Logistics transmission controller and control method thereof

Abstract

The invention relates to a logistics transmission controller and a control method thereof.The logistics transmission controller is installed on the edges of the two sides of a carrier tape vehicle and comprises a direct-current power source input module, a switching power source module, an MCU control module, an inverter circuit module, a sensor module, a communication module, a reverse connection protection module and a key input module; the MCU control module collects rotating speed and position signals of the motor from the Hall sensor and the encoder, monitors the system temperature through the NTC sensor and receives an external communication instruction input by the key input module. Then the MCU control module operates a vector control algorithm FOC and calculates an optimal PWM control signal in combination with the real-time feedback signal; and the inverter circuit module outputs a three-phase alternating current through the PWM signal for the operation of the motor. According to the invention, the roller motor can be driven by non-inductive FOC, and ultra-silence operation is realized; estimating the position of the rotor by detecting the phase current and the bus voltage; and under the condition that the Hall element is damaged, a non-inductive state can be directly switched, so that the service life of the roller motor is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of motor control, and in particular to a logistics transmission controller and a control method thereof. Background Art

[0002] Existing logistics transmission systems play a vital role in modern warehouses and distribution centers. These systems usually rely on efficient roller motors to drive conveyor belts to achieve fast and accurate movement of goods.

[0003] However, traditional drum motor controllers require multiple components to work together, such as drive circuits, control modules, and monitoring circuits; the connection and coordination between these components increases the complexity of the system, making maintenance and debugging difficult.

[0004] Moreover, due to the structural and algorithm limitations of traditional controllers, their response speed to changes in motor speed and load is slow and cannot meet the requirements of modern logistics systems for rapid response.

[0005] At the same time, the control accuracy of traditional controllers is limited by hardware and software, making it difficult to achieve precise speed and position control, affecting the accuracy and efficiency of logistics transmission.

[0006] In addition, traditional controllers have many complex components and are prone to failure, especially under long-term operation and high-load working conditions. The motor will generate severe heat inside, which can easily cause damage to the motor Hall. The failure rate is high, affecting the stability and reliability of the system.

[0007] Therefore, the existing roller motor controller for logistics transmission has many disadvantages such as complex structure, slow response speed, and low control accuracy. Summary of the invention

[0008] The technical problem to be solved by the present invention is to provide a logistics transmission controller and a control method thereof, which have the characteristics of simple structure, fast response speed, high control accuracy, low cost, silent operation, etc.

[0009] The technical solution adopted by the present invention to solve the technical problem is: a logistics transmission controller, including a DC power input module, a switching power module, an MCU control module, an inverter circuit module, a sensor module and a communication module;

[0010] The DC power input module is connected to the switching power module;

[0011] The switching power supply module converts the voltage input by the DC power supply input module and outputs two voltages, one of which is output to the MCU control module, the sensor module and the communication module, and the other is output to the inverter circuit module;

[0012] The MCU control module is connected to the sensor module, and the MCU control module collects the real-time signal of the sensor module, performs logic processing to generate a PWM signal and sends it to the inverter circuit module;

[0013] The inverter circuit module receives the PWM control signal from the MCU control module, outputs three-phase AC power through the power switch tube MOSFET, and drives the motor to rotate;

[0014] The sensor module includes a Hall sensor, an encoder and an NTC sensor; the Hall sensor detects the rough position of the motor rotor and outputs a pulse signal to the MCU control module; the encoder sends a speed and position signal; the NTC sensor detects the system temperature in real time;

[0015] The communication module is connected to an external control system to upload motor status and receive control commands.

[0016] Furthermore, the present invention also includes a reverse connection protection module and a key input module; the DC power input module is connected to the subsequent switching power module through the reverse connection protection module; the key input module includes a dip switch, and the user inputs the target instruction through the dip switch, and the MCU control module updates the motor operation status after collecting the signal.

[0017] Furthermore, the present invention also includes an OTA upgrade module; the upgrade method of the OTA upgrade module includes:

[0018] A. Upgrade request from APP to GTWL: APP sends an upgrade request to GTWL; after receiving the upgrade request, GTWL checks the transmission status; if the transmission status is good, GTWL sends a confirmation message to APP; if the transmission status is not good, GTWL rechecks the transmission status;

[0019] B. Upgrade request from GTWL to the host computer: GTWL sends an upgrade request to the host computer; after receiving the upgrade request, the host computer sends a confirmation message to the subordinate computer; if the host computer does not receive the confirmation message, GTWL waits for a while and then resends the upgrade request;

[0020] C. Data transmission process: GTWL starts to send file data, sending 200-byte data blocks each time; after receiving the data block, the host computer sends a confirmation message; if the host computer does not receive the confirmation message, GTWL resends the data packet; this process repeats until the entire file transfer is completed;

[0021] D. File verification and confirmation process: After the file transfer is completed, the host computer verifies the file; if the verification is successful, the host computer sends a verification success message; if the verification fails, the host computer sends a verification failure message, and GTWL resends the file data.

