A brushless direct current motor and a control method thereof

Abstract

The application discloses a brushless direct current motor and a control method thereof, and relates to the technical field of motor equipment, which comprises a motor shell and further comprises: a driving circuit, which is located in the interior of the motor shell; the application has the beneficial effects that: the application is provided with a motor shell, a rotor mechanism and a fixed positioning plate, a protective cover is arranged outside the rotor mounting cover, a positioning clamping seat is arranged on one side of the heat dissipation fan blade, the motor shell and the rotor mounting cover are reinforced and installed, and the connection stability during equipment use is improved; the application is provided with an auxiliary mounting mechanism, the motor shell and the mounting side plate are reinforced and connected through a first connecting shaft, and the overall routine maintenance treatment is facilitated; the application is provided with an MCU unit for receiving position feedback from a Hall sensor, the MCU controls the current switching of the stator winding, thereby generating a rotating magnetic field to drive the rotor to rotate, and the error is the difference between the target value and the actual value.

Description

TECHNICAL FIELD

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

[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 DC power supply. The brushless DC motor mainly consists of a rotor made of permanent magnet material and a stator with coil winding.

[0003] Chinese Patent Publication No. CN 116683666 A discloses a magnetic core brushless DC motor and a control method thereof, which solves the problems of low torque, complex production process and structure, high maintenance cost, and high power consumption of existing DC motors. The magnetic core brushless DC motor includes a stator, a rotor, 2N Hall sensors, a power supply unit, a driver, and a stator magnetic steel; the stator magnetic steel includes a first magnetic steel and a second magnetic steel; the word surface of the N Hall sensors faces the rotor structure, and the word surface of the N Hall sensors faces away from the rotor structure. When a coil is supplied with DC power, the magnetic field in the magnetic steel with the same polarity as the coil in the core counteracts and cancels out the induced magnetic field of the coil; the magnetic field of the other magnetic steel and the induced magnetic field of the coil are of opposite polarity, and the magnetic field of the magnetic steel and the induced magnetic field of the coil generated when the coil is powered together act on the core to generate a new mixed magnetic field, and the magnetic induction intensity of the new mixed magnetic field is much greater than the induced magnetic field intensity generated by the pure core.

[0004] However, the above-mentioned scheme still has the following problems: the existing brushless DC motor control chip has single function and cannot achieve various output waveform control, and the motor itself is not improved, which causes defects in the motor itself, thereby affecting subsequent motor control processing, and it is difficult to meet the application scenarios of various brushless DC motor products, so the present application needs to design a brushless DC motor and a control method thereof to solve the above-mentioned problems. SUMMARY

[0005] The present application aims to provide a brushless DC motor and a control method thereof to solve the problems raised in the background art.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a brushless DC motor, comprising a motor housing, further comprising:

[0007] The driving circuit is located inside the motor housing.

[0008] The mounting side plate is located at one end of the motor housing, and the mounting side plate is used for connecting the motor housing.

[0009] The auxiliary mounting mechanism is located at the end of the mounting side plate away from the motor shell, the auxiliary mounting mechanism comprises a fixed positioning plate, the end of the motor shell is provided with the mounting side plate, the side of the mounting side plate close to the motor shell is provided with a limiting disc, the inside of the limiting disc is provided with battery cells distributed at equal intervals, the shaft center of the mounting side plate is provided with a first connecting shaft, the outside of the first connecting shaft is sleeved with a matching disc, the matching disc is connected with the limiting disc, one end of the first connecting shaft extends into the inside of the motor shell, the side of the mounting side plate away from the motor shell is provided with the fixed positioning plate, the side of the fixed positioning plate close to the mounting side plate is provided with an auxiliary positioning frame, one side of the connecting sleeve is connected with the mounting side plate.

[0010] The rotor mechanism is located at the end of the motor shell away from the mounting side plate, the rotor mechanism comprises a rotor mounting cover, the end of the motor shell is provided with the rotor mounting cover, the side of the rotor mounting cover is provided with a rotor, one end of the rotor is provided with a heat dissipation fan blade extending into the inside of the motor shell.

[0011] The sealing flange cover is located at the end of the rotor mechanism away from the motor shell.

