Motor control system with dual power-on protection function

Abstract

The invention discloses a motor control system with a dual power-on protection function. The system comprises a plurality of functional modules such as a power-on protection module, a current sampling and overcurrent protection module, a temperature detection module, a dormancy module and a self-checking module, can effectively monitor the running state of the motor, automatically performs system self-checking, and triggers a protection mechanism in time when an abnormal condition occurs. By means of dual power-on protection, overcurrent protection, over-temperature protection and other protection means, the safety and stability of the motor control system are effectively improved, equipment damage caused by mistaken starting, overcurrent protection, over-temperature protection and other faults is avoided, and it is ensured that a motor efficiently operates under the safe condition.

Description

Technical Field

[0001] The present invention relates to the technical field of motor control, and in particular to a motor control system with dual power-on protection functions. Background Art

[0002] With the widespread adoption of modern motor control systems across a wide range of devices, motor protection and system stability are becoming increasingly important. In existing motor control systems, the motor startup process often presents issues such as excessive current and high temperatures, which can easily damage the motor. Furthermore, failure to promptly and effectively perform self-tests and fault protection after powering on the motor system can cause the device to start in an incorrect state, increasing the risk of failure. To address this issue, existing technologies have implemented a number of protection mechanisms, but most rely on a single protection method and are unable to effectively address various emergencies. Therefore, a more reliable and comprehensive motor protection system is needed. Summary of the Invention

[0003] The purpose of the present invention is to provide a motor control system with dual power-on protection functions, which has reliable power-on protection, overcurrent protection, temperature protection and self-test functions, can ensure that the motor will not be damaged due to unexpected conditions during the startup process, and can monitor the system status in real time during the operation of the motor, thereby improving the safety and stability of the system.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a motor control system with dual power-on protection function, comprising the following modules:

[0005] Monitoring module: monitors the motor operating status in real time through current sensors, voltage sensors and temperature sensors, and collects battery voltage, current and temperature parameters;

[0006] Power-on protection module: Through a combination of software and hardware, when power is detected, it determines whether the start button has been accidentally pressed and triggers the power-on protection function;

[0007] Current sampling and overcurrent protection module: Based on the sampled current data, it determines whether the current exceeds the preset threshold. If the current exceeds the threshold and lasts for a set time, the discharge MOS tube is turned off to achieve overcurrent protection;

[0008] Temperature detection module: detects battery temperature through NTC thermistor and stops working when the temperature exceeds the preset range;

[0009] Discharge control module: Based on the overcurrent and overtemperature protection status, it controls the opening and closing of the discharge MOS tube to achieve precise control;

[0010] Sleep module: When the system is not in operation, it turns off non-essential peripherals to reduce power consumption and enter sleep mode;

[0011] Self-check module: After the system is powered on, it automatically executes the self-check program to determine whether there are any abnormalities in the system. If there are any abnormalities, the machine will be prevented from starting;

[0012] Motor calibration and precision optimization module: used to perform preliminary calibration and error correction based on the collected current, voltage, and temperature data, and output accurate motor control parameters based on the corrected data;

[0013] Error correction and comprehensive evaluation module: Combines external environmental parameters and calibration data to further optimize motor control parameters and output the final comprehensive evaluation value.

[0014] Preferably, the motor calibration and precision optimization module includes the following steps:

[0015] S1: Data Collection

[0016] The sensors based on the monitoring module collect current, voltage and temperature data in real time;

[0017] Input: Real-time collected current I(t), voltage V(t), and temperature T(t) data;

[0018] Output: raw sensor data;

[0019] S2: Preliminary calculations

[0020] The collected data is preliminarily processed using the following formula to estimate the motor operating status parameters: τ est =k (t) I(t), where ω est : Preliminary estimated motor speed; τ est : Preliminary estimated motor torque; k e : Back electromotive force constant of the motor; k (t) : Torque constant of the motor; Φ(t): Magnetic flux of the motor;

[0021] S3: Preliminary calibration results generation

[0022] Output preliminary estimates of the motor's operating status, including speed and torque;

[0023] Output: Preliminary calibration results.

[0024] Preferably, the motor calibration and precision optimization module further includes:

[0025] S4: Error Correction

[0026] The preliminary calibration results are corrected based on external environmental parameters, including:

[0027] Temperature correction: ωcorr =ω est ·(1+α·(T env -T0)); τ corr =τ est ·(1+β·(T env -T0);

[0028] in:

[0029] ω corr : Corrected speed; τ corr : corrected torque; α, β: temperature sensitivity coefficient; T env : external ambient temperature; T0: reference temperature;

[0030] Correction for humidity: τ corr-final =τ corr ·(1-γ·H);

[0031] Where: γ: humidity influence coefficient; H: ambient humidity;

[0032] S5: Optimization result output

[0033] Output the corrected motor operating parameters;

[0034] Output: Optimized motor control parameters.

