Model-based fuel cell air compressor high-speed motor control rack and method

Abstract

The invention relates to a model-based fuel cell air compressor high-speed motor control rack and method. The control rack comprises an air compressor high-speed motor load control model, a high-power direct-current power supply, a three-phase two-level motor driver, a motor rapid prototype controller, an upper computer, a permanent magnet synchronous motor, an eddy current brake, a torque sensor and a signal acquisition and coding unit. The control rack constructs a load control model based on air compressor MAP data and a load torque optimization algorithm, calculates a target load torque corresponding to the highest adiabatic efficiency point according to any rotating speed, and controls the eddy current brake to perform accurate load simulation; meanwhile, a user-defined control algorithm is automatically compiled and deployed to a motor driver through a rapid prototype controller, the permanent magnet synchronous motor is driven to operate under a simulated load, and high-precision signal feedback is combined, so that safe, efficient and high-fidelity real-time closed-loop verification of the control algorithm is realized, and the research and development period is remarkably shortened.

Description

Technical Field

[0001] This invention relates to the field of electromechanical control technology for fuel cell systems, specifically to a model-based high-speed motor control frame and method for a fuel cell air compressor. Background Technology

[0002] The rapid development of fuel cell technology, especially in the fields of new energy vehicles and distributed energy, has placed extremely high demands on the dynamic response and control precision of its core component—the air compressor. The control algorithm of the high-speed motor of the air compressor directly determines the power output, energy conversion efficiency, and operational reliability of the fuel cell system. Therefore, thorough and reliable verification of the control algorithm is crucial in the early stages of its development.

[0003] Currently, the verification of high-speed motor control algorithms for fuel cell air compressors mainly relies on pure software simulation platforms or direct testing on real air compressors. While pure software simulation can perform preliminary algorithm design and parameter tuning, it cannot realistically simulate the nonlinear load disturbances, electromagnetic coupling effects, and actual physical hardware constraints (such as current / voltage limits and switching delays) faced by high-speed motors in actual operation. This leads to significant deviations between simulation results and actual operating conditions, often requiring extensive rework when migrating the algorithm to a physical system. On the other hand, direct testing on real air compressors carries the risk of equipment damage or even safety accidents due to improper parameter tuning or algorithm instability, as the control algorithm has not been fully verified. Furthermore, the testing is costly and time-consuming.

[0004] Therefore, there is an urgent need to develop a dedicated test bench and method that can efficiently, safely, and accurately simulate the real load characteristics of fuel cell air compressors and perform real-time closed-loop verification of high-speed motor control algorithms. This would enable rapid verification and performance evaluation of control algorithms from simulation design to actual operation, thereby providing reliable support for the engineering application of fuel cell air compressor control technology. Summary of the Invention

[0005] The purpose of this invention is to provide a model-based high-speed motor control frame and method for fuel cell air compressors, in order to solve the problems of large deviation between simulation and reality, low efficiency of algorithm verification, and high risk of direct testing in the prior art. It constructs an equivalent test environment that is highly consistent with the load characteristics of real air compressors, and realizes rapid and safe verification of control algorithms from simulation design to physical system operation.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a model-based high-speed motor control frame for a fuel cell air compressor, comprising:

[0007] The high-speed motor load control model for air compressors is used to output the target load torque of the motor at the highest adiabatic efficiency operating point of the air compressor based on the input speed information, using the air compressor MAP data and load torque optimization algorithm.

[0008] A high-power DC power supply provides DC power to the control frame;

[0009] A three-phase two-level motor driver is electrically connected to the high-power DC power supply and is used to invert DC power into controllable three-phase AC power.

[0010] The motor rapid prototyping controller is communicatively connected to the three-phase two-level motor driver. It is used to receive user-defined air compressor control algorithms, automatically compile and generate control code, and load the control code into the three-phase two-level motor driver.

[0011] The host computer is connected to the motor rapid prototyping controller to provide a human-machine interface and download the user-defined air compressor control algorithm.

