Integrated motor controller for aviation

Abstract

The invention provides an integrated motor controller for aviation, which belongs to the field of motor controllers, and comprises a main control module, three motor driving modules, a power supply module, a bus module and a position module, the power supply module and the three motor driving modules are respectively fixed on the side surface in the controller shell and are circumferentially distributed by taking the axis of the shell as the center, the main control module and the bus module are respectively and fixedly arranged at two ends of the motor driving modules and the power supply module, and the main control module is connected with the three motor driving modules and the power supply module through plug connectors. The bus module is connected with the three motor driving modules through screw terminals. The position module is fixedly arranged at the front end of a motor shaft and is coaxial with the motor shaft. The position module outputs pulse signals and communicates with the main control module, motor position information and rotating speed information are transmitted to the main control module, the main control module processes and calculates the motor position information and the rotating speed information to control the rotating speed and the position of the motor so as to generate driving signals, and three-phase control over the motor is achieved.

Description

Technical Field

[0001] The present application belongs to the technical field of motor controllers, and in particular, relates to an integrated motor controller for aviation. Background Art

[0002] In order to further improve the energy conversion efficiency of aircraft power systems and reduce fuel consumption and emissions, electric propulsion technology has become an important development direction for the electrification of aircraft power systems. The driving force of the electric propulsion system comes from the high-efficiency and high-power-to-weight ratio drive motor. To achieve the control of the motor, there must be a corresponding control and power conversion unit. Therefore, an efficient and high-power-to-weight ratio motor controller is very critical to the electric propulsion system.

[0003] Most current motors adopt the solution of separating the control driver from the motor body. This will inevitably lead to an increase in the length and volume of the power cable, control cable, and communication cable leads in some complex electromechanical control systems, resulting in low power-to-weight ratio, complex wiring, poor anti-interference ability, and other problems. Therefore, the use of a modular integrated electric drive system is an ideal choice, which can reduce system complexity and improve energy utilization and reliability. Therefore, a lightweight integrated electric drive system or control solution is needed. Summary of the invention

[0004] The purpose of the present application is to provide an integrated motor controller for aviation to solve or alleviate at least one problem in the background technology.

[0005] The technical solution of the present application is: an integrated motor controller for aviation, comprising: a main control module, three motor drive modules, a power module, a bus module and a position module, wherein the power module and the three motor drive modules are respectively fixed on the side surfaces inside the controller housing and are circumferentially distributed with the housing axis as the center, the main control module and the bus module are respectively fixedly arranged at both ends of the motor drive module and the power module, the main control module is connected to the three motor drive modules and the power module through a connector, the bus module is connected to the three motor drive modules through a screw terminal, and the position module is fixedly arranged at the front end of the motor shaft and is coaxially arranged with the motor shaft;

[0006] The position module outputs a pulse signal and communicates with the main control module, and transmits the motor position information and speed information to the main control module. The main control module generates a drive signal by processing the motor position information and speed information and calculating the speed of the motor, and controls the three phases of the motor by controlling the switching frequency and commutation timing of the motor drive circuit.

[0007] Preferably, the main control module includes a main control chip, a CAN bus communication circuit, a current and voltage sampling circuit, a temperature detection circuit, a logic circuit, a first voltage conversion circuit, a level conversion circuit and a driving power control circuit, and the main control chip is connected to the CAN bus communication circuit, the current and voltage sampling circuit, the temperature detection circuit, the logic circuit, the first voltage conversion circuit, the level conversion circuit and the driving power control circuit;

[0008] The main control chip is used to generate a PWM drive signal for the drive motor, realize CAN bus communication control, signal acquisition, conversion and processing of current and voltage sampling circuits and temperature detection circuits, capture and calculation of pulse signals of the position module, motor control current loop, speed loop closed-loop vector control calculation and motor vector control algorithm, coordinate transformation, PWM drive signal duty cycle calculation, drive fault signal recognition and drive signal wave sealing processing, and fault indicator light IO port control;

[0009] The CAN bus communication circuit is used to communicate with the host computer to monitor and control the main control chip;

[0010] The current and voltage sampling circuit is used to collect the three-phase current or bus voltage of the motor;

[0011] The temperature detection circuit is used to collect the motor temperature;

[0012] The logic circuit is used to perform a logic AND operation on the fault of the driving tube to generate a power half-bridge protection signal;

[0013] The first voltage conversion circuit is used to convert the second specification power supply into the first specification power supply for supplying power to the main control chip;

[0014] The level conversion circuit is used to convert the low level of the PWM drive signal into a high level;

[0015] The driving power supply control circuit is used to supply power to the driving module and perform on-off control. When a fault occurs, the power supply of the driving module is directly cut off.

