Electric roller control method and control system

Abstract

The invention discloses an electric roller control method and system. The method comprises the steps that a main control module drives an electric roller through a driving module; the signal acquisition module acquires discrete Hall signals generated in the running process of the electric roller and sends the discrete Hall signals to the main control module; the main control module performs square wave control on the electric roller according to the discrete Hall signal and calculates an electrical angle corresponding to the discrete Hall signal; the main control module calculates the running speed of the electric roller based on the time interval between the Hall signals, and when the running speed of the electric roller is larger than or equal to the preset speed, the main control module switches the control mode of the electric roller and conducts vector control on the electric roller based on the calculated electric angle. By adopting the method, the electric roller can be reliably, quickly and accurately controlled, various complex working condition requirements are met, and the control cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent controllers, and in particular to a control method and a control system for an electric roller. Background Art

[0002] The electric roller is a power device that has a motor and a reducer built into the roller. It is reliable, efficient and compact, and is commonly used in various sorting conveyors in the field of logistics sorting. With the continuous development of the logistics sorting industry, sorting conveyors that meet different conveying requirements have emerged, and higher requirements have been put forward for the control of the electric roller, the core component of the sorting conveyor.

[0003] At present, the most widely used core motor of electric rollers is a brushless DC motor with a Hall sensor. The control schemes for this type of electric roller mainly include square wave control and vector control. The torque fluctuations generated by square wave control are large, not stable enough, and the noise is also large, while the torque output by vector control is small, the voltage utilization rate is low, and it cannot reach the maximum, resulting in the output efficiency cannot reach the maximum, and its load starting performance is not high. At the same time, vector control requires precise electrical angles, so it has high requirements for position sensors.

[0004] Therefore, how to control the electric drum reliably, quickly and accurately to meet various conveying requirements is a problem that needs to be solved urgently. Summary of the invention

[0005] The embodiments of the present invention provide a control method and a control system for an electric roller, which can reliably, quickly and accurately control the electric roller, meet various complex working conditions and reduce control costs.

[0006] In order to solve the above technical problems, an embodiment of the present application provides an electric roller control method, comprising the following steps: a main control module sends a start instruction to a drive module, so that the drive module drives the electric roller according to the start instruction; a signal acquisition module collects discrete Hall signals generated during the operation of the electric roller, and sends the discrete Hall signals to the main control module; the main control module performs square wave control on the electric roller according to the discrete Hall signals, and calculates an electrical angle corresponding to the discrete Hall signals based on the discrete Hall signals; the main control module calculates the running speed of the electric roller based on the time interval between the Hall signals, and when the running speed of the electric roller is greater than or equal to a preset speed, the main control module switches the control mode of the electric roller, and performs vector control on the electric roller based on the electrical angle.

[0007] In one possible implementation, the main control module calculates the average electrical angular velocity based on the jump time of the discrete Hall signal; calculates the average electrical angle according to the average electrical angular velocity, the initial electrical angle corresponding to the current Hall signal and the jump time of the previous Hall signal; uses the phase-locked loop method to eliminate the error of the average electrical angle to obtain the electrical angle, which meets the requirements of vector control.

[0008] In another possible implementation, the main control module designs a phase-locked loop tracker according to the average electrical angular velocity and the average electrical angle; and performs error elimination on the average electrical angle based on the phase-locked loop tracker.

[0009] In another possible implementation, the main control module sends a start instruction to the drive module, and the start instruction includes a pulse width modulation signal; the drive module receives the pulse width modulation signal and amplifies the pulse width modulation signal, and the drive module uses the amplified pulse width modulation signal to drive the MOSFET tube to drive the electric roller.

[0010] In another possible implementation, the main control module sends information related to the operation of the electric drum to the display module; the display module uses an LCD screen to display the operating status of the electric drum, and the operating status includes a fault status, a speed status, and a current status.

[0011] In another possible implementation, the main control module sends a data acquisition instruction to the storage module; the storage module sends relevant control data to the main control module according to the data acquisition instruction, and the storage module stores parameters of different types of electric rollers, device addresses of electric roller control systems, and device addresses of electric rollers.

[0012] In order to solve the above technical problems, an embodiment of the present application also provides an electric roller control system, including: a main control module, used to send a start instruction to a drive module; a drive module, used to drive the electric roller according to the start instruction; a signal acquisition module, used to collect discrete Hall signals generated during the operation of the electric roller, and send the discrete Hall signals to the main control module; the main control module is also used to perform square wave control on the electric roller according to the discrete Hall signals, and calculate the electrical angle corresponding to the discrete Hall signals based on the discrete Hall signals; the running speed of the electric roller is calculated based on the time interval between the Hall signals, and when the running speed of the electric roller is greater than or equal to the preset speed, the main control module switches the control mode of the electric roller, and performs vector control on the electric roller based on the electrical angle.

