Brushless direct current motor and control method thereof

Abstract

The invention discloses a brushless direct current motor and a control method thereof, and relates to the technical field of motor equipment.The brushless direct current motor comprises a motor shell and further comprises a driving circuit, and the driving circuit is located in the motor shell. A protective cover is arranged on the outer side of the rotor mounting cover, and a positioning clamping seat is arranged on one side of a heat dissipation fan blade to reinforce and mount the motor shell and the rotor mounting cover, so that the connection stability of equipment in use is improved; the auxiliary mounting mechanism is arranged, the motor shell and the mounting side plate are subjected to reinforced connection treatment through the first connecting shaft, and daily maintenance treatment can be conveniently carried out on the whole; according to the invention, the MCU unit is used for receiving the position feedback from the Hall sensor, and the MCU unit can control the current switching of the stator winding, so that a rotating magnetic field is generated to drive the rotor to rotate, and the error is the difference between a target value and an actual value.

Description

Technical Field

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

[0002] A brushless DC motor, also known as an electronically commutated motor (ECM or EC motor) or synchronous DC motor, is a synchronous motor that uses a direct current (DC) power supply. A brushless DC motor consists primarily of a rotor made of permanent magnet material and a stator with coil windings.

[0003] Chinese Patent Publication No. CN 116683666 A discloses a magnetic core brushless DC motor and its control method, addressing the problems of low torque, complex production processes and structures, high maintenance costs, and high power consumption in existing DC motors. The magnetic core brushless DC motor comprises a stator, a rotor, 2N Hall sensors, a power supply unit, a driver, and stator magnets. The stator magnets comprise a first magnet and a second magnet. The N Hall sensors face the rotor structure, while the N Hall sensors face away from the rotor structure. The control method of the present invention, when DC current is applied to the coil, the magnetic field in the magnet in the iron core with the same polarity as the coil counteracts the induced magnetic field of the coil. The magnetic field of the other magnet has an opposite polarity to the induced magnetic field of the coil. The magnetic field of the magnet itself and the induced magnetic field generated when the coil is energized act together to generate a new mixed magnetic field on the iron core. The magnetic induction intensity of the new mixed magnetic field is much greater than the induced magnetic field intensity generated by the pure iron core.

[0004] However, the above scheme still has the following problems: the existing brushless DC motor control chip has a single function and cannot achieve various output waveform controls. At the same time, the motor equipment itself has not been improved, resulting in defects in the motor equipment itself, which affects the subsequent motor control processing and is difficult to meet various different brushless DC motor product application scenarios. Therefore, the present invention needs to design a brushless DC motor and its control method to solve the above problems. Summary of the Invention

[0005] The object of the present invention is to provide a brushless DC motor and a control method thereof to solve the problems raised in the above background technology.

[0006] To achieve the above object, the present invention provides the following technical solution: a brushless DC motor, comprising a motor housing, and further comprising: The drive circuit is located inside the motor housing; The mounting side plate is located at one end of the motor housing and is used to connect the motor housing; The auxiliary mounting mechanism, the auxiliary mounting mechanism is located at an end of the mounting side plate away from the motor housing, the auxiliary mounting mechanism includes a fixed positioning plate, one end of the motor housing is installed with a mounting side plate, a limit plate is installed on the side of the mounting side plate close to the motor housing, and batteries distributed equidistantly are installed inside the limit plate, a first connecting shaft is installed on the axis of the mounting side plate, a fitting disk is sleeved on the outer side of the first connecting shaft, the fitting disk is connected to the limiting disk, one end of the first connecting shaft extends into the interior of the motor housing, a fixed positioning plate is installed on the side of the mounting side plate away from the motor housing, an auxiliary positioning frame is installed on the side of the fixed positioning plate close to the mounting side plate, and one side of the connecting sleeve is connected to the mounting side plate; The rotor mechanism is located at one end of the motor housing away from the mounting side plate, the rotor mechanism includes a rotor mounting cover, one end of the motor housing is mounted with the rotor mounting cover, one side of the rotor mounting cover is mounted with a rotor, and one end of the rotor is mounted with a heat dissipation fan blade extending into the interior of the motor housing; The sealing flange cover is located at one end of the rotor mechanism away from the motor housing.

