Brushless motor control system based on photoelectric coupling gear disc detection

Abstract

The invention relates to the field of electronic control of treadmills, aims to solve the problems that a running belt of an existing treadmill is prone to passive sliding and unstable in running speed in a standby state, and particularly relates to a brushless motor control system based on photoelectric coupling gear disc detection. According to the running machine, the rotating speed of the running machine is collected through the photoelectric coupling assembly, real-time analysis is carried out according to the collected rotating speed data, in the standby state of the running machine, if the running belt slides, the standby braking function can be automatically started immediately, the motor generates reverse force which is gradually increased from low to high, and therefore the running machine is prevented from being damaged. When the running machine is in a running state, the control precision of the running machine and the rotating speed stability maintaining capability of a motor for coping with a variable load are checked according to the variable-speed running state and the constant-speed running state of the running machine, and quantitative grading is carried out according to a checking result; therefore, visual early warning of the running state of the running machine is realized, and the use safety of the running machine is improved.

Description

Technical Field

[0001] The present invention relates to the field of treadmill electronic control, and in particular to a brushless motor control system based on photoelectric coupling gear plate detection. Background Art

[0002] With the popularization of fitness awareness, treadmills are common indoor fitness equipment and are widely used in homes and commercial places. Electric treadmills use brushless motors with better performance to drive the running belt, allowing people to run or walk passively at different speeds. Because running and walking are formed passively, and because the electronic auxiliary equipment on electric treadmills has many functions, people can experience different running environments, such as flat running, uphill running, hilly running, variable speed running, etc., and can choose according to the purpose of exercise;

[0003] However, brushless treadmills currently on the market have obvious safety hazards in standby mode. When the treadmill is in standby mode and the running belt is pushed backward, the running belt will run due to the low friction of the transmission device. Especially when the treadmill is raised to a certain height, if the machine is not started and a person stands on the running belt, the horizontal component of the person's gravity is greater than the friction of the transmission device, causing the running belt to slide uncontrollably. This can easily cause the user to fall and get injured, seriously threatening the user's personal safety and posing a great risk to the user.

[0004] At the same time, when the user is running on the treadmill, the treadmill belt bears different weights when the foot steps down and when the foot is in the air, which will cause a slight difference in the speed of the treadmill. As the treadmill ages, this difference may be widened, causing the user to experience a sudden change in speed while running and fall.

[0005] In response to the above technical problems, this application proposes a solution. Summary of the Invention

[0006] In the present invention, the treadmill's rotation speed is collected in real time with high precision through a photoelectric coupling component, and real-time analysis is performed based on the collected high-precision rotation speed data. Therefore, when the treadmill is in standby mode, if the user accidentally touches or causes the running belt to slip, the standby brake function can be automatically activated immediately, and the system quickly calculates and sends a reverse force control signal to the motor, causing the motor to generate a reverse force that gradually increases from low to high, so that the running belt's rotation speed is quickly reduced and stabilized, avoiding the risk of falling due to accelerated sliding of the running belt. When the treadmill is in operation, the treadmill's control accuracy and the motor's ability to maintain stable rotation speed under varying loads are checked according to the treadmill's variable speed operation and uniform speed operation states, and quantitative classification is performed based on the check results, thereby achieving a visual early warning of the treadmill's operating status, improving the safety of the treadmill, and solving the problem that the running belt of the existing treadmill is prone to passive sliding and unstable operating speed when in standby mode. A brushless motor control system based on photoelectric coupling gear plate detection is proposed.

