A smart brushless motor power regulation system and method

Abstract

This invention discloses an intelligent brushless motor power regulation system and method, specifically relating to the field of motor automation control. This invention constructs a multi-dimensional evaluation index of torque, speed, and load, and calculates the estimated value of motor operation after comprehensive processing. Based on the target power value, it matches and optimizes the power by matching optimization coefficients, thereby achieving precise quantitative adjustment of the motor's operating state and the adaptability to the target power. This solves the defects of existing technologies, such as strong blind adjustment and lack of closed-loop linkage, and ensures that the motor dynamically matches the target power and operates stably.

Description

Technical Field

[0001] This invention relates to the field of motor automation control, and more specifically, to an intelligent brushless motor power regulation system and method. Background Technology

[0002] In industrial production, smart equipment and other fields, brushless motors are widely used due to their advantages such as high efficiency and long life. Their power output directly affects the operation of the equipment. As the application scenarios increase the requirements for motor operation accuracy, safety and energy economy, it is necessary to achieve dynamic adjustment of the actual power of the motor based on the target power set by the user. However, the motor is easily affected during operation, and the temperature change of the core components may cause safety risks. There is an urgent need for a power adjustment scheme that takes into account adaptability, safety and energy consumption control to ensure that the motor operates stably and close to the target power.

[0003] However, existing technologies still have the following shortcomings in practical applications:

[0004] First, there is a lack of a complete quantitative evaluation system for the adaptability of motor operating status to target power. Without comprehensive judgment based on parameters derived from torque, speed and load, power adjustment relies solely on a single parameter or experience, resulting in strong blindness. Furthermore, each adjustment link is isolated without closed-loop linkage, making it impossible to optimize the adjustment strategy based on real-time motor performance feedback.

[0005] Secondly, the winding, casing, and ambient temperature data were not incorporated into the core regulation logic, and a safety regulation boundary based on the temperature index was not constructed. It is difficult to avoid risks such as overheating and heat dissipation obstruction in advance. At the same time, a systematic energy consumption assessment mechanism was not established, and energy consumption estimates were not generated through parameters such as total energy consumption, average value, and peak value. It is impossible to quantify the economic rationality of the regulation scheme, and the contradiction of improved adaptability but increased ineffective energy consumption often occurs.

[0006] To address this, an intelligent brushless motor power regulation system and method are proposed. Summary of the Invention

[0007] To overcome the above-mentioned deficiencies of the prior art, embodiments of the present invention provide an intelligent brushless motor power regulation system and method.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] An intelligent brushless motor power regulation system includes the following modules:

[0010] Power setting module: The user sets the desired power value of the motor, i.e., the target power value, according to the requirements, and the system adjusts the actual power value of the motor to the target power value;

[0011] State Analysis Module: Analyzes the performance parameters of the motor during the process of adjusting to the target power to obtain the estimated motor operation value; compares it with the preset threshold, matches the optimization coefficient according to the rules, and multiplies the target power value by the optimization coefficient to obtain the power optimization value;

[0012] Adaptive compensation module: Receives the power optimization value, collects the temperature data of the motor after executing the optimization value and analyzes it to obtain the temperature index; compares it with the preset threshold, matches the temperature adjustment coefficient according to the rules, and multiplies the power optimization value with the temperature adjustment coefficient to obtain the final optimization value;

[0013] Energy consumption control module: Receives the final optimized value, analyzes the energy consumption changes when the motor runs stably at that value, obtains an estimated energy consumption, compares it with a preset threshold, and selectively triggers an abnormal energy consumption signal.

[0014] Specifically, the process for determining the torque evaluation index is as follows:

[0015] The adjustment time zone is defined as the process by which the target motor adjusts to the target power value.

[0016] The performance parameters of the target motor in the adjustment time zone are obtained and preprocessed, including torque, load power and motor speed.

[0017] Torque data is collected at a preset frequency, and the difference between the maximum and minimum torque values ​​is calculated as the torque range and the average torque value. The ratio is then calculated as the torque fluctuation rate.

[0018] Extract the maximum torque and compare it with the motor's rated torque to obtain a torque ratio.

[0019] Extract the average torque value, and determine the target torque by combining the target power value, the corresponding target speed, and the operating efficiency obtained from the motor's rated parameters. The ratio of the difference between the average torque value and the target torque to the target torque is the torque deviation rate.

[0020] Preset the allowable values ​​for torque ripple rate, torque relative ratio, and torque deviation rate respectively;

[0021] The torque evaluation index is obtained by comprehensively processing the torque fluctuation rate, torque relative ratio, and torque deviation rate.