[0012] A permanent magnet synchronous motor is electrically connected to the three-phase two-level motor driver and serves as the controlled object.

[0013] An eddy current brake, mechanically connected coaxially to the permanent magnet synchronous motor, is used to apply a simulated load according to the target load torque;

[0014] A torque sensor is used to detect the load torque output by the eddy current brake in real time.

[0015] The signal acquisition and encoding unit is used to acquire the angular displacement and speed information of the permanent magnet synchronous motor in real time, and convert it into a standard signal to be fed back to the load control model of the high-speed motor of the air compressor.

[0016] Furthermore, the load control model for the high-speed motor of the air compressor includes:

[0017] The data processing module is used to establish adiabatic efficiency conversion function, speed conversion function and power conversion function based on the acquired air compressor MAP matrix;

[0018] The operating condition optimization module is used to construct equally spaced flow rate and pressure ratio matrices based on the flow rate and pressure ratio parameter ranges in the air compressor MAP matrix, and combine them with the adiabatic efficiency conversion function to determine the suitable operating condition point corresponding to the maximum adiabatic efficiency in each preset direction.

[0019] The function fitting module is used to obtain the air compressor pressure ratio working function and air compressor flow working function by interpolation fitting based on the adapted operating point and its corresponding speed.

[0020] The load calculation module is used to calculate and output the target load torque based on the load torque optimization algorithm, according to the input speed, air compressor pressure ratio working function and flow working function.

[0021] Furthermore, the rapid prototyping controller for the motor adopts a modular architecture, including:

[0022] The power board is used to provide compatible operating power to the various boards inside the controller.

[0023] A simulated CPU board, connected to the host computer, is used to receive and compile the user-defined air compressor control algorithm;

[0024] A communication board is used for data communication with the host computer and the three-phase two-level motor driver.

[0025] An ADC board is used to acquire analog signals from drivers and motors.

[0026] The DIDO board is used to receive status signals from the driver and output control commands.

[0027] A PWM board is used to generate pulse width modulation signals to control the three-phase two-level motor driver.

[0028] Furthermore, the signal acquisition and encoding unit includes:

[0029] A 2048-line sine and cosine encoder is coaxially connected to the output shaft of the permanent magnet synchronous motor to collect the angular displacement and speed information of the motor and output sine and cosine signals.

[0030] A sine-cosine incremental pulse generator, connected to the 2048-line sine-cosine encoder, is used to convert sine and cosine signals into A, B, and Z three-phase incremental pulse signals.

[0031] An incremental signal decoding card, connected to the sine-cosine incremental pulse generator, is used to decode the incremental pulse signal into rotational speed and angular position information, and convert it into a standardized AIAO signal.

[0032] Furthermore, the console rack also includes:

[0033] The test bench mechanical structure includes a vibration-damping cast iron platform, a reference horizontal platform surface set on the vibration-damping cast iron platform, a motor bracket for mounting and fixing the permanent magnet synchronous motor, and vibration-damping springs set below the vibration-damping cast iron platform for vibration reduction.

[0034] A protective cover is provided over the coupling area between the permanent magnet synchronous motor and the eddy current brake.

[0035] An eddy current brake temperature controller is used to control the operating temperature of the eddy current brake.

[0036] An air-cooled radiator is used to dissipate heat from the permanent magnet synchronous motor.

[0037] An overvoltage protector is connected in series in the power supply circuit to provide overvoltage protection.

[0038] This invention also provides a model-based high-speed motor control method for a fuel cell air compressor, applied to the aforementioned control frame, comprising the following steps:

[0039] S1: Based on the air compressor MAP data and load torque optimization algorithm, construct a load control model for the high-speed motor of the air compressor;

[0040] S2: Download the user-defined air compressor control algorithm to the motor rapid prototyping controller via the host computer;

[0041] S3: The motor rapid prototyping controller compiles the air compressor control algorithm, automatically generates control code, and loads it into the three-phase two-level motor driver;

[0042] S4: Start the control console. The high-speed motor load control model of the air compressor calculates the target load torque based on arbitrary speed information and controls the electric eddy current brake to apply the corresponding simulated load.

