An electric rotating machine and its control system

Abstract

The present invention belongs to the technical field of equipment control, and specifically discloses an electric rotary machine and its control system. The electric rotary machine includes a rotary machine housing and an internal structure of the rotary machine. The internal structure of the rotary machine includes an outer ring of a precision ball shafting, a motor stator, a PCB control board, an encoder disk, a first connecting plate and a second connecting plate, steel balls, an inner ring of the precision ball shafting, a moving ring of a slip ring, and a stationary ring of the slip ring. Through the coordinated action of multi-layer connection and the precision ball shafting, the electric rotary machine of the present invention reduces vibration, displacement, and ensures the coaxiality and balance of rotating components, which is beneficial to the reliable operation of the motor and the improvement of precision in related application scenarios. At the same time, the encoder disk can accurately feedback position and speed information based on the precision ball shafting, and the moving ring of the slip ring and the stationary ring of the slip ring rely on the stable contact of the precision ball shafting to ensure reliable signal transmission, optimizing signal detection and transmission, and achieving good space utilization and compactness.

Description

Technical Field

[0001] The present invention belongs to the technical field of equipment control, and more particularly, relates to an electric rotating machine and its control system. Background Art

[0002] With the booming development of the manufacturing industry, the demand for power sources is increasing day by day. Electric rotating machines, with their high efficiency and cleanliness, have become the main power equipment in factory workshops. To ensure the stability of power supply, it is necessary to control their operation.

[0003] The prior art, such as the control method, control device, and rotating motor drive system disclosed in the Chinese patent application with the application number 201780045061.1, includes: a power module that outputs three-phase AC power for driving a rotating motor by turning on and off semiconductor switching elements; a drive circuit that generates PWM gate pulses for turning on and off the semiconductor switching elements; and an arithmetic control device that generates a gate drive signal using PWM with a specified carrier frequency. The gate drive signal is used to instruct the drive circuit to generate PWM gate pulses. The arithmetic control device determines whether the vibration frequency of the natural mode with a spatial order of 0 of the rotating motor overlaps with the frequency component of the electromagnetic exciting force that can generate this natural mode. If it is determined that they overlap, the value of the carrier frequency is switched from a first value to a second value different from the first value, thereby preventing the vibration frequency of the natural mode with a spatial order of 0 of the rotating motor from overlapping with the frequency component of the electromagnetic exciting force that can generate this natural mode, and thus being able to reliably suppress the vibration of the motor.

[0004] The prior art, such as the permanent magnet electric rotating machine disclosed in the Chinese patent application with the application number 201811216099.3, includes: a plurality of phase windings arranged in a plurality of slots around the circumference of the motor such that the phase windings in each phase are complementary and do not cancel each other out when excited by a single excitation current; a plurality of permanent magnets; a control system including: a power supply for transmitting a controlled amount of current to or from the rotating motor; and a commutation circuit for controlling the timing and duration of the square wave current transmitted to or from each phase winding. The commutation feedback loop includes a filter for filtering the sensed back EMF, and the filter introduces a phase shift to the sensed back EMF to synchronize the current pulses and the angular position signal. And the commutation circuit operates independently of the power supply.

[0005] For the above technical solutions, obviously, the current control of electric rotary machines mainly involves the control of various links in the process of electric energy conversion, and there are still the following deficiencies: 1. The above solutions consider relatively single elements in the control of electric rotary machines. In actual operation scenarios, it not only involves current but also temperature, rotor position, etc. At present, the actual control effect cannot be guaranteed, and there are also other interference hazards.

[0006] 2. The above solutions do not consider the rotational speed accuracy problem of electric rotary machines, nor do they mention how to compensate for rotational speed fluctuations and do not involve fine control of rotational speed accuracy, thus affecting the control accuracy. Summary of the Invention

[0007] In view of this, to solve the problems raised in the above background technology, a kind of electric rotary machine and its control system are proposed.

[0008] The object of the present invention can be achieved by the following technical solutions: In the first aspect of the present invention, an electric rotary machine is provided, which includes a rotary machine housing and an internal structure of the rotary machine.

[0009] The internal structure of the rotary machine includes an outer ring of a precision ball bearing system, a motor stator, a PCB control board, an encoder disk, a first connecting plate and a second connecting plate, steel balls, an inner ring of the precision ball bearing system, a moving ring of a slip ring and a fixed ring of the slip ring.

[0010] A first connecting plate is arranged at the side end of the motor stator, and a second connecting plate is arranged at the lower side end. The lower end of the first connecting plate is fixedly connected to the upper end of the inner ring of the precision ball bearing system.

[0011] The inner part of the motor stator is rotatably provided with an outer ring of the precision ball bearing system. An encoder disk is pasted on the upper side end of the outer ring of the precision ball bearing system, and a moving ring of the slip ring is installed on the lower side end.

[0012] The inner part of the outer ring of the precision ball bearing system is rotatably provided with an inner ring of the precision ball bearing system, and steel balls are arranged between the inner ring and the outer ring of the precision ball bearing system.

[0013] In the second aspect of the present invention, a control system for an electric rotary machine is provided. The system includes: a device information monitoring module, which is used to, when the electric rotary machine starts, monitor the operation data of the electric rotary machine in real time, including current, temperature and signal data.

[0014] A rotor information receiving module, which is used to receive the rotor position information, rotational speed information and contact information of the electric rotary machine fed back by the encoder disk.

[0015] A motor operation analysis module, which is used to judge whether there is an abnormality in the current electric rotary machine according to the operation data of the electric rotary machine and the rotor position information and rotational speed information of the electric rotary machine fed back in real time, and when there is an abnormality, identify the abnormal item and the processing information of the abnormal item.