[0013] In one possible implementation, the main control module is specifically used to: calculate the average electrical angular velocity based on the jump time of the discrete Hall signal; calculate the average electrical angle according to the average electrical angular velocity, the initial electrical angle corresponding to the current Hall signal and the jump time of the previous Hall signal; use the phase-locked loop method to eliminate the error of the average electrical angle to obtain the electrical angle, and the electrical angle meets the requirements of vector control.

[0014] In another possible implementation, the main control module is specifically used to: design a phase-locked loop tracker according to the average electrical angular velocity and the average electrical angle; and eliminate errors of the average electrical angle based on the phase-locked loop tracker.

[0015] In another possible implementation, the start instruction includes a pulse width modulation signal, and the driving module is specifically used to: receive the pulse width modulation signal and amplify the pulse width modulation signal, and use the amplified pulse width modulation signal to drive the MOSFET tube to drive the electric roller.

[0016] In another possible implementation, the system also includes a display module, and the main control module is further used to send information related to the operation of the electric roller to the display module; the display module is used to display the operating status of the electric roller using an LCD screen, and the operating status includes a fault status, a speed status, and a current status.

[0017] In another possible implementation, the system also includes a storage module, and the main control module is further used to issue data acquisition instructions to the storage module; the storage module is used to send relevant control data to the main control module according to the data acquisition instructions, and the storage module stores parameters of different types of electric rollers, device addresses of electric roller control systems and device addresses of electric rollers.

[0018] The electric roller control method and control system provided by the embodiment of the present invention collects discrete Hall signals generated during the operation of the electric roller, and uses the Hall signals to perform square wave control in the starting stage of the electric roller, so that the electric roller can start normally under various loads, thereby improving its load starting performance. At the same time, the continuous electrical angle position is calculated based on the discrete Hall signals. When the running speed of the electric roller reaches a preset speed, the control mode of the electric roller is switched, and the electric roller is vector controlled using the pre-calculated continuous electrical angle position, thereby achieving more stable and delicate control of the electric roller and adapting to various complex working conditions. This staged control method can reliably, quickly and accurately control the electric roller in the whole process to meet various transportation requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative labor.

[0020] Figure 1 It is a structural schematic diagram of an electric drum control system provided in an embodiment of the present application.

[0021] Figure 2 It is a flow chart of a method for controlling an electric drum provided in an embodiment of the present application.

[0022] Figure 3 This is a schematic diagram of electrical angle value division provided in an embodiment of the present application.

[0023] Figure 4 It is a schematic diagram of an electrical angle calculation method provided in an embodiment of the present application. DETAILED DESCRIPTION

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by technicians in the technical field of the present application; the terms used in the specification of the application herein are only for the purpose of describing specific embodiments and are not intended to limit the present application; the terms "including" and "having" and any variations thereof in the specification and claims of the present application and the above-mentioned drawings are intended to cover non-exclusive inclusions. The terms "first", "second", etc. in the specification and claims of the present application or the above-mentioned drawings are used to distinguish different objects, not to describe a specific order.