[0043] S5: The three-phase two-level motor driver drives the permanent magnet synchronous motor to run according to the control code, and at the same time, the motor running status is fed back in real time through the signal acquisition and encoding unit to realize the closed-loop verification of the air compressor control algorithm.

[0044] Furthermore, in step S1, a load control model for the high-speed motor of the air compressor is constructed, specifically including:

[0045] S11: Obtain the air compressor MAP matrix, which contains speed, flow rate, pressure ratio, adiabatic efficiency, and power data for multiple test points;

[0046] S12: Based on MAP matrix data, establish adiabatic efficiency conversion function, rotational speed conversion function, and power conversion function;

[0047] S13: Determine the upper and lower limits of flow rate and pressure ratio based on MAP data, and construct equally spaced flow rate and pressure ratio matrices;

[0048] S14: Combine the adiabatic efficiency conversion function to determine the sequence of suitable operating points with the highest adiabatic efficiency on the flow-pressure ratio plane;

[0049] S15: Based on the adapted operating point sequence and its corresponding speed, the air compressor pressure ratio working function and air compressor flow working function are obtained by interpolation fitting;

[0050] S16: Establish a load torque optimization algorithm so that for any input speed, the target load torque at the corresponding highest adiabatic efficiency operating point can be calculated based on the pressure ratio operating function and the flow rate operating function.

[0051] Furthermore, the target load torque T r The calculation formula is:

[0052]

[0053] Where, ω r f3 is the power conversion function, f4 is the air compressor pressure ratio function, and f5 is the air compressor flow rate function.

[0054] Furthermore, in step S4, the control of the eddy current brake to apply the simulated load adopts a closed-loop control method, specifically including:

[0055] The target load torque is compared with the actual load torque detected by the torque sensor to obtain a torque error signal;

[0056] The excitation current controller adjusts the excitation current of the eddy current brake according to the torque error signal, so that the actual load torque tracks the target load torque.

[0057] Furthermore, the control method also includes, during the closed-loop verification process, evaluating the dynamic response performance, stability, and tracking accuracy of the air compressor control algorithm under different speed step changes or load changes through the host computer.

[0058] Compared with the prior art, the present invention has the following beneficial effects:

[0059] This invention establishes a model-based rapid verification system for control algorithms. It can directly generate control code from control algorithms through a rapid prototyping controller and directly deploy it on a physical control rack for verification. This eliminates the complex code reconstruction and repeated debugging steps in the migration process from simulation models to physical systems, significantly improving the verification efficiency of control algorithms under real working conditions and shortening the cycle from R&D to engineering application of control algorithms.

[0060] This invention integrates a high-speed motor load control model, an eddy current brake, a power supply and its management system, a control frame monitoring system, and a permanent magnet synchronous motor. Based on the high-speed motor load control model of an air compressor, it controls the eddy current brake to output the target load torque of the motor at the highest adiabatic efficiency operating point of the air compressor at any given speed, thereby simulating the load of the high-speed motor at different speeds of the air compressor and establishing an equivalent test environment that is highly consistent with the actual operating characteristics of the high-speed motor of the fuel cell air compressor.

[0061] This invention features a highly integrated design for signal acquisition, control, and execution, reducing the risk of delay and distortion caused by multi-level signal conversion, enabling real-time feedback of key operating states such as high-speed motor speed and load torque, and improving the monitoring accuracy and control response capability of the control frame system.

[0062] This invention breaks through the limitations of the traditional control frame fixed resistance loading method. Through the load adjustment mechanism driven by the high-speed motor load control model of the fuel cell air compressor, it can simulate the load of the motor of the fuel cell air compressor under various working conditions such as startup, steady-state operation and dynamic load change. This makes the test environment highly consistent with the actual application scenario and effectively verifies the reliability of the control algorithm. Attached Figure Description

[0063] Figure 1 This is a schematic diagram of the high-speed motor control frame for a fuel cell air compressor based on a model, provided in an embodiment of the present invention.