[0022] At the same time, the present invention also proposes a control method for a logistics transmission controller, comprising the following steps:

[0023] S1, 24V DC power supply is input to the switching power supply module through the reverse connection protection module; the switching power supply module outputs 5V and 13V two-way voltage for use by the control circuit and the power circuit respectively;

[0024] S2, MCU control module collects the motor speed and position signals from the Hall sensor and encoder, monitors the system temperature through the NTC sensor, and receives external communication commands input by the key input module;

[0025] S3, MCU control module runs the vector control algorithm FOC, calculates the optimal PWM control signal based on the real-time feedback signal, and outputs it to the inverter circuit module;

[0026] S4, the inverter circuit module drives the power switch MOSFET through the PWM signal to output three-phase AC power for the motor to operate; the motor achieves the target speed and torque output according to the input three-phase AC power;

[0027] S5, RS485 communication module maintains data exchange with external devices, uploads status information and receives new instructions.

[0028] Furthermore, in step S3 of the present invention, the calculation method of the optimal PWM control signal includes the following steps:

[0029] S31, acquiring three-phase current signals in real time and converting them into a stationary coordinate system;

[0030] S32, performing current error calculation and saturation function gain adjustment;

[0031] S33, calculating the back electromotive force and filtering the back electromotive force;

[0032] S34, calculating the rotor angle and speed according to the filtered back electromotive force;

[0033] S35, performing coordinate conversion on the filtered back electromotive force to generate a corresponding control signal; and adjusting the drive signal in real time according to the calculated rotation speed and rotor angle.

[0034] Furthermore, in step S31 of the present invention, the three-phase current signals are ia, ib, ic, the stationary coordinate system is α-β, and the conversion method is:

[0035]

[0036] Furthermore, in step S32 of the present invention, the current error is calculated by converting the current iα, iβ in the stationary coordinate system to the dq coordinate system, and the conversion formula is: id = iαcos(θ) + iβsin(θ), iq = -iαsin(θ) + iβcos(θ); after comparing with the target current setting values ​​id*, iq*, the current error is: ed = id*-id, eq = iq*-iq;

[0037] The saturation function gain adjustment method is: according to the current error size, the control gain K is adjusted using the saturation function. The adjustment formula is: K = sat (Kinit + G (ed, eq)), where sat is the saturation function, which is used to limit the gain within the allowable range:

[0038]

[0039] Furthermore, in step S33 of the present invention, the back electromotive force ed,eq in the dq coordinate system is calculated according to the motor voltage equation:

[0040]

[0041] Among them, us is voltage and is is current;

[0042] The back electromotive force ed, eq is low-pass filtered using a first-order low-pass filter. The filtering formula is:

[0043]

[0044] Furthermore, in step S34 of the present invention, the rotor angle θ is calculated by using the filtered back electromotive force using the CORDIC algorithm or the inverse tangent formula:

[0045]

[0046] Calculate the rotation speed ω using the change in angle:

[0047]

[0048] Furthermore, in step S35 of the present invention, the back electromotive force e after filtering is d ,filtered,e q , filtered to perform 2r / 2s coordinate transformation.

[0049] The beneficial effects of the present invention are that the defects existing in the background technology are solved. The present invention can drive the drum motor with non-sensing FOC and achieve ultra-quiet operation. By detecting the phase current and bus voltage, an observer is established through mathematical modeling, and the rotor position is estimated in combination with the PLL technology. Moreover, under the condition of Hall damage, the non-sensing state can be directly switched to, thereby improving the service life of the drum motor. At the same time, the present invention uses dual-resistance sampling to collect phase current and reconstruct the third-phase current, and the speed loop, current loop, torque loop, and power loop can be configured in the program to meet the application of different scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 It is a circuit principle block diagram of the controller of the present invention;

[0051] Figure 2 is a schematic diagram of a power supply circuit of the present invention;

[0052] Figure 3 It is a schematic diagram of the input and output IO circuit of the present invention;

[0053] Figure 4 It is a schematic diagram of the structure of the MCU control module of the present invention;

[0054] Figure 5 1 is a schematic diagram of an encoder circuit of the present invention;

[0055] Figure 6 is a schematic diagram of a switch circuit of the present invention;

[0056] Figure 7 It is a schematic diagram of the 485 communication circuit of the present invention;