[0035] Preferably, the error correction and comprehensive evaluation module includes the following steps:

[0036] S1: Comprehensive Assessment

[0037] The preliminary calibration results and the corrected results are weighted and combined to generate the final comprehensive performance evaluation index:

[0038] P final =ω1·ω corr +ω2·τ corr-final ,in:

[0039] P final : Final performance evaluation value;

[0040] ω corr : Corrected speed;

[0041] τ corr-final : Corrected torque

[0042] ω1 and ω2: dynamic weights;

[0043] Dynamic weight calculation formula: ω2=1-ω1;

[0044] Where: ΔT = T env -T0 is the temperature difference;

[0045] k: weight sensitivity adjustment coefficient;

[0046] S2: Dynamically adjust control parameters

[0047] According to the final comprehensive performance evaluation value P final , adjust the motor's operating control parameters:

[0048] Control new =Control old ·(1+δ·P final ), where: Control new : Adjusted control parameters; Control old : initial control parameter; δ: adjustment sensitivity coefficient.

[0049] Preferably, the power-on protection module determines whether there is a power outage by detecting the state of the fok flag. If the power is turned on again after the power is off and the start button is in the pressed state, the power-on protection is triggered, specifically including:

[0050] FOK flag detection: The power-on protection module detects the FOK flag in the circuit to determine whether the system has experienced a power-on event. If the motor control system is powered on again after a power outage and the start button is still pressed, the system activates the protection mechanism.

[0051] Power-off and restart determination: By monitoring the power supply voltage changes and combining the internal flag bits of the control system to confirm whether it is a normal power-on process, if it is not normal, the protection mechanism is automatically triggered to prevent accidental startup.

[0052] Preferably, the current threshold in the current sampling and overcurrent protection module is inconsistent according to different torque gear settings, including that the first gear, the second gear and the third gear correspond to different current thresholds and delay judgments, specifically including:

[0053] Current sampling and threshold setting: In the current sampling and overcurrent protection module, the current threshold is dynamically set according to the motor torque gear; each gear corresponds to a different current threshold and delay judgment;

[0054] Threshold adjustment: For example, in low-torque gears, the current threshold is lower and the delay is shorter; in high-torque gears, the current threshold is higher, and to avoid misoperation, the delay is set longer. Through this adjustment, protection can be implemented in a timely manner according to the motor's operating status and load conditions;

[0055] Delay judgment: When the current exceeds the set threshold and lasts longer than the set delay, the overcurrent protection mechanism is immediately triggered, the discharge MOS tube is turned off, and the circuit and motor are protected.

[0056] Preferably, the temperature detection module collects temperature data through an NTC thermistor, and triggers a protection mechanism when the battery temperature is higher than 75°C or lower than -30°C, and stops working, specifically including:

[0057] NTC thermistor monitoring: The temperature detection module uses an NTC thermistor to collect battery temperature in real time; by measuring the change in the resistance value of the NTC thermistor, the battery temperature can be accurately determined;

[0058] Temperature range setting: Set the temperature threshold. When the battery temperature exceeds 75°C or drops below -30°C, the system triggers a protection mechanism to prevent battery damage or short circuit by shutting down the discharge MOS tube and cutting off the circuit.

[0059] Protection mechanism activated: When the temperature exceeds the standard, a stop signal is sent through the control module, triggering the current cut-off or motor shutdown to ensure that the battery is within a safe temperature range.

[0060] Preferably, the sleep module initializes the chip port before entering sleep mode and sets an interrupt wake-up mode to ensure that it can quickly respond to an external trigger signal to resume work in a low-power state, specifically including:

[0061] Chip port initialization: Before entering sleep mode, the sleep module initializes the key chip ports in the system to ensure that the system can enter a low-power state;

[0062] Interrupt wake-up mechanism: Configure the system's interrupt function. When an external trigger signal enters, the system will quickly recover from sleep mode and resume working state to ensure rapid response;

[0063] Low power management: By combining hardware and software, the system's low power state is optimized to ensure that the motor control system can save energy to the maximum extent possible when not in operation.

[0064] Preferably, the discharge control module determines whether to turn on or off the discharge MOS tube according to the overcurrent protection state value overload_flt to prevent the system from continuing to discharge under overcurrent conditions, specifically including:

[0065] Overcurrent protection status monitoring: The discharge control module monitors the overcurrent protection status value overload_flt in real time to determine whether an overcurrent condition occurs. overload_flt indicates that the current exceeds the safety threshold. The system uses this flag to determine whether the discharge MOS tube needs to be shut down.

[0066] Overcurrent protection: If overload_flt is true, indicating that the current exceeds the limit, the system will automatically control the discharge MOS tube to turn off to prevent the current from being too high and causing circuit damage or battery overheating;

[0067] Circuit protection: This protection mechanism can prevent damage to the battery or motor in a short period of time, ensuring the safe operation of the motor control system.