[0022] Specifically, the process for determining the speed evaluation index is as follows:

[0023] In the adjustment time zone, speed data is collected at a preset frequency. The actual speed and the corresponding power-adapted speed at each collection time point are extracted. The absolute difference between the two is calculated. The ratio of the sum of the absolute differences at each collection time point to the total number of collection points is used as the average deviation over the whole process. The ratio is calculated using the average deviation over the whole process as the numerator and the average adapted speed over the whole process as the denominator to obtain the overall speed deviation rate.

[0024] The absolute difference between the rotational speeds at adjacent time points is counted. If the difference is greater than the corresponding preset threshold, it is marked as a sudden change in rotational speed. The total number of sudden changes is counted and compared with the total duration of the adjustment time zone to obtain the frequency of sudden changes in rotational speed.

[0025] Preset the allowable values ​​for speed fluctuation rate, speed deviation rate, and speed response time respectively;

[0026] The speed evaluation index is obtained by comprehensively processing the speed fluctuation rate, speed deviation rate, and speed response time.

[0027] Specifically, the process for determining the load assessment index is as follows:

[0028] In the time zone adjustment, load power data is collected at a preset frequency to obtain a load dataset, the rated load power of the motor is identified, the average load power is calculated, and the load rate is obtained by calculating the ratio of the average load power to the rated load power.

[0029] The load range is obtained by extracting the maximum and minimum load values ​​from the load dataset and calculating the difference. The load fluctuation rate is obtained by using the load range as the numerator and the average load power as the denominator.

[0030] The absolute difference in load rate between adjacent time points is counted. If the difference is greater than a preset threshold, it is marked as a load mutation. The number of load mutations in the adjustment time zone is counted and the load mutation frequency is calculated by comparing it with the total duration of the adjustment time zone.

[0031] Preset the allowable values ​​for load rate, load volatility, and frequency of load mutations respectively;

[0032] The load assessment index is obtained by comprehensively processing the load rate, load volatility, and load mutation frequency.

[0033] Specifically, the process of obtaining the motor's operating estimate is as follows:

[0034] The torque evaluation index, speed evaluation index, and load evaluation index are normalized, and a Cartesian coordinate system is constructed. Starting from the origin, three rays are constructed along the positive x-axis, the 90° angle with the x-axis, and the 180° angle with the x-axis, respectively. The length of each ray corresponds to the three normalized evaluation indices. The vertices of the three rays are connected to form a triangle, and the area of ​​the triangle is calculated to obtain the estimated value of motor operation.

[0035] Specifically, the process of obtaining the target optimization value:

[0036] A preset operating estimate threshold is set. If the operating estimate is greater than the threshold, the motor continues to operate at the target power value. If it is less than the threshold, the difference between the operating estimate and the threshold is calculated as the operating estimate difference. The corresponding optimization coefficient is matched according to the preset difference range. The optimization coefficient is multiplied by the target power value to obtain the target optimization value. The motor executes the power setting according to the target optimization value.

[0037] Specifically, the process of obtaining the temperature index is as follows:

[0038] In the time zone adjustment, according to the preset acquisition frequency, the winding temperature, shell temperature and ambient temperature are extracted and pre-processed using pre-deployed temperature sensors.

[0039] Collect data on winding temperature and shell temperature at each time point, and take the average value to obtain the average winding temperature and average shell temperature.

[0040] The permissible temperature ranges corresponding to different power ranges of the motor include winding temperature range and housing temperature range. The highest value of each of the two ranges is selected as the permissible value of the winding temperature and housing temperature, respectively. An environmental additional coefficient is set, the ambient temperature is identified, and the corresponding environmental additional coefficient is matched according to the preset mapping rules.

[0041] A preset ambient temperature threshold is used. When the ambient temperature is greater than the ambient temperature threshold, the difference between the ambient temperature and the ambient temperature threshold is calculated to obtain the ambient standard deviation. The corresponding ambient standard deviation intervals are preset, and each set of ambient standard deviation intervals corresponds to an environmental additional coefficient. After comprehensive processing, the temperature index is obtained.

[0042] Specifically, the process of obtaining the final optimized value is as follows:

[0043] Set a temperature index threshold. If the temperature index is greater than the threshold, the motor continues to operate at the power optimization value. If it is less than the threshold, calculate the difference between the temperature index and the threshold as the temperature difference value. Match the corresponding temperature adjustment coefficient according to the preset temperature difference value range, and multiply the power optimization value by the temperature adjustment coefficient to obtain the final optimization value.