[0016] A conductive ring status analysis module, which is used to judge whether there is an abnormality in the conductive ring status based on the signal data and contact information, and if there is an abnormality, confirm the abnormal handling index of the conductive ring.

[0017] An information database, which is used to store the speed regulation tracking log of the electric rotating machine.

[0018] An equipment comprehensive control terminal, which is used to start corresponding components for processing based on the abnormal items, the processing information of the abnormal items, and the abnormal handling index of the conductive ring.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) Through the synergistic effect of multi-layer connection and precision ball bearing system, the present invention reduces vibration, displacement, and ensures the coaxiality and balance of rotating components, which is beneficial to the reliable operation of the motor and improves the precision in related application scenarios. At the same time, the encoder disk can accurately feedback position and speed information based on the precision ball bearing system, and the moving ring and fixed ring of the conductive ring rely on the stable contact of the precision ball bearing system to ensure reliable signal transmission, optimizing signal detection and transmission. Moreover, each component is integrated and cooperates with each other, reducing space waste, meeting the usage occasions with strict requirements on the equipment volume, and achieving good space utilization and compactness.

[0020] (2) By judging whether there is an abnormality in the current electric rotating machine from four aspects: current, temperature, rotor position, and rotor speed, the present invention can more systematically evaluate the operating condition of the electric rotating machine, solve the problem of relatively single consideration factors in the current control of the electric rotating machine, can more timely and accurately detect various abnormal conditions in the operation of the motor, provide a strong guarantee for the subsequent actual control effect, and further avoid other interference hazards.

[0021] (3) By identifying the abnormal items and the processing information of the abnormal items of the current electric rotating machine, the present invention can timely discover potential problems of the equipment, and then facilitate timely handling of these abnormalities, which can avoid sudden failures of the equipment during operation, thereby improving the overall reliability of the equipment.

[0022] (4) When the abnormal item is the rotor position or rotor speed abnormality, by statistically analyzing the speed adjustment deviation degree and setting a speed adjustment factor, and then calculating and adjusting the rotor speed, the present invention further ensures the speed accuracy of the electric rotating machine, makes up for the deficiencies in the current description of how to compensate for speed fluctuations and the lack of fine control of speed accuracy, and further guarantees the speed stability of the subsequent electric rotating machine. Description of the Drawings

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the accompanying drawings required for the description of the embodiments. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other accompanying drawings can be obtained based on these drawings.

[0024] Figure 1 It is a schematic diagram of the overall composition of the electric rotary machine of the present invention.

[0025] Figure 2 It is a schematic diagram of the internal structure of the electric rotary machine of the present invention.

[0026] Figure 3 It is a schematic diagram of the connection of the system modules of the present invention.

[0027] Figure 4 It is a schematic diagram of the overall control flow of the present invention.

[0028] Description of the drawings: 1. Outer ring of the precision ball bearing shafting, 2. Motor stator, 3. PCB control board, 4. Encoder disk, 5. First connecting plate, 6. Steel ball, 7. Inner ring of the precision ball bearing shafting, 8. Moving ring of the slip ring, 9. Fixed ring of the slip ring, 10. Second connecting plate. Detailed implementation manners

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, rather than all, embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention.

[0030] Please refer to Figure 1 and Figure 2 As shown, the first aspect of the present invention provides an electric rotary machine, including: a rotary machine housing and an internal structure of the rotary machine.

[0031] The internal structure of the rotary machine includes an outer ring 1 of the precision ball bearing shafting, a motor stator 2, a PCB control board 3, an encoder disk 4, a first connecting plate 5 and a second connecting plate 10, a steel ball 6, an inner ring 7 of the precision ball bearing shafting, a moving ring 8 of the slip ring and a fixed ring 9 of the slip ring.

[0032] A first connecting plate 5 is provided at the side end of the motor stator 2, and a second connecting plate 10 is provided at the lower side end. The lower end of the first connecting plate 5 is fixedly connected to the upper end of the inner ring 7 of the precision ball bearing shafting.

[0033] The outer ring 1 of the precision ball bearing shafting is rotatably arranged inside the motor stator 2. An encoder disk 4 is pasted on the upper side end of the outer ring 1 of the precision ball bearing shafting, and a moving ring 8 of the slip ring is installed on the lower side end.

[0034] A precision ball shafting outer ring 1 is rotatably arranged inside with a precision ball shafting inner ring 7, and steel balls 6 are arranged between the precision ball shafting inner ring 7 and the precision ball shafting outer ring 1.

[0035] It should be added that the shafting adopts precision ball bearings. The original structure of two bearings plus inner and outer housings is simplified into a structure composed of a precision ball shafting inner ring 7, six steel balls, a motor rotor, and a precision ball shafting outer ring, with a simple and compact structure.

[0036] In a specific embodiment, the precision ball shafting outer ring or the precision ball shafting inner ring can be defined according to different requirements. Among them, both the precision ball shafting outer ring and the precision ball shafting inner ring can be set as the motor stator or the motor rotor, and the two are organically combined together, saving a large amount of space. In addition, the shafting of the encoder is also cancelled. A code disk is pasted on one end face of the motor rotor, and the moving ring of the slip ring is installed on the other end face. The corresponding PCB circuit board is installed on the end face of the stator. The corresponding circuits of the encoder, the motor control circuit, the motor drive circuit, and the fixed ring of the slip ring are installed on the PCB circuit board, so that it truly becomes a rotating component integrating electrical control, signal transmission, and power transmission.