[0068] Preferably, the self-test module performs functions including short circuit detection, soft start function detection and timer interrupt detection, specifically including:

[0069] Short-circuit detection: By monitoring the current and voltage status of the circuit in real time, it can determine whether a short-circuit fault has occurred. If the current increases abnormally or the voltage fluctuates greatly, the system will determine that a short circuit may have occurred, stop the motor operation in time, and trigger protection;

[0070] Soft start function detection: When the motor starts, the current changes during the startup process are monitored to determine whether the motor can start smoothly. If it is detected that the current is too large or the speed does not change as expected during the startup process, the startup process is immediately terminated to prevent motor damage.

[0071] Timer interrupt detection: The timer sets the threshold time to ensure that the system completes the startup process within the preset time. If the motor startup or other critical processes are not completed within the specified time, the system triggers an interrupt signal through the timer to stop the startup or perform other protective measures.

[0072] Compared with the prior art, the present invention has the following beneficial effects:

[0073] 1. The present invention adds a double power-on protection mechanism to check the system status before the motor starts, preventing the motor from accidentally starting due to the wrong press of the start button, thereby effectively avoiding misoperation and failure;

[0074] 2. Through current sampling and overcurrent protection mechanism, it can monitor the current status in real time and shut down the discharge MOS tube in time to prevent overcurrent from causing damage to the motor;

[0075] 3. The temperature detection module and over-temperature protection mechanism can stop the system operation in time when the battery temperature is too high, ensuring the safety of the battery and motor;

[0076] 4. The self-test module can automatically execute the self-test program when powered on to ensure normal system operation, avoid potential failures and improve equipment reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] Figure 1 This is a functional module diagram of the motor control system of the present invention;

[0078] Figure 2 A signal flow and data transmission diagram of the motor control system of the present invention;

[0079] Figure 3 This is a flow chart of the motor calibration and precision optimization module of the present invention;

[0080] Figure 4 This is a flow chart of the dynamic adjustment of control parameters of the present invention. DETAILED DESCRIPTION

[0081] The following will provide a clear and complete description of the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0082] See also Figures 1 to 4 This invention provides a motor control system with dual power-on protection, designed to effectively protect the motor and its control system from damage caused by current, temperature, or voltage instability during motor startup. The system utilizes multiple modules working together to monitor the motor's operating status in real time and implement appropriate protective measures to ensure efficient and safe operation under various operating conditions. The following describes in detail the operating principles, implementation methods, and technical details of each functional module.

[0083] 1. Composition and working principle of motor control system

[0084] The motor control system mainly consists of the following modules:

[0085] Monitoring module, power-on protection module, current sampling and overcurrent protection module, temperature detection module, discharge control module, sleep module, self-test module, motor calibration and precision optimization module, error correction and comprehensive evaluation module;

[0086] These modules work together to monitor the motor's operating status in real time and adjust control parameters based on the motor's operating requirements. Together, they ensure the system's efficiency and stability in a variety of operating environments.

[0087] 2. Monitoring module

[0088] The monitoring module collects real-time motor operating data through multiple sensors (including current, voltage, and temperature sensors). Key data includes battery voltage, motor current, and temperature. The monitoring module continuously tracks motor status and provides necessary real-time feedback to the control system.

[0089] Input: I(t), voltage V(t), temperature T(t)

[0090] Output: Real-time motor operating status data

[0091] Working principle:

[0092] Current sensor: monitors the motor current in real time. When the current exceeds the set safety range, the sensor will warn the system to perform overcurrent protection to avoid motor overload.

[0093] Voltage sensor: monitors the battery voltage to ensure it is within the normal range. If the voltage is too low (e.g., over-discharge), the system will trigger protection measures and stop the motor.

[0094] Temperature sensor: Monitors battery and motor temperature changes to ensure the motor operates at a safe temperature. If the temperature exceeds a set threshold, the system activates overtemperature protection to prevent damage to the battery or motor due to overheating.

[0095] 3. Power-on protection module

[0096] The power-on protection module's primary function is to prevent the motor from accidentally starting when the power is on due to the start button being accidentally pressed. It combines hardware circuitry and software logic to ensure the motor starts only after the system is properly powered on.

[0097] Input: power supply voltage change, start button status

[0098] Output: Start protection signal

[0099] Working principle:

[0100] Power supply voltage detection: The power-on protection module first determines whether the system has just been powered on by observing the power supply voltage change. If the system power supply voltage change is consistent with the normal startup process, it proceeds to the next step of the determination.

[0101] Start button status detection: If the start button is in the pressed state after power-on, the system will trigger the protection mechanism to prevent the motor from starting due to misoperation.

[0102] Protection mechanism: If the system detects that the start button is pressed incorrectly or the power supply is abnormal, the system will prohibit the motor from starting through software logic until the start button status returns to normal.

[0103] 4. Current sampling and overcurrent protection module

[0104] The current sampling and overcurrent protection module monitors the motor's operating status by sampling current in real time, ensuring that the current does not exceed the maximum safety value set by the system. If the current exceeds the threshold and persists for longer than a preset time, the system immediately shuts off the discharge MOSFET, cutting off the current flow to the motor.