[0044] Specifically, the process of obtaining the energy consumption estimate is as follows:

[0045] The active power of each sampling point in the adjustment time zone is collected, the sampling interval and the total number of sampling points are recorded, and the total energy consumption in the adjustment time zone is obtained after comprehensive processing.

[0046] The average active power is obtained by summing the active power of each sampling point within the adjustment time zone and dividing it by the total number of sampling points. This average active power is then used as the average energy consumption.

[0047] Extract the maximum active power in the adjustment time zone as the peak energy consumption;

[0048] Based on the motor characteristics and scenario requirements, preset reference values ​​for total energy consumption, average energy consumption, and peak energy consumption;

[0049] The energy consumption estimate is obtained by comprehensively processing the total energy consumption, average energy consumption, and peak energy consumption.

[0050] A preset energy consumption estimate threshold is set. The energy consumption estimate is compared with the corresponding threshold. If it is lower than the threshold, the target motor continues to operate according to the final optimized value. If it is higher than the threshold, an energy consumption anomaly signal is triggered and sent to the management terminal.

[0051] The technical effects and advantages of this invention are as follows:

[0052] 1) This invention constructs a multi-dimensional evaluation index of torque, speed and load, calculates the estimated value of motor operation after comprehensive processing, and optimizes the power based on the target power value matching optimization coefficient. This achieves precise quantitative adjustment of the motor operation state and the adaptability of the target power, solves the defects of the existing technology of strong blind adjustment and no closed-loop linkage, and ensures that the motor dynamically fits the target power and operates stably.

[0053] 2) This invention collects temperature data of windings, housing and ambient temperature, calculates the average temperature and constructs a temperature index, matches the temperature adjustment coefficient to optimize the power in the second stage, and realizes the scientific construction of the motor safety adjustment boundary. It makes up for the shortcomings of the existing technology that does not combine temperature data, effectively avoids safety risks such as overheating and heat dissipation obstruction, and maintains the continuous operation of the equipment while protecting the core components such as the motor insulation layer.

[0054] 3) This invention collects active power data through an energy consumption control module, calculates the total energy consumption, average value, peak value and generates an estimated energy consumption, and triggers an abnormal signal to the management terminal by setting a preset threshold. This realizes a systematic assessment and abnormal warning of energy consumption after adjustment, solves the problem of energy waste caused by improved adaptability of existing technologies, takes into account the safety and reliability of motor operation and energy economy, and reduces ineffective energy consumption loss. Attached Figure Description

[0055] Figure 1 This is a schematic diagram of an intelligent brushless motor power regulation system according to the present invention.

[0056] Figure 2 This is a flowchart of an intelligent brushless motor power adjustment method according to the present invention. Detailed Implementation

[0057] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0058] Example 1

[0059] like Figure 1 As shown, a smart brushless motor power regulation system module is as follows:

[0060] Power setting module: The user sets the desired power value of the corresponding motor based on their needs. The desired power value is the target power value of the corresponding motor, and the actual power value of the corresponding motor is adjusted to the target power value.

[0061] State Analysis Module: Analyzes the performance parameters of the target motor during the process of adjusting to the target power value to obtain the motor operation estimate, presets the motor operation estimate threshold, compares the motor operation estimate with the preset threshold, matches the optimization coefficient according to the preset rules based on the comparison result, and multiplies the target power value with the optimization coefficient to obtain the power optimization value;

[0062] Specifically:

[0063] The adjustment time zone is defined as the process by which the target motor adjusts to the target power value.

[0064] The performance parameters of the target motor in the adjustment time zone are obtained and preprocessed, including torque, load power and motor speed.

[0065] In the adjustment time zone, torque data is collected at a preset frequency. The maximum and minimum torque values ​​in the data are extracted and the difference is calculated as the torque range. The average torque value is calculated, and the torque fluctuation rate Zb is obtained by using the torque range as the numerator and the average torque value as the denominator.

[0066] Extract the maximum torque value, identify the rated torque of the target motor, and calculate the torque ratio Zx by using the maximum torque value as the numerator and the rated torque as the denominator.

[0067] Extract the average torque, identify the target power value and the corresponding target motor speed, retrieve the motor operating efficiency through the motor's rated parameters, and then use the formula... The target torque is obtained, where 9550 is a simplified coefficient obtained after approximation with the adaptive unit; the torque deviation rate Zp is calculated by using the difference between the average torque and the target torque as the numerator and the target torque as the denominator.