[0037] Exemplarily, if the application scenario of the electric rotating machine has strict restrictions on the overall size and it is necessary to minimize the axial length as much as possible, then the motor stator can be designed as the outer ring of the precision ball shafting. For example, in some small precision instrument devices, such as the micro rotating motor in portable medical equipment, setting the stator as the outer ring and the rotor as the inner ring can make the overall axial size of the motor more compact. Because this layout allows other components such as the encoder code disk and the slip ring to be more closely arranged around the rotor, reducing the axial space occupation and facilitating installation and layout in a limited space. Another example is when the electric rotating machine needs to be installed in some devices with irregular shapes or special installation direction requirements. Determine the relationship between the stator and the rotor and the inner and outer rings of the precision ball shafting according to the installation position and direction. For example, in the electric power steering system of an automobile, the installation space of the motor may be restricted by the vehicle chassis structure and other components. If the installation position requires the output shaft direction of the motor to be perpendicular to a specific plane, then according to this installation direction, the part that can better adapt to the installation requirements, that is, the stator or the rotor, can be defined as the outer ring or the inner ring of the precision ball shafting to facilitate connection and transmission with other mechanical components.

[0038] It should be added that when current flows through the motor stator 2, a rotating magnetic field is generated, causing the outer ring 1 of the precision ball bearing system to rotate. When the outer ring 1 of the precision ball bearing system rotates, it drives the encoder disk 4 and the moving ring 8 of the slip ring to rotate, enabling the PCB control board 3 to read the signals of the encoder disk 4 and thus control the rotation position. At the same time, continuous signal power transmission is obtained through the connection between the fixed ring 9 of the slip ring and the moving ring 8 of the slip ring, solving the problem of the three shaft systems of the motor, encoder disk, and slip ring sharing a set of shaft systems, thereby simplifying the structure, improving the precision, and reducing the volume.

[0039] Through the coordinated action of multi-layer connection and the precision ball bearing system, the embodiments of the present invention reduce vibration, displacement, and ensure the coaxiality and balance of rotating components, which is beneficial to the reliable operation of the motor and the improvement of precision in related application scenarios. At the same time, the encoder disk can accurately feedback position and speed information based on the precision ball bearing system, and the moving ring and fixed ring of the slip ring rely on the stable contact of the precision ball bearing system to ensure reliable signal transmission, optimizing signal detection and transmission. Moreover, each component is integrated and cooperates with each other, reducing space waste, meeting the usage occasions with strict requirements for the volume of equipment, and achieving good space utilization and compactness.

[0040] Please refer to Figure 3 and Figure 4 As shown in the figure, the second aspect of the present invention provides an electric rotating machine control system, including: an equipment information monitoring module, a rotor information receiving module, a motor operation analysis module, a slip ring state analysis module, an information library, and an equipment comprehensive control terminal.

[0041] Among them, the motor operation analysis module is respectively connected to the equipment information monitoring module, the rotor information receiving module, the information library, and the equipment comprehensive control terminal, and the slip ring state analysis module is respectively connected to the equipment information monitoring module, the rotor information receiving module, and the equipment comprehensive control terminal.

[0042] The equipment information monitoring module is used to, when the electric rotating machine starts, monitor the operation data of the electric rotating machine in real time, including current, temperature, and signal data.

[0043] It can be understood that during the rotation of the electric rotating machine, continuous and stable transmission of various signals is required between the moving ring 8 and the fixed ring 9 of the slip ring, such as motor control signals including speed control signals, torque control signals, etc. and motor state feedback signals such as position signals, speed signals, temperature signals, etc. Specifically, the signal data includes but is not limited to real-time monitoring signal strength, transmission signal waveform, signal interruption times, and interruption duration at each signal interruption.

[0044] The rotor information receiving module is used to receive the rotor position information, speed information, and contact information of the electric rotating machine fed back by the encoder disk 4.

[0045] Specifically, the contact information includes the real-time contact resistance and real-time contact pressure between the moving ring 8 and the stationary ring 9 of the conductive ring, the rotational speed information is the real-time monitored rotational speed, and the rotor position information is the real-time rotor position within each operating cycle.

[0046] In a specific embodiment, for a synchronous motor, the operating cycle can be calculated based on the synchronous speed and the number of pole pairs of the motor. For an asynchronous motor, although its rotational speed is slightly lower than the synchronous speed, the operating cycle can also be approximately determined based on the rated speed. For example, for an asynchronous motor with a rated speed of 1500 revolutions per minute, its approximate operating cycle is about seconds. Within each determined operating cycle, the rotor position data fed back by the sensor is extracted in chronological order, and these data are the real-time rotor positions within each operating cycle. For example, within an operating cycle of 0.04 seconds, all the rotor position data points from 0 second to 0.04 seconds are extracted from the sensor data.

[0047] It should be added that when the motor starts, the encoder disk 4 can determine the starting state of the motor based on the initial position information, providing a basis for subsequent precise control. During the operation of the motor, the position and rotational speed data of the motor can be continuously updated and transmitted to the rotor information receiving module. For example, in the control of the spindle motor of a numerically controlled machine tool, the high-precision position and rotational speed information provided by the encoder control module can ensure the precise movement of the tool during machining, achieving a high-precision machining effect.

[0048] It should be added that the detection method of the contact resistance can use a special micro-ohmmeter to measure the contact resistance between the conductive rings. The micro-ohmmeter can provide high-precision low-resistance measurement functions and can usually measure resistances at the micro-ohm level. During measurement, connect the test probes of the micro-ohmmeter to the appropriate positions of the moving ring 8 and the stationary ring 9 of the conductive ring to ensure good contact, and then read the measurement result. This method is relatively simple to operate and is suitable for the rapid detection of the contact resistance of conductive rings in general industrial sites.

