Permanent magnet synchronous motor driving control system based on fault-tolerant topology and self-adaptive PI adjustment

Abstract

The invention provides a permanent magnet synchronous motor driving control system based on fault-tolerant topology and self-adaptive PI adjustment, which belongs to the technical field of power electronics and motor control and comprises a main control module, a power conversion module (comprising 1-3 redundant bridge arms), a fault-tolerant control module, a self-adaptive PI adjustment module, a motor state detection module and an electric energy input module. The motor state detection module synchronously transmits rotating speed, current and position signals to the three-core control module, the self-adaptive PI module dynamically generates PI parameters according to the signals, the fault-tolerant module identifies faults and outputs switching instructions, the main control module combines the parameters and the instructions to drive the power conversion module to operate a motor, and the electric energy input module supplies power in a stabilized voltage mode. The system solves the problems of easy shutdown, poor fixed PI adaptation, slow fault response and the like of a traditional system without redundancy, improves the fault-tolerant capability, the control precision and the operation stability, and is suitable for scenes with high requirements on continuous operation, such as new energy automobiles and industrial machine tools.

Description

Technical Field

[0001] This invention relates to the field of power electronics and motor control technology, specifically to a permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation. Background Technology

[0002] Currently, permanent magnet synchronous motor drive control systems face three core challenges in industrial applications. First, traditional power conversion modules often employ a non-redundant three-phase full-bridge topology. A failure in a single bridge arm or power switch can cause the entire module to fail, leading to motor shutdown. This fails to meet the demands of continuous operation in applications such as new energy vehicles and industrial machine tools. Second, PI control parameters are often fixed values. However, motors frequently experience load fluctuations and speed variations. Fixed parameters either exhibit slow response times with large deviations or are prone to overshoot with small deviations, making it difficult to balance control accuracy and stability under different conditions. Third, motor status detection often focuses on a single parameter (e.g., only speed or current), and the signal is only transmitted to the main control module. The fault-tolerant control module cannot synchronously acquire real-time status, resulting in delayed fault identification, inaccurate fault location, and potential fault propagation, further exacerbating system damage. Furthermore, some systems lack adaptation mechanisms for external power fluctuations. When the grid voltage is unstable, the power quality of the power conversion module's output deteriorates, directly impacting motor operational stability. These issues collectively result in significant shortcomings in the reliability, adaptability, and continuity of traditional systems, limiting the application of permanent magnet synchronous motors in demanding scenarios. Summary of the Invention

[0003] The present invention aims to solve the problems mentioned in the background art by providing a permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation.

[0004] The specific technical solution is as follows: A permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation includes a main control module, a power conversion module, a fault-tolerant control module, an adaptive PI regulation module, and a motor state detection module. The signal output terminal of the motor state detection module is connected to the first signal input terminal of the main control module, the signal input terminal of the fault-tolerant control module, and the signal input terminal of the adaptive PI regulation module, respectively, for acquiring the operating state signal of the permanent magnet synchronous motor and synchronously transmitting it to the main control module, the fault-tolerant control module, and the adaptive PI regulation module. The parameter output terminal of the adaptive PI regulation module is connected to the second signal input terminal of the main control module. The first input terminal is connected to the second input terminal, which is used to dynamically generate PI adjustment parameters based on the motor operating status signal and transmit them to the main control module; the control output terminal of the fault-tolerant control module is connected to the third signal input terminal of the main control module, which is used to identify faults based on the motor operating status signal and output fault-tolerant control commands to the main control module; the drive output terminal of the main control module is connected to the control input terminal of the power conversion module, which is used to generate drive signals by combining the PI adjustment parameters and the fault-tolerant control commands; the power output terminal of the power conversion module is connected to the power input terminal of the permanent magnet synchronous motor, which is used to convert the input electrical energy into electrical energy suitable for motor operation and drive the motor to run.

