Motor controller capable of driving multi-stator structure

Abstract

The invention discloses a motor controller capable of driving a multi-stator structure, which comprises an instruction layer, a control layer and an execution layer, and is characterized in that the control layer is provided with a single main control chip, is connected in series with the instruction layer and the execution layer, and synchronously processes a plurality of tasks, the instruction layer receives an externally input instruction, analyzes the instruction and transmits the instruction to the control layer, and the execution layer is connected with the instruction layer. The control layer receives information analyzed by the instruction layer and controls the execution layer to work, the execution layer at least comprises multiple sets of stators, stator displacement sensors and a driving circuit, and the control layer collects data fed back by the stator displacement sensors in real time, operates a motor control algorithm and outputs PWM control signals to the driving circuit. All stators are uniformly controlled through a single chip, cross-chip communication is avoided, the number of chips and redundant elements are reduced, the size and the cost are optimized, and meanwhile the maintenance difficulty is lowered.

Description

Technical Field

[0001] This invention relates to the field of motor controllers, and more particularly to a motor controller capable of driving a multi-stator structure. Background Technology

[0002] As motor technology evolves towards higher power and higher precision, multi-stator and multi-rotor structures have become an important direction for breaking through the performance bottleneck of traditional single-stator motors. However, traditional multi-stator motors use a decentralized control scheme of "one stator and one control chip," which has three major drawbacks: poor synchronization, high hardware cost, and large circuit board size, making them unsuitable for applications requiring miniaturization and high reliability. Summary of the Invention

[0003] In view of the above-mentioned shortcomings in the current field of motor controllers, the present invention provides a motor controller that can drive a multi-stator structure. It can control all stators through a single chip, eliminate cross-chip communication, reduce the number of chips and redundant components, optimize size and cost, and reduce maintenance difficulty.

[0004] To achieve the above objectives, the embodiments of the present invention adopt the following technical solutions:

[0005] A motor controller capable of driving a multi-stator structure includes an instruction layer, a control layer, and an execution layer. The control layer is configured as a single main control chip, connected in series with the instruction layer and the execution layer, and simultaneously processes multiple tasks. The instruction layer receives externally input instructions, parses the instructions, and transmits them to the control layer. The control layer receives the parsed information from the instruction layer and controls the execution layer to operate. The execution layer includes at least multiple sets of stators, stator displacement sensors, and drive circuits. The control layer collects data fed back from the stator displacement sensors in real time, runs a motor control algorithm, and outputs PWM control signals to the drive circuits.

[0006] According to one aspect of the present invention, the control layer includes at least:

[0007] The instruction receiving thread is used to parse received external instructions;

[0008] The sensor signal acquisition thread is used to read and filter the feedback displacement data;

[0009] The control algorithm thread is used to calculate PWM parameters by running the FOC algorithm;

[0010] The drive control thread is used to output PWM signals and monitor the status of the drive circuit. The duty cycle adjustment accuracy of the PWM signal output by the control layer is at most 1%.

[0011] According to one aspect of the present invention, the instruction layer includes an instruction receiving module for receiving externally input instructions, the externally input instructions including at least a transmission direction instruction, a torque instruction, and a speed instruction.

[0012] According to one aspect of the present invention, the stator displacement sensor is configured as a Hall sensor or a photoelectric encoder, and each stator displacement sensor is connected to the corresponding stator to collect the angular displacement signal and linear displacement signal of the corresponding stator in real time, and transmits them to the control layer after filtering out noise.

[0013] According to one aspect of the present invention, the stator displacement sensor employs an RC low-pass filter algorithm and a Kalman filter algorithm to filter signal noise caused by environmental vibration and temperature, so that the displacement detection accuracy error does not exceed 0.5°.

[0014] According to one aspect of the present invention, the driving circuit adopts an IGBT power transistor or a SiC power transistor. The driving circuit receives the PWM signal from the control layer, converts the weak current control signal into a strong current driving signal, outputs it to the stator, and drives the stator to switch on and off.

[0015] According to one aspect of the present invention, the driving circuit is provided with signal isolation, and the driving circuit and the control layer are optically isolated to block the interference of strong electrical signals on the weak electrical signals of the main control chip.

[0016] According to one aspect of the present invention, the drive circuit is provided with overcurrent protection and overvoltage protection. When the current exceeds 5A or the voltage exceeds 36V, the drive circuit immediately feeds back to the main control chip, and the main control chip cuts off the drive signal within 10μs.