[0064] Figure 2 This is a flowchart illustrating the implementation of the high-speed motor load control model for the air compressor in this embodiment of the invention.

[0065] Figure 3 This is a diagram showing the load simulation results in an embodiment of the present invention.

[0066] In the diagram: 1-Overvoltage protector; 2-High-power DC power supply; 3-Three-phase two-level motor driver; 4-Air-cooled radiator; 5-High-speed motor load control model for air compressor; 6-Incremental signal decoding card; 7-Sine / cosine-incremental pulse generator; 8-2048-line sine / cosine encoder; 9-Eddy current brake temperature controller; 10-Eddy current brake; 11-Torque sensor; 12-Vibration-resistant cast iron platform; 13-Reference horizontal platform surface; 14-Protective cover; 15-Coupling; 16-Permanent magnet synchronous motor; 17-Motor bracket; 18-Vibration damping spring; 19-Positioning bar; 20-Host computer; 21-Motor rapid prototyping controller. Detailed Implementation

[0067] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0068] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0069] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0070] like Figure 1 As shown, this embodiment provides a model-based high-speed motor control frame for a fuel cell air compressor, including a high-speed motor load control model 5, a high-power DC power supply 2, a three-phase two-level motor driver 3, a motor rapid prototyping controller 21, a host computer 20, a permanent magnet synchronous motor 16, an eddy current brake 10, a torque sensor 11, a signal acquisition and encoding unit, a frame mechanical structure, a protective cover 14, an eddy current brake temperature controller 9, an air-cooled radiator 4, and an overvoltage protector 1.

[0071] The high-speed motor load control model 5 for air compressors is based on the air compressor MAP data and load torque optimization algorithm. It outputs the target load torque of the motor at the highest adiabatic efficiency operating point of the air compressor at any input speed according to the speed information. It simulates the load of the air compressor drive motor from idle speed to peak power and reproduces the variation law of the load torque of the high-speed motor of the air compressor at different speeds.

[0072] In this embodiment, the high-speed motor load control model 5 of the air compressor is implemented through the following modules:

[0073] 1) Data processing module, used to establish adiabatic efficiency conversion function, speed conversion function and power conversion function based on the acquired air compressor MAP matrix;

[0074] 2) Operating condition optimization module, which is used to construct equally spaced flow rate and pressure ratio matrices based on the flow rate and pressure ratio parameter range in the air compressor MAP matrix, and determine the suitable operating condition point corresponding to the maximum adiabatic efficiency in each preset direction by combining the adiabatic efficiency conversion function.

[0075] 3) Function fitting module, used to obtain the air compressor pressure ratio working function and air compressor flow working function by interpolation fitting based on the adapted operating point and its corresponding speed;

[0076] 4) Load calculation module, which is used to calculate and output the target load torque based on the load torque optimization algorithm, according to the input speed, air compressor pressure ratio working function and flow working function.

[0077] The high-power DC power supply 2 provides a stable high-power DC voltage for the control rack.

[0078] The three-phase two-level motor driver 3 is electrically connected to the high-power DC power supply 2 and is used to invert DC power into controllable three-phase AC power. The three-phase two-level motor driver 3 inverts the input DC voltage into a frequency- and voltage-adjustable three-phase AC voltage output, and controls the motor speed by changing the AC voltage amplitude and vector direction.

[0079] The motor rapid prototyping controller 21 is connected to the three-phase two-level motor driver 3 for receiving user-defined air compressor control algorithms, automatically compiling and generating control code, and then loading the generated control code into the three-phase two-level motor driver 3 for execution, avoiding the tedious C language programming and debugging work.