[0007] The purpose of the present invention can be achieved through the following technical solutions:

[0008] A brushless motor control system based on photoelectric coupling gear plate detection includes an active control module, which can generate active control instructions for the brushless motor and switch the operating state and operating parameters of the brushless motor through the active control instructions;

[0009] A photoelectric coupling detection module detects the running speed of the brushless motor through a photoelectric coupling component to obtain a real-time rotation speed, and sends the real-time rotation speed to the passive control module;

[0010] a passive control module, wherein the passive control module obtains the operating status of the brushless motor through the active control module, selects different passive control modes according to the operating status of the brushless motor, analyzes the real-time speed of the brushless motor according to the different passive control modes, and generates a passive control signal according to the analysis result;

[0011] An active operation analysis module, which obtains the operating parameters of the brushless motor through the active control module and the real-time speed through the photoelectric coupling detection module, compares and analyzes the operating parameters and the real-time speed to obtain the brushless motor control overlap rate. At the same time, the active operation analysis module analyzes the change of the real-time speed to obtain the motor uniform speed deviation, and sends the motor uniform speed deviation and the brushless motor control overlap rate to the early warning reminder module;

[0012] The early warning reminder module generates corresponding early warning reminders according to the brushless motor control overlap rate and the motor uniform speed deviation.

[0013] As a preferred embodiment of the present invention, the active control instructions generated by the active control module include operating mode instructions and stop mode instructions, wherein the operating mode also includes motor operating speed instructions and motor operating acceleration instructions. The active control module switches the operating state of the brushless motor through the operating mode instructions and the stop mode instructions, and switches the operating parameters of the brushless motor through the motor operating speed instructions and the motor operating acceleration instructions.

[0014] As a preferred embodiment of the present invention, when detecting the operating speed of the brushless motor, the photoelectric coupling detection module calculates the light receiving frequency of the photoelectric coupling component to obtain the frequency of the teeth passing the detection position, and calculates the real-time rotational speed of the gear based on the total number of teeth on the gear and the passing frequency.

[0015] As a preferred embodiment of the present invention, after obtaining the stop mode instruction, the passive control module obtains the set brake trigger threshold and compares the real-time speed with the brake trigger threshold. If the real-time speed is greater than or equal to the brake trigger threshold, an emergency brake signal is generated; if the real-time speed is less than the brake trigger threshold, a continuous monitoring signal is generated.

[0016] As a preferred embodiment of the present invention, after generating an emergency brake signal, the passive control module sends a reverse force signal to the brushless motor, and drives the gear to decelerate through the brushless motor. During the deceleration process of the brushless motor, the passive control module compares the real-time speed with the set safety threshold. If the real-time speed decreases to the safety threshold, the emergency brake signal is stopped, where the safety threshold is less than the brake trigger threshold.

[0017] As a preferred embodiment of the present invention, after generating the continuous monitoring signal, the passive control module performs a change analysis on the real-time speed, specifically:

[0018] The passive control module calculates the difference of the real-time speeds obtained at different times, and calculates the ratio of the real-time speed difference between different times to time to obtain the speed variation amplitude;

[0019] The passive control module calculates the difference between the latest real-time speed and the brake trigger threshold to obtain the speed margin, and calculates the ratio of the speed margin and the speed change amplitude to obtain the time margin. If the time margin is less than the set threshold, a reverse force signal is generated. If the time margin is greater than the set threshold, no response is made.

[0020] As a preferred embodiment of the present invention, after generating a reverse force signal, the passive control module first applies a preset lowest gear reverse force through a brushless motor, and immediately obtains the real-time speed after applying the lowest gear reverse force for a preset short period, and compares and calculates the real-time speed with the real-time speed before applying the reverse force to obtain the deceleration degree. If the deceleration degree is greater than or equal to the set deceleration degree, the lowest gear reverse force is maintained. If the deceleration degree is less than the set deceleration degree, the applied reverse force is linearly increased, and the deceleration degree is continuously collected during the linear increase process. When the deceleration degree is greater than or equal to the set deceleration degree for the first time, the current reverse force is maintained.

[0021] As a preferred embodiment of the present invention, after obtaining the real-time speed, the active operation analysis module compares the real-time speed with the operating speed instruction in the set operating parameters and records the ratio as the speed overlap degree;

[0022] The active operation analysis module performs a dynamic curve analysis on the real-time speed, and obtains the acceleration and acceleration range of the real-time speed according to the analysis results. The active operation analysis module compares the motor operation acceleration instruction in the operation parameters with the acceleration and acceleration range to obtain the acceleration overlap degree and the acceleration time overlap degree;

[0023] The active operation analysis module performs weighted averaging on the speed overlap, acceleration overlap and acceleration time overlap to obtain the brushless motor control overlap rate.