[0105] Input: Real-time current data

[0106] Output: Overcurrent protection signal

[0107] Working principle:

[0108] Current sampling: The current sensor monitors the motor current in real time and feeds the data back to the system. If the current exceeds the set threshold and continues for more than the preset delay, the system will enter the protection state.

[0109] Overcurrent protection: When excessive current is detected, the system will immediately turn off the discharge MOS tube, cut off the current supply, and prevent the motor from overloading.

[0110] Threshold and delay settings: Based on different operating conditions (such as different loads and operating speeds), the system will dynamically adjust the current threshold and delay settings to cope with different motor operating conditions.

[0111] 5. Temperature detection module

[0112] The temperature detection module uses an NTC thermistor to monitor the temperature of the battery and motor. When the temperature exceeds a set safety threshold (such as 75°C or below -30°C), the module automatically triggers a protection mechanism, stopping the motor to prevent damage to the motor and battery due to excessive high or low temperatures.

[0113] Input: Battery and motor temperature data

[0114] Output: Temperature protection signal

[0115] Working principle:

[0116] Working Principle of NTC Thermistors: The resistance of an NTC thermistor changes with temperature. The system calculates the current temperature based on this resistance change, thereby monitoring the battery and motor temperatures in real time.

[0117] Temperature threshold setting: Set the maximum and minimum thresholds for battery temperature (such as 75°C and -30°C). When the temperature exceeds these ranges, the system will automatically trigger the protection mechanism.

[0118] Protection mechanism: When the temperature exceeds or falls below the set range, the system will cut off the battery current and stop the motor to ensure the safety of the battery and motor.

[0119] 6.Discharge control module

[0120] The discharge control module controls the opening and closing of the discharge MOS tube according to the system's overcurrent protection status and overtemperature protection status to prevent the system from continuing to discharge when the current is too large or the temperature is too high, protecting the battery and motor from damage.

[0121] Input: overcurrent protection status, overtemperature protection status

[0122] Output: discharge control signal

[0123] Working principle:

[0124] Overcurrent and overtemperature monitoring: The system monitors the current and temperature status in real time. When excessive current or high temperature is detected, the discharge control module will trigger the protection mechanism in time.

[0125] Cut off the current: By controlling the switch of the MOS tube, the system can cut off the current flowing to the motor to prevent the battery and motor from overloading.

[0126] 7. Hibernation module

[0127] The hibernation module reduces power consumption when the motor control system is not in operation. By shutting down non-essential peripherals, the system enters hibernation mode, minimizing energy consumption. Furthermore, when an external trigger signal is received, the system can quickly resume from hibernation mode.

[0128] Input: external trigger signal

[0129] Output: Resume working signal

[0130] Working principle:

[0131] Low Power Mode: The hibernation module turns off non-operating peripherals to reduce the overall power consumption of the system. At this time, the system enters a low-power state to ensure maximum power conservation during non-operating periods.

[0132] Interrupt wake-up mechanism: When an external trigger signal (such as button press, sensor signal, etc.) enters, the system will quickly resume working state from sleep mode through the interrupt mechanism to ensure fast response.

[0133] 8. Self-test module

[0134] The self-test module performs a self-test after the motor control system is powered on. This includes short-circuit detection, soft-start function detection, and timer interrupt detection. The self-test module ensures that there are no faults before the motor system starts, preventing damage to the motor.

[0135] Input: Motor operating data

[0136] Output: Self-test result signal

[0137] Working principle:

[0138] Short-circuit detection: By monitoring the current and voltage status in real time, it can determine whether a short circuit has occurred. If the current increases or the voltage fluctuates abnormally, the system will trigger a protection mechanism.

[0139] Soft start detection: Monitors the current changes during motor startup to determine whether the startup is smooth. If the current is too high or the startup fails, the system will terminate the startup process.

[0140] Timer interrupt detection: The timer ensures that the motor startup process is completed within the specified time. If the startup process times out, the timer triggers an interrupt signal to stop the startup.

[0141] 9. Motor calibration and precision optimization module

[0142] The motor calibration and precision optimization module primarily performs preliminary motor calibration using collected data such as current, voltage, and temperature. It then further optimizes the motor's control parameters based on changes in the external environment.

[0143] Input: current, voltage, temperature data

[0144] Output: Optimized control parameters

[0145] Working principle:

[0146] Preliminary calibration: The motor speed and torque are preliminarily estimated using current, voltage, and temperature data to generate preliminary calibration results.

[0147] Accuracy optimization: Modify the preliminary calibration results according to the external environment (such as humidity and temperature) to improve control accuracy.

[0148] 10. Error correction and comprehensive evaluation module

[0149] The error correction and comprehensive evaluation module combines the motor calibration results and external environment data, optimizes the motor control parameters through weighted combination, and outputs the final comprehensive evaluation value.