[0025] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0026] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0027] See also Figure 1 ,like Figure 1 As shown, the electric roller control system 100 may include a main control module 110, a drive module 120, a signal acquisition and processing module 130, a power module 140, a storage module 150, a display module 160 and a communication module 170. The power module 140 may be a power circuit composed of a voltage stabilizing circuit and a voltage stabilizing chip, and a three-level voltage drop structure is used to respectively supply power to the main control module 110, the drive module 120 and the electric roller 300; the communication module 170 is connected to the main control module 110 and the host computer 200, and the communication module 170 may be some communication interface to realize the instruction communication and data transmission between the host computer 200 and the main control module 110. For example, the host computer 200 can send speed instructions and stop start instructions to the main control module 110 through the communication module 170, and the main control module 110 can send instructions to the host computer 200 through the communication module 170. The upper computer 200 is a computer that issues control commands, such as a PC or a workstation, to provide feedback on the operating status of the electric roller and the location of the conveyed goods. The drive module 120 is connected to the main control module 110 and the electric roller 300, receives drive instructions (such as PWM signals) from the main control module, and drives the electric roller 300 through the pre-drive chip. The drive module 120 can also receive instructions such as stop and speed adjustment. The signal acquisition module 130 is connected to the main control module 110 and the electric roller 300. The signal acquisition module 130 can be various types of sensors. The signal acquisition module 130 can monitor the electric roller 300. The various parameters of the drum 300 are collected in real time, for example, the photoelectric signal is collected by using a photoelectric isolation circuit, the MOSFET tube current is collected by using an operational amplifier circuit, and the Hall high and low levels are collected by using a filter circuit, and the collected Hall signals, voltage signals, current signals, photoelectric signals, etc. are transmitted to the main control module 110; the storage module 150 is connected to the main control module 110, and the storage module 150 stores key operating data such as device address and electric drum parameters. The device address can be the IP address of the electric drum control system 100 and the electric drum 300. It should be understood that a host The host computer 200 can control multiple electric roller control systems 100, and one electric roller control system can control multiple electric rollers. The host computer 200 can find the corresponding electric roller control system and the specific electric roller by querying the IP address; the display module 160 is connected to the main control module 110, and can intuitively display the electric roller speed, temperature, fault and other signals from the main control module 110; the main control module 110 performs logic control and related signal and data processing according to the data collected by the signal acquisition and processing module 130 and the data stored in the storage module 150, so as to complete the implementation of the electric roller control algorithm.

[0028] It should be understood that Figure 1 The division and number of various modules in the embodiment are only for illustration purposes. More or fewer modules may be provided as required for implementation.

[0029] See also Figure 2 , Figure 2 A flow chart of a method for controlling an electric drum provided by an embodiment of the present invention is shown, and is described in detail as follows.

[0030] S201. The main control module collects discrete Hall signals generated during the operation of the electric drum and the time intervals between the Hall signals.

[0031] Specifically, before the main control module collects the Hall signal, it is first powered by the power module. Optionally, the power module provides a 24V voltage, which is reduced to 3.3V by a voltage regulator chip for use by the main control module. The power module also powers the drive module and the electric roller, providing them with 24V voltage and 5V voltage after voltage reduction processing, respectively. Then the main control module interacts with the host computer through a communication module, such as a CANopen communication module, to determine the target electric roller that needs to be controlled.

[0032] Furthermore, after determining the target electric roller, the main control module sends a start instruction to the drive module, which can be a PWM signal. The drive module uses a pre-drive chip with dead zone compensation to receive the PWM signal of the main control module and amplify it to drive the MOSFET tube, thereby driving the electric roller to run. A Hall sensor is deployed in the electric roller. After the electric roller is started, the Hall sensor generates a discrete Hall signal. The signal acquisition and processing module uses a filter circuit to collect the high and low levels of the Hall signal and sends the collected results to the main control module. In addition, the signal acquisition module also sends the time interval between the collected Hall signals to the main control module. The main control module calculates the running speed of the electric roller based on the time interval between the Hall signals, as well as the reduction ratio of the reducer inside the electric roller, the number of electrode pairs and other parameters.

[0033] S202, the main control module performs square wave control on the electric drum according to the discrete Hall signal.

[0034] Specifically, the main control module determines the position of the rotor at the next moment through analysis and calculation based on the collected Hall signal, and then energizes the two phases of the three-phase H bridge corresponding to the rotor position through the drive module, and repeats the above process until the speed of the electric drum meets the conditions.

[0035] S203: The main control module calculates the electrical angle based on the discrete Hall signal.

[0036] Specifically, the main control module uses discrete Hall signals to calculate continuous electrical angles and performs square wave control on the electric roller at the same time. After power is turned on, the main control module will continue to run the algorithm until the system stops controlling the electric roller.

[0037] In one possible implementation, the main control module calculates the average electrical angular velocity based on the jump time of the discrete Hall signal; calculates the average electrical angle according to the average electrical angular velocity, the initial electrical angle corresponding to the current Hall signal and the jump time of the previous Hall signal; uses the phase-locked loop method to eliminate the error of the average electrical angle to obtain the electrical angle that meets the vector control.

[0038] For example, assuming that there are three Hall sensors, the signals generated by these three Hall sensors are encoded in binary to obtain 6 groups of codes, namely: 001, 010, 011, 100, 101, 110. 000 and 111 generally appear when the machine is shut down or the machine fails. These two special cases are not considered here. When the installation error of the Hall sensor is ignored, the code values ​​corresponding to these signals divide the electrical angle into 6 parts on average, such as Figure 3 As shown, θ i is the starting electrical angle corresponding to the Hall signal, γ is a fixed electrical angle value, and different electric rollers have different corresponding γ values.