[0017] According to one aspect of the present invention, the stator is configured with a multi-group three-phase winding structure, and the stator receives a driving signal output by a driving circuit to change the on / off state of the windings, thereby generating a rotating magnetic field through the on / off state of the windings.

[0018] According to one aspect of the present invention, the control layer further includes a working condition identification module. The main control chip automatically identifies the motor working condition by analyzing the information parsed by the instruction layer, and dynamically adjusts the task priority, setting the stator displacement sensor signal acquisition and drive circuit control as high priority, and setting the fine-tuning processing of the instruction as high priority.

[0019] The advantages of this invention are as follows: It includes an instruction layer, a control layer, and an execution layer. The control layer is set as a single main control chip, connected in series with the instruction layer and the execution layer, and processes multiple tasks synchronously. The instruction layer receives externally input instructions, parses the instructions, and transmits them to the control layer. The control layer receives the parsed information from the instruction layer and controls the execution layer to work. The execution layer includes at least multiple sets of stators, stator displacement sensors, and drive circuits. The control layer collects data fed back by the stator displacement sensors in real time, runs the motor control algorithm, and outputs PWM control signals to the drive circuit. All stators can be controlled uniformly by a single chip, eliminating cross-chip communication, reducing the number of chips and redundant components, optimizing size and cost, and reducing maintenance difficulty. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the flow structure of a motor controller capable of driving a multi-stator structure according to the present invention. Detailed Implementation

[0022] 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.

[0023] Example 1:

[0024] like Figure 1 As shown, a motor controller capable of driving a multi-stator structure is disclosed. Each module of the controller follows a closed-loop control logic of instruction input, signal feedback, algorithm processing, and execution drive. The hardware components have a one-to-one correspondence with the stator and include an instruction layer, a control layer, and an execution layer. The execution layer includes multiple sets of corresponding stator displacement sensors, drive circuits, and stators.

[0025] The command layer includes a command receiving module, which receives externally input transmission direction commands, torque commands, and speed commands. After parsing the command format, the command layer transmits the commands to the control layer. The command layer supports RS485 and CAN communication protocols and serves as the starting point of the control closed loop, outputting standardized control commands to the control layer to ensure unambiguous commands.

[0026] The control layer is configured with a single master control chip, a 32-bit MCU, supporting multiple timers. The control layer connects the instruction layer and the execution layer, processing multiple tasks synchronously, and serves as the central hub for multi-stator coordination. The control layer receives signals parsed from the instruction layer, controls the execution layer to operate, collects stator displacement data from multiple sets of stator displacement sensors in real time, runs motor control algorithms such as FOC vector control, and outputs PWM control signals to the drive circuit. To avoid delays caused by multiple tasks competing for resources and to ensure that the signal acquisition, algorithm calculation, and command output closed loop are completed within 1ms, thus guaranteeing the stator's action response speed, the control layer adopts a real-time operating system plus task splitting mode. The main control chip's tasks are divided into four independent threads, including: a command receiving thread with a period of 10ms, used to parse received external commands; a sensor signal acquisition thread with a period of 1ms, used to read and filter the feedback displacement data; a control algorithm thread with a period of 1ms, used to calculate PWM parameters by running the FOC algorithm; and a drive control thread with a period of 0.1ms, used to output PWM signals and monitor the drive circuit status. The duty cycle adjustment accuracy of the PWM signal output by the control layer is at most 1%, ensuring smooth changes in the stator winding current.

[0027] The stator displacement sensor is configured as a Hall sensor or photoelectric encoder, and each stator displacement sensor is connected to the corresponding stator. It collects the angular and linear displacement signals of the corresponding stator in real time, and transmits them to the main control chip after noise filtering. This provides accurate position feedback to the main control chip, ensuring that the algorithm output matches the actual state of the stator and preventing rotor step loss. To reduce errors, the stator displacement sensor employs an RC low-pass filter algorithm and a Kalman filter algorithm to filter signal noise caused by environmental vibration and temperature, ensuring that the displacement detection accuracy error does not exceed 0.5°. The maximum filtered environmental vibration frequency is set to 500Hz, and the temperature is controlled between -20°C and 85°C.