[0049] Understandably, by monitoring the contact resistance between the moving ring 8 and the stationary ring 9 of the conductive ring, the poor contact condition of the conductive ring can be detected in a timely manner. For example, when the contact resistance gradually increases due to oxidation, wear, or pollutant accumulation on the surface of the conductive ring, the monitoring system can issue an alarm to remind the maintenance personnel to clean, repair, or replace the conductive ring. This can take measures before the conductive ring failure affects the normal operation of the motor, ensuring the stability and reliability of the electrical signal transmission, and improving the overall performance and safety of the electric rotating machine control system.

[0050] It should be added that the real-time rotor position obtains the rotor position information through position sensors such as photoelectric encoders or resolvers installed on the electric rotating machine. These sensors can sample the rotor position at a certain frequency, such as thousands of times per second.

[0051] The motor operation analysis module is used to judge whether there is an abnormality in the current electric rotating machine according to the operation data of the electric rotating machine, as well as the real-time feedback of the rotor position information and speed information of the electric rotating machine, and when there is an abnormality, identify the abnormal item and the processing information of the abnormal item.

[0052] Specifically, judging whether there is an abnormality in the current electric rotating machine includes: A1. Screening out the maximum current from the real-time monitored current of the electric rotating machine, and at the same time calculating the standard deviation of the real-time monitored current of the electric rotating machine to obtain the current fluctuation degree.

[0053] A2. Screening out the highest temperature from the real-time monitored temperature of the electric rotating machine, and at the same time constructing a temperature change curve with time as the abscissa and temperature as the ordinate, and extracting the slope of the temperature change curve as the temperature change rate.

[0054] A3. Extracting the real-time rotor position within each operation cycle from the rotor position information and statistically analyzing the rotor position coincidence degree 。

[0055] A4. Extracting the real-time monitored speed from the speed information and analyzing the rotor speed coincidence degree 。

[0056] A5. Defining that the maximum current exceeds the set safety current or the current fluctuation degree exceeds the set reference current fluctuation degree as condition 1, defining that the highest temperature exceeds the pre-set safe operating temperature or the temperature change rate exceeds the set reference temperature change rate as condition 2, defining that the rotor position coincidence degree is less than the set reference rotor position coincidence degree as condition 3, and defining that the rotor speed coincidence degree is less than the set reference rotor speed coincidence degree as condition 4.

[0057] A6. Judging whether there is a condition that holds among conditions 1, 2, 3 and 4. If there is, taking the existence of an abnormality as the judgment result, otherwise taking the non-existence of an abnormality as the judgment result.

[0058] In the embodiment of the present invention, by judging whether there is an abnormality in the current electric rotating machine from four aspects: current, temperature, rotor position and rotor speed, the operation condition of the electric rotating machine can be evaluated more systematically, solving the problem of relatively single consideration factors in the current control of the electric rotating machine, being able to discover various abnormal situations in the operation of the motor more timely and accurately, providing a strong guarantee for the subsequent actual control effect, and at the same time further avoiding other interference hazards.

[0059] Furthermore, the statistical rotor position consistency in step A3 includes: comparing the real-time rotor position in each operation cycle with the expected position calculated by a preset electric rotating machine operation model; if the deviation angle between the rotor position at a certain time point in a certain operation cycle and the corresponding calculated expected position exceeds a set reference deviation angle, the time point is marked as abnormal.

[0060] The number of abnormal markings in each operation cycle is counted and divided by the total number of time points in each operation cycle. The ratio is recorded as the abnormal marking frequency. The average abnormal marking ratio is calculated by the mean, which is recorded as .

[0061] The rotor position at the same time point in different operation cycles is compared with the expected position calculated at that time point. If the deviation angle between the rotor position at a certain time point and the calculated expected position is lower than the set reference deviation angle, the time point is recorded as a matching time point.

[0062] The number of coincident time points is counted and divided by the total number of time points in the operation cycle to obtain the rotor position coincidence repeatability, which is recorded as .

[0063] Statistical rotor position accuracy , , and They represent the rotor position matching repeatability and abnormal marking ratio of the set reference respectively. is a natural constant.

[0064] In a specific embodiment, the reference rotor position matching repeatability and abnormal marking frequency may be set to 0.8 and 0.6 respectively.

[0065] Furthermore, in step A4, the rotor speed consistency is analyzed, including: comparing the real-time monitored speed with the preset speed, if the difference between the monitored speed and the preset speed at a certain time point exceeds the set speed difference interval, then the time point is recorded as the speed abnormal time point, and the number of speed abnormal time points is counted and recorded as .

[0066] Two adjacent speed abnormal time points are combined into a speed abnormal time period. Each speed abnormal time period is traversed. If the duration corresponding to a speed abnormal time period is within the set reference time window, the speed abnormal time period is recorded as the target time period. The number of target time periods is counted and divided by the total number of speed abnormal time periods. The ratio is recorded as the speed abnormality duration ratio, which is recorded as .

[0067] Calculate the standard deviation of the real-time monitored speed to obtain the speed fluctuation .

[0068] Statistical Rotor Speed Conformity , , 、 and respectively represent the weights corresponding to the number of abnormal speed time points, the abnormal speed duration ratio, and the speed fluctuation degree. 、 and are respectively the number of abnormal speed time points, the abnormal speed duration ratio, and the speed fluctuation degree set as the reference.

[0069] In a specific embodiment, the number of abnormal speed time points is specifically set according to the cumulative monitoring duration. Exemplarily, when the cumulative monitoring duration is half an hour, the number of abnormal speed time points can take a value of 3.

