Hub motor data management and fault monitoring system and method and storage medium

Abstract

The invention relates to the technical field of motor control, and provides a hub motor data management and fault monitoring system and method and a storage medium. The system comprises a temperature and wheel speed sampling module which is connected with an MCU and is used for sampling temperature and wheel speed signals of a hub motor and transmitting the temperature and wheel speed signals to the MCU; the Hall signal sampling module is connected with the MCU and is used for sampling a three-phase Hall signal of the hub motor and transmitting the three-phase Hall signal to the MCU; a memory is integrated in the MCU, and the MCU is used for obtaining hub motor operation data based on the temperature and wheel speed signals and the three-phase Hall signals and storing the hub motor operation data in the memory; meanwhile, system fault event monitoring is carried out based on a three-phase Hall signal. According to the invention, the operation data of the hub motor can be decoupled from the vehicle control unit host, the fault monitoring of the internal elements of the hub motor can be realized, and the fault positioning efficiency of the hub motor is improved.

Description

Technical Field

[0001] This application relates to the field of motor control technology, and in particular to a hub motor data management and fault monitoring system, method and storage medium. Background Technology

[0002] Against the backdrop of the rapid development of electric vehicle technology (such as electric-assist bicycles and electric motorcycles), the independent traceability of the in-wheel motor's full life cycle operating data (such as temperature, speed, and mileage), as well as the accurate fault location of internal components (such as Hall sensors), directly affect the efficiency of vehicle after-sales maintenance and the reliability of the motor.

[0003] Existing technologies generally adopt a "vehicle-centric" architecture, integrating and storing the in-wheel motor's operating data (such as temperature, speed, and mileage) on the vehicle controller or a cloud-based vehicle data platform. Simultaneously, they rely on the vehicle controller host to perform motor fault diagnosis. This architecture results in a high degree of coupling between the in-wheel motor's operating data and data from other vehicle systems, making it difficult to independently trace the motor's performance evolution throughout its entire lifecycle. Furthermore, the controller host can only identify faults at the motor system level and cannot pinpoint specific failed components within the motor (such as distinguishing between a damaged Hall sensor and a faulty acquisition circuit on the controller side), leading to long after-sales maintenance cycles for the motor. Summary of the Invention

[0004] In view of the above, it is necessary to propose a hub motor data management and fault monitoring system, method and storage medium that can decouple the hub motor's operating data from the vehicle controller host and realize fault monitoring of internal components of the hub motor, thereby improving the efficiency of hub motor fault location.

[0005] The first aspect of this application provides a hub motor data management and fault monitoring system, the hub motor data management and fault monitoring system comprising: A temperature and wheel speed sampling module, connected to a microcontroller unit, is used to sample the temperature and wheel speed signals of the hub motor and transmit the temperature and wheel speed signals to the microcontroller unit; A Hall signal sampling module, connected to the microcontroller unit, is used to sample the three-phase Hall signals of the hub motor and transmit the three-phase Hall signals to the microcontroller unit; The microcontroller unit integrates a memory for obtaining hub motor operating data based on the temperature and wheel speed signals and the three-phase Hall signals, and storing the hub motor operating data in the memory; simultaneously, it monitors system fault events based on the three-phase Hall signals.

[0006] Optionally, the hub motor data management and fault monitoring system further includes: The signal multiplexing selection module is connected to the microcontroller unit and the controller host. It is used to receive the multiplexing selection control signal from the microcontroller unit and adaptively select whether to output the hub motor operating data or the temperature and wheel speed signals according to the multiplexing selection control signal.

[0007] Optionally, the memory stores a unique serial number of the hub motor, which is bound to the mileage data in the hub motor's operating data. The hub motor's operating data is written to the memory using a partitioned cyclic writing mechanism, and the mileage data is stored in intervals according to preset temperature thresholds.

[0008] Optionally, the temperature wheel speed sampling module includes: a wheel speed magnetic encoding element, a wheel speed Hall sensor, and a first signal sampling circuit; The wheel speed magnetic encoding element works in conjunction with the wheel speed Hall sensor to enable the Hall effect sensor to generate a first rectangular wave signal whose level switches periodically between high and low states; The first signal sampling circuit is connected to the wheel speed Hall sensor and the microcontroller unit. It is used to obtain temperature and wheel speed signals based on the high-level voltage value of the first rectangular wave signal and the pulse width of the wheel hub, and transmit them to the microcontroller unit.

[0009] Optionally, the first signal sampling circuit includes: a negative temperature coefficient thermistor and a fixed resistor connected in series; One end of the negative temperature coefficient thermistor is grounded, and the other end is connected to the fixed resistor; The other end of the fixed resistor is connected to the power supply; The electrical connection point between the negative temperature coefficient thermistor and the fixed resistor is the first sampling point. The first sampling point is used to output a temperature-related voltage signal, and the temperature-related voltage signal determines the high-level voltage value of the rectangular wave signal.

[0010] Optionally, the Hall signal sampling module includes a motor magnet, a three-phase Hall sensor, and a second signal sampling circuit; The motor magnet and the three-phase Hall sensor work together to enable the three-phase Hall sensor to generate a second rectangular wave signal whose level switches periodically between high and low states; The second signal sampling circuit is connected to the three-phase Hall sensor and the microcontroller unit, and is used to obtain the three-phase Hall signal based on the second rectangular wave signal and transmit it to the microcontroller unit.

[0011] Optionally, the second signal sampling circuit includes: a pull-up resistor and a pull-down resistor connected in series; One end of the pull-up resistor is connected to the power supply, and the other end is connected to the pull-down resistor; The other end of the pull-down resistor is grounded; The electrical connection point between the pull-up resistor and the pull-down resistor is the second sampling point, which is used to output a three-phase Hall signal.

[0012] A second aspect of this application provides a method for managing hub motor operating data, applied to the hub motor data management and fault monitoring system, wherein the hub motor operating data management method includes: After the system is powered on and initialized, the microcontroller sets the signal multiplexing selection module to communication port mode through a gating signal, and simultaneously starts the temperature wheel speed sampling module and the Hall signal sampling module to sample signals. The microcontroller receives the temperature and wheel speed signals sampled by the temperature and wheel speed sampling module, and the three-phase Hall signal sampled by the Hall signal sampling module; The microcontroller unit obtains hub motor operating data based on the temperature signal, the wheel speed signal, and the three-phase Hall signal, and stores the hub motor operating data in its internal integrated memory. The microcontroller unit monitors system fault events based on the three-phase Hall signals.

[0013] Optionally, the hub motor data management and fault monitoring method further includes: Upon receiving a communication request signal from the controller host, a multiplexing selection control signal is generated; based on the multiplexing selection control signal, the system adaptively selects whether to output the hub motor operating data or the temperature and wheel speed signals; and / or The serial number of the hub motor is stored in the memory, and the serial number is bound to the mileage data in the hub motor operation data. The hub motor operation data is written to the memory using a partitioned cyclic writing mechanism, and the mileage data is stored in intervals according to preset temperature thresholds.

[0014] A third aspect of this application provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the hub motor data management and fault monitoring method.