[0005] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation, wherein the power conversion module adopts a three-phase full-bridge topology with redundant bridge arms. This topology includes three main power bridge arms and at least one redundant power bridge arm. Each main power bridge arm and redundant power bridge arm consists of two power switching transistors connected in series, and each power switching transistor has a freewheeling diode connected in reverse parallel across its two ends.

[0006] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation includes 1-3 redundant power bridge arms. The fault-tolerant control module has built-in bridge arm fault switching logic. When any main power bridge arm is identified as faulty, the fault-tolerant control module triggers the redundant power bridge arm to start operation through the main control module and cuts off the power input of the faulty main power bridge arm.

[0007] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation, wherein the parameter adjustment basis of the adaptive PI regulation module includes the real-time speed deviation, stator current deviation and rotor position deviation of the permanent magnet synchronous motor. The module divides at least three adjustment intervals according to the absolute value of the above deviations, and pre-configures the corresponding PI parameter adjustment step size for each adjustment interval.

[0008] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation, wherein the adaptive PI regulation module uses a fuzzy control algorithm or a radial basis function neural network algorithm to dynamically generate PI parameters. When the motor operating status signal exceeds the preset stable range, the module automatically increases the PI parameter adjustment step size to accelerate the regulation response speed.

[0009] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation includes a fault-tolerant control module whose fault identification targets include overcurrent in the bridge arm of the power conversion module, overvoltage in the bridge arm, open circuit in the power switch, and short circuit in the stator winding of the permanent magnet synchronous motor. The module identifies and locates the fault type by comparing the motor operating status signal with a preset fault threshold.

[0010] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation includes fault-tolerant control commands output by the fault-tolerant control module, which include fault isolation commands and operating mode switching commands. The fault isolation commands are used to control the power conversion module to cut off the power path of the faulty component, and the operating mode switching commands are used to control the main control module to switch the motor drive mode from normal drive mode to derating drive mode or redundant drive mode.

[0011] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation includes a motor state detection module comprising a speed detection unit, a current detection unit, and a position detection unit. The speed detection unit is used to acquire the real-time speed signal of the motor, the current detection unit is used to acquire the three-phase stator current signal of the motor, and the position detection unit is used to acquire the real-time position signal of the motor rotor.

[0012] In the aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation, the speed detection unit adopts a Hall speed sensor or photoelectric encoder, the current detection unit adopts a series shunt resistor or Hall current sensor, and the position detection unit adopts a rotary transformer or absolute encoder.

[0013] The aforementioned permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation further includes an energy input module. The output terminal of the energy input module is connected to the energy input terminal of the power conversion module, and is used to convert external DC or AC power into a DC bus voltage adapted to the power conversion module. The energy input module has a built-in voltage regulation unit to suppress the influence of external power fluctuations on the stability of the output energy of the power conversion module.