[0012] As a preferred embodiment of the application, the inside of the sealing flange cover is provided with a sealing flange disc, the inside of the sealing flange disc is provided with a limiting shaft sleeve, the inside of the limiting shaft sleeve is provided with a second connecting shaft, one end of the second connecting shaft penetrates through the sealing flange cover and is fixedly connected with an output bearing, the other end of the second connecting shaft is connected with one end of the rotor, the second connecting shaft is driven to rotate in the limiting shaft sleeve by the rotation of the rotor, so as to drive the output bearing at one end to rotate and perform subsequent operation, the sealing flange disc is sleeved outside the sealing flange disc, which not only facilitates the connection of the rotor mounting cover and the sealing flange cover, but also protects the limiting shaft sleeve and the second connecting shaft inside to a certain extent, the outside of the sealing flange cover is provided with oil inlet cavities distributed at equal intervals, the oil inlet cavities reserved outside the sealing flange cover can be used for oiling and lubricating treatment during use, thereby prolonging the service life of the equipment.

[0013] As a preferred embodiment of the present application, the first mounting groove is arranged on the side of the mounting side plate close to the fixed positioning plate, the connecting sleeve is mounted on the outer side of the auxiliary positioning frame, the positioning bolt is threadedly connected to the four sides of the auxiliary positioning frame and penetrates through the fixed positioning plate, the limiting groove is arranged on the top of the fixed positioning plate, four positioning insertion rods are arranged on the side of the fixed positioning plate away from the mounting side plate, one end of the positioning bolt extends into the corresponding positioning insertion rod, and the oil guide hole is arranged on the bottom of the limiting groove. The positioning bolt and the positioning insertion rod are used for positioning the whole equipment on one side, thereby improving the overall stability during subsequent equipment operation, and the limiting groove can be used for adding lubricating oil to the surface of the connecting sleeve for lubricating part of the equipment.

[0014] As a preferred embodiment of the present application, the second mounting groove is arranged in the rotor mounting cover, the stator is mounted in the second mounting groove, the positioning clamping base is mounted on the end of the heat dissipation fan blade away from the limiting shaft sleeve, one end of the positioning clamping base extends into the driving circuit, the mounting inner cavity is arranged in the driving circuit and matched with the driving circuit, the protective cover is arranged on the outer side of the rotor mounting cover, the positioning clamping base is arranged on one side of the heat dissipation fan blade, the driving circuit, the Hall sensor, the temperature sensor, the vibration sensor, the battery, the heat dissipation fan blade, the rotor and the stator are electrically connected with the integrated chip, the integrated chip is used for controlling the driving circuit, the Hall sensor, the battery, the heat dissipation fan blade, the rotor and the stator to run, and unified management of the power equipment is realized.

[0015] As a preferred embodiment of the present application, the integrated chip is arranged in the driving circuit and between the Hall sensors, the driving circuit, the Hall sensor, the temperature sensor, the vibration sensor, the battery, the heat dissipation fan blade, the rotor and the stator are electrically connected with the integrated chip, the integrated chip is used for controlling the driving circuit, the Hall sensor, the battery, the heat dissipation fan blade, the rotor and the stator to run, and unified management of the power equipment is realized.

[0016] As a preferred embodiment of the present application, the integrated chip is arranged in the driving circuit and between the Hall sensors, the driving circuit, the Hall sensor, the temperature sensor, the vibration sensor, the battery, the heat dissipation fan blade, the rotor and the stator are electrically connected with the integrated chip, the integrated chip is used for controlling the driving circuit, the Hall sensor, the battery, the heat dissipation fan blade, the rotor and the stator to run, and unified management of the power equipment is realized.

[0017] The MCU unit is used to receive position feedback from the Hall sensor, detect the position of the rotor in real time, and control the current switching of the stator winding according to the position of the rotor, so as to generate a rotating magnetic field to drive the rotor to rotate. The temperature sensor is used to monitor the winding temperature rise, 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 an accurate algorithm to ensure timely switching of the stator current, avoiding motor out-of-step or overheating.

[0018] 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 required operation.

[0019] The motor control unit is used for remote and on-site control of the corresponding position of the motor by the staff, and the operating mode is switched.

[0020] The algorithm optimization unit is used to control and process the overall motor through a single algorithm or a combination of multiple algorithms. The algorithm includes a load vector variable frequency control algorithm and a PID motor control algorithm. The load 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, so that the motor works in the optimal state. The PID motor control algorithm is used to generate a control signal by weighting the average of the error, so as to adjust the input of the motor to achieve the expected output. The error is the difference between the target value and the actual value.