[0028] The drive circuit uses IGBT power transistors or SiC power transistors to receive PWM signals from the control layer, converting weak current control signals into strong current drive signals, outputting them to the stator to drive the on / off switching of the stator windings, and converting the logic signals of the main control chip into the physical actions of the stator. Simultaneously, when multiple stators are operating, the high-frequency switching signals of the drive circuit can easily interfere with the stator displacement sensor signals. If the stator displacement sensor signals are distorted, the main control chip will misjudge the stator position, causing the rotor to lose synchronization. Therefore, the drive circuit has signal isolation, using optocouplers such as TLP521 between the drive circuit and the main control chip to block interference from strong current signals to the weak current signals of the main control chip. Furthermore, the drive circuit also has a protection mechanism with built-in overcurrent and overvoltage protection. When the current reaches 5A or the voltage reaches 36V, the protection mechanism is triggered, and the drive circuit immediately feeds back to the main control chip, causing the main control chip to cut off the drive signal within 10μs.

[0029] The stator is configured with multiple three-phase windings, which directly determines the torque and speed output by the motor. The stator receives drive signals from the drive circuit to change the on / off state of the windings. By changing the on / off state of the windings, the three-phase current changes are achieved, generating a rotating magnetic field that drives the rotor to rotate.

[0030] The advantages of this invention are as follows: It includes an instruction layer, a control layer, and an execution layer. The control layer is set as a single main control chip, connected in series with the instruction layer and the execution layer, and processes multiple tasks synchronously. The instruction layer receives externally input instructions, parses the instructions, and transmits them to the control layer. The control layer receives the parsed information from the instruction layer and controls the execution layer to work. The execution layer includes at least multiple sets of stators, stator displacement sensors, and drive circuits. The control layer collects data fed back by the stator displacement sensors in real time, runs the motor control algorithm, and outputs PWM control signals to the drive circuit. All stators can be controlled uniformly by a single chip, eliminating cross-chip communication, reducing the number of chips and redundant components, optimizing size and cost, and reducing maintenance difficulty.

[0031] Example 2:

[0032] like Figure 1 As shown, a motor controller capable of driving a multi-stator structure is disclosed. Each module of the controller follows a closed-loop control logic of instruction input, signal feedback, algorithm processing, and execution drive. The hardware components have a one-to-one correspondence with the stator and include an instruction layer, a control layer, and an execution layer. The execution layer includes multiple sets of corresponding stator displacement sensors, drive circuits, and stators.

[0033] The command layer includes a command receiving module, which receives externally input transmission direction commands, torque commands, and speed commands. After parsing the command format, the command layer transmits the commands to the control layer. The command layer supports RS485 and CAN communication protocols and serves as the starting point of the control closed loop, outputting standardized control commands to the control layer to ensure unambiguous commands.

[0034] The control layer is configured with a single master control chip, a 32-bit MCU, supporting multiple timers. The control layer connects the instruction layer and the execution layer, processing multiple tasks synchronously, and serves as the central hub for multi-stator coordination. The control layer receives signals parsed from the instruction layer, controls the execution layer to operate, collects stator displacement data from multiple sets of stator displacement sensors in real time, runs motor control algorithms such as FOC vector control, and outputs PWM control signals to the drive circuit. To avoid delays caused by multiple tasks competing for resources and to ensure that the signal acquisition, algorithm calculation, and command output closed loop are completed within 1ms, thus guaranteeing the stator's action response speed, the control layer adopts a real-time operating system plus task splitting mode. The main control chip's tasks are divided into four independent threads, including: a command receiving thread with a period of 10ms, used to parse received external commands; a sensor signal acquisition thread with a period of 1ms, used to read and filter the feedback displacement data; a control algorithm thread with a period of 1ms, used to calculate PWM parameters by running the FOC algorithm; and a drive control thread with a period of 0.1ms, used to output PWM signals and monitor the drive circuit status. The duty cycle adjustment accuracy of the PWM signal output by the control layer is at most 1%, ensuring smooth changes in the stator winding current.

[0035] The stator displacement sensor is configured as a Hall sensor or photoelectric encoder, and each stator displacement sensor is connected to the corresponding stator. It collects the angular and linear displacement signals of the corresponding stator in real time, and transmits them to the main control chip after noise filtering. This provides accurate position feedback to the main control chip, ensuring that the algorithm output matches the actual state of the stator and preventing rotor step loss. To reduce errors, the stator displacement sensor employs an RC low-pass filter algorithm and a Kalman filter algorithm to filter signal noise caused by environmental vibration and temperature, ensuring that the displacement detection accuracy error does not exceed 0.5°. The maximum filtered environmental vibration frequency is set to 500Hz, and the temperature is controlled between -20°C and 85°C.