[0068] Based on the characteristics of the motor itself and the requirements of the application scenario, the allowable values ​​for torque ripple rate, torque relative ratio, and torque deviation rate are preset and marked as follows: , , ;

[0069] After normalizing the torque ripple rate, torque relative ratio, and torque deviation rate, they are substituted into the formula. The torque evaluation index Zip is obtained; where f1, f2, and f3 are the corresponding preset weight factors.

[0070] The torque evaluation index quantifies the health status of the motor torque in terms of torque operation stability, overload safety, and control precision. The larger the torque evaluation index, the smaller the fluctuation of the motor torque operation, the farther the torque peak is from the rated overload threshold, and the smaller the deviation between the actual output torque and the target torque. In other words, the torque operation is more stable, safe, and precise. Conversely, it indicates that there are problems such as excessive torque fluctuation, overload risk, or insufficient control precision.

[0071] Within the adjustment time zone, speed data is collected at a preset frequency. The actual speed and the corresponding power-adapted speed at each collection time point are extracted. The absolute difference between the actual speed and the corresponding adapted speed is calculated. The ratio of the sum of the absolute differences between the actual speed and the corresponding adapted speed at each time point to the total number of collection points is used as the average deviation over the entire range. The average adapted speed over the entire range is calculated. The ratio of the average deviation over the entire range to the average adapted speed over the entire range is used to calculate the overall speed deviation rate Nv.

[0072] The absolute difference between the rotational speeds at adjacent time points is counted. If the difference is greater than the corresponding preset threshold, it is marked as a sudden change in rotational speed. The number of times the rotational speed is marked as a sudden change in rotational speed in the adjustment time zone is counted as the total number of sudden changes in rotational speed. The frequency of sudden changes in rotational speed Nd is obtained by calculating the ratio of the total number of sudden changes in rotational speed to the total duration of the adjustment time zone.

[0073] Based on the characteristics of the motor itself and the requirements of the application scenario, allowable values ​​for speed fluctuation rate, speed deviation rate, and speed response time are preset and marked as follows. , ;

[0074] After normalizing the speed fluctuation rate, speed deviation rate, and speed response time, they are substituted into the formula. The rotational speed evaluation index Sed is obtained; where , These are the corresponding preset weighting factors;

[0075] The additional explanation is that the speed evaluation index quantifies the stability of the motor speed during power adjustment in terms of steady-state fluctuation, steady-state control accuracy, and dynamic response efficiency. The larger the value, the smaller the steady-state fluctuation of the speed during power adjustment, the lower the deviation between the actual speed and the target speed, and the shorter the time to respond to the adjustment command. In other words, the speed has better smooth operation capability, precise control capability, and fast response capability.

[0076] Within the adjusted time zone, load power data is collected at a preset frequency to obtain the load dataset. (n is the total number of samples collected), the rated load power of the motor is identified through the motor's factory calibration parameters. Substitute into the formula Obtain average load power The load factor is calculated by comparing the average load power with the rated load power. ;

[0077] The load range is obtained by calculating the difference between the maximum and minimum load values ​​in the load dataset. The load fluctuation rate is then calculated by dividing the load range by the average load power. ;

[0078] The absolute difference in load rate between adjacent time points is counted. If the absolute difference in load rate between a set of adjacent time points exceeds a preset threshold, it is marked as a load mutation. The number of load mutations in the adjustment time zone is counted and the ratio of this ratio to the total duration of the adjustment time zone is calculated as the load mutation frequency. ;

[0079] Based on the characteristics of the motor itself and the requirements of the application scenario, allowable values ​​for load rate, load fluctuation rate, and frequency of load changes are preset and marked as follows. , , ;

[0080] After normalizing the load factor, load volatility, and frequency of load fluctuations, the formula is used. After weighted calculation, the load assessment index kob is obtained; where , , These are the corresponding preset weighting factors;

[0081] In addition, the load assessment index quantifies the overall health status of the load from three dimensions: load matching degree, load steady-state fluctuation amplitude, and load dynamic impact frequency. The larger the index value, the closer the motor load is to the healthy operating range, the smoother the load fluctuation, and the sparser the load sudden impact, that is, the better the overall load status.

[0082] After normalizing the torque evaluation index, speed evaluation index, and load evaluation index, a Cartesian coordinate system is constructed. The origin of the coordinate system is used as the starting point of each ray. Three rays are constructed sequentially along the positive x-axis, the 90° angle with the x-axis, and the 180° angle with the x-axis. The lengths of the three rays correspond to the normalized torque evaluation index, speed evaluation index, and load evaluation index, respectively. The three vertices are connected sequentially to construct a triangle. The area of ​​the triangle is calculated to obtain the estimated value of motor operation.