[0024] As a preferred embodiment of the present invention, the active operation analysis module analyzes the acquired motor speed command, and records the motor speed command as a uniform speed operation stage when the motor speed command maintains the same speed for a set period;

[0025] The active operation analysis module counts the real-time speed during the uniform speed operation phase to obtain multiple speed samples, calculates the difference between each speed sample and the motor speed command, calculates the variance of all the differences to obtain the speed variance, and records the speed variance as the motor uniform speed deviation.

[0026] As a preferred embodiment of the present invention, the early warning reminder module performs independent threshold judgments on the motor uniform speed deviation and the brushless motor control overlap rate, and generates alarm reminders of different levels according to the judgment results.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1. In the present invention, when the treadmill is in standby mode, the treadmill's rotation speed can be collected in real time with high precision through a photoelectric coupling component, and real-time analysis can be performed based on the collected high-precision rotation speed data. Therefore, when the treadmill is in standby mode, if the user accidentally touches or causes the running belt to slip, the standby brake function can be automatically activated immediately, and the system quickly calculates and sends a reverse force control signal to the motor, causing the motor to generate a reverse force, so that the speed of the running belt is quickly reduced and stabilized, thereby avoiding the risk of falling due to accelerated sliding of the running belt.

[0029] 2. In the present invention, when the treadmill applies reverse force to control the treadmill brake function in the standby state, the reverse force is gradually increased from low to high, and when the deceleration degree of the treadmill reaches a certain level, the reverse force is no longer increased, thereby making the deceleration process of the treadmill smoother and the deceleration curve smoother, avoiding sudden braking and increasing the possibility of people on the treadmill falling.

[0030] 3. In the present invention, when the treadmill is in operation, comprehensive data is collected based on the treadmill's variable speed operation and uniform speed operation states, so as to verify the control accuracy of the treadmill and the motor's ability to maintain stable speed under varying loads, and quantitative classification is performed based on the verification results, thereby realizing a visual early warning of the treadmill's operating status and improving the safety of the treadmill. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] To facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0032] Figure 1 is a system block diagram of the present invention;

[0033] Figure 2 It is a system flow chart of the present invention. DETAILED DESCRIPTION

[0034] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0035] Example 1: Please refer to Figure 1 - Figure 2As shown, a brushless motor control system based on photoelectric coupling gear plate detection includes an active control module, a photoelectric coupling detection module, a passive control module, an active operation analysis module, and an early warning reminder module. The active control module can generate active control instructions for the brushless motor. The active control instructions include running mode instructions and stop mode instructions. The active control module switches the running state of the brushless motor through the running mode instructions and the stop mode instructions, and switches the running parameters of the brushless motor through the motor running speed instructions and the motor running acceleration instructions.

[0036] The operation mode also includes a motor speed command and a motor acceleration command. The motor speed command includes the motor speed in r / min. The motor acceleration command includes the motor speed acceleration / deceleration and the duration of the acceleration / deceleration.

[0037] The photoelectric coupling detection module detects the running speed of the brushless motor through the photoelectric coupling component, obtains the real-time speed, and sends the real-time speed to the passive control module;

[0038] When the photoelectric coupling detection module detects the running speed of the brushless motor, it calculates the light receiving frequency of the photoelectric coupling component to obtain the frequency f of the teeth passing the detection position, in units of per minute, and calculates the real-time speed V of the gear based on the total number of teeth on the gear and the passing frequency. Where X is the total number of teeth on the gear, and the unit of real-time speed V is r / min;

[0039] The light emitting source of the optical coupling component is generally an infrared light emitting diode, which converts electrical energy into light of a specific wavelength. The receiver is a light sensor, generally a photoresistor, photodiode, phototransistor, silicon controlled rectifier (SCR) or TRIAC, which senses light of a specific wavelength and may directly convert it into an electrical signal. There is an optical channel between the transmitting source and the receiver, but the optical channel has an opening. If other objects block the opening and prevent light from passing through, the signal generated by the receiver will also change accordingly. For example, in the present invention, a gear is provided on the output shaft of the brushless motor, and the gear is used to block the light through the optical channel, so that the receiver receives an intermittent electrical signal, thereby forming a pulse current. The processor can obtain the passing speed of the teeth on the gear based on the intermittent frequency of the pulse current, and then calculate the real-time rotation speed of the gear.