[0016] Preferably, the main control chip has a plurality of pins that can be reused as advanced timer functions, and the pins of the advanced timer functions are respectively connected to corresponding pins of the single-channel motor drive module, thereby generating multi-channel complementary PWM drive signals.

[0017] Preferably, the motor drive module includes a second voltage conversion circuit, a MOSFET and a MOSFET drive circuit and a current sensor, wherein the second voltage conversion circuit is used to convert a fourth specification power supply into a third specification power supply in which the MOSFET is turned on; the MOSFET and the MOSFET drive circuit control the on-off of the MOSFET according to the PWM drive signal issued by the main control chip to drive the motor to rotate; the current sensor is used to measure the magnitude of the motor phase current.

[0018] Preferably, the motor driving module drives the conduction time of the single-channel MOS tube of the motor according to the high and low level changes of the PWM driving signal sent by the main control chip.

[0019] Preferably, the power supply module includes a third voltage conversion circuit, and the third voltage conversion circuit is used to convert the fifth specification power supply into a fourth specification power supply for powering the motor drive module and into a second specification power supply for powering the main control module.

[0020] Preferably, the bus module includes a DC bus capacitor and a bus voltage-dividing resistor, the DC bus capacitor is a supporting capacitor, and the bus voltage-dividing resistor is used for sampling the bus voltage. The DC bus voltage is input through the bus module, and the bus voltage is provided to three motor drive modules through screw terminals to generate motor drive voltage to supply the motor.

[0021] Preferably, the position module comprises a magnetic encoder, which is located at the exact center of the position module and coaxial with the motor shaft. The position module is connected to the main control module via a shielded wire passing through a busbar module.

[0022] The integrated motor controller for aviation provided by the present application has a reasonable controller structure layout, compact structure, strong and weak electrical isolation, and DC and AC physical isolation, which can further improve the stability and safety of the controller; at the same time, the drive system greatly shortens the three-phase line from the driver to the motor and the signal line from the encoder to the controller, so that the system can be simplified. In addition, the motor controller of the present application is not affected by reflected waves, has strong anti-interference ability, high reliability, and miniaturized volume and mass, which improves the power density of the entire system and reduces material costs and maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solution provided by the present application, the following is a brief introduction to the accompanying drawings. Obviously, the accompanying drawings described below are only some embodiments of the present application.

[0024] Figure 1 This is a general schematic diagram of the integrated motor controller for aviation use in this application.

[0025] Figure 2This is a bottom view of the integrated motor controller for aviation use of the present application.

[0026] Figure 3 This is the functional block diagram of the main control chip of this application.

[0027] Figure 4 This is a schematic diagram of the main control chip of this application.

[0028] Reference numerals:

[0029] 11- Main control module

[0030] 12-Motor drive module

[0031] 13-Power module

[0032] 14-Bus module

[0033] 15-Location Module DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the implementation of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below in conjunction with the drawings in the embodiments of this application.

[0035] The present application proposes an integrated motor controller for aviation to reduce the volume and weight and further improve the power-to-weight ratio of this type of motor controller. The motor controller provided in the present application adopts a modular design. The controller has a compact structure and is easy to maintain, and can meet the driving requirements of different small electric aircraft for electric propulsion.