[0014] The present invention has the following beneficial effects: This system integrates a core solution of "multi-module collaborative architecture + fault-tolerant topology + adaptive PI adjustment + comprehensive state detection," addressing the pain points of traditional systems at a holistic level and ultimately achieving four major technical benefits: 1. Significantly Enhanced System Fault Tolerance and Continuous Operation Capability: Through the redundant bridge arm design of the power conversion module (1-3 redundant bridge arms), combined with the automated fault switching logic of the fault-tolerant control module, when the main bridge arm or switching transistor experiences faults such as overcurrent, overvoltage, or open circuit, the system can quickly disconnect the path of the faulty component and engage the redundant bridge arm, restoring the power conversion function without manual intervention. This solution avoids the problem of shutdown due to single-point failure in traditional non-redundant systems, ensuring that the motor can still maintain operation (or operate at reduced derating) under fault conditions, significantly reducing downtime losses; 2. Optimizing Motor Control Accuracy and Operating Condition Adaptability: The adaptive PI control module uses three core deviations—speed, stator current, and rotor position—as its basis, dividing the motor into multiple adjustment ranges and configuring corresponding step sizes. It also employs fuzzy control or radial basis function neural network algorithms to dynamically generate parameters. Compared to traditional fixed PI parameters, this solution can adjust the control strategy according to the motor's real-time operating conditions—accelerating the response speed to reduce deviations when they are large, and decreasing the step size to avoid overshoot when deviations are small. Simultaneously, it adapts to the nonlinear operating characteristics of the motor, resulting in more precise control of speed, current, and rotor position, and reduced operational fluctuations. 3. Enhanced System Stability and Anti-interference Capabilities: The motor status detection module comprehensively collects signals from three units—speed, current, and position—and transmits them synchronously to the main control, fault-tolerant, and adaptive PI modules. This ensures consistent and real-time information acquisition across all modules, preventing control decision deviations due to missing or delayed information. Simultaneously, the voltage regulation unit of the power input module suppresses external power fluctuations, providing a stable and compatible DC bus voltage for the power conversion module. This dual-source approach of "signal acquisition - power input" ensures system stability and reduces the impact of external interference on motor operation. 4. Enhance system reliability and fault prevention capabilities. The fault-tolerant control module covers the core fault types of the power conversion module (bridge arm overcurrent / overvoltage, switch open circuit) and the motor body (stator winding short circuit). It achieves accurate identification and location through signal and threshold comparison. Combined with fault isolation commands to cut off fault paths and mode switching commands to switch drive modes, it can not only prevent the spread of faults and cause secondary damage, but also flexibly select the operating mode according to the fault severity, further improving the overall system reliability and reducing maintenance costs. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the architecture of a permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation, provided in an embodiment of the present invention. Detailed Implementation

[0016] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0017] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this application. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0018] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0019] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0020] Example The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation provided in this embodiment is as follows: Figure 1As shown, the system includes a main control module, a power conversion module, a fault-tolerant control module, an adaptive PI adjustment module, and a motor status detection module. The signal output terminal of the motor status detection module is connected to the first signal input terminal of the main control module, the signal input terminal of the fault-tolerant control module, and the signal input terminal of the adaptive PI adjustment module, respectively, for collecting the operating status signal of the permanent magnet synchronous motor and synchronously transmitting it to the main control module, the fault-tolerant control module, and the adaptive PI adjustment module. The parameter output terminal of the adaptive PI adjustment module is connected to the second signal input terminal of the main control module, for dynamically generating PI adjustment parameters based on the motor operating status signal and transmitting them to the main control module. The control output terminal of the fault-tolerant control module is connected to the third signal input terminal of the main control module, for identifying faults based on the motor operating status signal and outputting fault-tolerant control commands to the main control module. The drive output terminal of the main control module is connected to the control input terminal of the power conversion module, for generating drive signals by combining PI adjustment parameters and fault-tolerant control commands. The power output terminal of the power conversion module is connected to the power input terminal of the permanent magnet synchronous motor, for converting the input electrical energy into electrical energy suitable for motor operation and driving the motor.

[0021] The core of this solution is to construct a complete system architecture consisting of "main control - power conversion - fault-tolerant control - adaptive PI regulation - motor status detection," and to clearly define the signal and control connection logic between each module. As shown in the solution, the motor status detection module can synchronously transmit operating status signals to the three core control modules, ensuring the real-time nature and consistency of information acquired by each module; the adaptive PI regulation module dynamically provides PI parameters, avoiding the problem of fixed parameters being difficult to adapt to different motor operating conditions; and the fault-tolerant control module promptly outputs fault handling commands, providing the main control module with a basis for fault response. The final technical effect is that the system can achieve comprehensive perception of the motor's operating status, dynamic parameter adjustment, and rapid fault response, ensuring stable drive of the permanent magnet synchronous motor under different operating conditions from the overall architecture level, and reducing operational fluctuations caused by information lag, parameter rigidity, or unhandled faults.

[0022] Specifically, in this embodiment, the power conversion module adopts a three-phase full-bridge topology with redundant bridge arms. This topology includes three main power bridge arms and at least one redundant power bridge arm. Each main power bridge arm and redundant power bridge arm consists of two power switches connected in series, and each power switch has a freewheeling diode connected in reverse parallel across its two ends.