[0083] A preset motor operating estimation threshold is set. When the motor operating estimation is greater than the motor operating estimation threshold, the target power value operation continues. When the motor operating estimation is less than the motor operating estimation threshold, the difference between the motor operating estimation and the corresponding threshold is calculated to obtain the operating estimation difference. A preset range of difference values ​​is set, and each range of difference values ​​corresponds to an optimization coefficient. The optimization coefficient is set between 0.891 and 0.956. The larger the operating estimation difference, the smaller the matching optimization coefficient. The optimization coefficient is multiplied by the target power value to obtain the target optimization value. The target motor executes the power setting based on the target optimization value.

[0084] For example, the original target power of the drive motor in an industrial production line was 10kW. During operation, due to mechanical wear, the torque fluctuation increased and the speed response lagged. The estimated operating value of the motor calculated by the state analysis module was lower than the preset threshold. If the difference in estimated value was small (performance slightly below the qualified standard), the matching optimization coefficient was 0.956, resulting in a target optimized value of 9.56kW. If the difference in estimated value was large (performance shortcomings were obvious), the matching optimization coefficient was 0.891, resulting in a target optimized value of 8.91kW. This avoids problems such as overheating, vibration, and even accelerated gear wear caused by the motor bearing a 10kW load when its performance is substandard. Furthermore, by adjusting the power within a reasonable range, the production line can still maintain stable conveying efficiency without the need for shutdown maintenance, thus balancing production continuity and equipment maintenance safety.

[0085] Adaptive compensation module: Receives the power optimization value, collects and analyzes the temperature data of the target motor during the operation phase after the target optimization value is executed to obtain the temperature index, sets the temperature index threshold, compares the temperature index with the temperature index threshold, matches the temperature adjustment coefficient according to the preset rules based on the comparison result, and multiplies the power optimization value with the temperature adjustment coefficient to obtain the final optimization value.

[0086] The temperature data includes winding temperature, casing temperature, and ambient temperature.

[0087] Specifically:

[0088] In the time zone adjustment, according to the preset acquisition frequency, the winding temperature, shell temperature and ambient temperature are extracted and pre-processed using pre-deployed temperature sensors.

[0089] The average winding temperature and average shell temperature are obtained by averaging the winding temperature data and shell temperature data at each collection time point, and are labeled as F1 and F2 respectively.

[0090] Identify the allowable temperature ranges corresponding to different power ranges of the motor. These allowable temperature ranges include the winding temperature range and the housing temperature range. The highest values ​​of both the winding and housing temperature ranges are selected as the allowable values ​​for the winding temperature and housing temperature, respectively, and marked as follows: , Set environmental additional coefficient Its value is set between 1.064 and 1.134, and it identifies the ambient temperature and matches the corresponding environmental additional coefficient according to the preset mapping rules;

[0091] A preset ambient temperature threshold is set. When the ambient temperature is greater than the ambient temperature threshold, the difference between the ambient temperature and the ambient temperature threshold is calculated to obtain the environmental standard deviation. The preset range of the environmental standard deviation is set, and each range of difference corresponds to an environmental additional coefficient. The higher the environmental standard deviation, the higher the matched environmental additional coefficient, and the lower the environmental standard deviation, the closer the matched environmental additional coefficient is to 1.

[0092] Using the uniform group temperature, uniform shell temperature, and uniform ring temperature as the numerators, and the corresponding allowable values ​​as the denominators, substitute them into the formula. Obtain the temperature index ;in Additional coefficients are added for the matching environment;

[0093] A temperature index threshold is set. When the temperature index is greater than the temperature index threshold, the target optimized power value continues to be executed. When the temperature index is less than the temperature index threshold, the temperature difference is calculated by subtracting the temperature index from the threshold. A temperature difference range is preset, and each temperature difference range corresponds to a temperature adjustment coefficient. The temperature adjustment coefficient is set between 0.792 and 0.861. The larger the temperature difference, the smaller the matching temperature adjustment coefficient. The temperature difference of the target motor is matched with the temperature difference range to determine the temperature adjustment coefficient.