[0036] like Figure 1 and Figure 2As shown, the integrated motor controller for aviation provided by the present application includes: a main control module 11, three motor drive modules 12, a power module 13, a bus module 14 and a position module 15, wherein the power module 13 and the three motor drive modules 12 are respectively fixed on the side heat dissipation plates inside the shell and are circumferentially distributed with the shell axis as the center, the main control module 11 and the bus module 14 are respectively fixed at the two ends of the motor drive module 12 and the power module 13, the main control module 11 is connected to the three motor drive modules 12 and the power module 13 through a connector, the bus module 14 is connected to the three motor drive modules 12 through a screw terminal, and the position module 15 is fixedly arranged at the front end of the motor shaft, and is connected to the main control module 11 through a shielded wire passing through the bus module 14. The position module 15 uses a magnetic encoder to output ABZ pulse signals to communicate with the main control module 11, and transmits the motor position information and speed information to the main control module 11. The main control module 11 controls the speed and position of the motor by processing and calculating the motor position information and speed information. The main control module 11 controls the switching frequency and commutation timing of the motor drive circuit 12, thereby generating a drive signal, controlling the ABC three phases of the motor, and then driving the motor to rotate.

[0037] The present application integrates the main control module 11, the motor drive module 12, the power module 13, the bus module 14 and the position module 15 into a compact shell space through connectors and screws, and adopts a series integrated structure to connect the motor and the motor controller, so that the A, B, and C three-phase output cables of the motor controller become extremely short, greatly reducing the number of wirings, and at the same time isolating the strong current from the weak current, solving the shortcomings of multiple drive and control wiring outputs and severe electromagnetic interference.

[0038] It should be noted that the main control module 11, the motor drive module 12, the power module 13, the bus module 14 and the position module 15 in the present application are usually constituted in the form of chips and integrated circuits. The following content of the present application will further explain the main control module 11, the motor drive module 12, the power module 13, the bus module 14 and the position module 15.

[0039] The main control module 11 mainly includes a main control chip, a CAN bus communication circuit, a current and voltage sampling circuit, a temperature detection circuit, a logic circuit, a first voltage conversion circuit, a level conversion circuit and a drive power control circuit. The main control chip is connected to the CAN bus communication circuit, the current and voltage sampling circuit, the temperature detection circuit, the logic circuit, the first voltage conversion circuit, the level conversion circuit and the drive power control circuit.

[0040] Among them, the CAN bus communication circuit is used to communicate with the host computer to monitor and control the main control chip. The current and voltage sampling circuit is used to collect the motor bus current or voltage. The temperature detection circuit is used to collect the motor temperature. The logic circuit is used to perform logical AND operations on the faults of the driver tube to generate a power half-bridge protection signal.

[0041] The first voltage conversion circuit is used to convert the DC 5V power supply into 3.3V to supply power to the main control chip, magnetic encoder and other chips; the level conversion circuit is used to convert the 3.3V level of the PWM drive signal into a 5V level. For example, in this embodiment of the present application, the chip used to convert the DC 5V into 3.3V in the first voltage conversion circuit is the TPS75233QPWPR chip, and the chip used to convert the 3.3V level of the PWM drive signal into a 5V level in the level conversion circuit is the SN74LVC8T245QPWRQ1 chip.

[0042] The driving power supply control circuit is used to supply power to the MOSFET driver in the power driving module 12 and perform on-off control. When a fault occurs, the MOSFET driving power supply is directly cut off.

[0043] like Figure 3 The main control chip in this application is shown as a functional block diagram. The main control chip is used to generate a PWM drive signal for driving the motor, realize CAN bus communication control, signal acquisition, conversion and processing of the current and voltage sampling circuit and the temperature detection circuit, capture and calculate the pulse signal of the magnetic encoder, perform motor control current loop, speed loop closed-loop vector control calculation and motor vector control algorithm, coordinate transformation, PWM drive signal duty cycle calculation, drive fault signal recognition and drive signal wave sealing processing, fault indicator light IO port control, and motor control parameter Flash storage.

[0044] The main control chip determines the switching frequency and commutation timing of the motor drive circuit 12 , and performs speed control and position control through the position information and speed information fed back by the magnetic encoder in the position module 15 .

[0045] like Figure 4The main control chip circuit diagram in this embodiment of the present application is shown. The main control chip uses TMS320F28035. The clock frequency of the chip can reach 60MHz, the instruction cycle is 16.67ns, and it is powered by a single 3.3V power supply. Up to 45 multiplexed general IO pins can meet the complex input and output states and control signal requirements of this system. For example, in this embodiment of the present application, pins 69, 67, 63 and pins 68, 66, 62 of the main control chip can be multiplexed as pins for advanced timer functions, thereby generating 6 complementary PWM drive signals, which are respectively connected to the pins of the single-channel motor drive chip. The current value is obtained through the current sensor, the position information can be obtained and converted into speed information through the magnetic encoder, and the duty cycle of the PWM drive signal in each control cycle can be calculated through the target speed set by the host computer, combined with the current loop, the speed loop and according to the vector control algorithm. The main control chip generates multiple complementary PWM drive signals and sends them to the motor drive module 12. According to the high and low level changes of the PWM drive signal, the conduction time of each phase of the motor ABC is driven to realize speed regulation, commutation, start and stop and other functions.