[0150] Input: calibration results, external environment data

[0151] Output: Motor performance evaluation value

[0152] Working principle:

[0153] Weighted combination: Dynamically adjust the weighting coefficient according to different working environments (such as temperature and humidity) to generate a comprehensive evaluation value.

[0154] Dynamic adjustment: Under different working conditions, the system adjusts the motor control parameters according to the weighted coefficients to ensure that the motor can operate efficiently under various working conditions.

[0155] The motor calibration and precision optimization module of this motor control system is responsible for accurately monitoring and calibrating the motor's operating status. It combines real-time data collected by the monitoring module with a multi-step algorithm for data processing and optimization, ensuring the motor maintains efficient and stable operation under varying operating conditions. This module performs data acquisition, preliminary calculations, and calibration through the following steps, ultimately outputting the motor's precise operating status.

[0156] S1: Data Collection

[0157] Data acquisition is the first step in this module. Its primary task is to collect real-time motor-related operating data using sensors in the monitoring module. The monitoring module includes current, voltage, and temperature sensors, collecting key data such as current, voltage, and temperature. This data provides the foundation for subsequent calibration and optimization processes.

[0158] Input: Real-time collected current I(t), voltage V(t), and temperature T(t) data;

[0159] Output: Raw sensor data, i.e. current, voltage and temperature data. Working principle:

[0160] Current sensor: This monitors the motor's current in real time and captures current fluctuations. Current changes are closely related to the motor's load and operating status. Using this data, the system can determine whether the motor is overloaded.

[0161] Voltage sensor: monitors the battery or motor supply voltage to ensure voltage stability and avoid excessive voltage fluctuations that may affect motor operation.

[0162] Temperature sensor: This sensor collects real-time temperature data from the motor and battery, providing the necessary basis for temperature protection and precision optimization. Temperature changes can affect motor performance, especially in high or low temperature conditions, which can reduce motor efficiency and lifespan.

[0163] The collected raw data will serve as the basis for subsequent calculations and calibrations and will be transmitted to the system's control unit for further processing.

[0164] S2: Preliminary calculations

[0165] After data collection, the preliminary calculation step uses the collected data to make a preliminary estimate of the motor's operating status, particularly speed and torque. This step processes current, voltage, and temperature data and uses specific formulas to estimate the motor's performance parameters.

[0166] Input: Real-time collected current I(t), voltage V(t), and temperature T(t) data;

[0167] Output: Preliminary estimated motor speed ω est and torque τ est ;

[0168] Estimation of motor speed: Estimation of motor torque: τ est =k (t) I(t);

[0169] ω est : Preliminary estimated motor speed; τ est : Preliminary estimated motor torque; ke : Back electromotive force constant of the motor; k (t) : Torque constant of the motor; Φ(t): Magnetic flux of the motor; The speed of the motor is closely related to the voltage and magnetic flux at the motor port.

[0170] The back electromotive force constant k e The relationship between the magnetic flux Φ(t) and the motor speed can be used to estimate the motor speed. The magnetic flux will change under different working conditions, especially affected by temperature; the motor torque is proportional to the motor current, and the current I(t) is proportional to the torque τ generated by the motor. est There is a direct relationship between the torque constant k of the motor. (t) , the motor's output torque can be estimated. In this step, the system uses the above formula to perform a preliminary motor state estimate based on real-time monitored current, voltage, and temperature data. The core of this step is to convert the collected raw data into useful motor performance indicators (speed and torque). These preliminary results provide a reference for subsequent accuracy optimization and error correction.

[0171] After completing the initial calculation, the motor's operating state (speed and torque) is estimated. These preliminary results serve as input data for subsequent calibration and optimization. The calibration process further processes these preliminary estimates to provide more accurate motor operating control parameters.

[0172] Input: Preliminary estimate of the motor's operating state, including the speed ω est and torque τ est ;

[0173] Output: Preliminary calibration results.

[0174] S4: Error Correction

[0175] Temperature significantly affects motor performance, particularly speed and torque. Because a motor's magnetic flux is temperature-dependent, temperature changes directly impact its performance parameters. Therefore, temperature correction is a crucial step in motor control systems.

[0176] Input: Preliminary estimated speed ω est , torque τ est .

[0177] Output: Corrected speed ω corr and torque τ corr .

[0178] Speed ​​correction formula: ω corr =ω est ·(1+α·(T env -T0)),ω corr : Corrected speed; τ corr: Corrected torque; α, β: Temperature sensitivity coefficient, indicating the response of the motor torque to temperature changes; T env : external ambient temperature; T0: reference temperature;

[0179] Torque correction formula: τ corr =τ est ·(1+β·(T env -T0);

[0180] Speed ​​correction: The speed of the motor is directly related to the temperature. The temperature rise will usually cause the magnetic flux of the motor to change, which in turn affects the speed of the motor. The correction formula corrects the speed by the temperature sensitivity coefficient α. According to the external ambient temperature T env The difference between the reference temperature T0 and the corrected speed ω corr It is closer to the actual operation of the motor in the actual working environment.