[0040] The passive control module obtains the running status of the brushless motor through the active control module, selects different passive control modes according to the running status of the brushless motor, analyzes the real-time speed of the brushless motor according to different passive control modes, and generates passive control signals based on the analysis results, where the controlled control signals include emergency brake signals, continuous monitoring signals, and reverse force signals;

[0041] The specific steps are:

[0042] After receiving the stop mode command, the passive control module obtains the set brake trigger threshold, where the brake trigger threshold is manually set by the designer, for example, it can be set to 0.15 km / h, and compares the real-time speed with the brake trigger threshold. If the real-time speed is greater than or equal to the brake trigger threshold, an emergency brake signal is generated. If the real-time speed is less than the brake trigger threshold, a continuous monitoring signal is generated.

[0043] After generating the emergency brake signal, the passive control module sends a reverse force signal to the brushless motor, and slows down the treadmill belt through the brushless motor. During the deceleration process of the brushless motor, the passive control module compares the real-time speed with the set safety threshold. If the real-time speed decreases to the safety threshold, the emergency brake signal is stopped. The safety threshold is less than the brake trigger threshold. Generally, the safety threshold is set to 0.1 km / h.

[0044] After generating the continuous monitoring signal, the passive control module performs a change analysis on the real-time speed, specifically:

[0045] The passive control module calculates the difference between the real-time speeds obtained at different times, and calculates the speed variation amplitude by calculating the ratio of the real-time speed difference between different times to time;

[0046] The passive control module calculates the difference between the latest real-time speed and the brake trigger threshold to obtain the speed margin, and calculates the time margin by calculating the ratio of the speed margin and the speed change amplitude. If the time margin is less than the set threshold, a reverse force signal is generated. If the time margin is greater than the set threshold, no response is taken.

[0047] After generating the reverse force signal, the passive control module first applies a preset lowest gear reverse force through the brushless motor. After applying the lowest gear reverse force for a preset short period, which in this embodiment is 100ms, the real-time speed is immediately obtained, and the real-time speed is compared with the real-time speed before the reverse force is applied to obtain the deceleration degree. If the deceleration degree is greater than or equal to the set deceleration degree, the lowest gear reverse force is maintained. If the deceleration degree is less than the set deceleration degree, the applied reverse force is linearly increased. During the linear increase process, the deceleration degree is continuously collected. When the deceleration degree is greater than or equal to the set deceleration degree for the first time, the current reverse force is maintained, thereby ensuring linear braking growth while decelerating and braking the treadmill, avoiding secondary injuries caused by sudden stops or increasing the possibility of falls.

[0048] In this embodiment, when the treadmill is in standby mode, if the user accidentally touches or causes the running belt to slide, such as accidentally pushing the running belt backward, the controller will immediately detect the speed generated by the motor rotation, and the motor controller will quickly send a reverse force control signal to the motor. After receiving the signal, the motor will generate a reverse force to quickly reduce the speed of the running belt and stabilize it within the safe speed range of 0.1 km / h. The user will clearly feel that the sliding speed of the running belt is suppressed, avoiding the risk of falling due to the accelerated sliding of the running belt.