[0023] This design specifies that the power conversion module adopts a "three-phase full-bridge topology with redundant bridge arms," ​​with each bridge arm consisting of two series-connected power switches and anti-parallel freewheeling diodes connected across the switches. As can be seen from the design, the redundant bridge arm design provides a fault replacement path for the power conversion stage, preventing the failure of a single bridge arm from causing the entire power conversion module to fail. The anti-parallel freewheeling diodes provide a path for the inductive load to continue flowing during power switch commutation, preventing excessively high voltage spikes across the switches. The final technical effect is: improved structural reliability of the power conversion module, reduced probability of power switch damage due to voltage spikes, and provision of hardware foundation for subsequent fault tolerance, ensuring the stability of the power conversion process.

[0024] Specifically, in this embodiment, the number of redundant power arms is 1-3, and the fault-tolerant control module has built-in arm fault switching logic. When any main power arm is identified as faulty, the fault-tolerant control module triggers the redundant power arms to start operation through the main control module and cuts off the power input of the faulty main power arm.

[0025] This solution further limits the number of redundant bridge arms to 1-3 and explicitly includes a built-in "bridge arm fault switching logic" in the fault-tolerant control module. In the event of a fault, the redundant bridge arm can be activated, and the power input to the faulty bridge arm can be cut off. The solution demonstrates that selecting 1-3 redundant bridge arms can adapt to different fault-tolerant scenarios, avoiding cost waste due to excessive redundancy or the inability to handle multiple bridge arm failures due to insufficient redundancy. The fault switching logic automates the "fault identification-redundancy activation-fault isolation" process without manual intervention. The final technical effect is: based on hardware redundancy, the automated switching logic enables rapid replacement of faulty bridge arms, preventing system downtime due to bridge arm failures, significantly improving the system's continuous operation capability, and reducing downtime losses caused by faults.

[0026] Specifically, in this embodiment, the parameter adjustment basis of the adaptive PI adjustment module includes the real-time speed deviation, stator current deviation and rotor position deviation of the permanent magnet synchronous motor. The module divides at least three adjustment intervals according to the absolute value of the above deviations and pre-configures the corresponding PI parameter adjustment step size for each adjustment interval.

[0027] This scheme limits the adaptive PI control module to use "speed deviation, stator current deviation, and rotor position deviation" as the parameter adjustment basis, and divides the adjustment into at least three adjustment ranges based on the absolute value of the deviation, configuring corresponding adjustment step sizes. As can be seen from the scheme, using three core deviations as the basis can comprehensively reflect the motor's operating deviation state, avoiding the one-sidedness of adjustment caused by using a single deviation as the adjustment basis. The design of multiple adjustment ranges and corresponding step sizes allows the PI parameter adjustment to better match the deviation magnitude—using a suitable large step size to accelerate the adjustment speed when the deviation is large, and using a suitable small step size to avoid overshoot when the deviation is small. The final technical effect is: making PI control more targeted, able to quickly reduce deviation when the motor deviation is large, and maintain adjustment accuracy when the deviation is small, avoiding the problems of "easy overshoot in fast adjustment and slow response in fine adjustment" of traditional fixed step size adjustment, and improving the stability of motor speed, current, and position control.

[0028] Specifically, in this embodiment, the adaptive PI adjustment module uses a fuzzy control algorithm or a radial basis function neural network algorithm to dynamically generate PI parameters. When the motor operating status signal exceeds the preset stable range, the module automatically increases the PI parameter adjustment step size to speed up the adjustment response.

[0029] This scheme specifies that the adaptive PI control module uses either a fuzzy control algorithm or a radial basis function neural network algorithm, and automatically increases the parameter adjustment step size when the state exceeds the preset range. As can be seen from the scheme, fuzzy control and radial basis function neural network algorithms have the ability to handle nonlinear and uncertain problems, and can better adapt to complex operating conditions (such as sudden load changes and speed fluctuations) during the operation of permanent magnet synchronous motors. Increasing the adjustment step size when the state exceeds the range can quickly respond to large deviations under abnormal operating conditions. The final technical effect is: further improving the real-time performance and accuracy of PI parameter adjustment, solving the problem that traditional linear algorithms are difficult to adapt to the nonlinear operating characteristics of motors, and when the motor experiences abnormal operating conditions, it can quickly pull the motor back to a stable operating range by accelerating the adjustment response speed, reducing the impact of abnormal operating conditions on the motor.