[0021] A control method of a brushless DC motor, comprising the following specific steps:

[0022] S1, assemble and install each component of the brushless DC motor, and test whether it can operate normally;

[0023] S2, construct 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;

[0024] Chip configuration, which includes: loading the MCU unit of the system integrated chip with a load vector variable frequency control algorithm and a PID motor control algorithm;

[0025] Control application, which includes: applying the system integrated chip to control the brushless DC motor;

[0026] S3, manage the system integrated chip through the drive circuit, control the switching between the on-site and remote control modes according to the required switching processing, and perform real-time imaging processing of each data during device operation through visual devices.

[0027] Compared with the prior art, the present application has the following advantages:

[0028] 1、The present application is provided with a middle motor shell, 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 and perform subsequent operations, the sealing flange cover is sleeved outside the sealing flange plate, which not only facilitates the connection of the rotor installation cover and the sealing flange cover, but also protects the limiting shaft sleeve and the second connecting shaft inside to a certain extent, the protective cover is arranged outside the rotor installation cover to perform daily protection treatment on the rotor mechanism, the positioning clamping base is arranged on one side of the heat dissipation fan blade to reinforce and install the motor shell and the rotor installation cover, and the connection stability during equipment use is improved;

[0029] 2、The present application is provided with an auxiliary installation mechanism, equidistantly distributed oil inlet cavities are arranged outside the sealing flange cover, oiling and lubrication treatment can be performed through the oil inlet cavities reserved outside the sealing flange cover during use, the service life of the equipment is prolonged, the positioning bolt and the positioning rod are used to perform one-side positioning treatment on the overall equipment, the overall stability during subsequent equipment operation is improved, the limiting groove can be used for adding lubricating oil until the lubricating oil falls on the surface of the connecting sleeve, thereby lubricating part of the equipment, the first connecting shaft is used to reinforce and connect the motor shell and the installation side plate, and daily maintenance treatment can be conveniently performed on the overall equipment;

[0030] 3、The present application is provided with an MCU unit for receiving position feedback from a Hall sensor, real-time detection of the position of the rotor, according to the position of the rotor, the MCU will control the current switching of the stator winding, thereby generating 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, avoiding motor out-of-step or overheating; a sensor control unit is used to control the Hall sensor to perform real-time monitoring and conveying treatment on the position of each device inside the motor shell, other sensors can be installed according to the operation requirements for auxiliary monitoring; a motor control unit is used for remote and on-site control of the motor at the corresponding position by the staff, and the operation mode is switched; an algorithm optimization unit is used to control the overall motor through a single algorithm or a combination of multiple algorithms, the error is weighted and averaged to generate a control signal, thereby adjusting the input of the motor to achieve the expected output, and the error is the difference between the target value and the actual value. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 It is a whole structure schematic diagram of the present application of a brushless DC motor and a control method thereof;

[0032] Figure 2 It is a whole structure explosion schematic diagram of the present application of a brushless DC motor and a control method thereof Figure 1 ;

[0033] Figure 3 Fig. 1 is an overall structure of a brushless DC motor and a control method thereof according to the present application; Figure 2 ;

[0034] Figure 4 Fig. 2 is an enlarged structure of a rotor mechanism of the brushless DC motor and the control method thereof according to the present application;

[0035] Figure 5 Fig. 3 is an enlarged structure of an auxiliary installation mechanism of the brushless DC motor and the control method thereof according to the present application; Figure 1 ;

[0036] Figure 6 Fig. 4 is an enlarged structure of the auxiliary installation mechanism of the brushless DC motor and the control method thereof according to the present application; Figure 2 ;

[0037] Figure 7 Fig. 5 is an enlarged structure of a part A of the brushless DC motor and the control method thereof according to the present application; Figure 3 ;

[0038] Figure 8 Fig. 6 is a flowchart of a control method of the brushless DC motor and the control method thereof according to the present application.