[0049] Example 2: Please refer to Figure 1 - Figure 2 As shown, the active operation analysis module obtains the operating parameters of the brushless motor through the active control module, and obtains the real-time speed through the photoelectric coupling detection module. After obtaining the real-time speed, the active operation analysis module compares the real-time speed with the speed of the motor in the operating speed instruction in the set operating parameters, and records the ratio as the speed overlap degree;

[0050] The active operation analysis module performs dynamic curve analysis on the real-time speed, creates a curve of real-time speed change over time, and records the part of the curve where the absolute value of the slope is greater than the set value as the acceleration interval. The set value can be set to 0.2m / s 2 , where the deceleration part is represented by a negative acceleration, thereby obtaining the acceleration and acceleration interval of the real-time speed. The active operation analysis module compares the motor operation acceleration instruction in the operation parameters with the acceleration and acceleration interval, and records the ratio of the acceleration of the real-time speed to the acceleration in the motor operation acceleration instruction as the acceleration overlap degree. The duration between the start and end points of the acceleration interval and the acceleration and deceleration duration interval in the motor operation acceleration instruction are compared to obtain the acceleration time overlap degree.

[0051] The active operation analysis module performs weighted average of the speed overlap, acceleration overlap, and acceleration time overlap to obtain the brushless motor control overlap rate η. Among them, α, θ, and β are weight values, which are manually set by designers based on experimental work during product development;

[0052] The active operation analysis module analyzes the acquired motor speed command. When the motor speed command maintains the same speed for a set period, it is recorded as a uniform speed operation stage. The set period can be 1 to 3 minutes. The active operation analysis module counts the real-time speed of the uniform speed operation stage to obtain multiple speed samples, and calculates the difference between each speed sample and the motor speed command. The variance of all differences is calculated to obtain the speed variance, and the speed variance is recorded as the motor uniform speed deviation. The motor uniform speed deviation and the brushless motor control overlap rate are sent to the early warning reminder module.

[0053] After obtaining the brushless motor control overlap rate, the early warning module will determine the brushless motor control overlap rate by threshold, where the threshold includes multiple gear intervals. Different degrees of early warning reminders are given according to the threshold interval in which the brushless motor control overlap rate is located. The lower the threshold gear interval, the higher the alarm intensity.

[0054] Similarly, the early warning module performs a threshold judgment on the motor uniform speed deviation, obtains the threshold gear to which the motor uniform speed deviation belongs, and issues different degrees of early warning according to different gears. The higher the gear to which the motor uniform speed deviation belongs, the higher the alarm intensity.

[0055] In the above embodiments, the settings of thresholds, preset values, preset ranges, etc. are for result comparison and analysis in order to determine whether they are good or bad. The values ​​of these values ​​are set based on a combination of large-scale model analysis of sample data and manual experience to enter and store them. Appropriate adjustments can also be made based on seasonal or common-sense influencing conditions. The settings of weight ratio coefficients, influencing factors, etc. are based on the influence of each parameter on the result to assign specific values ​​that ultimately reflect the influence on the result. These values ​​are also set based on a combination of large-scale model analysis of sample data and manual experience to enter and store them. Appropriate adjustments can also be made based on seasonal or common-sense influencing conditions.

[0056] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to specific embodiments. Obviously, many modifications and variations are possible based on the contents of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A brushless motor control system based on photoelectric coupling gear plate detection, characterized in that: The active control module can generate active control instructions for the brushless motor and switch the operating state and operating parameters of the brushless motor through the active control instructions; A photoelectric coupling detection module detects the running speed of the brushless motor through a photoelectric coupling component to obtain a real-time rotation speed, and sends the real-time rotation speed to the passive control module; a passive control module, wherein the passive control module obtains the operating status of the brushless motor through the active control module, selects different passive control modes according to the operating status of the brushless motor, analyzes the real-time speed of the brushless motor according to the different passive control modes, and generates a passive control signal according to the analysis result; An active operation analysis module, which obtains the operating parameters of the brushless motor through the active control module and the real-time speed through the photoelectric coupling detection module, compares and analyzes the operating parameters and the real-time speed to obtain the brushless motor control overlap rate. At the same time, the active operation analysis module analyzes the change of the real-time speed to obtain the motor uniform speed deviation, and sends the motor uniform speed deviation and the brushless motor control overlap rate to the early warning reminder module; The early warning reminder module generates corresponding early warning reminders according to the brushless motor control overlap rate and the motor uniform speed deviation.