[0007] As a preferred embodiment of the present invention, a sealing flange is provided inside the sealing flange cover, a limiting sleeve is installed inside the sealing flange, a second connecting shaft is installed inside the limiting sleeve, one end of the second connecting shaft passes through the sealing flange cover and is fixedly connected to the output bearing, the other end of the second connecting shaft is connected to one end of the rotor, and the second connecting shaft is driven to rotate inside the limiting sleeve by the rotation of the rotor, thereby driving the output bearing at one end to rotate for subsequent operations. By sleeved a sealing flange on the outside of the sealing flange, it is convenient to connect the rotor mounting cover and the sealing flange cover, and a certain degree of protection is provided for the internal limiting sleeve and the second connecting shaft. The outside of the sealing flange cover is provided with equidistantly distributed oil inlet chambers, which can be used for oil lubrication through the oil inlet chamber reserved on the outside of the sealing flange cover during use, thereby extending the service life of the equipment.

[0008] As a preferred embodiment of the present invention, the side of the mounting side plate close to the fixed positioning plate is provided with an equidistantly distributed first mounting groove, the outer side of the auxiliary positioning frame is installed with a connecting sleeve, the four sides of the auxiliary positioning frame are threadedly connected with positioning bolts that pass through the fixed positioning plate, the top of the fixed positioning plate is provided with a limiting groove, and the side of the fixed positioning plate away from the mounting side plate is provided with four equidistantly distributed positioning rods, one end of the positioning bolts extends to the inside of the corresponding positioning rod, and an oil guide hole is also provided at the bottom of the limiting groove, and the positioning bolts and the positioning rods are used to cooperate with each other to perform one-side positioning processing of the entire equipment, thereby improving the overall stability of the subsequent equipment operation, and the limiting groove can be used to add lubricating oil until it falls onto the surface of the connecting sleeve to lubricate part of the equipment.

[0009] As a preferred embodiment of the present invention, the interior of the rotor mounting cover is provided with second mounting grooves distributed equally, and the interior of the second mounting grooves is provided with a stator, and a positioning socket is installed at the end of the heat dissipation fan blade away from the limit sleeve, and one end of the positioning socket extends into the interior of the drive circuit, and the interior of the drive circuit is provided with an installation inner cavity for cooperating with the installation of the drive circuit, and a protective cover is provided on the outside of the rotor mounting cover. By providing a protective cover on the outside of the rotor mounting cover, the rotor mechanism is subjected to daily protection treatment, and by installing a positioning socket on one side of the heat dissipation fan blade to reinforce the installation of the motor housing and the rotor mounting cover, the connection stability of the equipment during use is improved, and the interior of the drive circuit is provided with equally distributed Hall sensors, temperature sensors and vibration sensors, and a mounting ring is installed at one end of the drive circuit, and the end of the mounting ring away from the drive circuit is connected to the first connecting shaft, and the motor housing and the mounting side plate are reinforced and connected through the first connecting shaft, which facilitates daily maintenance of the whole.

[0010] As a preferred embodiment of the present invention, an integrated chip is provided inside the drive circuit and between the Hall sensors. The drive circuit, Hall sensor, temperature sensor, vibration sensor, battery, heat dissipation fan blades, rotor and stator are all electrically connected to the integrated chip. The integrated chip is used to control the operation of the drive circuit, Hall sensor, battery, heat dissipation fan blades, rotor and stator, thereby realizing unified management of power equipment.

[0011] As a preferred embodiment of the present invention, the integrated chip is provided with an MCU unit, a sensor control unit, a motor control unit and an algorithm optimization unit, and the MCU unit, the sensor control unit, the motor control unit and the algorithm optimization unit are all communicatively connected to the integrated chip; The MCU unit is used to receive position feedback from the Hall sensor and detect the position of the rotor in real time. Based on the rotor position, the MCU controls the current switching of the stator winding, thereby generating a rotating magnetic field to drive the rotor to rotate. The temperature sensor is used to monitor the temperature rise of the winding, and the vibration sensor is used to detect the dynamic balance state of the rotor. The data is processed in real time by the sensor control unit of the integrated chip and triggers the protection mechanism. Commutation control usually relies on a precise algorithm to ensure timely switching of the stator current to prevent the motor from losing steps or overheating. The sensor control unit is used to control the Hall sensor to monitor and process the position of each device inside the motor housing in real time. Other sensors can be installed for auxiliary monitoring according to the needs of the operation. The motor control unit is used by staff to remotely and on-sitely control the motor at the corresponding position and switch the operation mode; The algorithm optimization unit is used to control the entire motor through a single algorithm or a combination of multiple algorithms. The algorithms include a loaded vector frequency conversion control algorithm and a PID motor control algorithm. The loaded vector frequency conversion control algorithm is used to control the stator current so that the direction of the motor rotor magnetic field is consistent with the direction of the stator magnetic field, thereby making the motor operate in an optimal state. The PID motor control algorithm is used to generate a control signal by weighted averaging the error, thereby adjusting the input of the motor to achieve the expected output. The error is the difference between the target value and the actual value.