[0094] The final optimized value is obtained by multiplying the power optimization value by the temperature regulation coefficient;

[0095] For example, after preliminary optimization, the power optimization value of an industrial fan motor is 7.5kW. After running at this power, the winding temperature, casing temperature, and ambient temperature within the adjustment time zone are collected and processed to obtain a temperature index of 85. The temperature difference from the preset threshold of 95 is 10 (good temperature conditions). The temperature regulation coefficient is matched with 0.845, and the final optimized value is 6.34kW. The fan maintains efficient ventilation while avoiding temperature accumulation. If the fan runs at full load for a long time, causing the temperature conditions to deteriorate, the calculated temperature index is 67, the temperature difference is 28, and the temperature regulation coefficient is matched with 0.798. The final optimized value is 5.99kW. By appropriately derating, the winding overheating is suppressed, which protects the motor from high temperature damage and ensures the basic ventilation needs of the workshop.

[0096] Energy consumption control module: Receives the final optimized value, identifies and analyzes the energy consumption changes of the target motor when it is running stably according to the final optimized value, obtains an energy consumption estimate, presets an energy consumption estimate threshold, and selectively triggers an energy consumption anomaly signal after comparing the energy consumption estimate with the corresponding threshold.

[0097] Specifically:

[0098] The active power at each sampling point is collected using the motor's built-in measuring instrument during the parameter analysis time period. Record the sampling interval and the total number of sampling points k; using the formula The total energy consumption Ead within the adjustment time zone is obtained by summing up the results.

[0099] The average active power is obtained by summing the active power collected at each sampling point through the motor's built-in measuring instrument in the adjustment time zone and dividing it by the total number of sampling points. This average active power is used as the energy consumption average value Eqa.

[0100] The maximum active power in the adjustment time zone is extracted as the peak energy consumption Ecy;

[0101] Based on the motor characteristics and scenario requirements, the preset reference values ​​for total energy consumption, average energy consumption, and peak energy consumption are marked as Ead3, Eqa3, and Ecy3, respectively.

[0102] After normalizing the total energy consumption, average energy consumption, and peak energy consumption, they are then entered into the formula. The energy consumption estimate Vae is obtained; where s1, s2, and s3 are the corresponding preset weighting factors.

[0103] The energy consumption estimate is preset to a corresponding energy consumption estimate threshold. The energy consumption estimate is compared with the corresponding threshold. If it is lower than the threshold, the target motor continues to run according to the final optimized value. If it is higher than the threshold, an energy consumption abnormality signal is triggered and sent to the management personnel terminal.

[0104] For example, if the workshop ventilation fan motor operates at a secondary optimized value of 6.8kW, and the preset energy consumption estimate threshold is 1.0, the energy consumption estimate calculated by the energy consumption control module is 0.89, which is lower than the preset threshold. The motor continues to operate stably at the secondary optimized value of 6.8kW. If dust accumulation on the fan impeller causes an increased load, the calculated energy consumption estimate rises to 1.23, which is higher than the threshold of 1.0. The system immediately triggers a fault alarm and sends it to the workshop management personnel terminal.

[0105] The above formulas are all dimensionless calculations. Dimensionless calculations can be performed using various methods such as standardization, which will not be elaborated here. The formulas are derived from software simulations based on a large amount of collected data, and the preset parameters in the formulas can be set by those skilled in the art according to the actual situation.

[0106] Example 2

[0107] Please see Figure 2 As shown, based on the intelligent brushless motor power regulation system provided in Embodiment 1 of this application, Embodiment 2 of this application proposes an intelligent brushless motor power regulation method. Embodiment 2 is merely a preferred embodiment of Embodiment 1, and the implementation of Embodiment 2 will not affect the individual implementation of Embodiment 1.

[0108] Specifically, Embodiment 2 of this application provides a method for regulating the power of an intelligent brushless motor, comprising:

[0109] Power setting: The user sets the desired power value of the motor, i.e. the target power value, according to the needs, and the system adjusts the actual power value of the motor to the target power value;

[0110] State analysis: Analyze the performance parameters of the motor during the process of adjusting to the target power to obtain the estimated motor operation value; compare it with the preset threshold, match the optimization coefficient according to the rules, and multiply the target power value by the optimization coefficient to obtain the power optimization value;

[0111] Adaptive compensation: Receives the power optimization value, collects the temperature data of the motor after executing the optimization value and analyzes it to obtain the temperature index; compares it with the preset threshold, matches the temperature adjustment coefficient according to the rules, and multiplies the power optimization value with the temperature adjustment coefficient to obtain the final optimization value;

[0112] Energy consumption control: Receive the final optimized value, analyze the energy consumption changes of the motor when it runs stably at that value, and obtain an estimated energy consumption; compare it with a preset threshold, and selectively trigger an abnormal energy consumption signal.