[0039] Furthermore, the average electrical angular velocity ω is estimated according to the average velocity method. avg , the average electrical angular velocity ω avg It can be calculated by the following formula:

[0040]

[0041]

[0042] Among them, T i It is the time between the six Hall signal jumps. It should be understood that during the rotation of the electric drum, the motor magnetic field inside it will also change, and the Hall sensor signal will change with the change of the magnetic field, continuously generating six Hall signals in a cycle. The speed of the Hall signal jump also reflects the speed of the electrical angle to a certain extent. Therefore, the average electrical angular velocity can be calculated here by calculating the time between the Hall signal jumps through the timer in the main control module.

[0043] Average electrical angle θ avg It can be calculated by the following formula:

[0044] θ avg =θ i +ω avg ×T i－1

[0045] 0≤ω avg ×T i ≤π / 3

[0046] Among them, θ i is the starting electrical angle corresponding to the current Hall signal, T i-1It is the time when the last Hall signal jumps.

[0047] In another possible implementation, the main control module designs a phase-locked loop tracker according to the average electrical angular velocity and the average electrical angle, and uses a phase-locked loop method to eliminate errors in the average electrical angle, thereby obtaining an electrical angle that satisfies vector control.

[0048] Specifically, see Figure 4 ,like Figure 4 As shown in the figure, after the average electrical angular velocity and average electrical angle of the three Hall signals are calculated by the average velocity method, the average electrical angle is eliminated by the phase-locked loop method to obtain the final required electrical angle, which can be calculated by the following formula:

[0049]

[0050]

[0051] Where ζ represents the system damping, which can be set to 7.07 so that the system closed-loop bandwidth ω c Approximately n , the average electrical angular velocity ω avg As ω c K can be obtained as the speed of the electric drum changes p and K i , and thus the electrical angle θ can be further obtained e .

[0052] S204: The main control module determines whether the running speed of the electric drum is greater than or equal to a preset speed.

[0053] Specifically, the main control module uses square waves to control the electric drum during the startup phase of the electric drum, and also compares the running speed of the electric drum with a preset speed in real time. The preset speed value can be set according to actual needs, and this application does not limit this.

[0054] When the running speed of the electric drum is less than the preset speed, the main control module keeps the current control mode unchanged, that is, continues to execute step S202; when the running speed of the electric drum is greater than or equal to the preset speed, the main control module switches the control mode of the electric drum and executes step S205.

[0055] S205. The main control module performs vector control on the electric drum using the electrical angle obtained by the above calculation.

[0056] Specifically, after switching the control mode of the electric roller, the main control module still needs to collect discrete Hall signals in real time and calculate the corresponding electrical angle, and then use the calculated electrical angle to perform vector control on the electric roller. That is, the electrical angle used for each control is constantly changing and updated in real time.

[0057] Optionally, the main control module sends information related to the operation of the electric roller to the display module, and the display module intuitively displays the operating status of the electric roller through the LCD screen, such as speed, temperature, and whether it is faulty. Compared with the traditional use of LED lights to display the status of the electric roller, this method is more intuitive and can better help users understand the various indicators and performance of the electric roller.

[0058] In this embodiment, by collecting the discrete Hall signal generated during the operation of the electric roller, the Hall signal is used to perform square wave control in the starting stage of the electric roller, so that the electric roller can start normally under various loads, thereby improving its load starting performance. At the same time, the continuous electrical angle position is calculated based on the discrete Hall signal. When the running speed of the electric roller reaches the preset speed, the control mode of the electric roller is switched, and the electric roller is vector controlled using the pre-calculated continuous electrical angle position, thereby achieving more stable and delicate control of the electric roller and adapting to various complex working conditions. This staged control method can reliably, quickly and accurately control the electric roller throughout the process to meet various transportation requirements.

[0059] It should be understood that the order of execution of the steps in the above embodiment does not necessarily mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiment of the present invention.

[0060] Through the description of the above implementation methods, those skilled in the art can clearly understand that the above-mentioned embodiment methods can be implemented by means of software plus a necessary general hardware platform, and of course by hardware, but in many cases the former is a better implementation method. Based on such an understanding, the technical solution of the present application, or the part that contributes to the prior art, can be embodied in the form of a software product, which is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk), and includes a number of instructions for a terminal device (which can be a mobile phone, computer, server, air conditioner, or network device, etc.) to execute the methods described in each embodiment of the present application.