[0012] A method for controlling a brushless DC motor comprises the following specific steps: S1. Assemble and install all components of the brushless DC motor to test whether they can operate normally; S2. Constructing a new system integrated chip, which includes: integrating the MCU unit and the Hall sensor in the same packaging structure to obtain a new system integrated chip; the system integrated chip adopts a double-base island packaging structure; Chip configuration includes: loading a vector frequency conversion control algorithm and a PID motor control algorithm into the MCU unit of the system integrated chip; A control application, comprising: applying the system integrated chip to control a brushless DC motor; S3. Manage the above uniformly through the driving circuit, switch between on-site and remote control modes as needed during control, and use visualization equipment to perform real-time imaging processing of various data when the equipment is running.

[0013] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention is provided with a middle motor housing, a rotor mechanism and a fixed positioning plate. The second connecting shaft is driven to rotate inside the limiting shaft sleeve by the rotation of the rotor, thereby driving the output bearing at one end to rotate for subsequent operations. By sleeved with a sealing flange on the outside of the sealing flange, it is convenient to connect the rotor mounting cover and the sealing flange cover, and a certain degree of protection is provided for the internal limiting shaft sleeve and the second connecting shaft. By providing a protective cover on the outside of the rotor mounting cover, the rotor mechanism is subjected to daily protection treatment. By installing a positioning card seat on one side of the heat dissipation fan blade to cooperate with the motor housing and the rotor mounting cover for reinforced installation, the connection stability of the equipment during use is improved. 2. The present invention is provided with an auxiliary installation mechanism. The outer side of the sealing flange cover is provided with equidistantly distributed oil inlet chambers. When in use, oil and lubrication can be carried out through the oil inlet chambers reserved on the outer side of the sealing flange cover, thereby extending the service life of the equipment. The positioning bolts and the positioning rods cooperate to position the entire equipment on one side, thereby improving the overall stability during subsequent equipment operations. The limiting groove can be used to add lubricating oil until it falls onto the surface of the connecting sleeve, thereby lubricating part of the equipment. The motor housing and the mounting side plate are reinforced and connected through the first connecting shaft, thereby facilitating daily maintenance of the entire equipment. 3. The present invention sets an MCU unit to receive position feedback from the Hall sensor and detect the position of the rotor in real time. According to the position of the rotor, the MCU controls the current switching of the stator winding to generate a rotating magnetic field to drive the rotor to rotate. Commutation control usually relies on an accurate algorithm to ensure timely switching of the stator current to avoid motor loss of step or overheating; the sensor control unit is used to control the Hall sensor to monitor and process the position of each device inside the motor housing in real time, and other sensors can be installed for auxiliary monitoring according to the needs of the operation; the motor control unit is used for remote and on-site control of the motor at the corresponding position by the staff to switch the operation mode; the algorithm optimization unit is used to control the entire motor through a single algorithm or a combination of multiple algorithms, and generate a control signal by weighted averaging the error, thereby adjusting the input of the motor to achieve the expected output. The error is the difference between the target value and the actual value. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic diagram of the overall structure of a brushless DC motor and a control method thereof according to the present invention; Figure 2 Schematic diagram of the overall structure of a brushless DC motor and its control method according to the present invention Figure 1 ; Figure 3 Schematic diagram of the overall structure of a brushless DC motor and its control method according to the present invention Figure 2 ; Figure 4 It is a schematic diagram of the enlarged structure of the rotor mechanism of a brushless DC motor and a control method thereof according to the present invention; Figure 5 A schematic diagram of the enlarged structure of the auxiliary mounting mechanism of a brushless DC motor and its control method according to the present invention Figure 1 ; Figure 6 A schematic diagram of the enlarged structure of the auxiliary mounting mechanism of a brushless DC motor and its control method according to the present invention Figure 2 ; Figure 7 This is an appendix to the present invention of a brushless DC motor and its control method Figure 3A schematic diagram of the structure enlargement at point A; Figure 8 The present invention provides a flow chart of a brushless DC motor and a control method thereof.