[0030] Specifically, in this embodiment, the fault identification objects of the fault-tolerant control module include overcurrent of the bridge arm current of the power conversion module, overvoltage of the bridge arm voltage, open circuit of the power switch tube, and short circuit of the stator winding of the permanent magnet synchronous motor. The module identifies and locates the fault type by comparing the motor operating status signal with the preset fault threshold.

[0031] This solution limits the fault identification targets of the fault-tolerant control module to include "bridge arm current overcurrent, bridge arm voltage overvoltage, power switch open circuit, and stator winding short circuit," and achieves fault identification and location through "signal comparison with preset fault thresholds." As can be seen from the solution, it covers the core fault types of the power conversion module and the motor itself, comprehensively monitoring the fault risks of key system components and avoiding missed detections due to incomplete fault identification. The threshold comparison method enables quantitative fault identification, ensuring the accuracy of fault judgment, while clearly identifying the fault location, avoiding the problem of vague fault prompts failing to provide targeted solutions. The final technical effect is: achieving comprehensive monitoring and precise location of core system faults, providing accurate fault information for subsequent fault isolation and mode switching, reducing the spread of faults due to missed fault detection or inaccurate fault location, and lowering the risk of secondary system damage.

[0032] Specifically, in this embodiment, the fault-tolerant control instructions output by the fault-tolerant control module include fault isolation instructions and operating mode switching instructions; the fault isolation instructions are used to control the power conversion module to cut off the power path of the faulty component, and the operating mode switching instructions are used to control the main control module to switch the motor drive mode from normal drive mode to derating drive mode or redundant drive mode.

[0033] This solution limits the output of "fault isolation commands" and "operating mode switching commands" by the fault-tolerant control module. These commands are used to disconnect the path to the faulty component and switch to either derating or redundant drive modes, respectively. The fault isolation command quickly disconnects the faulty component from the rest of the system, preventing the fault from spreading to non-faulty areas. The operating mode switching command selects an appropriate drive mode based on the fault condition—derating mode maintains basic motor operation after a fault, while redundant mode maintains normal drive capability through redundant components. The ultimate technical effect is: effectively preventing fault propagation and avoiding severe system damage caused by an expanded fault range; simultaneously, through mode switching, it ensures that the motor does not stop directly under fault conditions, maintaining appropriate drive capability according to the severity of the fault, thus improving the system's fault tolerance and operational continuity.

[0034] Specifically, in this embodiment, the motor status detection module includes a speed detection unit, a current detection unit, and a position detection unit; the speed detection unit is used to collect the real-time speed signal of the motor, the current detection unit is used to collect the three-phase current signal of the motor stator, and the position detection unit is used to collect the real-time position signal of the motor rotor.

[0035] This solution defines the motor status detection module as including a "speed detection unit, current detection unit, and position detection unit," which respectively collects speed, stator three-phase current, and rotor position signals. As the solution shows, speed, stator current, and rotor position are core parameters reflecting the operating status of the permanent magnet synchronous motor—speed determines whether the motor's output speed meets the standard, stator current reflects the motor's load and power, and rotor position affects the accuracy of magnetic field control. The setup of these three units comprehensively collects these core parameters, preventing the control module from being unable to accurately determine the motor status due to the lack of key parameters. The final technical effect is: providing complete and critical motor operating data support for each control module, avoiding control decision deviations caused by missing information, and ensuring that the main control module, adaptive PI adjustment module, and fault-tolerant control module can formulate control strategies based on accurate status information, thus guaranteeing the precision of motor control.

[0036] Specifically, in this embodiment, the speed detection unit uses a Hall speed sensor or a photoelectric encoder, the current detection unit uses a series shunt resistor or a Hall current sensor, and the position detection unit uses a rotary transformer or an absolute encoder.