[0080] In this embodiment, the motor rapid prototyping controller 21 adopts a modular architecture, including:

[0081] 1) Power supply board, used to provide compatible operating power to the various boards inside the controller;

[0082] 2) A simulated CPU board, connected to the host computer, is used to receive and compile user-defined air compressor control algorithms;

[0083] 3) Communication board, used for data communication with the host computer and the three-phase two-level motor driver;

[0084] 4) ADC board, used to acquire analog signals from the driver and motor;

[0085] 5) DIDO board, used to receive driver status signals and output control commands;

[0086] 6) PWM board, used to generate pulse width modulation signals to control three-phase two-level motor drivers.

[0087] The host computer 20 is connected to the motor rapid prototyping controller 21 to provide a human-machine interface and download user-defined air compressor control algorithms to the motor rapid prototyping controller 21.

[0088] The permanent magnet synchronous motor 16 is electrically connected to the three-phase two-level motor driver 3 as the controlled object. As the equivalent control carrier of the high-speed motor of the fuel cell air compressor, the permanent magnet synchronous motor 16 has core parameters such as rated speed and power that are matched with the actual working conditions of the high-speed motor of the air compressor. It obtains three-phase drive voltage by connecting to the three-phase two-level motor driver 3 through a power cable, and is coaxially connected to the eddy current brake 10 through the coupling 15 to realize the mechanical transmission of the load.

[0089] The eddy current brake 10 is mechanically connected coaxially to the permanent magnet synchronous motor and is used to apply a simulated load according to the target load torque. The eddy current brake 10 is connected to the torque sensor 11 via a CAN bus. Based on the load control model of the high-speed motor of the air compressor, it receives the real-time load torque information from the torque sensor 11 and adjusts the magnetic current to change the output torque.

[0090] The torque sensor 11 is used to detect the load torque output by the eddy current brake 10 in real time.

[0091] The signal acquisition and encoding unit is used to acquire the angular displacement and speed information of the permanent magnet synchronous motor 16 in real time and convert it into a standard signal to be fed back to the high-speed motor load control model 5 of the air compressor.

[0092] In this embodiment, the signal acquisition and encoding unit includes:

[0093] 1) A 2048-line sine and cosine encoder 8 is coaxially connected to the output shaft of the permanent magnet synchronous motor 16. It is used to collect the angular displacement and speed information of the motor in real time and output sine and cosine signals to achieve high-resolution data acquisition.

[0094] 2) The sine-cosine incremental pulse generator 7 is connected to the 2048-line sine-cosine encoder 8. It is used to convert the sine and cosine signals into A, B, and Z three-phase incremental pulse signals according to a preset ratio, and to provide real-time feedback on the dynamic changes of motor speed and angular displacement, so as to achieve low-delay signal transmission.

[0095] 3) Incremental signal decoding card 6, connected to sine-cosine incremental pulse generator 7, is used to decode the phase difference of A and B phase pulses into speed and angular position information based on incremental pulse signals, and convert the information into standardized AIAO signal input control model.

[0096] The mechanical structure of the test bench includes a vibration-damping cast iron platform 12, a reference horizontal platform 13 set on the vibration-damping cast iron platform 12, a motor bracket 17 for mounting and fixing the permanent magnet synchronous motor 16, a vibration-damping spring 18 set below the vibration-damping cast iron platform 12 for vibration reduction, and a positioning bar 19.

[0097] In this embodiment, the anti-vibration cast iron platform 12 measures 200 cm × 400 cm, with four vibration-damping springs supporting its four corners. The reference horizontal platform surface 13 serves as the basic load-bearing structure for the control frame, providing a unified horizontal installation benchmark, stable support for core components, vibration damping and interference resistance, and a unified testing benchmark, ensuring the platform's installation accuracy, operational stability, and the accuracy and robustness of data acquisition. The motor bracket 17 secures the motor with T-bolts, ensuring the coaxiality of the motor and the eddy current brake. The vibration-damping springs 18 effectively absorb the high-frequency vibrations generated by the operation of the motor and brake. The positioning strip 19 defines the motor's installation position, preventing eccentric vibrations in the coupling transmission due to installation misalignment.