[0070] In another specific embodiment, the abnormal speed duration ratio can take a value of 0.3, the speed fluctuation degree can take a value of 10 revolutions per minute, and the number of abnormal time points intuitively reflects the frequency of the speed not meeting expectations. If there are many abnormal time points, even if the duration of each abnormality is short, it will have a greater impact on the overall conformity. For example, in a monitoring cycle, if there are more time points with abnormal speed, it indicates poor stability of the motor speed, and this part of the weight is relatively high. Exemplarily, can take a value of 0.45. The abnormal speed duration ratio reflects the proportion of the abnormal state duration in the total operating time. A long duration indicates that the motor may have relatively serious problems. Exemplarily, can take a value of 0.35. The speed fluctuation degree mainly focuses on the change range of the speed, and it can reflect the smoothness of the motor operation. Even if the number of abnormal time points is small and the duration is short, but if the speed fluctuation degree is too large, it will also affect the motor performance. However, compared with the previous two factors, its direct impact on the overall operation of the motor may be slightly smaller. Exemplarily, can take a value of 0.2.

[0071] Another specifically, identifying abnormal items and the processing information of abnormal items, including: B1. According to each condition, confirm abnormal items, including input current abnormality, temperature abnormality, rotor position abnormality, and rotor speed abnormality.

[0072] Among them, confirming abnormal items includes: if condition 1 is established, taking the input current abnormality as an abnormal item; if condition 2 is established, taking the temperature abnormality as an abnormal item; if condition 3 is established, taking the rotor position abnormality as an abnormal item; if condition 4 is established, taking the rotor speed abnormality as an abnormal item.

[0073] B2. If the abnormal item is an input current abnormality, record the duty cycle of the PWM signal corresponding to the electronic current limiter in the power transmission line as , and based on the maximum current and the current fluctuation degree, set the adjustment factor , calculate and adjust the duty cycle of the PWM signal , , use the adjusted PWM signal duty cycle as processing information, and set the reference PWM signal duty cycle as 0.5.

[0074] B3. If the abnormal item is temperature abnormality, based on the highest temperature and the temperature change rate, set the temperature adjustment factor in the same way as is set, , record the pre-set heat dissipation frequency as , calculate and adjust the heat dissipation frequency , , use the adjusted heat dissipation frequency as processing information.

[0075] B4. If the abnormal item is rotor position or rotor speed abnormality, extract the speed regulation tracking log of the electric rotating machine from the information library, count the speed adjustment deviation degree, and set the speed adjustment factor .

[0076] B5. Match and compare the speed adjustment deviation degree with the speed adjustment deviation degrees corresponding to the set speed compensation amounts to obtain the matching speed compensation amount , calculate and adjust the rotor speed , , , set the reference reference rotor speed as , use the adjusted rotor speed as processing information,

[0077] In the embodiment of the present invention, by identifying the abnormal items and the processing information of the abnormal items of the current electric rotating machine, potential problems of the equipment can be discovered in time, and then these abnormalities can be processed in time, which can avoid sudden failures of the equipment during operation, thereby improving the overall reliability of the equipment.

[0078] Understandably, when there is an abnormal input current, especially when the current is too large, it may cause damage to the motor. By adjusting the duty cycle of the PWM signal in the electronic current limiter, the input current of the motor can be effectively limited. According to Joule's law, an excessive current will generate too much heat inside the motor, which may lead to problems such as damage to the insulation of the motor winding and burnout. Reducing the duty cycle of the PWM signal can reduce the input voltage of the motor, thereby limiting the current, avoiding damage to the motor due to overcurrent, extending the service life of the motor, and at the same time protecting other electrical equipment connected to the motor, such as drivers and controllers, from malfunctioning due to overcurrent. And during the operation of the motor, a stable current input helps to maintain a stable electromagnetic torque output. By adjusting the duty cycle of the PWM signal to control the current, the torque of the motor can be made more stable. Among them, the reference PWM signal duty cycle is set to 0.5.

[0079] Understandably, when the motor temperature is abnormal, especially when the maximum temperature is too high or the temperature change rate is too large, the motor temperature can be more effectively controlled by adjusting the heat dissipation frequency. Long-term operation of the motor in a high temperature environment may cause problems such as winding insulation aging and bearing lubrication failure, and by adjusting the heat dissipation frequency, such changes can be more sensitively responded to, keeping the motor temperature within a relatively stable range.

[0080] It is also understandable that by counting the speed adjustment deviation from the speed control tracking log and calculating the rotor speed in combination with the speed adjustment factor, the rotor speed abnormality can be accurately compensated. During the operation of the motor, the rotor speed may deviate from the set value due to factors such as load changes, power supply fluctuations, or changes in the motor's own characteristics. This adjustment method can determine the degree of deviation based on the actual operation history data, and then find the appropriate speed compensation amount so that the rotor speed reaches the expected value more accurately. For example, in precision industrial automation equipment, such as high-speed placement machines, the accuracy of the motor's rotor speed directly affects the accuracy and efficiency of placement. Accurate speed compensation can ensure that every action of the placement machine can be completed accurately. Through this adjustment method based on historical data and matching compensation, these changes can be better adapted, and the rotor position abnormality is often closely related to the rotor speed abnormality. When the rotor speed is accurately adjusted, it helps to improve the rotor position accuracy. Because the position of the rotor is accumulated over time at a certain speed, a stable and accurate speed can make the rotor closer to the expected position at each time point.

[0081] Furthermore, setting the signal adjustment factor in step B2 includes: recording the maximum current, the set safety current, the current fluctuation and the set reference current fluctuation as , as well as and .

[0082] Set the signal adjustment factor , , and are the weights corresponding to the maximum current and current fluctuation respectively.