[0057] Figure 8 It is a flow chart of the vector control method of the present invention for estimating the rotor position and measuring the speed;

[0058] Fig. 9 This is the block diagram of the Hall / sensorless FOC control of the present invention;

[0059] Fig.10 This is a flowchart of the OTA upgrade process of the present invention;

[0060] In the figure: 1. DC power input module; 2. Switching power module; 3. Switching power 5V output; 4. MCU control module; 5. Switching circuit; 6. Switching power 13V output; 7. Inverter circuit module; 8. Motor; 9. Hall sensor; 10. NTC sensor; 11. Encoder; 12. DIP switch; 13. Reverse connection protection; 14. 485 communication module. DETAILED DESCRIPTION

[0061] The present invention will now be described in further detail in conjunction with the accompanying drawings and preferred embodiments. These drawings are simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0062] like Figure 1-Figure 10 A logistics transmission controller shown is installed on the edges of both sides of the carrier vehicle, and includes a DC power input module, a switching power module, an MCU control module, an inverter circuit module, a sensor module, a communication module, a reverse connection protection module and a key input module.

[0063] in,

[0064] The input voltage of the DC power input module 1 is DC 24V. The DC power input module is connected to the subsequent switching power module through the reverse connection protection module to ensure that the circuit can be automatically disconnected when the polarity of the input power is reversed to protect the safety of the equipment.

[0065] The switching power supply module 2 converts the 24V voltage input by the DC power supply input module and outputs two voltages, namely the switching power supply 5V output 3 and the switching power supply 13V output 6. One 5V voltage is output to low-voltage devices such as the MCU control module, sensor module and communication module, and the other 13V voltage is output to the inverter circuit module to provide working voltage for the power devices.

[0066] The sensor module includes a Hall sensor 9, an encoder 10, and an NTC sensor 11; the Hall sensor detects the rough position of the motor rotor and outputs a pulse signal to the MCU control module for speed estimation. The encoder provides high-precision speed and position signals, and the MCU calculates the real-time speed and angle of the motor through the heterodyne method to achieve precise control. The NTC sensor detects the system temperature in real time. If the temperature exceeds the set value, the MCU triggers the protection mechanism and stops the motor.

[0067] MCU control module 4 is the control core, connected to the sensor module, and performs the following functions:

[0068] Signal acquisition: Get real-time signals from Hall sensors, encoders, NTC sensors, and DIP switches.

[0069] Logic processing: Based on the collected motor speed, position, temperature and input information, the vector control algorithm (FOC) is run to generate PWM signals in real time.

[0070] Output control: Send the generated PWM signal to the inverter circuit and exchange data with external devices through the 485 communication module.

[0071] The inverter circuit module 7 receives the PWM control signal and 13V power supply from the MCU control module, outputs three-phase AC power through the power switch tube MOSFET, and drives the motor to rotate.

[0072] The motor 8 receives the three-phase alternating current output by the inverter circuit, and realizes the target speed and torque according to the frequency and amplitude of the input current.

[0073] The communication module is connected to the external control system to upload the motor status and receive control commands.

[0074] The key input module includes a dial switch 12. The user inputs the target instruction through the dial switch, and the MCU control module updates the motor running state after collecting the signal.

[0075] The reverse connection protection module 13 ensures that the circuit can be automatically disconnected when the polarity of the input power is reversed, thereby protecting the safety of the equipment.

[0076] The RS485 communication module 14 is connected to the external control system for uploading the motor status and receiving control commands (such as start, stop and target speed).

[0077] OTA upgrade module, used for interaction between APP, GTWL and host computer; involving operations such as upgrade request, data transmission, verification and confirmation;

[0078] The detailed process of the OTA upgrade module includes:

[0079] A. Upgrade request from APP to GTWL: APP sends an upgrade request to GTWL; after receiving the upgrade request, GTWL checks the transmission status; if the transmission status is good, GTWL sends a confirmation message to APP; if the transmission status is not good, GTWL rechecks the transmission status;

[0080] B. Upgrade request from GTWL to the host computer: GTWL sends an upgrade request to the host computer; after receiving the upgrade request, the host computer sends a confirmation message to the subordinate computer; if the host computer does not receive the confirmation message, GTWL waits for a while and then resends the upgrade request;

[0081] C. Data transmission process: GTWL starts to send file data, sending 200-byte data blocks each time; after receiving the data block, the host computer sends a confirmation message; if the host computer does not receive the confirmation message, GTWL resends the data packet; this process repeats until the entire file transfer is completed;

[0082] D. File verification and confirmation process: After the file transfer is completed, the host computer verifies the file; if the verification is successful, the host computer sends a verification success message; if the verification fails, the host computer sends a verification failure message, and GTWL resends the file data.