[0015] The hub motor data management and fault monitoring system of this application does not collect signals in isolation, but synchronously correlates temperature and speed data. Through a temperature and wheel speed sampling module and the MCU's built-in memory, the motor's operating data is directly stored within the motor itself, decoupling the hub motor's operating data from the vehicle controller host. This enables independent traceability of motor data, completely eliminating dependence on the vehicle controller or cloud platform. A Hall signal sampling module directly collects the three-phase Hall signals inside the motor, and the MCU performs fault identification locally, allowing after-sales maintenance to directly pinpoint the fault location and significantly shorten troubleshooting time. This application addresses the pain points of the existing "vehicle-centric" architecture, improving the traceability, maintainability, and reliability of the hub motor. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 A diagram illustrating the architecture of a hub motor data management and fault monitoring system provided in this application embodiment; Figure 2 This is a schematic diagram of the communication link between the microcontroller unit and the controller host provided in an embodiment of this application; Figure 3 This is a structural diagram of the temperature wheel speed sampling module provided in an embodiment of this application; Figure 4 This is a structural diagram of the Hall signal sampling module provided in an embodiment of this application; Figure 5 A logic structure diagram for signal multiplexing selection provided in embodiments of this application; Figure 6 A logical structure diagram of the data storage for the in-wheel motor operation provided in this application embodiment; Figure 7 A flowchart illustrating a hub motor data management and fault monitoring method provided in this application embodiment; Figure 8 A flowchart of another hub motor data management and fault monitoring method provided in an embodiment of this application. Detailed Implementation

[0018] To better understand the above-mentioned objectives, features, and advantages of this application, the application will be described in detail below with reference to the accompanying drawings and specific embodiments. Unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing an embodiment in one alternative implementation and is not intended to be limiting of the application.

[0020] With the rapid development of electric vehicle technology (such as electric-assist bicycles and electric motorcycles), the in-wheel motor, as a core drive component, directly impacts the efficiency of after-sales maintenance and the reliability of the motor due to the independent traceability of its full lifecycle operating data (such as temperature, speed, and mileage) and the accurate fault location of internal components (such as Hall sensors). Currently, the industry generally adopts a "vehicle-centric" architecture, integrating and storing the in-wheel motor's operating data in the vehicle controller or a cloud-based vehicle data platform, while relying on the vehicle controller host to perform motor fault diagnosis. This architecture has two major problems: First, the motor's dedicated data is highly coupled with data from other vehicle systems, making it difficult to independently trace the motor's full lifecycle performance evolution and lacking dedicated data to support condition analysis and lifespan prediction; second, the fault diagnosis chain is long and highly coupled across systems, meaning the vehicle controller host can only identify "motor system faults" and cannot locate specific failed components within the motor (such as distinguishing between Hall sensor damage and controller-side acquisition circuit failure), resulting in long after-sales repair cycles and high costs.

[0021] In view of the problem that the "vehicle-centralized" architecture in the prior art leads to the tight coupling between the hub motor data and the vehicle system, and the inability to accurately locate faults in the internal components of the motor, this application provides a hub motor data management and fault monitoring system, method and computer-readable storage medium.

[0022] The hub motor data management and fault monitoring system, method, and computer-readable storage medium provided in this application can: First, decouple hub motor operating data from the vehicle controller, construct a dedicated data pool through a local independent storage unit for the motor, ensure independent traceability of motor data throughout its entire lifecycle, and provide data support for operating condition analysis and lifespan prediction; Second, decentralize fault diagnosis functions to the motor itself, accurately identify the failure state of internal motor components (such as Hall sensors) through real-time acquisition and logic verification of the motor's three-phase Hall signals, shorten the fault diagnosis chain, and improve the efficiency of after-sales fault location; Third, coordinate data acquisition, processing, storage, and fault diagnosis through a local microcontroller unit, reduce dependence on the vehicle controller, and simplify system upgrade and maintenance processes.

[0023] See Figures 1-2 The diagram shown is an architecture diagram of the hub motor data management and fault monitoring system provided in an embodiment of this application.

[0024] The hub motor data management and fault monitoring system 1 is integrated inside the hub motor end cover. A hub motor is a drive system that integrates the motor directly into the wheel of an electric-assist vehicle. Electric-assist vehicles refer to vehicles that combine human riding with motor-assisted power, and can include electric-assist bicycles, electric-assist motorcycles, electric-assist mountain bikes, electric-assist folding bikes, etc.

[0025] The overall architecture of the hub motor data management and fault monitoring system 1 includes: a temperature and wheel speed sampling module 10, a Hall signal sampling module 20, a microcontroller unit (MCU) 30, and a signal multiplexing selection module 40. The temperature and wheel speed sampling module 10, the Hall signal sampling module 20, the microcontroller unit 30, and the signal multiplexing selection module 40 can be electrically connected via a printed circuit board (PCB).

[0026] The temperature and wheel speed sampling module 10 is connected to the pins of the microcontroller unit 30 via a wiring harness (e.g., a 2-pin wiring harness). The temperature and wheel speed sampling module 10 is used to sample the temperature signal and wheel speed signal of the hub motor and transmit the sampled temperature signal and wheel speed signal to the microcontroller unit 30. For ease of description below, the temperature signal and wheel speed signal will be referred to simply as the temperature and wheel speed signal.

[0027] The Hall signal sampling module 20 is connected to the pins of the microcontroller unit 30 via a wiring harness (e.g., a 3-pin wiring harness). The temperature and wheel speed sampling module 10 is used to sample the three-phase Hall signals of the hub motor and transmit the sampled three-phase Hall signals to the microcontroller unit 30.

[0028] The microcontroller unit 30, soldered onto the PCB board, for example, into the central area of ​​the PCB board, is responsible for coordinating signal processing, data storage, and fault monitoring. The microcontroller unit 30 obtains and stores the hub motor operating data based on the temperature and wheel speed signals and the three-phase Hall signals; it also performs system fault event monitoring based on the three-phase Hall signals and triggers an abnormal state snapshot when a system fault event is detected.

[0029] In an optional embodiment, the microcontroller unit 30 integrates an analog-to-digital converter (ADC), a timer, a memory unit, and a communication interface.

[0030] The microcontroller unit 30 uses a built-in timer to time the pulses of the wheel speed signal to assist in calculating the current wheel hub rotation speed. Specifically, the rotation speed is calculated based on the pulse width and period. For example, assuming the encoder outputs 1000 pulses per revolution (N=1000), and the period T=0.001s (i.e., 1ms), the rotation speed n=0.001×100060=60RPM. The microcontroller unit 30 uses an ADC to measure the amplitude of the wheel speed signal to assist in calculating the current ambient temperature. Specifically, the temperature corresponding to the voltage amplitude is determined based on the linear relationship between temperature and voltage. The microcontroller unit 30 uses a built-in timer to time the three-phase Hall signals to assist in verifying whether the phase difference logic between the three-phase Hall signals conforms to a preset commutation sequence table to determine whether its state is normal. The storage unit is used to independently store the wheel hub motor operating data processed by the microcontroller unit 30. Thus, the microcontroller unit 30 does not need to rely on the controller host to store the wheel hub motor operating data. The wheel hub motor operating data may include, but is not limited to, temperature, rotation speed, and mileage. The communication interface is used to interact with the signal multiplexing selection module 40.