[0181] Torque correction:

[0182] Similarly, motor torque is affected by temperature. As temperature changes, the motor's current and magnetic flux characteristics may change, affecting the motor's output torque. The formula uses a temperature sensitivity factor, β, to correct the torque, ensuring that the torque parameter remains consistent with actual operating temperature fluctuations.

[0183] Through this step, the operating state of the motor is adjusted more accurately, enabling it to adapt to temperature changes in different environments and avoid performance degradation or damage caused by excessively high or low temperatures.

[0184] Humidity primarily affects motor performance through torque output. Excessively high humidity can affect the motor's insulation and current conduction characteristics, leading to torque deviations. To address this, we've incorporated a humidity correction mechanism into the error correction step.

[0185] Input: Corrected torque τ corr , output: final corrected torque τ corr-final , formula: τ corr-final =τ corr ·(1-γ·H), τ corr-final : Humidity-corrected torque, τ corr : Torque after temperature correction; γ: Humidity influence coefficient; H: Ambient humidity, normalized to a value between 0 and 1;

[0186] Changes in humidity can affect motor efficiency, especially in high-humidity environments. The motor's insulation performance may degrade, leading to changes in current conduction and, in turn, affecting torque output. Using the humidity correction formula, the system can correct the torque based on the real-time measured humidity H, thereby compensating for torque errors caused by humidity changes. The humidity influence coefficient γ reflects the degree of humidity's impact on the motor's torque. This coefficient is pre-calibrated based on the motor's operating environment and design parameters and is typically determined experimentally. When humidity increases, the motor's torque is negatively affected and appropriately reduced. Using the correction formula, the system can dynamically adjust the torque to ensure the motor can continue to operate smoothly in high-humidity environments.

[0187] S5: Optimization result output

[0188] After completing the error correction (including temperature and humidity correction), the system will generate the final optimization results. These results represent the final control parameters of the motor under the current operating conditions, including the corrected speed and torque. The optimized parameters output in this step will be used for subsequent motor control to ensure efficient operation of the motor under various environmental conditions.

[0189] Input: Corrected speed ω corr , the corrected torque τ corr-final

[0190] Output: optimized motor control parameters (corrected speed, torque);

[0191] Optimization result generation: The final speed and torque values ​​will be provided to the motor control system as optimized motor control parameters for real-time adjustment and control; dynamic adjustment: The system continuously monitors environmental changes and corrects the motor control parameters in real time to ensure that the motor can always maintain optimal performance under different temperature and humidity conditions.

[0192] Comprehensive evaluation and dynamic adjustment of control parameters work together to ensure the motor maintains optimal operating conditions under different environmental conditions. The following is a detailed explanation of each step.

[0193] S1: Comprehensive evaluation In this step, the system performs a weighted combination of the preliminary calibration results and the error-corrected results to generate the final comprehensive performance evaluation index P final , this indicator is used for subsequent control parameter adjustment; Input: Corrected speed ω corr and torque τ corr-final ; Output: Final performance evaluation value P final Formula: P final =ω1·ω corr +ω2·τ corr-final , P final : Final performance evaluation value; ωcorr : Corrected speed; τ corr-final : Corrected torque; ω1 and ω2: Dynamic weights;

[0194] The dynamic weights ω1 and ω2 are calculated using the following formulas. These weights are dynamically adjusted based on temperature changes to reflect the motor's performance under different operating conditions. The dynamic weight adjustment ensures that the system can flexibly adjust the comprehensive evaluation of speed and torque in the case of large temperature changes.

[0195] ω2=1-ω1; ω1: corrected speed weight; ω2: corrected torque weight; k: weight sensitivity adjustment coefficient, used to adjust the effect of temperature on weight calculation; ΔT: temperature difference, calculated as ΔT=T env -T0, where T env : External ambient temperature; T0: Reference temperature (such as the operating temperature or room temperature when the motor is designed);

[0196] ω1 is a weight coefficient related to the speed, which is dynamically adjusted based on the temperature difference ΔT. env When the temperature changes, ω1 and ω2 will automatically adjust according to the adjustment formula to ensure that the weights of speed and torque are appropriately weighted according to the actual working environment; through the exponential function in the formula, the greater the temperature difference ΔT, the more obvious the change of weight coefficients ω1 and ω2, ensuring that the system can make more flexible adjustments in extreme environments; the final performance evaluation value: P final It is a comprehensive performance indicator that combines the corrected speed and torque and weights them according to the dynamic weight; the system uses this performance evaluation value to reflect the overall operating status of the motor, thereby determining subsequent control parameter adjustments.

[0197] S2: Dynamically adjust control parameters

[0198] After obtaining the final comprehensive performance evaluation value P final The system then dynamically adjusts the motor's operating control parameters based on the evaluation results. This step aims to optimize the motor's operating state based on the comprehensive performance evaluation results, ensuring that the motor always operates in optimal working condition.