[0083] The control method of the controller comprises the following steps:

[0084] S1, 24V DC power supply is input to the switching power supply module through the reverse connection protection module; the switching power supply module outputs 5V and 13V two-way voltage for use by the control circuit and the power circuit respectively;

[0085] S2, MCU control module collects the motor speed and position signals from the Hall sensor and encoder, monitors the system temperature through the NTC sensor, and receives external communication commands input by the key input module;

[0086] S3, MCU control module runs the vector control algorithm FOC, calculates the optimal PWM control signal based on the real-time feedback signal, and outputs it to the inverter circuit module;

[0087] S4, the inverter circuit module drives the power switch MOSFET through the PWM signal to output three-phase AC power for the motor to operate; the motor achieves the target speed and torque output according to the input three-phase AC power;

[0088] S5, RS485 communication module maintains data exchange with external devices, uploads status information and receives new instructions.

[0089] The calculation method of the optimal PWM control signal includes the following steps:

[0090] First, the permanent magnet synchronous motor and control system are initialized and measured to determine the system's resonant frequency f0 and bandwidth Δf. The resonant frequency range is defined as [f0-Δf, f0+Δf], and the frequency hysteresis width fhys and initial gain Kinit are set. In addition, the static parameters of the motor are measured, including the stator resistance R, stator inductance Ls, and flux linkage ψf. These parameters are recorded for subsequent control and calculation.

[0091] S31, real-time acquisition of three-phase current signals, and conversion to a stationary coordinate system; the three-phase current signals are ia, ib, ic, the stationary coordinate system is α-β, and the conversion method is: iα=ia,

[0092] S32, performing current error calculation and saturation function gain adjustment;

[0093] The current iα, iβ in the stationary coordinate system is converted to the dq coordinate system. The conversion formula is: id = iαcos(θ) + iβsin(θ), iq = -iαsin(θ) + iβcos(θ); after comparing with the target current setting value id*, iq*, the current error is: ed = id*-id, eq = iq*-iq; according to the current error, the control gain K is adjusted using the saturation function. The adjustment formula is: K = sat(Kinit+G(ed, eq)), where sat is a saturation function used to limit the gain within the allowable range:

[0094]

[0095] S33, calculating the back electromotive force and filtering the back electromotive force;

[0096] Calculate the back electromotive force ed in the dq coordinate system according to the motor voltage equation, eq:

[0097]

[0098] Among them, us is voltage and is is current;

[0099] In order to reduce noise interference, the back electromotive force ed, eq is low-pass filtered using a first-order low-pass filter. The filtering formula is:

[0100]

[0101] S34, calculating the rotor angle and speed according to the filtered back electromotive force;

[0102] The rotor angle θ is calculated using the filtered back EMF using the CORDIC algorithm or the inverse tangent formula:

[0103]

[0104] Calculate the rotation speed ω using the change in angle:

[0105]

[0106] S35, the filtered back electromotive force e d ,filtered,e q , filtered performs 2r / 2s coordinate transformation to generate corresponding control signals; and according to the calculated speed and rotor angle, the drive signal is adjusted in real time to ensure stable operation of the motor.

[0107] The hysteresis controller ensures that the motor operates within the specified frequency range. If the system detects that the resonant frequency f0 exceeds the set range [f0-Δf, f0+Δf], the gain adjustment mechanism is triggered to restore the motor to a steady state.

[0108] The above description only describes the specific implementation mode of the present invention. Various examples do not limit the essential content of the present invention. After reading the description, ordinary technicians in the relevant technical field can modify or deform the specific implementation modes described above without departing from the essence and scope of the invention.

Claims

1. A logistics transmission controller, characterized in that: It includes a DC power input module, a switching power module, an MCU control module, an inverter circuit module, a sensor module and a communication module; The DC power input module is connected to the switching power module; The switching power supply module converts the voltage input by the DC power supply input module and outputs two voltages, one of which is output to the MCU control module, the sensor module and the communication module, and the other is output to the inverter circuit module; The MCU control module is connected to the sensor module, and the MCU control module collects the real-time signal of the sensor module, performs logic processing to generate a PWM signal and sends it to the inverter circuit module; The inverter circuit module receives the PWM control signal from the MCU control module, outputs three-phase AC power through the power switch tube MOSFET, and drives the motor to rotate; The sensor module includes a Hall sensor, an encoder and an NTC sensor; the Hall sensor detects the rough position of the motor rotor and outputs a pulse signal to the MCU control module; the encoder sends a speed and position signal; the NTC sensor detects the system temperature in real time; The communication module is connected to an external control system to upload motor status and receive control commands.