[0098] A protective cover 14 is installed over the area of ​​the coupling 15 between the permanent magnet synchronous motor 16 and the eddy current brake 10. The coupling 15 enables the coaxial mechanical connection between the permanent magnet synchronous motor 16 and the eddy current brake 10. The protective cover 14 effectively isolates metal debris and oil splashes that may be generated during the test, preventing operators from accidentally touching the high-speed rotating coupling 15. The bottom is tightly and seamlessly connected to the pre-embedded screw holes on the surface of the vibration-damping cast iron table 12 by bolts.

[0099] The eddy current brake temperature controller 9 is used to control the operating temperature of the eddy current brake 10. The eddy current brake temperature controller 9 is connected to the eddy current brake 10 through a cooling pipe, and collects the operating temperature of the eddy current brake 10 in real time to control the constant temperature environment.

[0100] The air-cooled radiator 4 is used to dissipate heat from the permanent magnet synchronous motor 16. The air-cooled radiator 4 is connected to the permanent magnet synchronous motor 16 through cooling pipes to dissipate heat from the motor and ensure stable motor operation.

[0101] Overvoltage protector 1 is connected in series in the power supply circuit to provide overvoltage protection. Overvoltage protector 1 can prevent electrical accidents in core components such as the drive and permanent magnet synchronous motor by cutting off power when the control frame circuit is overvoltageed.

[0102] This embodiment also provides a high-speed motor control method for a fuel cell air compressor applied to the above-mentioned control frame, the implementation steps of which are as follows.

[0103] S1: Based on the air compressor MAP data and load torque optimization algorithm, construct a load control model for the high-speed motor of the air compressor.

[0104] S2: Download the user-defined air compressor control algorithm to the motor rapid prototyping controller via the host computer.

[0105] S3: The motor rapid prototyping controller compiles the air compressor control algorithm, automatically generates control code, and loads it into the three-phase two-level motor driver.

[0106] S4: Start the control console. The high-speed motor load control model of the air compressor calculates the target load torque based on arbitrary speed information and controls the electric eddy current brake to apply the corresponding simulated load.

[0107] The control of applying a simulated load to the eddy current brake employs a closed-loop control method, specifically including:

[0108] 1) Compare the target load torque with the actual load torque detected by the torque sensor to obtain the torque error signal;

[0109] 2) The excitation current of the eddy current brake is adjusted by the excitation current controller according to the torque error signal, so that the actual load torque tracks the target load torque.

[0110] S5: The three-phase two-level motor driver drives the permanent magnet synchronous motor according to the control code, and simultaneously provides real-time feedback on the motor's operating status through the signal acquisition and encoding unit, thereby achieving closed-loop verification of the air compressor control algorithm. During the closed-loop verification process, the host computer evaluates the dynamic response performance, stability, and tracking accuracy of the air compressor control algorithm under different speed step changes or load variations.

[0111] The method for constructing the load control model for the high-speed motor of the air compressor is as follows:

[0112] S11: Obtain the air compressor MAP matrix, which contains speed, flow rate, pressure ratio, adiabatic efficiency, and power data for multiple test points;

[0113] S12: Based on MAP matrix data, establish adiabatic efficiency conversion function, rotational speed conversion function, and power conversion function;

[0114] S13: Determine the upper and lower limits of flow rate and pressure ratio based on MAP data, and construct equally spaced flow rate and pressure ratio matrices;

[0115] S14: Combine the adiabatic efficiency conversion function to determine the sequence of suitable operating points with the highest adiabatic efficiency on the flow-pressure ratio plane;

[0116] S15: Based on the adapted operating point sequence and its corresponding speed, the air compressor pressure ratio working function and air compressor flow working function are obtained by interpolation fitting;

[0117] S16: Establish a load torque optimization algorithm so that for any input speed, the target load torque at the corresponding highest adiabatic efficiency operating point can be calculated based on the pressure ratio operating function and the flow rate operating function.