[0113] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more sets of available media. The available medium can be a magnetic medium (e.g., floppy disk, ATA hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. The semiconductor medium can be a solid-state ATA hard disk.

[0114] It should be understood that in the various embodiments of this application, the order of the above-mentioned processes does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0115] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0116] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0117] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0118] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0119] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable ATA hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0120] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An intelligent brushless motor power regulation system, characterized in that, Includes the following modules: Power setting module: The user sets the desired power value of the motor, i.e., the target power value, according to the requirements, and the system adjusts the actual power value of the motor to the target power value; Status analysis module: The adjustment time zone is defined as the process of the target motor adjusting to the target power value; The performance parameters of the target motor in the adjustment time zone are obtained and preprocessed. The performance parameters include torque, load power and motor speed. The performance parameters during the motor adjustment to the target power are analyzed to obtain the motor operation estimate. The estimate is compared with the preset threshold, and the optimization coefficient is matched according to the rules. The target power value is multiplied by the optimization coefficient to obtain the power optimization value. The specific process of obtaining the motor's operating estimate: The torque evaluation index, speed evaluation index, and load evaluation index are normalized. A Cartesian coordinate system is constructed. Starting from the origin, three rays are constructed along the positive x-axis, the 90° angle with the x-axis, and the 180° angle with the x-axis, respectively. The length of each ray corresponds to the three normalized evaluation indices. The vertices of the three rays are connected to form a triangle. The area of ​​the triangle is then calculated to obtain the estimated value of the motor operation. A preset motor operating estimate threshold is set. If the operating estimate is greater than the threshold, the motor continues to operate at the target power value. If it is less than the threshold, the difference between the operating estimate and the threshold is calculated as the operating estimate difference. The corresponding optimization coefficient is matched according to the preset difference range. The optimization coefficient is multiplied by the target power value to obtain the power optimization value. The motor executes the power setting according to the power optimization value. Adaptive compensation module: Receives the power optimization value, collects the temperature data of the motor after executing the optimization value and analyzes it to obtain the temperature index; compares it with the preset threshold, matches the temperature adjustment coefficient according to the rules, and multiplies the power optimization value with the temperature adjustment coefficient to obtain the final optimization value; Energy consumption control module: Receives the final optimized value, analyzes the energy consumption changes when the motor runs stably at that value, and obtains an estimated energy consumption. Compare it with a preset threshold and selectively trigger an abnormal energy consumption signal.

2. The intelligent brushless motor power regulation system according to claim 1, characterized in that, The specific process for determining the torque evaluation index is as follows: Torque data is collected at a preset frequency, and the difference between the maximum and minimum torque values ​​is calculated as the torque range and the average torque value. The ratio is then calculated as the torque fluctuation rate. Extract the maximum torque value and compare it with the motor's rated torque to obtain a torque ratio. Extract the average torque value, and determine the target torque by combining the target power value, the corresponding target speed, and the operating efficiency obtained from the motor's rated parameters. The ratio of the difference between the average torque value and the target torque to the target torque is the torque deviation rate. Preset the allowable values ​​for torque ripple rate, torque relative ratio, and torque deviation rate respectively; The torque evaluation index is obtained by comprehensively processing the torque fluctuation rate, torque relative ratio, and torque deviation rate.

3. The intelligent brushless motor power regulation system according to claim 1, characterized in that, The specific process for determining the speed evaluation index is as follows: In the adjustment time zone, speed data is collected at a preset frequency. The actual speed and the corresponding power-adapted speed at each collection time point are extracted. The absolute difference between the two is calculated. The ratio of the sum of the absolute differences at each collection time point to the total number of collection points is used as the average deviation over the whole process. The ratio is calculated using the average deviation over the whole process as the numerator and the average adapted speed over the whole process as the denominator to obtain the overall speed deviation rate. The absolute difference between the rotational speeds at adjacent time points is counted. If the difference is greater than the corresponding preset threshold, it is marked as a sudden change in rotational speed. The total number of sudden changes is counted and compared with the total duration of the adjustment time zone to obtain the frequency of sudden changes in rotational speed. Preset the allowable values ​​for speed fluctuation rate, speed deviation rate, and speed response time respectively; The speed evaluation index is obtained by comprehensively processing the speed fluctuation rate, speed deviation rate, and speed response time.