2. A logistics transmission controller according to claim 1, characterized in that: It also includes a reverse connection protection module and a key input module; the DC power input module is connected to the subsequent switching power module through the reverse connection protection module; the key input module includes a dip switch, the user inputs the target instruction through the dip switch, and the MCU control module updates the motor operation status after collecting the signal.

3. A control method of a logistics transmission controller according to claim 1, characterized in that: The following steps are included: S1, 24V DC power supply is input to the switching power supply module through the reverse connection protection module; the switching power supply module outputs 5V and 13V two-way voltage for use by the control circuit and the power circuit respectively; S2, MCU control module collects the motor speed and position signals from the Hall sensor and encoder, monitors the system temperature through the NTC sensor, and receives external communication commands input by the key input module; S3, MCU control module runs the vector control algorithm FOC, calculates the optimal PWM control signal based on the real-time feedback signal, and outputs it to the inverter circuit module; S4, the inverter circuit module drives the power switch MOSFET through the PWM signal to output three-phase AC power for the motor to operate; the motor achieves the target speed and torque output according to the input three-phase AC power; S5, RS485 communication module maintains data exchange with external devices, uploads status information and receives new instructions.

4. A control method for a logistics transmission controller as claimed in claim 3, characterized in that: In step S3, the calculation method of the optimal PWM control signal includes the following steps: S31, acquiring three-phase current signals in real time and converting them into a stationary coordinate system; S32, performing current error calculation and saturation function gain adjustment; S33, calculating the back electromotive force and filtering the back electromotive force; S34, calculating the rotor angle and speed according to the filtered back electromotive force; S35, performing coordinate conversion on the filtered back electromotive force to generate a corresponding control signal; And according to the calculated speed and rotor angle, the drive signal is adjusted in real time.

5. A control method for a logistics transmission controller as claimed in claim 4, characterized in that: In the step S31, the three-phase current signals are ia, ib, ic, the stationary coordinate system is α-β, and the conversion method is: iα=ia, 6. A control method for a logistics transmission controller as claimed in claim 4, characterized in that: In the step S32, the current error is calculated by converting the current iα, iβ in the stationary coordinate system to the dq coordinate system, and the conversion formula is: id = iαcos(θ) + iβsin(θ), iq = -iαsin(θ) + iβcos(θ); after comparing with the target current setting values ​​id, iq, the current error is: ed = id*-id, eq = iq*-iq; The saturation function gain adjustment method is: according to the current error size, the control gain K is adjusted using the saturation function. The adjustment formula is: K = sat (Kinit + G (ed, eq)), where sat is the saturation function, which is used to limit the gain within the allowable range:

7. A control method for a logistics transmission controller according to claim 6, characterized in that: In step S33, the back electromotive force ed,eq in the dq coordinate system is calculated according to the motor voltage equation: Among them, us is voltage and is is current; The back electromotive force ed, eq is low-pass filtered using a first-order low-pass filter. The filtering formula is:

8. A control method for a logistics transmission controller as claimed in claim 4, characterized in that: In step S34, the rotor angle θ is calculated by using the filtered back electromotive force using the CORDIC algorithm or the inverse tangent formula: Calculate the rotation speed ω using the change in angle:

9. A control method for a logistics transmission controller according to claim 7, characterized in that: In step S35, the filtered back electromotive force e d ,filtered,e q , filtered to perform 2r / 2s coordinate transformation.

10. A logistics transmission controller according to claim 1, characterized in that: It also includes an OTA upgrade module; the upgrade method of the OTA upgrade module includes: A. Upgrade request from APP to GTWL: APP sends an upgrade request to GTWL; after receiving the upgrade request, GTWL checks the transmission status; if the transmission status is good, GTWL sends a confirmation message to APP; if the transmission status is not good, GTWL rechecks the transmission status; B. Upgrade request from GTWL to the host computer: GTWL sends an upgrade request to the host computer; after receiving the upgrade request, the host computer sends a confirmation message to the subordinate computer; if the host computer does not receive the confirmation message, GTWL waits for a while and then resends the upgrade request; C. Data transmission process: GTWL starts to send file data, sending 200-byte data blocks each time; after receiving the data block, the host computer sends a confirmation message; if the host computer does not receive the confirmation message, GTWL resends the data packet; this process repeats until the entire file transfer is completed; D. File verification and confirmation process: After the file transfer is completed, the host computer verifies the file; if the verification is successful, the host computer sends a verification success message; if the verification fails, the host computer sends a verification failure message, and GTWL resends the file data.

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