[0015] In the picture: 1. Motor housing; 11. Drive circuit; 12. Mounting collar; 13. Hall sensor; 2. Install side panel; 21. Limit plate; 22. Battery; 23. First installation slot; 24. Lamination plate; 25. First connecting shaft; 3. Fixed positioning plate; 31. Positioning rod; 32. Limiting groove; 33. Auxiliary positioning frame; 34. Positioning bolt; 35. Connecting sleeve; 4. Sealing flange cover; 41. Output bearing; 42. Sealing flange; 43. Limiting sleeve; 44. Second connecting shaft; 5. Rotor mounting cover; 51. Heat dissipation fan blades; 52. Positioning card seat; 53. Rotor; 54. Second mounting slot; 55. Stator. DETAILED DESCRIPTION

[0016] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0017] See also Figure 1-Figure 7 The present invention provides a technical solution: a brushless DC motor, comprising a motor housing 1, and further comprising: a drive circuit 11, the drive circuit 11 being located inside the motor housing 1; an installation side plate 2, the installation side plate 2 being located at one end of the motor housing 1, and the installation side plate 2 being used for connecting the motor housing 1; In this solution, the auxiliary mounting mechanism is located at the end of the mounting side plate 2 away from the motor housing 1. The auxiliary mounting mechanism includes a fixed positioning plate 3. The mounting side plate 2 is installed at one end of the motor housing 1. A limit plate 21 is installed on the side of the mounting side plate 2 close to the motor housing 1. The internal space of the limit plate 21 is equipped with equidistantly distributed batteries 22. The battery 22 is a backup power module for the brushless DC motor, and is used to provide emergency power support when the main power supply is abnormal, ensuring the continuous operation of the motor control system. At the same time, the battery 22 is connected to the drive circuit 11 through an integrated chip to buffer the instantaneous current fluctuation when the motor starts, thereby improving the power supply stability. At the moment of the brushless DC motor starting current impact, the battery 22 provides a certain amount of power support. The circuit between the battery 22 and the brushless DC motor buffers the instantaneous current, thereby avoiding unstable power supply caused by excessive instantaneous current. The battery 22 works in conjunction with the external main power supply to provide initial current when the brushless DC motor starts. After the main power supply is put into normal operation, the battery 22 is charged again to maintain the charging state and current balance of the battery 22; A first connecting shaft 25 is installed on the axis of the mounting side plate 2, and a fitting disk 24 is sleeved on the outer side of the first connecting shaft 25. The fitting disk 24 is connected to the limit disk 21. One end of the first connecting shaft 25 extends into the interior of the motor housing 1. A fixed positioning plate 3 is installed on the side of the mounting side plate 2 away from the motor housing 1. An auxiliary positioning frame 33 is installed on the side of the fixed positioning plate 3 close to the mounting side plate 2. One side of the connecting sleeve 35 is connected to the mounting side plate 2; In practice, to prevent the first connecting shaft 25 from rotating due to the motor's reaction force, a keyway structure (not shown) is provided between the first connecting shaft 25 and the mounting side plate 2, and the shaft is secured with radial pins. Furthermore, an interference fit is employed between the contact plate 24 and the limiting plate 21, further limiting the circumferential displacement of the first connecting shaft 25 and ensuring the overall stability of the motor housing 1, mounting side plate 2, fixed positioning plate 3, and sealing flange cover 4. In this embodiment, the rotor 53 mechanism is located at one end of the motor housing 1 away from the mounting side plate 2. The rotor 53 mechanism includes a rotor mounting cover 5. The rotor mounting cover 5 is mounted on one end of the motor housing 1. The rotor 53 is mounted on one side of the rotor mounting cover 5. The rotor 53 is mounted on one end of the rotor 53. A heat dissipation fan blade 51 extending into the interior of the motor housing 1 is installed; The sealing flange cover 4 is located at the end of the rotor 53 away from the motor housing 1.

[0018] See also Figure 1-Figure 3In this solution, a sealing flange 42 is provided inside the sealing flange cover 4, and a limiting sleeve 43 is installed inside the sealing flange 42. A second connecting shaft 44 is installed inside the limiting sleeve 43. One end of the second connecting shaft 44 passes through the sealing flange cover 4 and is fixedly connected to the output bearing 41. The other end of the second connecting shaft 44 is connected to one end of the rotor 53. The second connecting shaft 44 is driven to rotate inside the limiting sleeve 43 by the rotation of the rotor 53, thereby driving the output bearing 41 at one end to rotate for subsequent operations. By sleeved with a sealing flange 42 on the outside of the sealing flange 42, it is convenient to connect the rotor mounting cover 5 and the sealing flange cover 4, and it also provides a certain degree of protection for the internal limiting sleeve 43 and the second connecting shaft 44.