[0031] The signal multiplexing selection module 40 is integrated on the PCB board (e.g., at the edge of the PCB board) and connected to the pins of the microcontroller unit 30 via a wire harness (e.g., a 4-pin wire harness).

[0032] In an optional embodiment, the signal multiplexing selection module 40 is also connected to the controller host 60. Optionally, the signal multiplexing selection module is connected to the controller host 60 through an external interface module 50. The signal multiplexing selection module 40 is used to receive the multiplexing selection control signal from the microcontroller unit 30, and adaptively select whether to output the hub motor operating data or the temperature and wheel speed signals according to the multiplexing selection control signal.

[0033] See Figure 3 The diagram shown is a structural diagram of the temperature wheel speed sampling module.

[0034] The temperature and wheel speed sampling module 10 is the core unit in the hub motor data management and fault monitoring system 1 that realizes the coordinated acquisition of temperature and wheel speed. Through hardware circuit design, the temperature signal and wheel speed signal are coupled into the same rectangular wave signal to realize the acquisition of multiple parameters of a single signal.

[0035] In an optional embodiment, the temperature wheel speed sampling module 10 includes: a wheel speed magnetic encoding element 101, a wheel speed Hall sensor 102, and a first signal sampling circuit 103.

[0036] The wheel speed magnetic encoding element 101 refers to a magnetic component used to generate periodic magnetic field changes. In this embodiment, a ring magnet can be attached to the inner side of the rotor end cover of the hub motor, coaxial with the rotor, and rotate synchronously with the hub (the rotational angular velocity is consistent with the hub).

[0037] The wheel speed Hall sensor 102 refers to a magnetoelectric conversion element based on the Hall effect, used to convert the magnetic field change of the wheel speed magnetic encoding element 101 into an electrical signal. The wheel speed Hall sensor 102 can be fixed to the PCB board by soldering, with its sensing surface facing the annular magnet and spaced at a certain distance from the annular magnet, for example, 1.0 mm, to sense the rotation of the magnet and generate an electrical signal.

[0038] As the annular magnet rotates with the wheel hub, the Hall effect sensor 102 senses the alternating magnetic field. That is, the wheel speed magnetic encoding element 101 and the wheel speed Hall sensor 102 work together to generate a rectangular wave signal (first rectangular wave signal) that periodically switches between high and low levels. A high level corresponds to a strong magnetic field, and a low level corresponds to a weak magnetic field, providing the raw electrical signal for subsequent extraction of temperature and wheel speed signals.

[0039] The first signal sampling circuit 103, connected to the wheel speed Hall sensor 102 and the microcontroller unit 30, is used to obtain temperature and wheel speed signals based on the high-level voltage value of the first rectangular wave signal and the pulse width of the wheel hub, and transmit them to the microcontroller unit 30. Specifically, the high-level voltage value of the first rectangular wave signal reflects temperature information, and the pulse width of the first rectangular wave signal reflects wheel speed information. The high-level voltage value is determined by a temperature-related voltage divider circuit in the first signal sampling circuit.

[0040] In an optional embodiment, the first signal sampling circuit 103 includes a negative temperature coefficient thermistor and a fixed resistor. The fixed resistor and the negative temperature coefficient thermistor are connected in series to form a voltage divider branch.

[0041] In this embodiment, an MF52-10K type NTC thermistor can be selected as the temperature sensitive element of the voltage divider circuit. The MF52-10K type NTC thermistor can completely cover the normal operating temperature range of the hub motor.

[0042] One end of the negative temperature coefficient thermistor is grounded (GND), and the other end is connected to the fixed resistor. The other end of the fixed resistor is connected to the power supply (VDD). The electrical connection point between the negative temperature coefficient thermistor and the fixed resistor is the first sampling point. The first sampling point is connected to the power supply pin (VCC) of the wheel speed Hall sensor 102 and the ADC sampling pin of the microcontroller unit 30 via two wires, respectively.

[0043] The first sampling point, also called the voltage divider point, is both the voltage output terminal of the voltage divider circuit and the coupling node between the temperature signal and the wheel speed signal. The voltage signal output by the voltage divider point is a temperature-related voltage signal. This temperature-related voltage signal determines the high-level voltage value of the first rectangular wave signal generated by the wheel speed Hall sensor, and the temperature signal can then be derived based on this high-level voltage value.

[0044] During actual installation, the NTC thermistor can be tightly attached to the surface of the hub motor winding coil using a thermally conductive silicone pad, ensuring accurate acquisition of the motor's core temperature. When the motor is running, the negative temperature coefficient thermistor (NTC Thermistor) acts as a voltage divider resistor, and its resistance value exhibits a non-linear exponential decay characteristic as the motor temperature rises, causing the voltage divider at the first sampling point to change synchronously. This voltage divider is the power supply voltage for the wheel speed Hall sensor 102, making the high-level amplitude of the first rectangular wave signal (high-level voltage = power supply voltage, low-level voltage = 0V) output by the wheel speed Hall sensor 102 based on this power supply voltage strongly correlated with temperature. Simultaneously, the alternating magnetic field generated by the ring magnet as the hub rotates causes the first rectangular wave signal output by the wheel speed Hall sensor 102 to generate periodic pulses. The pulse width varies with the hub rotation frequency. In this way, the temperature and wheel speed signals are coupled into the same rectangular wave, providing a signal basis for the subsequent MCU calculation of the hub motor's temperature and wheel speed.

[0045] One of the two wires connected to the first sampling point transmits the complete waveform of the first rectangular wave signal (including high-level voltage and pulse width information) to the MCU's timer capture pin. The MCU acquires the pulse width of the first rectangular wave signal using its built-in timer (configured in input capture mode) and calculates the rotational speed based on the correspondence between pulse width and rotational speed. The other wire connected to the first sampling point transmits the voltage divider of the first sampling point to the MCU's ADC sampling pin. The MCU acquires the high-level voltage of the first rectangular wave signal using its built-in ADC module and then looks up the temperature corresponding to the high-level voltage using the pre-stored NTC voltage-temperature calibration curve within the MCU.

[0046] Compared to existing technologies that combine a separate temperature sensor with a separate wheel speed sensor, the aforementioned optional embodiment utilizes the resistance-temperature nonlinearity of an NTC thermistor to convert temperature changes into supply voltage changes. Then, by leveraging the correlation between the supply voltage and output level of the wheel speed Hall sensor, the rectangular wave high-level voltage becomes the temperature carrier, enabling a single sensor to simultaneously output a temperature-wheel speed correlated signal. This eliminates the need for a separate temperature sensor, simplifying the hardware structure. Furthermore, based on the unique correspondence between the rectangular wave high-level voltage and temperature, and the unique correspondence between pulse width and rotational speed, the MCU's timer and ADC module extract the two parameters separately, achieving decoupled calculation of the two physical quantities within the same signal and ensuring that parameter measurements do not interfere with each other.

[0047] See Figure 4 The diagram shown is a structural diagram of the Hall signal sampling module.

[0048] The Hall signal sampling module 20 is the core unit in the hub motor data management and fault monitoring system 1 for realizing rotor position detection and component-level fault location. By collecting the three-phase Hall signals when the motor rotor rotates, it can provide position basis for motor commutation and accurately identify faults in Hall sensors and related circuits.