[0046] The main control chip in this embodiment of the present application integrates a wealth of peripherals. 16 12-bit ADC analog-to-digital conversion peripherals can be used to measure phase current, bus voltage, temperature and other data. The timer can be used to generate 6-way PWM waveforms to drive the motor driver chip. The eQEP module can be used to capture the ABZ pulse signal emitted by the position detection magnetic encoder and then convert it to obtain the rotation angle value.

[0047] The motor drive module 12 mainly includes a second voltage conversion circuit, a MOSFET and a MOSFET drive circuit and a current sensor. The second voltage conversion circuit is used to convert a 24V power supply into an 18V power supply for the MOSFET to conduct. The motor drive module 12 drives the conduction time of the motor single-channel MOS tube according to the high and low level changes of the PWM drive signal. Furthermore, the motor drive module 12 controls the three phases of the motor ABC according to the PWM drive signal sent by the main control chip to drive the motor to rotate.

[0048] In this embodiment of the present application, the MOSFET driver chip adopts the SiC driver chip SIC1182K, which adopts a single-channel SiC MOSFET gate driver in an eSOP-R16B package, and its peak output drive current can reach ±8A, which can directly drive a switch device below 600A (typical value). After the multi-channel PWM drive signal generated by the main control chip is converted by the level conversion circuit, multiple SiC MOSFET gate drivers are controlled respectively, so that the current flows through the motor in sequence to generate a forward or reverse rotating magnetic field, and interacts with the permanent magnet of the rotor to rotate the motor. For example, in this embodiment of the present application, the SiC MOSFET device C3M0016120K is used in parallel in the motor drive module 12 to form a three-phase full bridge.

[0049] The power module 13 mainly includes a third voltage conversion circuit, which is used to convert a DC 28V power supply into 24V for supplying power to the motor drive module 12 and into 5V for supplying power to the main control module 11 .

[0050] The bus module 14 mainly includes a DC bus capacitor and a bus voltage divider resistor. The DC bus capacitor is a supporting capacitor, and the bus voltage divider resistor is mainly used for sampling the bus voltage. The DC bus voltage is input through the bus module 14, and the bus voltage is provided to the three motor drive modules through the screw terminals to generate a motor drive voltage to supply the motor.

[0051] The position module 15 is mainly a magnetic encoder, which is located at the center of the position module 15 and is coaxial with the motor shaft. In this embodiment of the present application, the magnetic encoder uses the MT6825 chip, which converts the mechanical geometric displacement on the output shaft into a pulse quantity through photoelectric conversion, and can accurately measure the angle range of 0 to 360°. In order to ensure the reliability of signal transmission, the A, B, and Z pulse signals output by the magnetic encoder are input into the main control chip through a two-stage LVDS (Low Voltage Differential Signaling) conversion circuit for calculation, so that the main control chip can obtain accurate angle information and rotation direction, and then calculate the motor speed, and finally control the motor rotation.

[0052] The integrated motor controller for aviation provided in this application has a reasonable controller structure layout, compact structure, strong and weak electrical isolation, and DC and AC physical isolation, which can further improve the stability and safety of the controller; at the same time, the drive system greatly shortens the three-phase line from the driver to the motor and the signal line from the encoder to the controller, so that the system can be simplified. In addition, the motor controller of this application is not affected by reflected waves, has strong anti-interference ability, high reliability, and miniaturized volume and mass, which improves the power density of the entire system, reduces material costs and maintenance costs, and can be applied to fields with strictly controlled volume and mass and high anti-interference requirements.

[0053] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be based on the protection scope of the claims.