[0199] Input: Final comprehensive performance evaluation value P final ; Output: Adjusted motor control parameters Control new , formula: Control new =Control old ·(1+δ·P final ); where: Control new : Adjusted control parameters; Control old: initial control parameters; δ: adjustment sensitivity coefficient; through the above formula, the system is based on the final performance evaluation value P final To adjust the motor control parameters. When the comprehensive evaluation value is high (indicating good motor performance), the system will appropriately increase the motor control parameters to enhance performance; conversely, if the performance is poor, the control parameters will be reduced to ensure that the motor operates within a stable and safe operating range;

[0200] The sensitivity coefficient δ in the system is used to adjust the amplitude of the control parameter changes. The larger the sensitivity coefficient, the more sensitive the system is to the performance evaluation results, and the larger the adjustment amplitude of the control parameter. Conversely, the smaller the sensitivity coefficient, the smaller the adjustment amplitude. The sensitivity coefficient can be adjusted according to actual needs through experiments to meet the optimization requirements under different working conditions.

[0201] During operation, the motor's control parameters (such as current, speed, etc.) will change with P final This dynamic adjustment mechanism allows the system to optimize control strategies in real time based on the actual operating state of the motor and changes in the external environment (such as temperature and humidity), thereby improving the system's robustness and adaptability.

[0202] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A motor control system with dual power-on protection function, characterized in that: Includes the following modules: Monitoring module: monitors the motor running status in real time through current sensors, voltage sensors and temperature sensors, and collects battery voltage, current and temperature parameters; Power-on protection module: through the combination of software and hardware, when power-on is detected, it determines whether the start button is accidentally pressed and triggers the power-on protection function; Current sampling and overcurrent protection module: Based on the sampled current data, it determines whether the current exceeds the preset threshold. If it exceeds the threshold and lasts for a set time, the discharge MOS tube is turned off to achieve overcurrent protection; Temperature detection module: detects battery temperature through NTC thermistor and stops working when the temperature exceeds the preset range; Discharge control module: Based on the over-current and over-temperature protection status, it controls the opening and closing of the discharge MOS tube to achieve precise control; Hibernation module: When the system is not in operation, it turns off non-essential peripherals to reduce power consumption and enter hibernation mode; Self-check module: After the system is powered on, it automatically executes the self-check program to determine whether there is any abnormality in the system. If there is any abnormality, the machine will be prevented from starting; Motor calibration and precision optimization module: used to perform preliminary calibration and error correction based on the collected current, voltage, and temperature data, and output accurate motor control parameters according to the corrected data; Error correction and comprehensive evaluation module: Combines external environmental parameters and calibration data to further optimize motor control parameters and outputs the final comprehensive evaluation value.

2. The motor control system with dual power-on protection function according to claim 1, characterized in that: The motor calibration and precision optimization module includes the following steps: S1: Data Collection Based on the sensors of the monitoring module, real-time collection of current, voltage and temperature data; Input: real-time collected current I(t), voltage V(t), and temperature T(t) data; Output: raw sensor data; S2: Preliminary calculations The collected data is preliminarily processed using the following formula to estimate the motor operating status parameters: τ est =k (t) I(t), where ω est : Preliminary estimated motor speed; τ est : Preliminary estimated motor torque; k e : The back electromotive force constant of the motor; k (t) : Torque constant of the motor; Φ(t): Magnetic flux of the motor; S3: Preliminary calibration results generation Input: Preliminary estimate of the motor's operating state, including speed and torque; Output: Preliminary calibration results.

3. The motor control system with dual power-on protection function according to claim 2 is characterized in that: The motor calibration and precision optimization module further includes: S4: Error Correction The preliminary calibration results are corrected in combination with external environmental parameters, including: Correction for temperature: ω corr =ω est ·(1+α·(T env -T0)); τ corr =τ est ·(1+β·(T env -T0); in: ω corr : Corrected speed; τ corr : Corrected torque; α, β: Temperature sensitivity coefficient; T env : External ambient temperature; T0: Reference temperature; Correction for humidity: τ corr-final =τ corr ·(1-γ·H); Where: γ: humidity influence coefficient; H: ambient humidity; S5: Optimize result output Output the corrected motor operating parameters; Output: Optimized motor control parameters.

4. The motor control system with dual power-on protection function according to claim 3 is characterized in that: The error correction and comprehensive evaluation module includes the following steps: S1: Comprehensive evaluation The preliminary calibration results and the corrected results are weighted and combined to generate the final comprehensive performance evaluation index: P final =ω1·ω corr +ω2·τ corr-final , among which: P final : Final performance evaluation value; ω corr : Corrected speed; τ corr-final : Corrected torque ω1 and ω2: dynamic weights; Dynamic weight calculation formula: ω2=1-ω1; Where: ΔT = T env -T0 is the temperature difference; k: weight sensitivity adjustment coefficient; S2: Dynamically adjust control parameters According to the final comprehensive performance evaluation value P final , adjust the motor's operating control parameters: Control new =Control old ·(1+δ·P final ), where: Control new :Adjusted control parameters; Control old : initial control parameter; δ: adjustment sensitivity coefficient.