[0037] This solution specifies that the speed detection unit uses a Hall effect speed sensor or photoelectric encoder, the current detection unit uses a series shunt resistor or Hall effect current sensor, and the position detection unit uses a rotary transformer or absolute encoder. As can be seen from the solution, the selected sensors are all mature and reliable choices in the industrial field—Hall effect sensors have strong anti-interference capabilities, photoelectric encoders and absolute encoders have high detection accuracy, series shunt resistors are low-cost and suitable for low-current scenarios, and rotary transformers have strong resistance to harsh environments. The appropriate sensor selection ensures that each detection unit operates stably in different application scenarios. The final technical effect is to improve the accuracy and reliability of motor operating status signal acquisition, reduce signal interference, acquisition errors, or poor environmental adaptability caused by improper sensor selection, further ensure the accuracy of the signals acquired by the control module, and provide a high-quality data foundation for subsequent control decisions.

[0038] Specifically, in this embodiment, a power input module is also included. The output terminal of the power input module is connected to the power input terminal of the power conversion module, and is used to convert the external DC power supply or AC power supply into a DC bus voltage that is compatible with the power conversion module. The power input module has a built-in voltage regulation unit to suppress the impact of external power supply fluctuations on the stability of the output power of the power conversion module.

[0039] This solution adds a "power input module," whose functions include "converting external power to a voltage compatible with the power conversion module" and "using a built-in voltage regulator to suppress power fluctuations." As the solution demonstrates, external power sources may differ in type (e.g., DC, AC) or experience voltage fluctuations (e.g., unstable grid voltage). The power input module's power conversion function resolves the compatibility issue between the power conversion module and the external power source, while the voltage regulator smooths out voltage fluctuations. The ultimate technical effect is to ensure that the power conversion module receives stable and compatible input power, preventing problems such as the module malfunctioning due to incompatible external power sources or reduced power conversion efficiency and unstable motor operation due to voltage fluctuations, thus guaranteeing stable system operation from the source of power input.

[0040] In summary, this system uses "real-time signal acquisition - multi-module collaborative processing - dynamic driving and fault response" as its core logic, and the modules work collaboratively according to the following process: 1. Signal Acquisition Stage The motor status detection module's speed detection unit (Hall sensor or photoelectric encoder), current detection unit (shunt resistor or Hall current sensor), and position detection unit (rotary transformer or absolute encoder) respectively collect the motor's real-time speed, stator three-phase current, and rotor position signals. The collected signals are synchronously transmitted to the main control module, fault-tolerant control module, and adaptive PI adjustment module, providing consistent status data for the three core modules.

[0041] 2. Parameters and Troubleshooting 2.1 After receiving the status signal, the adaptive PI control module calculates the speed deviation, stator current deviation, and rotor position deviation. Based on the absolute value of the deviation, it matches a preset adjustment range and then generates dynamic PI parameters using fuzzy control or a radial basis function neural network algorithm, transmitting these parameters to the main control module. If the signal exceeds the preset stable range, the module automatically increases the parameter adjustment step size to accelerate the adjustment response. 2.2 The fault-tolerant control module compares the status signals with the preset fault thresholds to identify whether there are faults such as bridge arm overcurrent, open circuit of switching transistor, or short circuit of stator winding. If a fault is detected, it immediately generates a fault isolation command and an operating mode switching command and transmits them to the main control module.

[0042] 3. Driving and Execution Phase The main control module combines the dynamic parameters of the adaptive PI adjustment module and the fault command of the fault-tolerant control module (only PI parameters are used when there is no fault) to generate an appropriate drive signal, which is then transmitted to the power conversion module. The power conversion module (a three-phase full-bridge topology with redundant bridge arms) receives the stable DC bus voltage provided by the power input module and converts it into electrical energy suitable for the motor to drive the permanent magnet synchronous motor.