4. The intelligent brushless motor power regulation system according to claim 1, characterized in that, The specific process for determining the load assessment index is as follows: In the time zone adjustment, load power data is collected at a preset frequency to obtain a load dataset, the rated load power of the motor is identified, the average load power is calculated, and the load rate is obtained by calculating the ratio of the average load power to the rated load power. The load range is obtained by extracting the maximum and minimum load values ​​from the load dataset and calculating the difference. The load fluctuation rate is obtained by using the load range as the numerator and the average load power as the denominator. The absolute difference in load rate between adjacent time points is counted. If the difference is greater than a preset threshold, it is marked as a load mutation. The number of load mutations in the adjustment time zone is counted and the load mutation frequency is calculated by comparing it with the total duration of the adjustment time zone. Preset the allowable values ​​for load rate, load volatility, and frequency of load mutations respectively; The load assessment index is obtained by comprehensively processing the load rate, load volatility, and load mutation frequency.

5. The intelligent brushless motor power regulation system according to claim 1, characterized in that, The specific process for obtaining the temperature index is as follows: In the time zone adjustment, according to the preset acquisition frequency, the winding temperature, shell temperature and ambient temperature are extracted and pre-processed using pre-deployed temperature sensors. Collect the winding temperature and shell temperature data at each time point, and take the average value to obtain the average winding temperature and average shell temperature. The permissible temperature ranges corresponding to different power ranges of the motor include winding temperature range and housing temperature range. The highest value of each of the two ranges is selected as the permissible value of the winding temperature and housing temperature, respectively. An environmental additional coefficient is set, the ambient temperature is identified, and the corresponding environmental additional coefficient is matched according to the preset mapping rules. A preset ambient temperature threshold is used. When the ambient temperature is greater than the ambient temperature threshold, the difference between the ambient temperature and the ambient temperature threshold is calculated to obtain the ambient standard deviation. The corresponding ambient standard deviation intervals are preset, and each set of ambient standard deviation intervals corresponds to an environmental additional coefficient. After comprehensive processing, the temperature index is obtained.

6. The intelligent brushless motor power regulation system according to claim 5, characterized in that, The specific process for obtaining the final optimized value is as follows: Set a temperature index threshold. If the temperature index is greater than the threshold, the motor continues to operate at the power optimization value. If it is less than the threshold, calculate the difference between the temperature index and the threshold as the temperature difference value. Match the corresponding temperature adjustment coefficient according to the preset temperature difference value range, and multiply the power optimization value by the temperature adjustment coefficient to obtain the final optimization value.

7. The intelligent brushless motor power regulation system according to claim 1, characterized in that, The specific process for obtaining the energy consumption estimate is as follows: The active power of each sampling point in the adjustment time zone is collected, the sampling interval and the total number of sampling points are recorded, and the total energy consumption in the adjustment time zone is obtained after comprehensive processing. The average active power is obtained by summing the active power of each sampling point within the adjustment time zone and dividing it by the total number of sampling points. This average active power is then used as the average energy consumption. Extract the maximum active power within the adjustment time zone as the peak energy consumption; Based on the motor characteristics and scenario requirements, preset reference values ​​for total energy consumption, average energy consumption, and peak energy consumption; The energy consumption estimate is obtained by comprehensively processing the total energy consumption, average energy consumption, and peak energy consumption. A preset energy consumption estimate threshold is set. The energy consumption estimate is compared with the corresponding threshold. If it is lower than the threshold, the target motor continues to operate according to the final optimized value. If it is higher than the threshold, an energy consumption anomaly signal is triggered and sent to the management terminal.

8. A method for regulating the power of an intelligent brushless motor, applied to an intelligent brushless motor power regulation system according to any one of claims 1-7, characterized in that, include: Power setting: The user sets the desired power value of the motor, i.e. the target power value, according to the needs, and the system adjusts the actual power value of the motor to the target power value; State analysis: Analyze the performance parameters of the motor during the process of adjusting to the target power to obtain the estimated motor operation value; compare it with the preset threshold, match the optimization coefficient according to the rules, and multiply the target power value by the optimization coefficient to obtain the power optimization value; Adaptive compensation: Receives the power optimization value, collects the temperature data of the motor after executing the optimization value and analyzes it to obtain the temperature index; compares it with the preset threshold, matches the temperature adjustment coefficient according to the rules, and multiplies the power optimization value with the temperature adjustment coefficient to obtain the final optimization value; Energy consumption control: Receive the final optimized value, analyze the energy consumption changes of the motor when it runs stably at that value, and obtain an estimated energy consumption; compare it with a preset threshold, and selectively trigger an abnormal energy consumption signal.

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