2. A brushless motor control system based on photoelectric coupling gear plate detection according to claim 1, characterized in that: The active control instructions generated by the active control module include operating mode instructions and stop mode instructions, wherein the operating mode also includes motor operating speed instructions and motor operating acceleration instructions. The active control module switches the operating state of the brushless motor through the operating mode instructions and the stop mode instructions, and switches the operating parameters of the brushless motor through the motor operating speed instructions and the motor operating acceleration instructions.

3. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 1, characterized in that: When detecting the running speed of the brushless motor, the photoelectric coupling detection module calculates the light receiving frequency of the photoelectric coupling component to obtain the frequency of the teeth passing the detection position, and calculates the real-time speed of the gear based on the total number of teeth on the gear and the passing frequency.

4. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 1, characterized in that: After obtaining the stop mode instruction, the passive control module obtains the set brake trigger threshold and compares the real-time speed with the brake trigger threshold. If the real-time speed is greater than or equal to the brake trigger threshold, an emergency brake signal is generated; if the real-time speed is less than the brake trigger threshold, a continuous monitoring signal is generated.

5. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 4, characterized in that: After generating the emergency brake signal, the passive control module sends a reverse force signal to the brushless motor, and drives the gear to decelerate through the brushless motor. During the deceleration process of the brushless motor, the passive control module compares the real-time speed with the set safety threshold. If the real-time speed decreases to the safety threshold, the emergency brake signal is stopped, where the safety threshold is less than the brake trigger threshold.

6. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 4, characterized in that: After generating the continuous monitoring signal, the passive control module performs a change analysis on the real-time speed, specifically: The passive control module calculates the difference of the real-time speeds obtained at different times, and calculates the ratio of the real-time speed difference between different times to time to obtain the speed variation amplitude; The passive control module calculates the difference between the latest real-time speed and the brake trigger threshold to obtain the speed margin, and calculates the ratio of the speed margin and the speed change amplitude to obtain the time margin. If the time margin is less than the set threshold, a reverse force signal is generated. If the time margin is greater than the set threshold, no response is made.

7. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 6, characterized in that: After generating the reverse force signal, the passive control module first applies a preset lowest gear reverse force through the brushless motor, and immediately obtains the real-time speed after applying the lowest gear reverse force for a preset short period, compares and calculates the real-time speed with the real-time speed before applying the reverse force to obtain the deceleration degree. If the deceleration degree is greater than or equal to the set deceleration degree, the lowest gear reverse force is maintained. If the deceleration degree is less than the set deceleration degree, the applied reverse force is linearly increased, and the deceleration degree is continuously collected during the linear increase process. When the deceleration degree is greater than or equal to the set deceleration degree for the first time, the current reverse force is maintained.

8. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 1, characterized in that: After obtaining the real-time speed, the active operation analysis module compares the real-time speed with the operating speed instruction in the set operating parameters and records the ratio as the speed overlap degree; The active operation analysis module performs a dynamic curve analysis on the real-time speed, and obtains the acceleration and acceleration range of the real-time speed according to the analysis results. The active operation analysis module compares the motor operation acceleration instruction in the operation parameters with the acceleration and acceleration range to obtain the acceleration overlap degree and the acceleration time overlap degree; The active operation analysis module performs weighted averaging on the speed overlap, acceleration overlap and acceleration time overlap to obtain the brushless motor control overlap rate.

9. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 1, characterized in that: The active operation analysis module analyzes the acquired motor speed command, and records the motor speed command as a uniform speed operation stage when the motor speed command maintains the same speed for a set period; The active operation analysis module counts the real-time speed during the uniform speed operation phase to obtain multiple speed samples, calculates the difference between each speed sample and the motor speed command, calculates the variance of all the differences to obtain the speed variance, and records the speed variance as the motor uniform speed deviation.

10. The brushless motor control system based on photoelectric coupling gear plate detection according to claim 1, characterized in that: The early warning module performs independent threshold judgments on the motor uniform speed deviation and the brushless motor control overlap rate, and generates alarm reminders of different levels according to the judgment results.

Images