[0083] In a specific embodiment, and The values ​​can be 0.6 and 0.4 respectively, and the value of the safety current is usually closely related to the rated current of the motor. Generally speaking, the maximum current takes into account the upper limit, and the upper limit of the safety current generally takes into account the overload capacity of the motor. Most motors have a certain overload capacity, and are usually allowed to withstand 120%-150% of the rated current for a short period of time (such as a few minutes). Therefore, the upper limit of the safety current can be set to 120%-150% of the rated current of the motor. For example, for the above-mentioned motor with a rated current of 10A, the upper limit of the safety current can be set to 12-15A, that is, for example, The value can be 15A. In normal and stable operation, the current fluctuation is relatively small. The reference current fluctuation can be set to about 5%-10% of the rated current. For example, for a motor with a rated current of 10A, the allowable current fluctuation range can be ±0.5-±1A. For example, The value can be 1A.

[0084] Furthermore, in step B4, the speed adjustment deviation is calculated, including: extracting the adjusted rotor speed and the monitored rotor speed at each tracking from the speed control tracking log, and subtracting the two to obtain the actual adjusted speed difference.

[0085] Count the number of tracking times when the actual adjustment speed difference is greater than the set reference adjustment speed difference interval, and divide it by the total number of tracking times. The ratio is taken as the speed adjustment deviation ratio, recorded as .

[0086] The actual adjusted speed difference of each tracking when the actual adjusted speed difference is less than 0 is averaged, and the absolute value of the calculation result is taken and recorded as .

[0087] Statistical speed adjustment deviation , , To set the reference adjustment speed difference, and They respectively represent the weight coefficients corresponding to the speed adjustment deviation ratio and the actual adjustment speed difference.

[0088] In a specific embodiment, the speed adjustment deviation ratio is analyzed from an overall dimension, and the actual adjustment speed difference is analyzed from a numerical dimension. For example, and The values ​​can be 0.55 and 0.45 respectively.

[0089] Furthermore, the setting formula of the speed adjustment factor in step B4 is as follows: , and They are the rotor position consistency and rotor speed consistency of the set reference respectively.

[0090] In a specific embodiment, and both can take the value of 0.3.

[0091] When the abnormal item in the embodiment of the present invention is the abnormal rotor position or rotor speed, by statistically analyzing the deviation degree of speed adjustment and setting a speed adjustment factor at the same time, and then calculating and adjusting the rotor speed, the speed accuracy of the electric rotating machine is further ensured, making up for the current deficiency of not mentioning how to compensate for speed fluctuations and not involving the fine control of speed accuracy, and further ensuring the speed stability of the subsequent electric rotating machine.

[0092] The conductive ring state analysis module is used to judge whether there is an abnormality in the conductive ring state based on the signal data and contact information, and if there is an abnormality, confirm the abnormal handling index of the conductive ring.

[0093] Specifically, judging whether there is an abnormality in the conductive ring state includes: E1. Extract the real-time monitoring signal intensity from the signal data, compare the real-time monitoring signal intensity with the normal range of the set signal intensity, and calculate the proportion of the time points exceeding the normal range in the total monitoring time points as the abnormal signal intensity ratio.

[0094] E2. Extract the transmission signal waveform from the signal data, perform a coincidence comparison between the transmission signal waveform and the pre-set reference transmission signal waveform, and count the ratio of the length of the coincident waveform to the length of the transmission signal waveform, denoted as the transmission waveform integrity ratio.

[0095] E3. Extract the signal interruption times and the interruption durations at each signal interruption from the signal data, denote the signal interruption times as At the same time, calculate the average value of the interruption durations at each signal interruption to obtain the average interruption duration, denoted as and count the signal interruption interference degree.

[0096] E4. Extract the real-time contact resistance and real-time contact pressure between the moving ring 8 and the fixed ring 9 of the conductive ring from the contact information, and compare them with their set values respectively, and then define the abnormal contact resistance ratio and abnormal contact pressure ratio in the same way as the definition method of the abnormal signal intensity ratio.

[0097] E5. If any one of the abnormal signal intensity ratio, signal interruption interference degree, abnormal contact resistance ratio, and abnormal contact pressure ratio is greater than 0 or the transmission waveform integrity ratio is less than the set reference value, it is judged that there is an abnormality. If all four items are 0 and the transmission waveform integrity ratio is greater than or equal to the set reference value, it is judged that there is no abnormality.

[0098] Further, the specific statistical formula for counting the signal interruption interference degree in step E3 is: , and respectively represent the number of signal interruptions and the interruption duration set as a reference, indicating the signal interruption interference degree.

[0099] In a specific embodiment, the number of signal interruptions set as a reference is determined according to the operation duration, not exceeding 2 times per hour, and the signal interruption duration set as a reference can take a value of 50 milliseconds.

[0100] In another specific case, confirm the abnormal handling indexes of the slip ring, including: regarding the abnormal signal intensity ratio, signal interruption interference degree, abnormal contact resistance ratio, and abnormal contact pressure ratio as each type-I parameter, and recording the abnormal signal intensity ratio as the type-II parameter.

[0101] If a certain type-I parameter is greater than 0 or the type-II parameter is less than the set reference value, perform an abnormal mark, and count the number of abnormal marks, denoted as .

[0102] If a certain type-I parameter is greater than the set warning value or the type-II parameter is less than the set warning value, perform a target abnormal mark, and count the number of target abnormal marks, denoted as .

[0103] Record the currently set contact pressure as , and use as the adjusted contact pressure, being the set contact pressure compensation adjustment value, and respectively represent the weights of the number of abnormal marks and the number of target abnormal marks.

[0104] In a specific embodiment, if the electric rotating machine is small, the set contact pressure compensation adjustment value can take a value of 0.05 N; if it is medium-sized, the set contact pressure compensation adjustment value can take a value of 0.5 N; if it is large-sized, the set contact pressure compensation adjustment value can take a value of 2 N. and can respectively take values of 0.4 and 0.6.