[0019] In this solution, the outer side of the sealing flange cover 4 is provided with equidistantly distributed oil inlet cavities. When in use, oil can be added and lubricated through the oil inlet cavities reserved on the outer side of the sealing flange cover 4, thereby extending the service life of the equipment.

[0020] See also Figure 1-Figure 7 In this solution, a first mounting groove 23 is evenly distributed on the side of the mounting side plate 2 close to the fixed positioning plate 3, a connecting sleeve 35 is installed on the outer side of the auxiliary positioning frame 33, and the auxiliary positioning frame 33 is threadedly connected with positioning bolts 34 that pass through the fixed positioning plate 3 on all four sides.

[0021] In this solution, a limiting groove 32 is provided on the top of the fixed positioning plate 3. Four positioning rods 31 are installed at equal distances on the side of the fixed positioning plate 3 away from the mounting side plate 2. One end of the positioning bolt 34 extends into the inside of the corresponding positioning rod 31. An oil guide hole is also provided at the bottom of the limiting groove 32. In actual application, the lubricating oil flows into the contact surface between the connecting sleeve 35 and the first connecting shaft 25 through the oil guide hole, and penetrates into the interior of the limiting sleeve 43 along the axial direction, ensuring lubrication between the second connecting shaft 44 and the limiting sleeve 43. The oil inlet chamber of the sealing flange cover 4 is connected to the limiting sleeve 43 through the internal oil channel, forming a closed-loop lubrication system to prevent the lubricating oil from remaining only on the surface. In order to improve the lubrication efficiency, an oil guide hole of the same structure can be opened at the bottom of the rotor mounting cover 5 to facilitate direct entry of lubricating oil; The entire device is positioned on one side by cooperating with the positioning bolt 34 and the positioning rod 31, thereby improving the overall stability during subsequent device operation. The limiting groove 32 can be used to add lubricating oil until it falls onto the surface of the connecting sleeve 35 to lubricate part of the equipment.

[0022] See also Figures 1-4 In this embodiment, the rotor mounting cover 5 is provided with second mounting grooves 54 distributed evenly, and the stators 55 are installed inside the second mounting grooves 54. The end of the heat dissipation fan blade 51 away from the limiting sleeve 43 is provided with a positioning seat 52. One end of the positioning card holder 52 is fixed to the end surface of the heat dissipation fan blade 51 by a bolt, and the other end is embedded in the card slot on the side wall of the drive circuit 11 to form a rigid connection, thereby strengthening the docking between the motor housing 1 and the rotor mounting cover 5. At the same time, in actual application, an insulating gasket is also provided in the card slot to prevent electromagnetic interference between the positioning card holder 52 and the Hall sensor 13; One end of the positioning card seat 52 extends to the interior of the drive circuit 11. The interior of the drive circuit 11 is provided with an installation cavity for the installation of the drive circuit 11. A protective cover is provided on the outside of the rotor mounting cover 5. By providing a protective cover on the outside of the rotor mounting cover 5, a detachable dust filter is also installed on the inside of the through hole of the rotor mounting cover 5. The filter is made of a high-efficiency air flow permeable material. A dust filter material with better air permeability is selected. The filter material with a microporous structure can effectively prevent dust from entering while allowing air to flow, reducing air flow resistance, and performing daily protection treatment on the rotor 53 mechanism. By installing a positioning card seat 52 on one side of the heat dissipation fan blade 51 to reinforce the motor housing 1 and the rotor mounting cover 5, the connection stability of the equipment during use is improved.

[0023] See also Figures 1-8 In this solution, Hall sensors 13 are installed in the interior of the driving circuit 11 at equal intervals. A mounting collar 12 is installed at one end of the driving circuit 11. The end of the mounting collar 12 away from the driving circuit 11 is connected to the first connecting shaft 25. The motor housing 1 and the mounting side plate 2 are reinforced and connected through the first connecting shaft 25, which facilitates daily maintenance of the entire unit.

[0024] In this solution, an integrated chip is provided inside the drive circuit 11 and between the Hall sensors 13. The drive circuit 11, the Hall sensor 13, the battery 22, the heat dissipation fan blades 51, the rotor 53 and the stator 55 are all electrically connected to the integrated chip. The integrated chip is used to control the operation of the drive circuit 11, the Hall sensor 13, the battery 22, the heat dissipation fan blades 51, the rotor 53 and the stator 55, thereby realizing unified management of the power equipment.