[0049] In an optional embodiment, the Hall signal sampling module 20 includes: a motor magnet 201, a three-phase Hall sensor 202, and a second signal sampling circuit 203.

[0050] The motor magnet 201 is a permanent magnet assembly fixed to the rotor of the hub motor, providing a periodically changing magnetic field source for the three-phase Hall sensor 202. In this embodiment, neodymium iron boron arc-shaped magnets can be used as the motor magnet 201, uniformly distributed along the outer circumference of the rotor core. They can be bonded to the magnet slots in the rotor core using high-temperature resistant anaerobic adhesive. The air gap between the outer circumference of the magnet and the inner circumference of the stator core is controlled at a certain distance, for example, 0.5 mm.

[0051] The three-phase Hall sensor 202 is a magnetoelectric conversion element group based on the switching Hall effect, used to convert the magnetic field polarity change of the motor magnet 201 into a digital level signal. In this embodiment, an A3144 type switching Hall sensor can be selected, outputting three-phase signals U, V, and W. The three-phase Hall sensor 202 can be soldered onto the PCB board on the stator side and evenly distributed along the inner circle of the motor stator, with an angle of 120° between each phase (consistent with the spatial phase difference of the three-phase windings of the motor). The sensing surface of the three-phase Hall sensor 202 faces the motor magnet 201, and the distance between its sensing center and the outer circle of the motor magnet 201 is controlled between 0.8mm and 1.2mm to ensure that when each magnet rotates to the front of the three-phase Hall sensor 202, the level switching can be accurately triggered.

[0052] When the motor is running, the motor magnet 201 and the three-phase Hall sensor 202 work together to generate a rectangular wave signal (i.e., a second rectangular wave signal) whose level switches periodically between high and low states.

[0053] The second signal sampling circuit 203, connected to the three-phase Hall sensor 202 and the microcontroller unit 30, is used to obtain the three-phase Hall signal based on the second rectangular wave signal and transmit it to the microcontroller unit 30. The second rectangular wave signal is the original level signal output by the three-phase Hall sensor 202, and the three-phase Hall signal is the signal conditioned by the second signal sampling circuit 203. In an optional embodiment, the second signal sampling circuit 203 includes a series pull-up resistor and a pull-down resistor. In specific implementation, each phase Hall sensor is equipped with one set of independent pull-up resistor and pull-down resistor branches, for a total of three branches, corresponding to phases U, V, and W respectively.

[0054] One end of the pull-up resistor is connected to the power supply (VDD), and the other end is connected to the pull-down resistor; the other end of the pull-down resistor is grounded (GND); the electrical connection point between the pull-up resistor and the pull-down resistor is the second sampling point, which is used to output a three-phase Hall signal.

[0055] The second sampling point is the common electrical connection point between the pull-up resistor, the pull-down resistor, and the output pin of the three-phase Hall sensor. It is both the output node after signal conditioning and the signal transmission node connected to the MCU IO port. It is connected to the MCU's PB0 (U phase), PB1 (V phase), and PB2 (W phase) pins through shielded wires to reduce the impact of motor electromagnetic interference on the signal.

[0056] When the hub motor is powered on, the rotor drives the motor magnet 201 to rotate synchronously. The N and S poles of the motor magnet 201 alternately pass through the sensing surface of the three-phase Hall sensor 202. The alternating change in magnetic field polarity triggers the switching circuit inside the three-phase Hall sensor 202. When the magnetic field strength exceeds the positive threshold (e.g., +200 Gauss), the sensor outputs a high level (≥2.4V); when the magnetic field strength is below the negative threshold (e.g., -200 Gauss), the sensor outputs a low level (≤0.4V). Therefore, as the motor magnet 201 rotates, the U, V, and W three-phase Hall sensors output a second rectangular wave signal with levels periodically switching between high and low states. The second signal sampling circuit 203 conditions the original output signal of the three-phase Hall sensor through pull-up and pull-down resistors, stabilizing the high level of the second rectangular wave signal at 5V±0.2V and the low level at 0V±0.1V, meeting the MCU's I / O port level recognition requirements.

[0057] The MCU is configured with PB0-PB2 pins set to digital input mode, enabling I / O port interrupts or timer scanning. It reads the U, V, and W phase levels at fixed intervals (e.g., 1 mm) and stores the real-time status in memory. The MCU internally stores a pre-stored table of the normal commutation sequence of the three-phase Hall signals during motor rotation. Taking clockwise rotation as an example, the normal commutation sequence is: 101→100→110→010→011→001→101 (a total of 6 valid states, each corresponding to a 60° electrical angle rotation of the rotor). The MCU compares the real-time acquired signal sequence frame-by-frame with the normal commutation sequence table to determine if it conforms to logical rules.

[0058] If the real-time acquired signal sequence perfectly matches the normal commutation sequence table, the MCU determines that the three-phase Hall sensor is working normally and uses the signal status as the position basis for motor commutation control. If the real-time acquired signal sequence does not match the normal commutation sequence table, the MCU determines that the three-phase Hall signal is faulty and further locates the faulty component through single-phase signal detection. For example, regardless of how the magnet rotates, if the U-phase signal remains at a high level for a long time, the U-phase Hall sensor is determined to be damaged; if the U-phase signal is low when passing through the N and S poles, the U-phase pull-up resistor of the second signal sampling circuit is determined to be open.

[0059] After fault identification, the MCU immediately triggers an abnormal state snapshot, recording the timestamp of the fault, motor speed, three-phase level status and fault code, and sends a fault prompt signal to the controller host through the UART interface.

[0060] Compared to existing technologies that can only identify motor system faults but cannot locate specific components, the above-mentioned optional embodiments can distinguish between Hall sensor damage and pull-up / pull-down resistor failure, thereby achieving component-level fault location and shortening after-sales troubleshooting time.

[0061] It should be understood that all sampling circuits can be integrated on the PCB board. The PCB board can be fixed inside the end cover of the hub motor by an insulating bracket to prevent the vibration of the hub motor from affecting the circuit. At the same time, a waterproof coating can be applied to the surface of the PCB board to enable the electric-assisted vehicle to better adapt to the outdoor humid environment.

[0062] See Figure 5 The diagram shown is a logic structure diagram for signal multiplexing selection.

[0063] The signal multiplexing selection module 40 is the core unit in the hub motor data management and fault monitoring system 1 that enables compatibility with multiple interface specifications. By switching hardware via software control, the system can adapt to controllers of different functional levels. For example, high-end models support data communication, while low-end models only require basic signals and do not need additional hardware interfaces, which significantly improves the system's adaptability.

[0064] The signal multiplexing and selection module 40 includes an interface multiplexing selector, which has one signal output port and two signal input channels: one for data communication and the other for basic signals. The data communication channel is connected to the UART_TX pin of the microcontroller unit, and the input signal is the hub motor operating data processed by the MCU, transmitted in UART protocol frame format. The basic signal channel is connected to the output of the first signal sampling circuit, and the input signals are the conditioned temperature signal and the wheel speed signal. The signal output port is connected to the signal receiving end of the controller host via a 2-pin shielded cable, and a Type-C diagnostic interface is also reserved.