[0105] The information database is used to store the rotation speed regulation tracking log of the electric rotating machine.

[0106] The device comprehensive control terminal is used to start the corresponding components for processing based on the abnormal items, the processing information of the abnormal items, and the abnormal handling indexes of the slip ring.

[0107] The above content is only an example and explanation of the concept of the present invention. Those skilled in the art of this technology can make various modifications or supplements to the described specific embodiments or use similar methods for substitution, as long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they should all fall within the protection scope of the present invention.

Claims

1. An electric rotating machine control system for controlling an electric rotating machine, which includes a rotating machine housing and an internal structure of the rotating machine; The internal structure of the rotating machine includes an outer ring of a precision ball bearing system, a motor stator, a PCB control board, an encoder disk, a first connecting plate and a second connecting plate, steel balls, an inner ring of the precision ball bearing system, a moving ring of a slip ring, and a fixed ring of the slip ring; A first connecting plate is provided at the side end of the motor stator, and a second connecting plate is provided at the lower side end. The lower end of the first connecting plate is fixedly connected to the upper end of the inner ring of the precision ball bearing system; An outer ring of a precision ball bearing system is rotatably arranged inside the motor stator. An encoder disk is pasted on the upper side end of the outer ring of the precision ball bearing system, and a moving ring of a slip ring is installed on the lower side end; A precision ball bearing inner ring is rotatably arranged inside the outer ring of the precision ball bearing system, and steel balls are arranged between the precision ball bearing inner ring and the outer ring of the precision ball bearing system; characterized in that: This control system includes: An equipment information monitoring module, which is used to, when the electric rotating machine starts, monitor the operating data of the electric rotating machine in real time, including current, temperature, and signal data; A rotor information receiving module, which is used to receive the rotor position information, rotation speed information, and contact information of the electric rotating machine fed back by the encoder disk; A motor operation analysis module, which is used to judge whether there is an abnormality in the current electric rotating machine according to the operating data of the electric rotating machine and the rotor position information and rotation speed information of the electric rotating machine fed back in real time, and when there is an abnormality, identify the abnormal item and the processing information of the abnormal item; A slip ring state analysis module, which is used to judge whether there is an abnormality in the slip ring state based on the signal data and contact information. If there is an abnormality, confirm the abnormal processing index of the slip ring; An information database, which is used to store the rotation speed regulation tracking log of the electric rotating machine; An equipment comprehensive control terminal, which is used to start the corresponding components for processing based on the abnormal item and the processing information of the abnormal item and the abnormal processing index of the slip ring; Judging whether there is an abnormality in the slip ring state includes: extracting the real-time monitoring signal intensity from the signal data, comparing the real-time monitoring signal intensity with the normal range of the set signal intensity, calculating the proportion of the time points exceeding the normal range in the total monitoring time points, and taking it as the abnormal signal intensity ratio; Extracting the transmitted signal waveform from the signal data, overlapping and comparing the transmitted signal waveform with the pre-set reference transmitted signal waveform, and calculating the ratio of the length of the overlapping waveform to the length of the transmitted signal waveform, which is recorded as the transmitted waveform integrity ratio; Extract the number of signal interruptions from the signal data and the interruption duration at each signal interruption. Calculate the average value of the interruption durations at each signal interruption to obtain the average interruption duration, denoted as , and statistically calculate the signal interruption interference degree; Extracting the real-time contact resistance and real-time contact pressure between the moving ring and the fixed ring of the slip ring from the contact information, and comparing them with their set values respectively, and then defining the abnormal contact resistance ratio and abnormal contact pressure ratio in the same way as the definition method of the abnormal signal intensity ratio; If any one of the abnormal signal intensity ratio, signal interruption interference degree, abnormal contact resistance ratio, and abnormal contact pressure ratio is greater than 0 or the transmitted waveform integrity ratio is less than the set reference value, it is judged that there is an abnormality. If all four items are 0 and the transmitted waveform integrity ratio is greater than or equal to the set reference value, it is judged that there is no abnormality.

2. The control system of an electric rotating machine according to claim 1, wherein: The judgment of whether there is an abnormality in the current electric rotating machine includes: Screening out the maximum current from the current of the electric rotating machine monitored in real time, and at the same time calculating the standard deviation of the current of the electric rotating machine monitored in real time to obtain the current fluctuation degree; Screen out the highest temperature from the real-time monitoring of the temperature of the electric rotating machine, and at the same time, use time as the abscissa and temperature as the ordinate to construct a temperature change curve, and extract the slope of the temperature change curve as the temperature change rate; Extract the real-time rotor position within each operating cycle from the rotor position information, and count the rotor position coincidence degree ; Extract the real-time monitored rotational speed from the rotational speed information and analyze the rotor rotational speed compliance ; Define that the maximum current exceeds the set safety current or the current fluctuation degree exceeds the set reference current fluctuation degree as condition 1, define that the highest temperature exceeds the pre-set safe operating temperature or the temperature change rate exceeds the set reference temperature change rate as condition 2, define that the rotor position coincidence degree is less than the set reference rotor position coincidence degree as condition 3, and define that the rotor speed coincidence degree is less than the set reference rotor speed coincidence degree as condition 4; Judge whether there is a condition that holds among conditions 1, 2, 3, and 4. If there is, take the existence of an abnormality as the judgment result; otherwise, take the non-existence of an abnormality as the judgment result.

