P = V × I.

[0190] After low-pass filtering the instantaneous power of the motor, the parameter representing the motor's operating power is obtained, P' = PF (V × I). The functional relationship between the output pressure F and the motor power P' can be calibrated by experimental methods and then fitted. The specific steps are as follows:

[0191] (1) The controller drives the actuator to operate, and the external pressure sensor reads the actuator's output pressure F. In speed mode, start at 200 rpm, and record the P' parameter and output pressure F value after the operation stabilizes. Then increase the given speed by 100 rpm, and record the P' parameter and output pressure F value one by one until the maximum pressure is reached.

[0192] (2) Using a mathematical tool such as Matlab, a quadratic polynomial is fitted with P′ as the horizontal coordinate and F as the vertical coordinate. The three coefficients a, b, and c of the fitting curve function of the current actuator output pressure F and motor operating power P′ are obtained. The obtained fitting curve function is shown in Formula 1.

[0193] F=a×P′ 2 +b×P′+c Formula 1

[0194] The coefficients a, b, and c obtained experimentally serve as calibration parameters for the actuator and are independent of the controller structure. During operation, the controller calculates instantaneous power P' in real time based on the collected bus voltage and current, and uses Equation 1 to estimate the current output pressure F.

[0195] This embodiment describes the specific steps of the control method in the third mode. The subsequent steps of step S105 in embodiment 1 and step S205 in embodiment 2 refer to embodiment 3.

[0196] In summary, Examples 1-3 disclose the specific steps of the control method in the first mode, the second mode and the third mode, respectively. At the same time, Examples 1-3 disclose the structural adjustments of the multi-function controller for three different types of actuators, respectively.

[0197] According to the multifunctional controller and control method provided in Examples 1-3, the present disclosure can cope with the three current mainstream actuators, and after the sensor is damaged and fails, the normal operation of the multifunctional controller can be maintained by switching the control mode without the need to carry out out-of-well maintenance of the actuator.

[0198] Those skilled in the art will appreciate that the above embodiments are merely intended to clearly illustrate the present disclosure and are not intended to limit the scope of the present disclosure. Other changes or modifications may be made based on the above disclosure, and such changes or modifications are still within the scope of the present disclosure.

Claims

1. A control method for a rotary steering actuator, characterized in that: Applied to a rotary guide actuator having a brushless DC motor and an output mechanism, wherein the brushless DC motor is drivingly connected to the output mechanism, the control method comprises the following steps: Select the control mode; Obtain the operating parameters of the brushless DC motor during operation; The signal detection module detects whether the received sensor signal is normal; The digital signal processing module receives the target pressure of the actuator; Perform PI calculation based on operating parameters and target pressure and output PWM wave; The motor drive module drives the brushless DC motor to operate according to the given target pressure based on the PWM wave; The operating parameters include Hall sensor signals, current pressure signals, phase currents, phase voltages, bus currents and bus voltages; The control mode includes a first mode, a second mode and a third mode; The first mode is based on an actuator having a Hall sensor and a pressure sensor; The second mode is based on an actuator without a Hall sensor but with a pressure sensor; The third mode is based on an actuator without a Hall sensor and a pressure sensor; When the actuator has a Hall sensor, the control mode selects the first mode, and the signal detection module detects whether the Hall sensor signal during the operation of the motor is normal; When a fault is detected in the Hall sensor signal, the control mode is reselected; When the actuator has a pressure sensor, the control mode selects the first mode or the second mode, and the signal detection module detects whether the pressure sensor signal is normal. When a pressure sensor failure is detected, the control mode is reselected.