[0025] See also Figures 1-8 ,In this solution, the integrated chip is equipped with an MCU unit, a sensor control unit, a motor control unit and an algorithm optimization unit, and the MCU unit, the sensor control unit, the motor control unit and the algorithm optimization unit are all communicatively connected to the integrated chip; The MCU unit is used to receive position feedback from the Hall sensor 13 and detect the position of the rotor 53 in real time. Based on the position of the rotor 53, the MCU controls the current switching of the stator 55 winding, thereby generating a rotating magnetic field to drive the rotor 53 to rotate. Commutation control usually relies on a precise algorithm to ensure timely switching of the stator 55 current to prevent the motor from losing steps or overheating. The sensor control unit is used to control the Hall sensor 13 to monitor and process the position of each device inside the motor housing 1 in real time. Other sensors can be installed for auxiliary monitoring according to the needs of the operation; The motor control unit is used by staff to remotely and on-sitely control the motor at the corresponding position and switch the operation mode; The algorithm optimization unit is used to control the entire motor through a single algorithm or a combination of multiple algorithms. The algorithms include a loaded vector frequency conversion control algorithm and a PID motor control algorithm. The loaded vector frequency conversion control algorithm is used to control the stator current so that the direction of the motor rotor magnetic field is consistent with the direction of the stator magnetic field, thereby making the motor work in the optimal state. The PID motor control algorithm is used to generate a control signal by weighted averaging the error, thereby adjusting the input of the motor to achieve the expected output. The error is the difference between the target value and the actual value.

[0026] A method for controlling a brushless DC motor comprises the following specific steps: S1. Assemble and install all components of the brushless DC motor to test whether they can operate normally; S2. Constructing a new system integrated chip, which includes: integrating the MCU unit and the Hall sensor in the same package structure to obtain a new system integrated chip; the system integrated chip adopts a double-base island package structure; Chip configuration includes: loading a vector frequency conversion control algorithm and a PID motor control algorithm into the MCU unit of the system integrated chip; Control applications, including: using system integrated chips to control brushless DC motors; S3. Manage the above uniformly through the driving circuit, switch between on-site and remote control modes as needed during control, and use visualization equipment to perform real-time imaging processing of various data when the equipment is running.

[0027] Working principle of the present invention: The present invention is provided with a middle motor housing 1, a rotor mechanism and a fixed positioning plate 3. The rotor 53 rotates to drive the second connecting shaft 44 to rotate inside the limiting sleeve 43, thereby driving the output bearing 41 at one end to rotate for subsequent operations.

[0028] By sleeved the sealing flange 42 on the outside of the sealing flange 42 , it is convenient to connect the rotor mounting cover 5 and the sealing flange cover 4 , and it also provides a certain degree of protection for the internal limiting shaft sleeve 43 and the second connecting shaft 44 .

[0029] By opening a protective cover on the outside of the rotor mounting cover 5, the rotor 53 mechanism is subjected to daily protection treatment, and by installing a positioning bracket 52 on one side of the heat dissipation fan blade 51 to reinforce the motor housing 1 and the rotor mounting cover 5, the connection stability of the equipment during use is improved.

[0030] The integrated chip is used to control the operation of the drive circuit 11, the Hall sensor 13, the battery 22, the heat dissipation fan blades 51, the rotor 53 and the stator 55, thus achieving unified management of the power equipment; The integrated chip communicates with the drive circuit 11, the Hall sensor 13, and the visualization device via the SPI bus. A data acquisition module is provided within the chip to receive real-time signals of the magnetic pole position of the rotor 53 detected by the Hall sensor 13, and output current control signals for the stator 55 windings via the PWM module. Visualization uses the chip's built-in graphics processing unit (GPU) to convert speed, current, and temperature data into dynamic waveforms, which are then transmitted to an external display via the HDMI interface. The present invention is provided with an auxiliary installation mechanism, and the outer side of the sealing flange cover 4 is provided with equidistantly distributed oil inlet cavities. When in use, oil and lubrication can be carried out through the oil inlet cavities reserved on the outer side of the sealing flange cover 4, thereby extending the service life of the equipment.

[0031] The positioning bolt 34 and the positioning rod 31 cooperate to position the entire device on one side, thereby improving the overall stability of the device during subsequent operation.

[0032] The limiting groove 32 can be used to add lubricating oil until it falls onto the surface of the connecting sleeve 35, thereby lubricating part of the equipment. The motor housing 1 and the mounting side plate 2 are reinforced and connected through the first connecting shaft 25, making it convenient for daily maintenance of the entire unit. The present invention sets an MCU unit to receive position feedback from the Hall sensor 13 and detect the position of the rotor 53 in real time. According to the position of the rotor 53, the MCU controls the current switching of the stator 55 winding, thereby generating a rotating magnetic field to drive the rotor 53 to rotate. Commutation control usually relies on an accurate algorithm to ensure timely switching of the stator 55 current to avoid motor loss of step or overheating.