[0039] In the drawings:

[0040] 1, motor housing; 11, driving circuit; 12, installation collar; 13, Hall sensor;

[0041] 2, installation side plate; 21, limiting disc; 22, storage battery; 23, first installation groove; 24, adhering disc; 25, first connecting shaft;

[0042] 3, fixed positioning plate; 31, positioning plug; 32, limiting groove; 33, auxiliary positioning frame; 34, positioning bolt; 35, connecting sleeve;

[0043] 4, sealing flange cover; 41, output bearing; 42, sealing flange; 43, limiting shaft sleeve; 44, second connecting shaft;

[0044] 5, rotor installation cover; 51, heat dissipation fan blade; 52, positioning clamping base; 53, rotor; 54, second installation groove; 55, stator. DETAILED DESCRIPTION

[0045] Clearly, the embodiments described are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments of the present application, all other embodiments obtained by a person of ordinary skill in the art without creative effort belong to the scope of protection of the present application.

[0046] Please refer to Figures 1-7 The present application provides a technical solution: a brushless DC motor, comprising a motor housing 1, further comprising: a 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, and the mounting side plate 2 is used for connecting the motor housing 1;

[0047] In the present scheme, the auxiliary mounting mechanism is located at the end of the mounting side plate 2 away from the motor housing 1, and the auxiliary mounting mechanism comprises a fixed positioning plate 3, one end of the motor housing 1 is provided with the mounting side plate 2, the mounting side plate 2 is provided with a limiting disc 21 on the side close to the motor housing 1, and the limiting disc 21 is provided with equally distributed storage batteries 22 in the inside;

[0048] The storage battery 22 is a backup power module of the brushless DC motor, which is used to provide emergency power support when the main power is abnormal, to ensure the continuous operation of the motor control system. At the same time, the storage battery 22 is connected with the drive circuit 11 through an integrated chip, buffers the transient current fluctuation when the motor starts, improves the power supply stability, provides certain power support at the moment of the starting current impact of the brushless DC motor, buffers the transient current between the storage battery 22 and the brushless DC motor, thereby avoiding the power supply instability caused by the too large transient current, and the storage battery 22 cooperates with the external main power to provide the initial current when the brushless DC motor starts, and the storage battery 22 is charged again after the main power is put into normal work, so as to maintain the charging state and current balance of the storage battery 22;

[0049] The first connecting shaft 25 is arranged on the axis of the mounting side plate 2, the outer side of the first connecting shaft 25 is provided with a matching disc 24, the matching disc 24 is connected with the limiting disc 21, one end of the first connecting shaft 25 extends into the inside of the motor housing 1, the fixed positioning plate 3 is arranged on the side of the mounting side plate 2 away from the motor housing 1, the fixed positioning plate 3 is provided with an auxiliary positioning frame 33 on the side close to the mounting side plate 2, and one side of the connecting sleeve 35 is connected with the mounting side plate 2;

[0050] In practical application, in order to prevent the first connecting shaft 25 from rotating deviation due to the motor reaction force, the first connecting shaft 25 and the mounting side plate 2 are provided with a key groove structure (not shown in the figure), and are fixed by a radial pin. In addition, the interference fit is adopted between the matching disc 24 and the limiting disc 21, which further limits the circumferential displacement of the first connecting shaft 25, and ensures the overall stability of the motor shell 1, the mounting side plate 2, the fixed positioning plate 3 and the sealing flange cover 4;

[0051] In the scheme, the rotor mechanism is located at one end of the motor shell 1 away from the mounting side plate 2, and the rotor mechanism includes a rotor mounting cover 5, the rotor mounting cover 5 is installed at one end of the motor shell 1, one side of the rotor mounting cover 5 is installed with a rotor 53, and one end of the rotor 53 is installed with a heat dissipation fan blade 51 extending into the inside of the motor shell 1.

[0052] The sealing flange cover 4 is located at one end of the rotor mechanism away from the motor shell 1.

[0053] Please refer to Figures 1-3 In the scheme, the inside of the sealing flange cover 4 is provided with a sealing flange plate 42, the inside of the sealing flange plate 42 is installed with a limiting shaft sleeve 43, the inside of the limiting shaft sleeve 43 is installed with a second connecting shaft 44, one end of the second connecting shaft 44 penetrates through the sealing flange cover 4 and is fixedly connected with an output bearing 41, the other end of the second connecting shaft 44 is connected with one end of the rotor 53, and the second connecting shaft 44 is driven to rotate in the limiting shaft sleeve 43 through the rotation of the rotor 53, so as to drive the output bearing 41 at one end to rotate and perform subsequent operation. By sleeving the sealing flange plate 42 outside the sealing flange plate 42, the rotor mounting cover 5 and the sealing flange cover 4 are conveniently connected, and the limiting shaft sleeve 43 and the second connecting shaft 44 inside are protected to a certain extent.