[0065] When the hub motor system is powered on, the MCU executes the initialization program, initializes the signal multiplexing selection module 40 to communication port mode via a gating signal, and begins to detect whether a request data frame from the controller host is received. If a valid communication request is detected, the MCU outputs a high-level multiplexing selection control signal to the control terminal of the signal multiplexing selection module 40. After receiving the high-level control signal, the signal multiplexing selection module 40 maintains the communication port in UART (Universal Asynchronous Receiver / Transmitter) communication mode. At this time, the output port is connected to the MCU's UART_TX pin. The signal multiplexing selection module 40 selects to transmit the hub motor operation data processed by the MCU to the signal multiplexing selection module 40 through the communication interface, and then the signal multiplexing selection module 40 transmits it to the controller host through the interface module. If no request is detected within a certain time after power-on (i.e., communication timeout), the MCU outputs a low-level multiplexing selection control signal to the control terminal of the signal multiplexing selection module 40. After receiving the low-level control signal, the signal multiplexing selection module 40 switches the port to the output signal terminal of the wheel speed and temperature sampling circuit, and selects to transmit the temperature signal and wheel speed signal conditioned by the first signal sampling circuit to the signal multiplexing selection module 40, which then transmits them to the controller host through the interface module.

[0066] In this embodiment, the software logic (timeout detection) of the MCU dynamically controls the channel of the hardware switching chip, enabling the same physical port to be compatible with two signal types. This eliminates the need to design two motors with different interfaces to adapt to high-end and low-end controller hosts respectively. By replacing hardware selection with software decision-making, the system's dependence on the type of controller host is reduced. This ensures that even when working with a controller host that does not have communication capabilities, the system can still output and collect temperature and wheel speed signals normally, thereby enhancing the system's adaptability and reliability.

[0067] To improve the lifespan of the memory integrated within the MCU, in one optional embodiment, Figure 6 This is a logical structure diagram of the data storage for the in-wheel motor operation provided in an embodiment of this application.

[0068] The memory integrated within the MCU can include Read-Only Memory (ROM), Programmable Read-Only Memory (PROM), Erasable Programmable Read-Only Memory (EPROM), One-time Programmable Read-Only Memory (OTPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), CompactDisc Read-Only Memory (CD-ROM) or other optical disc storage, disk storage, magnetic tape storage, or any other computer-readable medium capable of carrying or storing data.

[0069] The memory stores the unique serial number (SN code) of the hub motor, which is used to identify the unique identity of the hub motor. During the motor production line stage, the SN code is written into the basic information area of ​​the storage using a dedicated programmer (such as ST-LINK). After writing, the MCU configures this area to a write-protected state to ensure that the SN code is unique and cannot be tampered with for life.

[0070] In existing technology, motor operating data is bound to the vehicle identification number (VIN). When a motor is removed from the original vehicle and installed in a new vehicle for repair or replacement, its historical mileage data remains associated with the original VIN, while subsequent mileage data for the new vehicle is bound to the new VIN. This results in the entire lifecycle mileage data of the same motor being split across two VINs, preventing the formation of a complete data chain. Furthermore, if a new motor is installed in the original vehicle, the new motor's mileage data overwrites the old motor's data under the original VIN, making it impossible to trace the historical operating conditions of the old motor. This embodiment binds the serial number to the hub motor's operating data. All operating data (including mileage data) is stored using a unique SN code. Even if the motor undergoes multiple replacements and installations in different vehicles, its historical mileage data remains associated with its own SN code and will not be split or confused due to changes in vehicle or VIN. During after-sales maintenance, repair personnel only need to read the motor's SN code to retrieve the complete mileage data from the motor's production line to the current moment, thereby determining the overall operating condition of the motor, such as whether it has been operating under heavy load and high temperature for a long time, avoiding misjudgments caused by data misclassification.

[0071] In an optional embodiment, the memory can be divided into multiple functional areas. Dynamically updated runtime data is written to the memory using a partitioned, cyclical write mechanism, rather than repeated erasing and writing at fixed addresses. The memory can be divided into five functional areas. The first functional area stores the serial number (SN), while the remaining four functional areas store the actual runtime data, as well as the storage count, checksum, etc. Using a partitioned, cyclical write mechanism helps to balance memory wear and significantly reduce the number of erase / write cycles.

[0072] In an optional embodiment, the mileage data can be stored in segments according to preset temperature threshold intervals. These preset temperature threshold intervals include multiple temperature threshold intervals. The MCU periodically reads the temperature signal according to a timer, compares the real-time temperature with the multiple temperature threshold intervals, determines the temperature threshold interval to which the current real-time temperature belongs, and accumulates the mileage data increment (real-time mileage data calculated based on engine speed) within that temperature threshold interval into the corresponding mileage counter, ensuring accurate matching between mileage data and temperature conditions.

[0073] The system triggers data storage operations in two situations: first, the MCU immediately executes storage upon receiving a shutdown command from the vehicle controller; second, it automatically saves data when the accumulated mileage data within a certain temperature threshold range reaches a set mileage threshold and the MCU detects a continuous wheel speed signal duration of 0 (i.e., the system is stationary). The accumulated mileage data for that temperature threshold range is stored in memory, while the mileage counter for that range is cleared and accumulation restarts. This strategy effectively avoids frequent write operations to the memory, extending memory lifespan while ensuring the reliability and integrity of data recording.

[0074] Example 2 Figure 7 This is a flowchart illustrating a method for managing and monitoring hub motor data, as provided in an embodiment of this application. The method specifically includes the following steps.

[0075] S71, after the system is powered on and initialized, the microcontroller sets the signal multiplexing selection module to communication port mode through a gating signal, and simultaneously starts the temperature wheel speed sampling module and the Hall signal sampling module to sample signals.

[0076] When the user turns on the power switch of the electric-assisted vehicle, the entire vehicle system powers on, and the intelligent motor data management and fault diagnosis system of this application starts up. The MCU first initializes its own peripherals. Initialization includes configuring the parameters of timers, analog-to-digital converters, and communication interfaces. The MCU outputs a high-level gating signal through the I / O port to switch the communication interface channel to UART communication mode, and at the same time sends a device ready signal frame to the vehicle controller.

[0077] S72, the microcontroller receives the temperature and wheel speed signals sampled by the temperature and wheel speed sampling module, and receives the three-phase Hall signal sampled by the Hall signal sampling module.

[0078] The temperature and wheel speed sampling module 10 and the Hall signal sampling module 20 are powered on synchronously. The NTC thermistor begins to sense the temperature of the motor windings. Its resistance value changes with the current temperature. The voltage divider circuit converts the resistance change into a voltage signal, which is input to the analog-to-digital converter pin of the MCU. The wheel speed Hall sensor begins to generate a periodic first rectangular wave signal when the magnetic gear ring of the motor rotor rotates, which is input to the timer capture pin of the MCU. The three-phase Hall sensor also begins to output three-phase signals according to the position change of the rotor permanent magnet.

[0079] S73, the microcontroller obtains hub motor operating data based on the temperature signal, the wheel speed signal and the three-phase Hall signal, and stores the hub motor operating data in its internal integrated memory.

[0080] When the motor starts running, the MCU's timer periodically captures the pulse width of the first rectangular wave signal output by the wheel speed Hall sensor to calculate the real-time rotational speed and store the speed value in the MCU's buffer. At the same time, the analog-to-digital converter periodically acquires the voltage signal of the NTC thermistor voltage divider circuit to calculate the temperature and determine the current temperature threshold range.