2. The control method according to claim 1, characterized in that: When the first mode is selected, the control method includes the following steps: Receive target pressure of the actuator; Get the current pressure signal of the actuator; The signal detection module detects whether the received sensor signal is normal. If normal, continue; otherwise, reselect the control mode; Perform pressure loop PI calculation according to the target pressure and the current pressure signal to obtain the pressure loop PI calculation result; Acquire Hall sensor signals and obtain electronic commutation and speed of the motor according to the Hall sensor signals; Perform speed loop PI calculation based on the pressure loop PI calculation result and the obtained speed, and output PWM wave; After receiving the PWM wave, the motor drive module controls the DC brushless motor to operate according to the given target pressure.

3. The control method according to claim 1, characterized in that: When the second mode is selected, the control method includes the following steps: Receive target pressure of the actuator; Get the current pressure signal of the actuator; The signal detection module detects whether the received sensor signal is normal. If normal, continue; otherwise, reselect the control mode; Perform pressure loop PI calculation according to the target pressure and the current pressure signal to obtain the pressure loop PI calculation result; Get phase voltage and phase current; The current rotor electrical angular velocity and Iq current value are estimated based on the phase voltage and phase current; Perform speed loop PI calculation based on the electrical angular velocity and pressure loop PI calculation results to obtain the speed loop PI calculation results; Perform current loop PI calculation based on the speed loop PI calculation result and Iq current value, and output PWM wave; After receiving the PWM wave, the motor drive module controls the DC brushless motor to operate according to the given target pressure.

4. The control method according to claim 1, characterized in that: When the third mode is selected, the control method includes the following steps: Receive target pressure of the actuator; Read bus voltage signal and bus current; According to the bus voltage signal and bus current signal, the output pressure of the brushless DC motor is estimated based on the pressure-free algorithm. According to the target pressure and output pressure, the pressure loop PI operation is performed to obtain the pressure loop PI operation result; Read phase voltage and phase current; Estimate the current rotor electrical angle value and Iq current value based on the phase voltage and phase current; Perform differential operation on the estimated electrical angle value to obtain the current electrical angular velocity of the rotor; According to the electrical angular velocity and pressure loop PI calculation results, the speed loop PI calculation is performed to obtain the speed loop PI calculation results; According to the speed loop PI calculation result and Iq current value, the current loop PI calculation is performed to output PWM wave; The motor drive module controls the brushless DC motor to operate according to the given target pressure based on the PWM wave.

5. The control method according to claim 4, characterized in that: The pressure-free algorithm includes the following steps: Calculate the instantaneous power of the brushless DC motor based on the bus voltage and bus current; Perform low-pass filtering on the instantaneous power to obtain the operating power of the brushless DC motor; The output pressure is calculated based on the operating power.

6. The control method according to claim 5, characterized in that: The calculation formula of the instantaneous power is: P = V × I; The calculation formula of the operating power is: P′=LPF(V×I); The calculation formula of the output pressure is: F=a×P′ 2 +b×P′+c; in: P is the instantaneous power of the motor, V is the bus voltage, I is the bus current, F is the output pressure, P' is the operating power of the motor, LPF is a low-pass filter algorithm. a, b, and c are the calibration parameters of the actuator.

7. A multifunctional controller for a rotary guide actuator, used to execute the control method according to any one of claims 1 to 6, characterized in that: include: A signal detection module is used to detect whether the received sensor signal is normal; The acquisition circuit module is used to collect the operating parameters of the motor of the actuator during operation; The digital signal processing module receives the target pressure of the actuator through the communication circuit, performs calculations based on the operating parameters and the target pressure, and outputs a PWM wave; The motor drive module drives the brushless DC motor to operate according to the target pressure through the received PWM wave.

8. The multifunctional controller according to claim 7, characterized in that: The acquisition circuit module includes: A three-phase current acquisition circuit module for obtaining the phase current of the DC brushless motor during operation; A three-phase voltage acquisition circuit module for obtaining the phase voltage of the brushless DC motor during operation; A Hall signal acquisition circuit module for acquiring Hall sensor signals; A pressure signal acquisition circuit module for acquiring a current pressure signal of the actuator; Bus voltage and current acquisition circuit module for obtaining bus voltage and bus current.

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