[0054] In the scheme, the outside of the sealing flange cover 4 is provided with equidistantly distributed oil inlet cavities, which can be used for oiling and lubricating treatment through the oil inlet cavities reserved outside the sealing flange cover 4 during use, thereby prolonging the service life of the equipment.

[0055] Please refer to Figures 1-7 In the scheme, the mounting side plate 2 is provided with equidistantly distributed first mounting grooves 23 on the side close to the fixed positioning plate 3, a connecting sleeve 35 is installed outside the auxiliary positioning frame 33, and a positioning bolt 34 penetrating through the fixed positioning plate 3 is threadedly connected around the auxiliary positioning frame 33.

[0056] In the scheme, the top of the fixed positioning plate 3 is provided with a limiting groove 32, four equidistantly distributed positioning insertion rods 31 are installed on the side of the fixed positioning plate 3 away from the mounting side plate 2, and one end of the positioning bolt 34 extends into the inside of the corresponding positioning insertion rod 31. The bottom of the limiting groove 32 is also provided with an oil guide hole;

[0057] In practical application, the lubricating oil flows into the contact surface of the connecting sleeve 35 and the first connecting shaft 25 through the oil guide hole, and penetrates into the inside of the limiting shaft sleeve 43 in the axial direction, ensuring the lubrication between the second connecting shaft 44 and the limiting shaft sleeve 43, and the oil inlet cavity of the sealing flange cover 4 is communicated with the limiting shaft sleeve 43 through the internal oil channel, forming a closed-loop lubrication system, avoiding that the lubricating oil only stays on the surface;

[0058] In order to improve the lubrication efficiency, the oil guide hole with the same structure can be arranged at the bottom of the rotor mounting cover 5, so as to facilitate the direct introduction of lubricating oil;

[0059] The overall equipment is positioned on one side by the cooperation of the positioning bolt 34 and the positioning plug rod 31, so as to improve the overall stability during subsequent equipment operation. The limiting groove 32 can be used for adding lubricating oil until it falls on the surface of the connecting sleeve 35, so as to lubricate part of the equipment.

[0060] Please refer to Figures 1-4 In the scheme, the second installation groove 54 is arranged inside the rotor mounting cover 5, the stator 55 is arranged inside the second installation groove 54, and the positioning clamping seat 52 is arranged at one end of the heat dissipation fan blade 51 away from the limiting shaft sleeve 43.

[0061] One end of the positioning clamping seat 52 is fixed to the end face of the heat dissipation fan blade 51 through a bolt, and the other end is embedded in the clamping groove in the side wall of the driving circuit 11, so as to form a rigid connection, thereby reinforcing the butt joint of the motor shell 1 and the rotor mounting cover 5. In practical application, an insulating gasket is also arranged in the clamping groove, so as to avoid electromagnetic interference between the positioning clamping seat 52 and the Hall sensor 13.

[0062] One end of the positioning clamping seat 52 extends to the inside of the driving circuit 11, the installation inner cavity matched with the driving circuit 11 is arranged in the inside of the driving circuit 11, the protective cover is arranged outside the rotor mounting cover 5, the detachable dustproof filter screen is arranged inside the through hole of the rotor mounting cover 5, the filter screen is made of high-efficiency airflow permeable material, the dustproof filter screen material with better air permeability is selected, the filter material with microporous structure is adopted, dust can be effectively prevented from entering, air flow is allowed to flow, airflow resistance is reduced, the rotor mechanism is protected on a daily basis, the motor shell 1 and the rotor mounting cover 5 are reinforced and installed through the cooperation of the positioning clamping seat 52 arranged on one side of the heat dissipation fan blade 51, and the connection stability of the equipment during use is improved.

[0063] Please refer to Figures 1-8 In the scheme, the Hall sensor 13 is arranged inside the driving circuit 11, the mounting sleeve ring 12 is arranged at one end of the driving circuit 11, and the other end of the mounting sleeve ring 12 is connected with the first connecting shaft 25, so as to reinforce and connect the motor shell 1 and the mounting side plate 2 through the first connecting shaft 25, thereby facilitating the daily maintenance of the overall equipment.