[0043] 4. Fault switching process If the fault-tolerant control module detects a fault, the main control module, according to the fault command, first controls the power conversion module to cut off the power path of the faulty bridge arm or component (fault isolation), and then triggers the redundant bridge arm to start operation (if any), while switching the drive mode to derating or redundant mode; the whole process does not require manual intervention, ensuring that the motor can continue to run after the fault.

[0044] How to use The usage process of this system revolves around "deployment-initialization-running-troubleshooting-shutdown", and the specific steps are as follows: 1. System Deployment and Connection Connect the input terminal of the power input module to an external DC or AC power source, and connect the output terminal to the power input terminal of the power conversion module to ensure that the power input is compatible with the DC bus voltage requirements of the power conversion module; Connect the power output terminal of the power conversion module to the power input terminal of the permanent magnet synchronous motor. Install each detection unit (speed, current, position) of the motor status detection module at the corresponding detection point of the motor (e.g., the speed sensor is installed at the motor shaft end, and the current sensor is connected in series in the stator circuit). Connect the signal output terminal of each detection unit to the main control module, the fault-tolerant control module, and the adaptive PI adjustment module. Complete the control circuit connections between each module (e.g., connect the output of the fault-tolerant control module to the main control module, and connect the output of the adaptive PI adjustment module to the main control module) to ensure that signals and control commands can be transmitted normally.

[0045] 2. System initialization settings Start the main control module, enter the parameter configuration interface, and set the motor basic parameters (such as rated speed and rated current), fault thresholds (such as bridge arm overcurrent threshold and voltage overvoltage threshold), adaptive PI adjustment range (such as the range division corresponding to the deviation size), and parameter adjustment step size for each range; Configure redundant bridge arms for the fault-tolerant control module, set the number of redundant bridge arms to be put into operation (1-3) according to actual needs, and activate the fault switching logic; set the voltage regulation range for the voltage regulation unit of the power input module to ensure that the output voltage is stable at the value adapted to the power conversion module.

[0046] 3. Normal operation control The power input module is activated, and its voltage regulation unit suppresses external power fluctuations, outputting a stable DC bus voltage to the power conversion module. Simultaneously, the motor status detection module is activated, starting to collect motor speed, current, and rotor position signals, and transmitting them synchronously to the three core control modules. The adaptive PI control module dynamically generates PI parameters based on real-time signals, and the fault-tolerant control module monitors in real-time whether the signal triggers the fault threshold (no fault command is output when there is no fault); the main control module combines the PI parameters to generate drive signals, controls the power conversion module to output adapted electrical energy, and drives the motor to operate according to the set operating conditions. During operation, staff can view the motor's operating status (speed, current, position) and the working status of each module through the main control module's display interface. No additional operation is required; the system automatically completes parameter adjustment and status monitoring.

[0047] 4. Troubleshooting and Recovery If a fault occurs in the motor or power conversion module (such as bridge arm overcurrent or open circuit of the switching transistor), the fault-tolerant control module will quickly identify the fault type and location, and output fault isolation command and mode switching command to the main control module; The main control module responds immediately: first, it controls the power conversion module to cut off the power path to the faulty component to prevent the fault from spreading; then, it triggers the redundant bridge arm to start operation (if configured), and at the same time switches the drive mode to derating or redundant mode to ensure continuous motor operation (the motor output power is appropriately reduced in derating mode, and normal output is maintained in redundant mode); After troubleshooting, the staff issued a fault reset command through the main control module. The fault-tolerant control module stopped outputting fault commands, and the system automatically switched back to normal drive mode, restoring the motor to normal operating conditions. 5. System shutdown operation When a shutdown is required, the operator issues a shutdown command through the main control module. The main control module first reduces the drive signal strength, then controls the power conversion module to gradually reduce the output power, causing the motor speed to slowly drop to zero. After the motor stops, shut down the motor status detection module and the adaptive PI control module, then shut down the power input module, and disconnect the external power supply from the power conversion module; finally, check the status of each module (such as the temperature of the power switch tube and the connection status of the sensors) to complete the shutdown process.