[0033] The sensor control unit is used to control the Hall sensor 13 to monitor and process the position of each device inside the motor housing 1 in real time. Other sensors can be installed for auxiliary monitoring according to the needs of the operation.

[0034] The motor control unit is used by staff to remotely and on-sitely control the motor at the corresponding position and switch the operating mode.

[0035] The algorithm optimization unit is used to control the entire motor through a single algorithm or a combination of multiple algorithms. The algorithms include a loaded vector variable frequency control algorithm and a PID motor control algorithm. The loaded vector variable frequency control algorithm is used to control the stator current so that the direction of the motor rotor magnetic field is consistent with the direction of the stator magnetic field, thereby making the motor work in the optimal state. The PID motor control algorithm is used to generate a control signal by weighted averaging the error, thereby adjusting the motor input to achieve the expected output. The error is the difference between the target value and the actual value; The MCU unit determines the energization sequence of the stator 55 windings by looking up a table based on the rotor position signal fed back by the Hall sensor 13 to ensure synchronization of the rotating magnetic field with the permanent magnet of the rotor 53. The specific steps include: Position signal decoding → phase switching logic calculation → drive signal output; The temperature sensor monitors the temperature rise of the windings, and the vibration sensor detects the dynamic balance state of the rotor 53. The data is processed in real time by the sensor control unit of the integrated chip and triggers the protection mechanism; By combining the vector frequency conversion control algorithm with the PID control algorithm, more complex and precise waveform control can be achieved. The specific implementation method is as follows: On the basis of vector control, the PID controller is used to adjust the speed of the motor. Through the PID motor control algorithm, the speed of the motor can be accurately adjusted, and the control waveform can be dynamically adjusted according to the load changes to ensure the smooth operation of the motor.

[0036] PID controllers can also be used to control the position of a motor. In specific applications, feedback control is used to adjust the motor's rotation angle to ensure that its output waveform is accurate.

[0037] By adjusting the motor's current vector, the magnitude and phase of the d-axis and q-axis currents, and combining them with the speed feedback of the PID control, different output waveforms can be generated.

[0038] Assemble and install the various components of the brushless DC motor to test whether they can operate normally; Constructing a new system integrated chip, which includes: integrating an MCU unit and a Hall sensor in the same package structure to obtain a new system integrated chip; the system integrated chip adopts a double base island package structure; Chip configuration includes: loading a vector frequency conversion control algorithm and a PID motor control algorithm into the MCU unit of the system integrated chip; Control applications, including: using system integrated chips to control brushless DC motors; The above are managed uniformly through the driving circuit, and the on-site and remote control modes are switched as needed during control. The real-time imaging of various data during equipment operation is performed through the visualization device.

[0039] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A brushless DC motor, comprising a motor housing (1), characterized in that: Also includes: The drive circuit (11), the drive circuit (11) is located inside the motor housing (1); The mounting side plate (2) is located at one end of the motor housing (1); The auxiliary mounting mechanism is located at one end of the mounting side plate (2) away from the motor housing (1), and the auxiliary mounting mechanism includes a fixed positioning plate (3). The mounting side plate (2) is installed at one end of the motor housing (1), and a limiting disk (21) is installed on the side of the mounting side plate (2) close to the motor housing (1), and batteries (22) are installed inside the limiting disk (21) at equal intervals. A first connecting shaft (25) is installed on the axis of the mounting side plate (2), and a fitting disk (24) is sleeved on the outer side of the first connecting shaft (25). A fixed positioning plate (3) is installed on the side of the mounting side plate (2) away from the motor housing (1), and an auxiliary positioning frame (33) is installed on the side of the fixed positioning plate (3) close to the mounting side plate (2), and one side of the connecting sleeve (35) is connected to the mounting side plate (2); The rotor (53) mechanism is located at one end of the motor housing (1) away from the mounting side plate (2), and the rotor (53) mechanism includes a rotor mounting cover (5), one end of the motor housing (1) is mounted with the rotor mounting cover (5), one side of the rotor mounting cover (5) is mounted with the rotor (53), and one end of the rotor (53) is mounted with a heat dissipation fan blade (51) extending into the interior of the motor housing (1); The sealing flange cover (4) is located at an end of the rotor (53) mechanism away from the motor housing (1).