3. The control system of an electric rotating machine according to claim 2, characterized in that: The statistical rotor position coincidence degree includes: Compare the real-time rotor position within each operating cycle with the expected position calculated by the pre-set operating model of the electric rotating machine. If the deviation angle between the rotor position and the corresponding calculated expected position at a certain time point within a certain operating cycle exceeds the set reference deviation angle, mark this time point as abnormal; Count the number of corresponding anomaly marks in each operation cycle and divide it by the total number of time points in each operation cycle. Denote the ratio as the anomaly mark frequency. Calculate the average anomaly mark ratio through the mean value and denote it as ; Compare the rotor positions at the same time point within different operating cycles with the expected positions calculated at this time point. If the deviation angle between the rotor position and the calculated expected position at a certain time point is lower than the set reference deviation angle, mark this time point as a coincidence time point; Count the number of time points with statistical coincidence, divide it by the total number of time points in the operating cycle, and obtain the rotor position coincidence repeatability, denoted as ; Statistical rotor position coincidence , , and respectively represent the repetition degree of rotor position coincidence and the abnormal marking ratio of the set reference, is the natural constant.

4. The control system of an electric rotating machine according to claim 2, characterized in that: The analysis of the rotor speed coincidence degree includes: Compare the real-time monitored rotational speed with the pre-set rotational speed. If the difference between the monitored rotational speed and the pre-set rotational speed at a certain time point exceeds the set rotational speed difference range, then record this time point as a rotational speed abnormal time point, count the number of rotational speed abnormal time points, and record it as ; Combine two adjacent abnormal rotation speed time points into an abnormal rotation speed time period, traverse each abnormal rotation speed time period. If the duration corresponding to a certain abnormal rotation speed time period is within the set reference time window, record this abnormal rotation speed time period as the target time period, count the number of target time periods, divide it by the total number of abnormal rotation speed time periods, and record the ratio as the abnormal rotation speed continuous ratio, denoted as ; Calculate the standard deviation of the real-time monitored rotational speed to obtain the rotational speed fluctuation degree ; Statistical rotor speed matching degree , , , and respectively represent the weights corresponding to the number of abnormal speed time points, the abnormal speed duration ratio, and the speed fluctuation degree. , and are respectively the number of abnormal speed time points, the abnormal speed duration ratio, and the speed fluctuation degree set as the reference.

5. The control system of an electric rotating machine according to claim 2, characterized in that: The identification of abnormal items and the processing information of abnormal items includes: According to each condition, confirm abnormal items, including input current abnormality, temperature abnormality, rotor position abnormality, and rotor speed abnormality; If the abnormal item is the abnormal input current, record the duty cycle of the PWM signal corresponding to the electronic current limiter in the transmission line as , set an adjustment factor based on the maximum current and the current fluctuation , calculate the adjusted duty cycle of the PWM signal , , use the adjusted duty cycle of the PWM signal as the processing information to set the reference duty cycle of the PWM signal; If the abnormal item is a temperature anomaly, based on the highest temperature and the temperature change rate, set the temperature adjustment factor in the same way as the setting method . Denote the pre-set heat dissipation frequency as , calculate the adjusted heat dissipation frequency , , and use the adjusted heat dissipation frequency as the processing information; If the abnormal item is the abnormal rotor position or rotor speed, extract the speed regulation tracking log of the electric rotating machine from the information database, calculate the speed adjustment deviation degree, and set the speed adjustment factor at the same time ; Match and compare the rotational speed adjustment deviation with the rotational speed adjustment deviations corresponding to the set rotational speed compensation amounts for each to obtain the matching rotational speed compensation amount , calculate the adjusted rotor rotational speed , , is the set reference reference rotor rotational speed, and the adjusted rotor rotational speed is used as the processing information is the current monitored rotational speed.

6. The control system of an electric rotating machine according to claim 5, wherein: The confirmation of abnormal items includes: If condition 1 holds, take the input current abnormality as an abnormal item. If condition 2 holds, take the temperature abnormality as an abnormal item. If condition 3 holds, take the rotor position abnormality as an abnormal item. If condition 4 holds, take the rotor speed abnormality as an abnormal item.

7. The control system of an electric rotating machine according to claim 5, characterized in that: The statistical speed adjustment deviation degree includes: Extract the adjusted rotor speed and the monitored rotor speed during each tracking from the speed regulation tracking log, and take the difference between the two to obtain the actual adjustment speed difference; Count the number of tracking times when the actual adjusted speed difference is greater than the set reference adjusted speed difference range, and divide it by the total number of tracking times. Take the ratio as the speed adjustment deviation ratio, denoted as ; Calculate the average value of the actual adjustment speed differences during each tracking where the actual adjustment speed difference is less than 0, take the absolute value of the calculation result, and denote it as ; Statistical rotational speed adjustment deviation degree , , is the set reference adjustment rotational speed difference, and respectively represent the weight coefficients corresponding to the rotational speed adjustment deviation ratio and the actual adjustment rotational speed difference.

8. The control system of an electric rotating machine according to claim 1, characterized in that: The confirmation of the abnormal handling index of the slip ring includes: Take the abnormal signal intensity ratio, signal interruption interference degree, abnormal contact resistance ratio, and abnormal contact pressure ratio as each type I parameter, and record the abnormal signal intensity ratio as the type II parameter; If a certain type-I parameter is greater than 0 or a type-II parameter is less than the set reference value, an anomaly flag is set, and the number of anomaly flags is counted, denoted as ; If a certain type-I parameter is greater than the set warning value or a type-II parameter is less than the set warning value, perform target anomaly marking, count the number of target anomaly markings, denoted as ; Denote the currently set contact pressure as , and use as the adjusted contact pressure, which is the set contact pressure compensation adjustment value, and represent the number of abnormal marks and the weight of the target number of abnormal marks respectively.

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