[0048] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation, characterized in that, The system includes a main control module, a power conversion module, a fault-tolerant control module, an adaptive PI control module, and a motor status detection module. The signal output terminal of the motor status detection module is connected to the first signal input terminal of the main control module, the signal input terminal of the fault-tolerant control module, and the signal input terminal of the adaptive PI control module, respectively, for acquiring the operating status signal of the permanent magnet synchronous motor and synchronously transmitting it to the main control module, the fault-tolerant control module, and the adaptive PI control module. The parameter output terminal of the adaptive PI control module is connected to the second signal input terminal of the main control module, for dynamically generating PI control parameters based on the motor operating status signal and transmitting them to the main control module. The control output terminal of the fault-tolerant control module is connected to the third signal input terminal of the main control module, for identifying faults based on the motor operating status signal and outputting fault-tolerant control commands to the main control module. The drive output terminal of the main control module is connected to the control input terminal of the power conversion module, for generating drive signals by combining PI control parameters and fault-tolerant control commands. The power output terminal of the power conversion module is connected to the power input terminal of the permanent magnet synchronous motor, for converting input electrical energy into electrical energy suitable for motor operation and driving the motor.

2. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 1, characterized in that, The power conversion module adopts a three-phase full-bridge topology with redundant bridge arms. This topology includes three main power bridge arms and at least one redundant power bridge arm. Each main power bridge arm and redundant power bridge arm consists of two power switches connected in series, and each power switch has a freewheeling diode connected in reverse parallel across its two ends.

3. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 2, characterized in that, The number of redundant power bridge arms is 1-3, and the fault-tolerant control module has built-in bridge arm fault switching logic. When any main power bridge arm is identified as faulty, the fault-tolerant control module triggers the redundant power bridge arm to start operation through the main control module and cuts off the power input of the faulty main power bridge arm.

4. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 1, characterized in that, The parameter adjustment basis of the adaptive PI adjustment module includes the real-time speed deviation, stator current deviation and rotor position deviation of the permanent magnet synchronous motor. The module divides at least three adjustment intervals according to the absolute value of the above deviations and pre-configures the corresponding PI parameter adjustment step size for each adjustment interval.

5. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 4, characterized in that, The adaptive PI control module uses a fuzzy control algorithm or a radial basis function neural network algorithm to dynamically generate PI parameters. When the motor operating status signal exceeds the preset stable range, the module automatically increases the PI parameter adjustment step size to speed up the adjustment response.

6. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 1, characterized in that, The fault identification objects of the fault-tolerant control module include overcurrent of the bridge arm current of the power conversion module, overvoltage of the bridge arm voltage, open circuit of the power switch tube, and short circuit of the stator winding of the permanent magnet synchronous motor. The module identifies and locates the fault type by comparing the motor operating status signal with the preset fault threshold.

7. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 6, characterized in that, The fault-tolerant control module outputs fault-tolerant control commands including fault isolation commands and operating mode switching commands. The fault isolation command is used to control the power conversion module to cut off the power path of the faulty component, and the operating mode switching command is used to control the main control module to switch the motor drive mode from normal drive mode to derating drive mode or redundant drive mode.

8. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 1, characterized in that, The motor status detection module includes a speed detection unit, a current detection unit, and a position detection unit; the speed detection unit is used to collect the real-time speed signal of the motor, the current detection unit is used to collect the three-phase current signal of the motor stator, and the position detection unit is used to collect the real-time position signal of the motor rotor.

9. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to claim 8, characterized in that, The speed detection unit uses a Hall speed sensor or photoelectric encoder, the current detection unit uses a series shunt resistor or Hall current sensor, and the position detection unit uses a rotary transformer or absolute encoder.

10. The permanent magnet synchronous motor drive control system based on fault-tolerant topology and adaptive PI regulation according to any one of claims 1-9, characterized in that, It also includes a power input module, the output of which is connected to the power input of the power conversion module, for converting external DC or AC power into a DC bus voltage that is compatible with the power conversion module; the power input module has a built-in voltage regulation unit to suppress the impact of external power fluctuations on the stability of the power output of the power conversion module.

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