[0036] The drive circuit uses IGBT power transistors or SiC power transistors to receive PWM signals from the control layer, converting weak current control signals into strong current drive signals, outputting them to the stator to drive the on / off switching of the stator windings, and converting the logic signals of the main control chip into the physical actions of the stator. Simultaneously, when multiple stators are operating, the high-frequency switching signals of the drive circuit can easily interfere with the stator displacement sensor signals. If the stator displacement sensor signals are distorted, the main control chip will misjudge the stator position, causing the rotor to lose synchronization. Therefore, the drive circuit has signal isolation, using optocouplers such as TLP521 between the drive circuit and the main control chip to block interference from strong current signals to the weak current signals of the main control chip. Furthermore, the drive circuit also has a protection mechanism with built-in overcurrent and overvoltage protection. When the current reaches 5A or the voltage reaches 36V, the protection mechanism is triggered, and the drive circuit immediately feeds back to the main control chip, causing the main control chip to cut off the drive signal within 10μs.

[0037] The stator is configured with multiple three-phase windings, which directly determines the torque and speed output by the motor. The stator receives drive signals from the drive circuit to change the on / off state of the windings. By changing the on / off state of the windings, the three-phase current changes are achieved, generating a rotating magnetic field that drives the rotor to rotate.

[0038] Meanwhile, in this embodiment, the main control chip also includes a working condition identification module. By analyzing command parameters such as speed change rate and torque demand, the main control chip automatically identifies motor working conditions, such as start-up, emergency stop, constant speed, and sudden load changes, and dynamically adjusts task priorities: In start-up and emergency stop conditions, stator displacement sensor signal acquisition and drive circuit control are set to high priority, using preemptive scheduling to ensure rapid stator response; in constant speed conditions, command fine-tuning processing is set to high priority to optimize torque and speed stability, reducing errors to a maximum of 2%; in sudden load changes, the priority of overcurrent and overvoltage detection is temporarily increased to prevent overload damage. Compared to fixed priorities, the working condition identification module can improve the motor's control accuracy under different working conditions by 15% to 20%, and increase response speed by 20%.

[0039] Meanwhile, the main control chip in this embodiment also has an environmental parameter acquisition function. By connecting external low-cost temperature and humidity sensors and vibration sensors, an environmental-signal deviation compensation model is established, including temperature compensation: for every 10°C increase in temperature, the sensor output value is corrected according to a preset curve. For example, if the temperature coefficient of the Hall sensor is 0.1% / degree Celsius, the maximum accuracy error after compensation is 0.3°. Vibration compensation: when the vibration frequency exceeds 300Hz, an adaptive filtering algorithm is activated to filter vibration interference signals. Through the environmental parameter acquisition function, the applicable ambient temperature range of the controller can be extended from -20°C to 85°C to -40°C to 105°C, and the control error in vibration scenarios is reduced by 25%, making it suitable for harsh scenarios such as industrial high temperatures and outdoor vibration.

[0040] In this embodiment, the drive circuit and stator displacement sensor are integrated into a standardized module. The module's power interface, signal interface, and communication interface are unified with the main control chip port. This embodiment uses a 2.54mm pitch pin header, allowing users to assemble modules according to the number of stators without redesigning the circuit board. The module size is standardized to 30mm*20mm, compatible with stators of different power ratings less than 100W. Furthermore, this embodiment includes a module quantity recognition function within the main control chip, automatically detecting the number of connected modules upon power-up and loading the corresponding control algorithm. By integrating standardized modules, the controller adaptation cycle is shortened from the traditional two weeks to one day, and customization costs are reduced by 60%, meeting the needs of small-batch, multi-specification motors.

[0041] Meanwhile, the main control chip in this embodiment also features dual feedback interfaces, including local feedback and remote diagnostics, eliminating the need for additional load hardware. In the local feedback, external green, yellow, and red LED indicators are connected. A green indicator shows normal operation, a yellow indicator shows a warning, and a red indicator shows a fault, visually displaying the operating status of each stator. In the remote diagnostics, a serial RS232 connection to a host computer outputs real-time data such as stator displacement, current, and temperature, supporting fault code lookup. E01 is set to indicate a sensor fault, and E02 to indicate a drive overcurrent. Maintenance personnel can diagnose faults without disassembling the equipment, reducing troubleshooting time from one hour to 10 minutes and lowering maintenance costs.