[0064] The internal drive circuit 11 in this scheme and between the Hall sensor 13 is provided with an integrated chip, drive circuit 11, Hall sensor 13, battery 22, heat dissipation fan blade 51, rotor 53 and stator 55 are electrically connected with integrated chip, integrated chip is used for controlling drive circuit 11, Hall sensor 13, battery 22, heat dissipation fan blade 51, rotor 53 and stator 55 operation, realizes the unified management of electric power equipment.

[0065] Please refer to Figures 1-8 , the internal integrated chip is provided with MCU unit, sensor control unit, motor control unit and algorithm optimization unit, MCU unit, sensor control unit, motor control unit and algorithm optimization unit are in communication connection with integrated chip;

[0066] MCU unit is used for receiving position feedback from Hall sensor 13, real-time detection of the position of rotor 53, according to the position of rotor 53, MCU will control the current switching of stator 55 winding, so as to generate rotating magnetic field driving rotor 53 rotation, commutation control usually relies on an accurate algorithm to ensure timely switching of stator 55 current, to avoid motor out of step or overheat;

[0067] Sensor control unit is used for controlling Hall sensor 13 to monitor and transport the position of each device in motor housing 1 in real time, and other sensors can be installed for auxiliary monitoring according to the needs of operation;

[0068] Motor control unit is used for remote and on-site control of corresponding position motor by staff, and operation mode switching;

[0069] Algorithm optimization unit is used for controlling the whole motor by single algorithm or multiple algorithm combination, and the algorithm includes loading vector variable frequency control algorithm and PID motor control algorithm, loading vector variable frequency control algorithm is used for controlling stator current, so that the direction of motor rotor magnetic field is consistent with the direction of stator magnetic field, so that the motor works in the optimal state, PID motor control algorithm is used for generating control signal by weighted average of error, so as to adjust the input of motor, so as to achieve the expected output, the error is the difference between target value and actual value.

[0070] A control method of brushless DC motor, comprising the following specific steps:

[0071] S1, each component of the brushless DC motor is combined and installed, and whether it can normally operate is tested;

[0072] S2, a new system integrated chip is constructed, which comprises: integrating MCU unit and 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.

[0073] The chip configuration comprises: loading a vector variable frequency control algorithm and a PID motor control algorithm into an MCU unit of a system integrated chip;

[0074] The control application comprises: controlling a brushless direct current motor by using the system integrated chip.

[0075] S3, the system integrated chip is uniformly managed through the driving circuit, and the switching processing between the on-site and remote control modes is controlled according to the requirement; and the real-time imaging processing of various data during the equipment operation is performed through the visual device.

[0076] The working principle of the application is as follows:

[0077] The application is provided with a middle motor shell 1, a rotor mechanism and a fixed positioning plate 3, the second connecting shaft 44 is driven to rotate in the limiting shaft sleeve 43 through the rotation of the rotor 53, so as to drive the output bearing 41 at one end to rotate and perform subsequent operation.

[0078] The sealing flange cover 42 is sleeved outside the sealing flange cover 42, which is convenient for connecting the rotor installation cover 5 and the sealing flange cover 4, and also protects the limiting shaft sleeve 43 and the second connecting shaft 44 inside to a certain extent.

[0079] The protective cover is arranged outside the rotor installation cover 5 to perform daily protection on the rotor mechanism, the motor shell 1 and the rotor installation cover 5 are reinforced and installed through the positioning clamping seat 52 installed on one side of the heat dissipation fan blade 51, and the connection stability of the equipment during use is improved.

[0080] The integrated chip is used for controlling the driving circuit 11, the Hall sensor 13, the storage battery 22, the heat dissipation fan blade 51, the rotor 53 and the stator 55 to run, and realizes the unified management of the power equipment.

[0081] The integrated chip communicates with the driving circuit 11, the Hall sensor 13 and the visual device through the SPI bus, is internally provided with a data acquisition module, receives the rotor 53 magnetic pole position signal detected by the Hall sensor 13 in real time, and outputs the current control signal of the stator 55 winding through the PWM module, the speed, current and temperature data are converted into dynamic waveform diagrams through the built-in graphic processing unit (GPU) of the chip, and are transmitted to the external display screen through the HDMI interface.

[0082] The application is provided with an auxiliary installation mechanism, the sealing flange cover 4 is provided with equidistantly distributed oil inlet cavities outside, and the oiling and lubricating treatment can be performed through the oil inlet cavities reserved outside the sealing flange cover 4 during use, so that the service life of the equipment is prolonged.