[0081] The three-phase signals output by the three-phase Hall sensors are synchronously sampled by the second sampling circuit and then converted into digital signals that are input to the MCU. The MCU reads the level status of the three-phase signals periodically.

[0082] S74, the microcontroller unit performs system fault event monitoring based on the three-phase Hall signals.

[0083] The MCU compares the level states of the three-phase signals it reads with a preset commutation sequence table to monitor system fault events. If the comparison is inconsistent, the MCU detects a system fault event, determines that the three-phase Hall signals are abnormal, immediately triggers an abnormal state snapshot, and temporarily stores the abnormal state snapshot data, such as the current fault time, speed, temperature, and fault code, in the memory. At the same time, the MCU sends a fault prompt signal to the vehicle controller host through the UART communication interface. After receiving the signal, the vehicle controller host controls the instrument panel of the electric-assisted vehicle to display a motor Hall fault prompt, reminding the user to stop riding and perform maintenance.

[0084] In an optional embodiment, the hub motor data management and fault monitoring method further includes: Upon receiving a communication request signal from the controller host, a multiplexing selection control signal is generated; The multiplexing selection control signal adaptively selects whether to output the hub motor operating data or the temperature and wheel speed signals.

[0085] The signal multiplexing selection module 40 includes a signal selection chip controlled by the MCU, which is used to adaptively switch the output channel to wheel speed pulse signal or digital communication protocol according to the request of external device, thereby adaptively switching the output temperature and wheel speed signal or hub motor operation data.

[0086] The MCU continuously listens for communication requests from the vehicle controller host via the UART interface. If the user is using a high-end e-bike (equipped with a controller host that supports UART communication), the vehicle controller host will periodically send data request signal frames. Upon receiving these frames, the MCU immediately sends real-time operating data back to the vehicle controller host via the UART interface and maintains the UART communication mode of the signal selection chip. If the user is using a low-end e-bike (with a controller host that only supports wheel speed pulse signals), and the MCU does not detect any communication requests within a preset time, it is considered a communication timeout. In this case, the MCU outputs a low-level gating signal through the I / O port, and the control signal selection chip switches the interface channel to the temperature wheel speed signal output mode. The calculated rotation speed signal is converted into wheel speed pulses and output to the controller. Simultaneously, the temperature signal is converted into an analog voltage signal for output, ensuring that the low-end controller can obtain motor operating data normally.

[0087] Alternatively, a diagnostic tool supporting UART communication (such as a laptop with a USB-to-UART module) can be connected to the motor's external communication interface via a wiring harness. The diagnostic tool sends a data request command, and upon receiving the command, the MCU uploads the entire lifecycle operating data (including mileage data for each temperature threshold range, historical abnormal state snapshots, SN codes, etc.) stored in its memory to the diagnostic tool via the UART interface. Maintenance personnel can then view the data and perform fault diagnosis using the diagnostic tool software. If the diagnostic tool cannot connect, maintenance personnel can directly read the data from the MCU's built-in memory using a dedicated tool (such as a programmer), thus obtaining complete operating data and fault records.

[0088] In an optional embodiment, the hub motor data management and fault monitoring method further includes: The serial number of the hub motor is stored in the memory; The serial number is then bound to the mileage data in the hub motor's operating data.

[0089] In an optional embodiment, the hub motor data management and fault monitoring method further includes: The hub motor's operating data is written to the memory using a partitioned cyclic writing mechanism.

[0090] In an optional embodiment, the hub motor data management and fault monitoring method further includes: The MCU analyzes temperature, speed, and mileage data under different operating conditions and automatically adjusts the thresholds and parameters for fault diagnosis.

[0091] After the motor has been running for a period of time, when the MCU is powered on, it reads the preset initial parameters from the MCU’s built-in memory. The initial parameters may include: temperature zone thresholds (such as 80℃, 120℃, 160℃), fault diagnosis thresholds corresponding to each temperature zone (such as triggering an early warning after running at >160℃ for 5 minutes) and learning cycle (default 30 days / 500km, whichever comes first).

[0092] Real-time recording and storage of detailed operating condition data, including: cumulative mileage, average speed, duration, and number of faults in each interval divided by preset temperature zoning thresholds. When a preset learning period is reached or the fault incidence rate in a certain detailed temperature interval increases by a preset percentage compared to the previous period, a clustering algorithm is used to identify characteristic temperature nodes based on the cumulative mileage distribution of the detailed intervals, thereby dynamically adjusting the temperature zoning thresholds. For example, assuming that the cumulative mileage in the 70-80℃ and 80-90℃ intervals accounts for 60% of the total mileage, and the difference in fault incidence rates between the two is <5%, the original 80℃ threshold is adjusted to 75℃. Furthermore, assuming that the 150-160℃ interval has a low mileage percentage (<5%) but a fault incidence rate of 20%, a new 155℃ threshold is added to refine the high-temperature risk intervals. The adjusted temperature differentiation thresholds are stored as the currently valid temperature differentiation thresholds. Based on the currently valid temperature differentiation thresholds, fault diagnosis parameters are optimized, including fault warning duration and speed fluctuation diagnosis thresholds. For example, for the adjusted high-temperature risk range (e.g., 155-160℃), the duration of fault warning is shortened from 5 minutes to 3 minutes; for the low-fault-risk high-frequency operating range (e.g., 75-90℃), the diagnostic threshold for speed fluctuation is appropriately relaxed (e.g., adjusted from ±5 rpm to ±8 rpm) to reduce false alarms.

[0093] The above-mentioned optional implementation method can more accurately reflect the health status of the motor by dynamically adjusting the statistical method of temperature zone mileage according to the actual operating temperature range and the corresponding mileage distribution.

[0094] Figure 8 This is a flowchart of another hub motor data management and fault monitoring method provided in an embodiment of this application. The hub motor data management and fault monitoring method specifically includes the following steps.

[0095] S801, the system is powered on.

[0096] After the system is powered on, the MCU and each sampling module complete initialization and load the SN code and historical configuration parameters stored in the memory (e.g., EEPROM) to prepare for subsequent signal acquisition.

[0097] S802 detects the status of the three-phase Hall signals of the motor and detects wheel speed signal events.

[0098] The Hall signal sampling module acquires the three-phase levels of U / V / W in real time, while the wheel speed sampling module monitors for pulse signals (generated by rotor rotation). Both types of signals are transmitted synchronously to the MCU.

[0099] S803, is the Hall signal status normal?

[0100] The MCU compares the real-time Hall signal sequence with the preset commutation sequence table to determine whether there are invalid states (such as 111, 000).

[0101] If an invalid state exists, execute S804; if no invalid state exists, execute S805.

[0102] S804 triggers Hall signal fault code reporting.

[0103] The MCU generates the corresponding fault code (such as U-phase fault 0x02), stores it in the fault snapshot area, and reports the fault information to the controller host via the CAN bus.

[0104] S805, keep the detection running.

[0105] Maintain continuous monitoring of the three-phase Hall signals to ensure that abnormal Hall signals can be detected in a timely manner during subsequent operating conditions, and switch to S806.

[0106] S806, has a wheel speed signal event occurred?