[0042] The advantages of this invention are as follows: It includes an instruction layer, a control layer, and an execution layer. The control layer is set as a single main control chip, connected in series with the instruction layer and the execution layer, and processes multiple tasks synchronously. The instruction layer receives externally input instructions, parses the instructions, and transmits them to the control layer. The control layer receives the parsed information from the instruction layer and controls the execution layer to work. The execution layer includes at least multiple sets of stators, stator displacement sensors, and drive circuits. The control layer collects data fed back by the stator displacement sensors in real time, runs the motor control algorithm, and outputs PWM control signals to the drive circuit. All stators can be controlled uniformly by a single chip, eliminating cross-chip communication, reducing the number of chips and redundant components, optimizing size and cost, and reducing maintenance difficulty.

[0043] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention 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 the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A motor controller capable of driving a multi-stator structure, characterized in that, It includes an instruction layer, a control layer, and an execution layer. The control layer is configured with a single main control chip, which connects the instruction layer and the execution layer in series and processes multiple tasks synchronously. The instruction layer receives externally input instructions, parses the instructions, and transmits them to the control layer. The control layer receives the parsed information from the instruction layer and controls the execution layer to work. The execution layer includes at least multiple sets of stators, stator displacement sensors, and drive circuits. The control layer collects data fed back by the stator displacement sensors in real time, runs the motor control algorithm, and outputs PWM control signals to the drive circuits.

2. The motor controller capable of driving a multi-stator structure according to claim 1, characterized in that, The control layer includes at least: The instruction receiving thread is used to parse received external instructions; The sensor signal acquisition thread is used to read and filter the feedback displacement data; The control algorithm thread is used to calculate PWM parameters by running the FOC algorithm; The drive control thread is used to output PWM signals and monitor the status of the drive circuit. The duty cycle adjustment accuracy of the PWM signal output by the control layer is at most 1%.

3. The motor controller capable of driving a multi-stator structure according to claim 1, characterized in that, The instruction layer includes an instruction receiving module, which is used to receive externally input instructions, including at least transmission direction instructions, torque instructions, and speed instructions.

4. The motor controller capable of driving a multi-stator structure according to claim 1, characterized in that, The stator displacement sensor is configured as a Hall sensor or a photoelectric encoder, and each stator displacement sensor is connected to the corresponding stator to collect the angular displacement signal and linear displacement signal of the corresponding stator in real time, and transmit them to the control layer after filtering out noise.

5. The motor controller capable of driving a multi-stator structure according to claim 4, characterized in that, The stator displacement sensor employs an RC low-pass filter algorithm and a Kalman filter algorithm to filter signal noise caused by environmental vibration and temperature, ensuring that the displacement detection accuracy error does not exceed 0.5°.

6. The motor controller capable of driving a multi-stator structure according to claim 1, characterized in that, The driving circuit uses IGBT power transistors or SiC power transistors. The driving circuit receives the PWM signal from the control layer, converts the weak current control signal into a strong current driving signal, outputs it to the stator, and drives the stator to switch on and off.

7. The motor controller capable of driving a multi-stator structure according to claim 6, characterized in that, The driving circuit is equipped with signal isolation, and the driving circuit and the control layer are optically isolated to block the interference of strong electrical signals on the weak electrical signals of the main control chip.

8. The motor controller capable of driving a multi-stator structure according to claim 6, characterized in that, The drive circuit is equipped with overcurrent protection and overvoltage protection. When the current exceeds 5A or the voltage exceeds 36V, the drive circuit immediately feeds back to the main control chip, and the main control chip cuts off the drive signal within 10μs.

9. The motor controller capable of driving a multi-stator structure according to claim 1, characterized in that, The stator is configured with multiple sets of three-phase windings. The stator receives the driving signal output by the driving circuit to change the on / off state of the windings and generate a rotating magnetic field by switching the windings on and off.

10. The motor controller capable of driving a multi-stator structure according to any one of claims 1 to 9, characterized in that, The control layer also includes a working condition identification module. The main control chip automatically identifies the motor working condition by analyzing the information parsed by the instruction layer, and dynamically adjusts the task priority, setting the stator displacement sensor signal acquisition and drive circuit control as high priority, and setting the fine-tuning processing of instructions as high priority.

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