Claims

1. An integrated motor controller for aviation, characterized in that: include: A main control module, three motor drive modules, a power module, a bus module and a position module, wherein the power module and the three motor drive modules are respectively fixed on the side surfaces inside the controller housing and are circumferentially distributed with the housing axis as the center, the main control module and the bus module are respectively fixedly arranged at both ends of the motor drive module and the power module, the main control module is connected to the three motor drive modules and the power module through a connector, the bus module is connected to the three motor drive modules through a screw terminal, and the position module is fixedly arranged at the front end of the motor shaft and is coaxially arranged with the motor shaft; The position module outputs a pulse signal and communicates with the main control module, and transmits the motor position information and speed information to the main control module. The main control module generates a drive signal by processing the motor position information and speed information and calculating the speed of the motor, and controls the three phases of the motor by controlling the switching frequency and commutation timing of the motor drive circuit.

2. The integrated motor controller for aviation according to claim 1, characterized in that: The main control module includes a main control chip, a CAN bus communication circuit, a current and voltage sampling circuit, a temperature detection circuit, a logic circuit, a first voltage conversion circuit, a level conversion circuit and a driving power control circuit, and the main control chip is connected to the CAN bus communication circuit, the current and voltage sampling circuit, the temperature detection circuit, the logic circuit, the first voltage conversion circuit, the level conversion circuit and the driving power control circuit; The main control chip is used to generate a PWM drive signal for the drive motor, realize CAN bus communication control, signal acquisition, conversion and processing of current and voltage sampling circuits and temperature detection circuits, capture and calculation of pulse signals of the position module, motor control current loop, speed loop closed-loop vector control calculation and motor vector control algorithm, coordinate transformation, PWM drive signal duty cycle calculation, drive fault signal recognition and drive signal wave sealing processing, and fault indicator light IO port control; The CAN bus communication circuit is used to communicate with the host computer to monitor and control the main control chip; The current and voltage sampling circuit is used to collect the three-phase current or bus voltage of the motor; The temperature detection circuit is used to collect the motor temperature; The logic circuit is used to perform a logic AND operation on the fault of the driving tube to generate a power half-bridge protection signal; The first voltage conversion circuit is used to convert the second specification power supply into the first specification power supply for supplying power to the main control chip; The level conversion circuit is used to convert the low level of the PWM drive signal into a high level; The driving power supply control circuit is used to supply power to the driving module and perform on-off control. When a fault occurs, the driving module power supply is directly cut off.

3. The integrated motor controller for aviation according to claim 2, characterized in that: The main control chip has a plurality of pins that can be reused as advanced timer functions, and the pins of the advanced timer functions are respectively connected to corresponding pins of the single-channel motor drive module, thereby generating multi-channel complementary PWM drive signals.

4. The integrated motor controller for aviation according to claim 3, characterized in that: The motor drive module includes a second voltage conversion circuit, a MOSFET and a MOSFET drive circuit, and a current sensor. The second voltage conversion circuit is used to convert a fourth-specification power supply into a third-specification power supply that turns on the MOSFET; the MOSFET and the MOSFET drive circuit control the on-off of the MOSFET according to the PWM drive signal sent by the main control chip to drive the motor to rotate; the current sensor is used to measure the magnitude of the motor phase current.

5. The integrated motor controller for aviation according to claim 4, characterized in that: The motor driving module drives the conduction time of the single-channel MOS tube of the motor according to the high and low level changes of the PWM driving signal sent by the main control chip.

6. The integrated motor controller for aviation according to claim 5, characterized in that: The power supply module includes a third voltage conversion circuit, which is used to convert the fifth specification power supply into a fourth specification power supply for supplying power to the motor drive module and into a second specification power supply for supplying power to the main control module.

7. The integrated motor controller for aviation according to claim 6, characterized in that: The bus module includes a DC bus capacitor and a bus voltage-dividing resistor, wherein the DC bus capacitor is a supporting capacitor and the bus voltage-dividing resistor is used for sampling the bus voltage. The DC bus voltage is input through the bus module, and the bus voltage is provided to three motor drive modules through screw terminals to generate motor drive voltage to supply the motor.

8. The integrated motor controller for aviation according to claim 7, characterized in that: The position module comprises a magnetic encoder, which is located at the exact center of the position module and is coaxial with the motor shaft. The position module is connected to the main control module via a shielded line passing through a busbar module.

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