[0061] Obviously, the embodiments described above are only some embodiments of the present application, rather than all embodiments. The preferred embodiments of the present application are given in the accompanying drawings, but they do not limit the patent scope of the present application. The present application can be implemented in many different forms. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present application more thorough and comprehensive. Although the present application is described in detail with reference to the aforementioned embodiments, for those skilled in the art, it is still possible to modify the technical solutions recorded in the aforementioned specific implementation methods, or to perform equivalent replacement of some of the technical features therein. Any equivalent structure made using the contents of the specification and drawings of this application, directly or indirectly used in other related technical fields, is similarly within the scope of patent protection of this application.

Claims

1. A method for controlling an electric drum, It is characterized in that The method comprises: The main control module sends a start instruction to the drive module, so that the drive module drives the electric drum according to the start instruction; The signal acquisition module acquires discrete Hall signals generated during the operation of the electric drum, and sends the discrete Hall signals to the main control module; The main control module performs square wave control on the electric drum according to the discrete Hall signal, and calculates the electrical angle corresponding to the discrete Hall signal based on the discrete Hall signal; The main control module calculates the running speed of the electric drum based on the time interval between the Hall signals. When the running speed of the electric drum is greater than or equal to a preset speed, the main control module switches the control mode of the electric drum and performs vector control on the electric drum based on the electrical angle.

2. The method according to claim 1, It is characterized in that The main control module calculates the electrical angle corresponding to the discrete Hall signal based on the discrete Hall signal, including: Based on the jump time of the discrete Hall signal, the average electrical angular velocity is calculated; based on the average electrical angular velocity, the initial electrical angle corresponding to the current Hall signal and the jump time of the previous Hall signal, the average electrical angle is calculated; The average electrical angle is subjected to error elimination using a phase-locked loop method to obtain the electrical angle, which meets the requirements of vector control.

3. The method according to claim 2, It is characterized in that The method of using the phase-locked loop method to eliminate the error of the average electrical angle includes: Designing a phase-locked loop tracker according to the average electrical angular velocity and the average electrical angle; Error elimination is performed on the average electrical angle based on the phase-locked loop tracker.

4. The method according to any one of claims 1 to 3, It is characterized in that The method further comprises: The main control module sends the information related to the operation of the electric drum to the display module; The display module uses an LCD screen to display the operating status of the electric drum, and the operating status includes a fault status, a speed status, and a current status.

5. The method according to any one of claims 1 to 3, It is characterized in that The method further comprises: The main control module sends a data acquisition instruction to the storage module; The storage module sends relevant control data to the main control module according to the data acquisition instruction, and the storage module stores parameters of different types of electric rollers, device addresses of electric roller control systems and device addresses of electric rollers.

6. A control system for an electric drum, It is characterized in that The system comprises: The main control module is used to send a startup instruction to the drive module; A driving module, used for driving the electric drum according to the starting instruction; A signal acquisition module, used for acquiring discrete Hall signals generated during the operation of the electric drum and sending the discrete Hall signals to the main control module; The main control module is also used to perform square wave control on the electric roller according to the discrete Hall signal, and calculate the electrical angle corresponding to the discrete Hall signal based on the discrete Hall signal; calculate the running speed of the electric roller based on the time interval between the Hall signals. When the running speed of the electric roller is greater than or equal to the preset speed, the main control module switches the control mode of the electric roller and performs vector control on the electric roller based on the electrical angle.

7. The electric drum control system according to claim 6, It is characterized in that The main control module is specifically used for: Based on the transition time of the discrete Hall signal, an average electrical angular velocity is calculated; The average electrical angle is calculated based on the average electrical angular velocity, the initial electrical angle corresponding to the current Hall signal and the transition time of the previous Hall signal; The average electrical angle is subjected to error elimination using a phase-locked loop method to obtain the electrical angle, which meets the requirements of vector control.

8. The electric drum control system according to claim 7, It is characterized in that The main control module is specifically used for: Designing a phase-locked loop tracker according to the average electrical angular velocity and the average electrical angle; Error elimination is performed on the average electrical angle based on the phase-locked loop tracker.

9. The electric drum control system according to any one of claims 6 to 8, It is characterized in that The system further comprises a display module, The main control module is also used to send information related to the operation of the electric drum to the display module; The display module is used to display the operating status of the electric drum using an LCD screen, and the operating status includes a fault status, a speed status, and a current status.

10. The electric drum control system according to any one of claims 6 to 8, It is characterized in that The system also includes a storage module, The main control module is also used to send data acquisition instructions to the storage module; The storage module is used to send relevant control data to the main control module according to the data acquisition instruction. The storage module stores parameters of different types of electric rollers, device addresses of electric roller control systems and device addresses of electric rollers.

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