[0107] Determine whether the temperature wheel speed sampling module detects a pulse signal (i.e., whether the motor is rotating).

[0108] If a pulse signal is detected, execute S807; if no pulse signal is detected, return to S802 and continue monitoring.

[0109] S807 calculates the current wheel speed and temperature.

[0110] The MCU calculates the rotational speed (rpm) based on the wheel speed pulse width, converts the current motor temperature (°C) through the voltage divider value of the NTC thermistor, and accumulates the mileage data for the corresponding temperature range.

[0111] S808, has the mileage data reached the storage threshold?

[0112] Determine whether the cumulative mileage in the current temperature range has reached a preset threshold (e.g., 1000m).

[0113] If the preset threshold is reached, execute S809; if the preset threshold is reached, jump to S810.

[0114] S809 performs data storage.

[0115] The current mileage data, temperature, and SN code are bound together and written to the EEPROM using a partitioned cyclic writing mechanism. At the same time, the write count and CRC check code are updated. After completion, the process jumps to S810.

[0116] S810, MCU control signal multiplexing selector opens the communication port.

[0117] The MCU outputs a low-level control signal to switch the signal multiplexer to the UART communication channel, preparing to receive requests from external devices.

[0118] S811, is there a communication request from the controller host?

[0119] Monitor whether the UART port receives a request frame (such as a data read command) from the controller host. If a request frame from the controller host is received, execute S812; if no request frame from the controller host is received, execute S813.

[0120] S812, keep the communication port enabled.

[0121] Keep the communication port open, and the MCU sends motor operation data (such as mileage data divided into temperature threshold ranges) to the controller host as requested. After completion, S814 is executed.

[0122] S813, control interface multiplexer, switches the port to the output signal terminal of the rapid temperature wheel sampling module.

[0123] The MCU outputs a high-level control signal, switches the port to the basic signal channel, and outputs wheel speed and temperature signals to the controller host.

[0124] S814 waits for the controller host to communicate and responds.

[0125] It continuously listens to the communication port. If a request is received from the controller host, it immediately switches back to the communication port and responds, while simultaneously jumping to S815.

[0126] S815, is the shutdown command being detected?

[0127] Monitor whether a shutdown signal (e.g., high level for 100ms) is received from the controller host.

[0128] When a shutdown signal is received from the controller host, execute S816; if no shutdown signal is received from the controller host, return to S802 and continue the loop monitoring.

[0129] S816 is used for data storage.

[0130] Write all currently unstored mileage and fault information into the EEPROM, turn off the power to each sampling module, and complete the data protection before system shutdown.

[0131] Since the core hardware of the hub motor data management and fault monitoring system 1 (temperature and wheel speed sampling module, Hall signal sampling module, MCU, and signal multiplexing selection module) is integrated into the end cover of the hub motor through a PCB board, forming a physical "integrated structure" with the core components of the hub motor such as the stator, rotor, and windings, for the convenience of the following description, the hub motor with the integrated hub motor data management and fault monitoring system 1 will be referred to as the intelligent hub motor, and the hub motor with only basic drive capability and relying on the vehicle controller host to realize data storage and fault judgment will be referred to as the ordinary hub motor.

[0132] To visually highlight the technical advantages of the intelligent hub motor in the vehicle power steering system, a comparative experiment was designed: by analyzing the differences in operating data between the intelligent hub motor and a conventional hub motor under the same operating conditions, the improvement effect of the intelligent hub motor in data management, operating condition adaptation, and power steering reliability was verified. The specific experimental scheme is as follows: The testing method in this application involves the same tester riding the same type of electric-assist bicycle to conduct a combined test of urban road sections and uphill sections (70% urban road sections, including flat roads and traffic light intersections, with an average speed of 15-20 km / h; 30% uphill sections, with a gradient of 5-8° and an average speed of 8-12 km / h), for a total test mileage of approximately 150 km. All experimental data are collected from the vehicle's communication bus to ensure the consistency and comparability of the data sources.

[0133] The data interaction logic of the intelligent wheel hub motor: The vehicle controller host can directly obtain the operating data calculated and stored locally by the intelligent wheel hub motor through the communication link; the motor publishes its own data to the Controller Area Network (CAN) bus in accordance with the protocol format through a unique device identifier (ID), realizing the unique binding of "motor-data".

[0134] Data interaction logic of ordinary wheel hub motors: Ordinary wheel hub motors have no local data processing and storage capabilities. The vehicle controller host needs to indirectly estimate the motor operation data through external signals (such as wheel speed pulses and current), and can only use the controller host's own device ID to publish data to the CAN bus, which cannot achieve independent association between the motor and the data.

[0135] Table 1 below shows the data obtained from the motor-specific device ID on the CAN bus when using a smart hub motor.

[0136] Table 1 CAN bus data for intelligent hub motor Serial Number data describe 1 12345 Motor's unique serial number (device identification code) 2 1 Motor Hall signal status (obtained from local motor diagnostics) 4 0 Wheel speed (unit: RPM, calculated locally by the motor) 5 26 Motor temperature (unit: °C, collected locally by the motor) 6 129.6 Cycling distance in temperatures ≤80℃ (unit: km) 7 7.86 Cycling distance in the temperature range of 80℃ to 120℃ (unit: km) 8 3.83 Cycling distance in the temperature range of 120℃ to 160℃ (unit: km) 9 18.1 Cycling distance in areas with temperatures above 160℃ (unit: km) Table 2 below shows the device ID data obtained from the controller host on the CAN bus when using a standard hub motor.

[0137] Table 2 CAN bus data for ordinary hub motors Serial Number data describe 1 1 Motor Hall signal status (estimated by the controller host) 2 0 Wheel speed (unit: RPM, estimated by the controller host) 3 26 Motor temperature (unit: °C, estimated by the controller host) 4 156.2 Total mileage of the vehicle (unit: km, no temperature correlation) A comparison of experimental data from the two types of motors clearly shows that: intelligent hub motors achieve lifelong "device-data" binding through a dedicated SN code and can record historical mileage across different temperature ranges (e.g., 11% of the mileage in this test occurred under extreme conditions with temperatures >160℃). This refined data can be directly used as the basis for fault attribution analysis when the motor fails or its performance degrades; while ordinary hub motors can only store the total vehicle mileage through the controller host. If the motor is replaced, the new motor's mileage will be completely disconnected from the total vehicle mileage, making it impossible to trace the motor's own historical operating conditions. Intelligent hub motors can independently perform local diagnostics of Hall signal status, completely decoupling from the controller host. When a Hall signal fault indication occurs, it is only necessary to quickly determine whether the fault is located at the motor end or the controller end through the data source (motor ID or controller ID), significantly shortening after-sales troubleshooting time; the Hall signal status of ordinary hub motors relies entirely on the controller host for estimation, requiring cross-system troubleshooting when a fault occurs, which is extremely inefficient.