[0118] Figure 2 The specific implementation flow of the load control model for a high-speed motor of an air compressor is shown. This flow is based on a method combining the air compressor's MAP (Modular Mapping) and a load torque optimization algorithm. The specific steps are as follows:

[0119] (1) Obtain the air compressor MAP, the contents of which are as follows:

[0120]

[0121] In the formula, Map is the air compressor MAP matrix, m is the number of test points, and ω i M i U i η i , λi (i=1,2,…,m) represents the test values ​​of air compressor speed, air compressor flow rate, air compressor pressure ratio, air compressor thermal efficiency, and air compressor power at the test point, and test values ​​with the same subscript indicate that they come from the same test point.

[0122] (2) Establish the adiabatic efficiency conversion function f1(x,y):

[0123]

[0124] Make:

[0125]

[0126] in:

[0127]

[0128] (3) Obtain the maximum flow rate W of the air compressor based on the air compressor MAP. max Minimum flow rate W min Pressure ratio upper limit P max and the lower limit of pressure ratio P min .

[0129] (4) Through the W max With W min Establish the flow matrix T W1 And through the P max With P min Establish the pressure ratio matrix T P1 The flow rate matrix and the pressure ratio matrix have the same dimension and their elements are distributed at equal intervals, as shown in the following expression:

[0130]

[0131] In the formula, n is the matrix dimension, and W i (i=1,2…n), P j (j=1,2…n) are the elements of the flow rate matrix and the pressure ratio matrix, and satisfy:

[0132]

[0133] (5) Using the flow rate matrix and pressure ratio matrix, substitute each matrix element with the same subscript into the adiabatic efficiency conversion function to obtain the adiabatic efficiency matrix elements with the same subscript, and establish the adiabatic efficiency matrix T. η1 .

[0134] (6) Extract the adiabatic efficiency data column by column along the preset direction of the adiabatic efficiency matrix, and determine the flow rate and pressure ratio corresponding to the maximum adiabatic efficiency in each column, and use them as the corresponding adaptation operating point of the column.

[0135] (7) Establish the rotational speed conversion function f2(x,y):

[0136] Make:

[0137]

[0138] in:

[0139]

[0140] (8) Establish the power conversion function f3(x,y):

[0141] Make:

[0142]

[0143] in:

[0144]

[0145] (9) Based on the speed conversion function, calculate the speed corresponding to each suitable operating point to form a suitable operating point speed sequence; perform interpolation fitting with the speed in the suitable operating point as the independent variable and the pressure ratio as the dependent variable to obtain the air compressor pressure ratio working function f4(x); perform interpolation fitting with the speed in the suitable operating point as the independent variable and the flow rate as the dependent variable to obtain the air compressor flow rate working function f5(x); so that the corresponding flow rate and pressure ratio can be obtained simultaneously under any given speed condition;

[0146] (10) Establish a load torque optimization algorithm, and input arbitrary speed information ω. r The load torque of the air compressor motor at the operating point of highest adiabatic efficiency can be calculated, and it is defined as the simulated target torque T of the air compressor load. r Its expression is as follows:

[0147]

[0148] Where, ω r f3 is the power conversion function, f4 is the air compressor pressure ratio function, and f5 is the air compressor flow rate function.

[0149] like Figure 3 As shown, a step response analysis of the high-speed motor control frame and method for fuel cell air compressors based on a model is performed on the motor. The motor is initially loaded to 4000 rpm, then steps to 5000 rpm after 2 seconds, and then steps to 6000 rpm after another 2 seconds. Subsequently, it steps back to 5000 rpm and 4000 rpm at the 6th and 8th seconds, respectively. Figure 3It can be seen that under the closed-loop regulation of the excitation current of the eddy current brake, the actual torque can converge to the vicinity of the target torque in a short time and maintain stable tracking without obvious continuous deviation or instability. The average absolute error, average relative error, and root mean square error of the load simulated actual torque compared with the load simulated target torque are 0.2899 Nm, 1.649%, and 0.3941 Nm, respectively, all within a reasonable range. This indicates that under frequent speed changes, the load simulated actual torque can still maintain high tracking accuracy and stability.