[0083] The overall equipment is positioned on one side through the cooperation of the positioning bolt 34 and the positioning plug 31, and the overall stability during subsequent equipment operation is improved.

[0084] The limiting groove 32 can be used to add lubricating oil until it falls on the surface of the connecting sleeve 35, so as to lubricate part of the equipment; the motor housing 1 and the mounting side plate 2 are reinforced and connected through the first connecting shaft 25, so that the overall equipment can be conveniently maintained daily;

[0085] The MCU unit is arranged to receive position feedback from the Hall sensor 13, and the position of the rotor 53 is detected in real time; according to the position of the rotor 53, the MCU controls the current switching of the stator 55 winding, so as to generate a rotating magnetic field to drive the rotor 53 to rotate; the commutation control usually relies on an accurate algorithm to ensure the timely switching of the stator 55 current, so as to avoid motor out-of-step or overheating.

[0086] The sensor control unit is used to control the Hall sensor 13 to monitor and transmit the position of each device in the motor housing 1 in real time, and other sensors can be installed according to the operation requirements for auxiliary monitoring.

[0087] The motor control unit is used for remote and on-site control of the corresponding position of the motor by the staff, and the operation mode is switched.

[0088] The algorithm optimization unit is used to control the overall motor through a single algorithm or a combination of multiple algorithms, and the algorithm includes 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, so that the motor works in the optimal state; the PID motor control algorithm is used to generate a control signal by weighting the error, so as to adjust the input of the motor to achieve the expected output; the error is the difference between the target value and the actual value;

[0089] The MCU unit determines the energization sequence of the stator 55 winding according to the rotor position signal fed back by the Hall sensor 13 through the look-up table method, so as to ensure that the rotating magnetic field is synchronized with the permanent magnet of the rotor 53, and the specific steps include:

[0090] Position signal decoding→phase switching logic calculation→drive signal output;

[0091] The temperature sensor monitors the winding temperature rise, 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;

[0092] By combining the vector variable frequency control algorithm with the PID control algorithm, more complex and fine waveform control can be realized. The specific implementation method is as follows:

[0093] On the basis of vector control, the speed of the motor is adjusted using a PID controller. 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 change, ensuring smooth operation of the motor.

[0094] The PID controller can also be used to control the position of the motor. In specific applications, the motor angle is adjusted through feedback control, ensuring accurate output waveform.

[0095] By adjusting the current vector of the motor, the size and phase of the d-axis and q-axis currents, combined with the speed feedback of the PID control, different output waveforms can be generated.

[0096] The components of the brushless DC motor are combined and installed to test whether they can operate normally.

[0097] A new system integration chip is constructed, which includes: integrating the MCU unit and the Hall sensor in the same packaging structure to obtain a new system integration chip; the system integration chip adopts a double-base island packaging structure.

[0098] The chip configuration includes: loading the vector frequency conversion control algorithm and the PID motor control algorithm into the MCU unit of the system integration chip.

[0099] The control application includes: using the system integration chip to control the brushless DC motor.

[0100] The system integration chip is uniformly managed by the drive circuit. When controlling, the on-site and remote control modes are switched according to the needs, and the real-time imaging of various data during equipment operation is processed through visual equipment.

[0101] Although embodiments of the present application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A brushless DC motor comprising a motor housing (1), characterized in that Also include: Drive circuit (11), drive circuit (11) is located in the motor shell (1) inside; Mounting side plate (2), the mounting side plate (2) is located in one end of motor shell (1); Auxiliary mounting mechanism, the auxiliary mounting mechanism is located in the end of mounting side plate (2) away from the motor shell (1), the auxiliary mounting mechanism includes fixed positioning plate (3), the mounting side plate (2) is installed in one end of the motor shell (1), the mounting side plate (2) is installed in one side of the motor shell (1) close to the limit disc (21), the inside of the limit disc (21) is installed with equidistantly distributed battery (22), the shaft of the mounting side plate (2) is installed with first connecting shaft (25), the outside of the first connecting shaft (25) is sleeved with the matching disc (24), the mounting side plate (2) is installed with fixed positioning plate (3) away from the motor shell (1) of one side, the fixed positioning plate (3) is installed with auxiliary positioning frame (33) close to one side of the mounting side plate (2), the outside of the auxiliary positioning frame (33) is installed with connecting sleeve (35), one side of the connecting sleeve (35) is connected with the mounting side plate (2); Rotor mechanism, the rotor mechanism is located in the end of the motor shell (1) away from the mounting side plate (2), the rotor mechanism includes rotor installation cover (5), the rotor installation cover (5) is installed in one end of the motor shell (1), one side of the rotor installation cover (5) is installed with rotor (53), one end of the rotor (53) is installed with heat dissipation fan blade (51) extending to the inside of the motor shell (1); Sealing flange cover (4), the sealing flange cover (4) is located in the end of the rotor mechanism away from the motor shell (1).