2. The brushless DC motor according to claim 1, wherein: A sealing flange (42) is provided inside the sealing flange cover (4), a limiting sleeve (43) is installed inside the sealing flange cover (42), a second connecting shaft (44) is installed inside the limiting sleeve (43), one end of the second connecting shaft (44) passes through the sealing flange cover (4) and is fixedly connected to the output bearing (41), and the other end of the second connecting shaft (44) is connected to one end of the rotor (53).

3. The brushless DC motor according to claim 2, wherein: The outer side of the sealing flange cover (4) is provided with oil inlet cavities distributed at equal intervals.

4. The brushless DC motor according to claim 3, wherein: The side of the mounting side plate (2) close to the fixed positioning plate (3) is provided with first mounting grooves (23) distributed at equal intervals, the outer side of the auxiliary positioning frame (33) is provided with a connecting sleeve (35), and the four sides of the auxiliary positioning frame (33) are all threadedly connected with positioning bolts (34) that penetrate the fixed positioning plate (3).

5. The brushless DC motor according to claim 4, wherein: A limiting groove (32) is provided on the top of the fixed positioning plate (3), and four positioning rods (31) are installed at equal intervals on the side of the fixed positioning plate (3) away from the mounting side plate (2). One end of each positioning bolt (34) extends into the interior of the corresponding positioning rod (31), and an oil guide hole is also provided at the bottom of the limiting groove 32.

6. The brushless DC motor according to claim 4, wherein: The rotor mounting cover (5) is provided with second mounting grooves (54) distributed at equal intervals, and the stators (55) are installed in the interior of each of the second mounting grooves (54). A positioning card seat (52) is installed at one end of the heat dissipation fan blade (51) away from the limiting shaft sleeve (43), and one end of the positioning card seat (52) extends into the interior of the drive circuit (11). The interior of the drive circuit (11) is provided with an installation cavity for matching the installation of the drive circuit (11), and a protective cover is provided on the outside of the rotor mounting cover (5).

7. The brushless DC motor according to claim 6, wherein: The driving circuit (11) is internally installed with equally spaced Hall sensors (13), a temperature sensor, and a vibration sensor. A mounting collar (12) is installed at one end of the driving circuit (11), and an end of the mounting collar (12) away from the driving circuit (11) is connected to a first connecting shaft (25).

8. The brushless DC motor according to claim 7, wherein: An integrated chip is provided inside the driving circuit (11) and between the Hall sensors (13); the driving circuit (11), the Hall sensors (13), the temperature sensor, the vibration sensor, the battery (22), the heat dissipation fan blades (51), the rotor (53) and the stator (55) are all electrically connected to the integrated chip.

9. The brushless DC motor according to claim 8, characterized in that: The integrated chip is internally provided with an MCU unit, a sensor control unit, a motor control unit and an algorithm optimization unit, and the MCU unit, the sensor control unit, the motor control unit and the algorithm optimization unit are all communicatively connected to the integrated chip; The MCU unit is used to receive position feedback from the Hall sensor (13) and detect the position of the rotor (53) in real time. According to the position of the rotor (53), the MCU controls the current switching of the stator (55) winding, thereby generating a rotating magnetic field to drive the rotor (53) to rotate; The temperature sensor is used to monitor the temperature rise of the winding, and the vibration sensor is used to detect the dynamic balance state of the rotor (53). The data is processed in real time by the sensor control unit of the integrated chip and a protection mechanism is triggered; The sensor control unit is used to control the Hall sensor (13) to perform real-time monitoring and transmission processing on the position of each device inside the motor housing (1); The motor control unit is used by staff to remotely and on-site control the motor at the corresponding position; The algorithm optimization unit is used to control the entire motor through a single algorithm or a combination of multiple algorithms, and the algorithms include a loaded vector frequency conversion control algorithm and a PID motor control algorithm.

10. A method for controlling a brushless DC motor, for implementing the brushless DC motor according to any one of claims 1 to 9, characterized in that: The specific steps include: S1. Assemble and install all components of the brushless DC motor to test whether they can operate normally; S2. constructing a new system integrated chip, which includes: integrating the MCU unit and the Hall sensor into the same package structure to obtain a new system integrated chip; Chip configuration includes: loading a vector frequency conversion control algorithm and a PID motor control algorithm into the MCU unit of the system integrated chip; A control application, comprising: applying the system integrated chip to control a brushless DC motor; S3. Manage the above uniformly through the driving circuit, switch between on-site and remote control modes as needed during control, and use visualization equipment to perform real-time imaging processing of various data when the equipment is running.

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