[0138] The hub motor data management and fault monitoring system of this application does not collect signals in isolation, but synchronously correlates temperature and speed data, and combines three-phase Hall signals to achieve real-time fault monitoring. By storing mileage in different temperature ranges (<80℃, 80–120℃, >120℃, etc.), the abstract equipment lifespan is transformed into concrete operating mileage, providing accurate data support for motor health assessment. Simultaneously, the system introduces a unique serial number (SN) code and CRC verification mechanism, constructing a complete security system for data generation, storage, and retrieval, ensuring data authenticity and immutability, significantly improving data credibility and legal validity. Through an architecture of MCU monitoring and signal selection chip execution, the output protocol is software-defined and dynamically switched. The system can automatically identify the type of external device (such as after-sales diagnostic instruments or vehicle controller hosts) and seamlessly switch between wheel speed pulses (compatible with traditional instruments) and UART (Universal Asynchronous Receiver / Transmitter) digital communication protocols (supporting large data volume transmission), resolving the contradiction between device compatibility and data interaction efficiency.

[0139] Example 3 This embodiment provides a computer-readable storage medium storing a computer program. When executed by a processor, this computer program implements the steps described in the embodiment of the hub motor data management and fault monitoring method. Figure 8 S81-S84 are shown.

[0140] S71, after the system is powered on and initialized, the microcontroller sets the signal multiplexing selection module to communication port mode through a gating signal, and simultaneously starts the temperature wheel speed sampling module and the Hall signal sampling module to sample signals.

[0141] S72, the microcontroller receives the temperature and wheel speed signals sampled by the temperature and wheel speed sampling module, and receives the three-phase Hall signal sampled by the Hall signal sampling module.

[0142] S73, the microcontroller obtains hub motor operating data based on the temperature signal, the wheel speed signal and the three-phase Hall signal, and stores the hub motor operating data in its internal integrated memory.

[0143] S74, the microcontroller unit performs system fault event monitoring based on the three-phase Hall signals.

[0144] It will be apparent to those skilled in the art that this application is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this application. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this application is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be embraced within this application. No reference numerals in the claims should be construed as limiting the scope of the claims. Furthermore, it is clear that the word "comprising" does not exclude other elements or, and the singular does not exclude the plural. Multiple elements or devices recited in the specification may also be implemented by a single element or device through software or hardware. The terms "first," "second," etc., are used to indicate names and do not indicate any particular order.

[0145] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this application without departing from the spirit and scope of the technical solutions of this application.

Claims

1. A hub motor data management and fault monitoring system, characterized in that, The hub motor data management and fault monitoring system includes: A temperature and wheel speed sampling module, connected to a microcontroller unit, is used to sample the temperature and wheel speed signals of the hub motor and transmit the temperature and wheel speed signals to the microcontroller unit; A Hall signal sampling module, connected to the microcontroller unit, is used to sample the three-phase Hall signals of the hub motor and transmit the three-phase Hall signals to the microcontroller unit; The microcontroller unit integrates a memory for obtaining hub motor operating data based on the temperature and wheel speed signals and the three-phase Hall signals, and storing the hub motor operating data in the memory; simultaneously, it monitors system fault events based on the three-phase Hall signals.

2. The hub motor data management and fault monitoring system as described in claim 1, characterized in that, The hub motor data management and fault monitoring system also includes: The signal multiplexing selection module is connected to the microcontroller unit and the controller host. It is used to receive the multiplexing selection control signal from the microcontroller unit and adaptively select whether to output the hub motor operating data or the temperature and wheel speed signals according to the multiplexing selection control signal.

3. The hub motor data management and fault monitoring system as described in claim 2, characterized in that, The memory stores a unique serial number of the hub motor. The serial number is bound to the mileage data in the hub motor's operating data. The hub motor's operating data is written to the memory using a partitioned cyclic writing mechanism, and the mileage data is stored in intervals according to preset temperature thresholds.

4. The hub motor data management and fault monitoring system as described in any one of claims 1 to 3, characterized in that, The temperature wheel speed sampling module includes: a wheel speed magnetic encoding element, a wheel speed Hall sensor, and a first signal sampling circuit; The wheel speed magnetic encoding element works in conjunction with the wheel speed Hall sensor to enable the Hall effect sensor to generate a first rectangular wave signal whose level switches periodically between high and low states; The first signal sampling circuit is connected to the wheel speed Hall sensor and the microcontroller unit. It is used to obtain temperature and wheel speed signals based on the high-level voltage value of the first rectangular wave signal and the pulse width of the wheel hub, and transmit them to the microcontroller unit.

5. The hub motor data management and fault monitoring system as described in claim 4, characterized in that, The first signal sampling circuit includes: a negative temperature coefficient thermistor and a fixed resistor connected in series; One end of the negative temperature coefficient thermistor is grounded, and the other end is connected to the fixed resistor; The other end of the fixed resistor is connected to the power supply; The electrical connection point between the negative temperature coefficient thermistor and the fixed resistor is the first sampling point. The first sampling point is used to output a temperature-related voltage signal, and the temperature-related voltage signal determines the high-level voltage value of the rectangular wave signal.

6. The hub motor data management and fault monitoring system as described in any one of claims 1 to 3, characterized in that, The Hall signal sampling module includes a motor magnet, a three-phase Hall sensor, and a second signal sampling circuit. The motor magnet and the three-phase Hall sensor work together to enable the three-phase Hall sensor to generate a second rectangular wave signal whose level switches periodically between high and low states; The second signal sampling circuit is connected to the three-phase Hall sensor and the microcontroller unit, and is used to obtain the three-phase Hall signal based on the second rectangular wave signal and transmit it to the microcontroller unit.

7. The hub motor data management and fault monitoring system as described in claim 6, characterized in that, The second signal sampling circuit includes: a pull-up resistor and a pull-down resistor connected in series; One end of the pull-up resistor is connected to the power supply, and the other end is connected to the pull-down resistor; The other end of the pull-down resistor is grounded; The electrical connection point between the pull-up resistor and the pull-down resistor is the second sampling point, which is used to output a three-phase Hall signal.

8. A method for data management and fault monitoring of a hub motor, characterized in that, The hub motor data management and fault monitoring system according to any one of claims 1 to 7, wherein the hub motor operation data management method includes: After the system is powered on and initialized, the microcontroller sets the signal multiplexing selection module to communication port mode through a gating signal, and simultaneously starts the temperature wheel speed sampling module and the Hall signal sampling module to sample signals. The microcontroller receives the temperature and wheel speed signals sampled by the temperature and wheel speed sampling module, and the three-phase Hall signal sampled by the Hall signal sampling module; The microcontroller unit obtains hub motor operating data based on the temperature signal, the wheel speed signal, and the three-phase Hall signal, and stores the hub motor operating data in its internal integrated memory. The microcontroller unit monitors system fault events based on the three-phase Hall signals.

9. The hub motor data management and fault monitoring method as described in claim 8, characterized in that, The hub motor data management and fault monitoring method also includes: Upon receiving a communication request signal from the controller host, a multiplexing selection control signal is generated; based on the multiplexing selection control signal, the system adaptively selects whether to output the hub motor operating data or the temperature and wheel speed signals; and / or The serial number of the hub motor is stored in the memory, and the serial number is bound to the mileage data in the hub motor operation data. The hub motor operation data is written to the memory using a partitioned cyclic writing mechanism, and the mileage data is stored in intervals according to preset temperature thresholds.

10. A computer-readable storage medium storing a computer program thereon, characterized in that, When the computer program is executed by the processor, it implements the hub motor data management and fault monitoring method according to claim 8 or 9.

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