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

3. The brushless DC motor of claim 2, wherein: The outside of the sealing flange cover (4) is provided with equidistantly distributed oil inlet cavity.

4. The brushless DC motor of claim 3, wherein: The mounting side plate (2) is provided with equidistantly distributed first mounting groove (23) close to one side of the fixed positioning plate (3), the auxiliary positioning frame (33) is threadedly connected with positioning bolt (34) penetrating the fixed positioning plate (3) around.

5. The brushless DC motor of claim 4, wherein: The top of the fixed positioning plate (3) is provided with limit groove (32), the fixed positioning plate (3) is installed with four equidistantly distributed positioning insertion rods (31) away from one side of the mounting side plate (2), one end of the positioning bolt (34) extends to the inside of the corresponding positioning insertion rod (31), the bottom of the limit groove (32) is also provided with oil guide hole.

6. The brushless DC motor of claim 4, wherein: The inside of the rotor mounting cover (5) is provided with second mounting grooves (54) distributed at equal intervals, the inside of each second mounting groove (54) is mounted with a stator (55), one end of the heat dissipation fan blade (51) away from the limiting shaft sleeve (43) is mounted with a positioning clamping seat (52), one end of the positioning clamping seat (52) extends to the inside of the driving circuit (11), the inside of the driving circuit (11) is provided with a mounting inner cavity matched with the driving circuit (11), and the outside of the rotor mounting cover (5) is provided with a protective cover.

7. The brushless DC motor of claim 6, wherein: The inside of the driving circuit (11) is mounted with Hall sensors (13), temperature sensors and vibration sensors distributed at equal intervals, one end of the driving circuit (11) is mounted with a mounting collar (12), and one end of the mounting collar (12) away from the driving circuit (11) is connected with the first connecting shaft (25).

8. The brushless DC motor of claim 7, wherein: The inside of the driving circuit (11) and between the Hall sensors (13) is provided with an integrated chip, and the driving circuit (11), the Hall sensors (13), the temperature sensors, the vibration sensors, the storage battery (22), the heat dissipation fan blade (51), the rotor (53) and the stator (55) are electrically connected with the integrated chip.

9. The brushless DC motor of claim 8, wherein: The inside of 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 in communication connection with the integrated chip. The MCU unit is used for receiving position feedback from the Hall sensors (13), detecting the position of the rotor (53) in real time, and controlling the current switching of the stator (55) winding according to the position of the rotor (53), so as to generate a rotating magnetic field to drive the rotor (53) to rotate; The temperature sensor is used for monitoring the winding temperature rise, and the vibration sensor is used for detecting the dynamic balance state of the rotor (53), and data is processed in real time by the sensor control unit of the integrated chip and triggers a protection mechanism; The sensor control unit is used for controlling the Hall sensors (13) to monitor and process the position of each device in the motor housing (1) in real time; The motor control unit is used for remote and on-site control of the corresponding position of the motor by the staff; The algorithm optimization unit is used for controlling and processing the whole motor by a single algorithm or a combination of multiple algorithms, and the algorithm includes a load vector variable frequency control algorithm and a PID motor control algorithm.

10. A method of controlling a brushless DC motor for implementing a brushless DC motor as claimed in any one of claims 1 to 9, characterized by: The following specific steps are included: S1, combining and installing each component of the brushless DC motor, and testing whether it can normally operate; 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; Chip configuration, which includes: loading the vector variable frequency control algorithm and the PID motor control algorithm on the MCU unit of the system integrated chip; Control application, which includes: applying the system integrated chip to control the brushless DC motor; S3, through the drive circuit to the system integrated chip unified management, control time according to the required on-site and remote control mode between switching processing, through the visual equipment for equipment operation each data real-time imaging processing.

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