5. The motor control system with dual power-on protection function according to claim 4, characterized in that: The power-on protection module determines whether there is a power outage by detecting the state of the fok flag. If the power is turned on again after the power is off and the start button is in the pressed state, the power-on protection is triggered, which specifically includes: fok flag detection: The power-on protection module determines whether the system has experienced a power-on event by detecting the fok flag in the circuit; if the motor control system is powered on again after power failure and the start button is still pressed, the system starts the protection mechanism; Power-off and restart judgment: By monitoring the power supply voltage changes and combining the internal flag of the control system to confirm whether it is a normal power-on process, if it is not normal, the protection mechanism will be automatically triggered to prevent accidental startup.

6. The motor control system with dual power-on protection function according to claim 5, characterized in that: The current sampling and overcurrent protection module has different current thresholds according to different torque gear settings, including the first gear, the second gear and the third gear corresponding to different current thresholds and delay judgments, specifically including: Current sampling and threshold setting: In the current sampling and overcurrent protection module, the current threshold is dynamically set according to the motor torque gear; each gear corresponds to a different current threshold and delay judgment; Threshold adjustment: For example, in low torque gear, the current threshold is low and the delay is short; in high torque gear, the current threshold is high, and in order to avoid misoperation, the delay is set longer; through this adjustment, protection can be carried out in time according to the working state and load conditions of the motor; Delay judgment: When the current exceeds the set threshold and lasts longer than the set delay, the overcurrent protection mechanism is immediately triggered, the discharge MOS tube is turned off, and the circuit and motor are protected.

7. The motor control system with dual power-on protection function according to claim 6, characterized in that: The temperature detection module collects temperature data through an NTC thermistor. When the battery temperature is higher than 75°C or lower than -30°C, a protection mechanism is triggered and the battery stops working. Specifically, the protection mechanism includes: NTC thermistor monitoring: The temperature detection module uses NTC thermistor to collect battery temperature in real time; by measuring the change in resistance value of NTC thermistor, the battery temperature can be accurately determined; Temperature range setting: Set the temperature threshold. When the battery temperature exceeds 75°C or is lower than -30°C, the system triggers the protection mechanism to prevent battery damage or short circuit by shutting down the discharge MOS tube and cutting off the circuit. Protection mechanism starts: When the temperature exceeds the standard, a stop signal is sent through the control module, triggering the action of cutting off the current or shutting down the motor to ensure that the battery is within a safe temperature range.

8. The motor control system with dual power-on protection function according to claim 7, characterized in that: The sleep module initializes the chip port before entering sleep mode and sets the interrupt wake-up mode to ensure that it can quickly respond to external trigger signals and resume work in a low-power state, specifically including: Chip port initialization: Before entering the sleep mode, the sleep module initializes the key chip ports in the system to ensure that the system can enter a low-power state; Interrupt wake-up mechanism: configure the system's interrupt function. When an external trigger signal enters, the system will quickly recover from sleep mode and resume working state to ensure rapid response; Low power management: By combining hardware and software, the system's low power state is optimized to ensure that the motor control system can save energy to the maximum extent when not in operation.

9. The motor control system with dual power-on protection function according to claim 8, characterized in that: The discharge control module determines whether to turn on or off the discharge MOS tube according to the overcurrent protection state value overload_flt to prevent the system from continuing to discharge under overcurrent conditions, specifically including: Overcurrent protection status monitoring: The discharge control module monitors the overcurrent protection status value overload_flt in real time to determine whether an overcurrent condition occurs; overload_flt indicates that the current exceeds the safety threshold, and the system determines whether the discharge MOS tube needs to be turned off through this flag bit; Overcurrent protection: If overload_flt is true, it means the current exceeds the limit, and the system will automatically control the discharge MOS tube to turn off to prevent the current from being too high and causing circuit damage or battery overheating; Circuit protection: This protection mechanism can prevent damage to the battery or motor in a short period of time and ensure the safe operation of the motor control system.

10. The motor control system with dual power-on protection function according to claim 9, characterized in that: The self-test module performs functions including short circuit detection, soft start function detection and timer interrupt detection, specifically including: Short circuit detection: By real-time monitoring of the current and voltage status of the circuit, determine whether a short circuit fault has occurred. If the current increases abnormally or the voltage fluctuates greatly, the system determines that a short circuit may have occurred, stops the motor operation in time and triggers protection; Soft start function detection: When the motor starts, the current changes during the starting process are monitored to determine whether the motor can start smoothly; if it is detected that the current is too large or the speed cannot change as expected during the starting process, the starting process is terminated immediately to prevent motor damage; Timer interrupt detection: The threshold time is set by the timer to ensure that the system completes the startup process within the preset time. If the motor startup or other critical processes are not completed within the specified time, the system triggers an interrupt signal through the timer to stop the startup or perform other protection measures.

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