[0150] Preferably, the eddy current brake in this invention uses the target torque output by the high-speed motor load control model of the air compressor as the control input. It adjusts the braking torque through closed-loop control, thereby simulating the actual load condition of the fuel cell air compressor high-speed motor on the control frame. In specific implementation, the high-speed motor load control model calculates the target load torque under the corresponding operating condition based on arbitrary speed information and inputs the target torque into the braking torque control loop. The target torque is compared with the actual braking torque collected in real time by a torque sensor, and the difference is used as a torque error signal input to the braking torque controller. A corresponding desired current command is generated based on the torque error and input to the excitation current controller. The excitation current controller performs closed-loop adjustment of the current command and drives the DC regulated power supply to output a stable excitation current, forming an eddy current magnetic field of corresponding strength inside the brake. This generates a braking torque on the brake rotor that corresponds to the excitation current, i.e., the load simulation torque.

[0151] Preferably, the model-based high-speed motor control chassis and method for fuel cell air compressors provided by this invention require the motor rapid prototyping controller to employ a power board with an output voltage of 220 V and a built-in wide-voltage regulator module; a CPU board with 2 MB of program memory, 512 KB of data memory, 16 KB of stack memory, a main frequency of 300 MHz, a bit width of 32 bits, and support for single-precision floating-point operations; a communication board compatible with EtherCAT / CANopen dual protocols, a transmission rate of 100 Mbps, and support for 3 communication interfaces; an ADC board with 24 external channels, 16-bit precision, a sampling rate of 200 KPSP, and an input range of ±10 V; a DIDO board with 8 external DO channels, 12 external channels, one set of QEP / 3-channel CAPD, and TTL level; and a PWM board with 12 external groups, 24 pulse width modulation signals, and a switching frequency of 100 kHz. This provides a solid hardware foundation for the motor rapid prototyping controller, ensuring its efficient, stable, and safe operation.

[0152] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0153] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0154] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0155] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0156] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A model-based high-speed motor control frame for a fuel cell air compressor, characterized in that, include: The high-speed motor load control model for air compressors is used to output the target load torque of the motor at the highest adiabatic efficiency operating point of the air compressor based on the input speed information, using the air compressor MAP data and load torque optimization algorithm. A high-power DC power supply provides DC power to the control frame; A three-phase two-level motor driver is electrically connected to the high-power DC power supply and is used to invert DC power into controllable three-phase AC power. The motor rapid prototyping controller is communicatively connected to the three-phase two-level motor driver. It is used to receive user-defined air compressor control algorithms, automatically compile and generate control code, and load the control code into the three-phase two-level motor driver. The host computer is connected to the motor rapid prototyping controller to provide a human-machine interface and download the user-defined air compressor control algorithm. A permanent magnet synchronous motor is electrically connected to the three-phase two-level motor driver and serves as the controlled object. An eddy current brake, mechanically connected coaxially to the permanent magnet synchronous motor, is used to apply a simulated load according to the target load torque; A torque sensor is used to detect the load torque output by the eddy current brake in real time. The signal acquisition and encoding unit is used to acquire the angular displacement and speed information of the permanent magnet synchronous motor in real time, and convert it into a standard signal to be fed back to the load control model of the high-speed motor of the air compressor.

2. The model-based high-speed motor control frame for fuel cell air compressors according to claim 1, characterized in that, The load control model for the high-speed motor of the air compressor includes: The data processing module is used to establish adiabatic efficiency conversion function, speed conversion function and power conversion function based on the acquired air compressor MAP matrix; The operating condition optimization module is used to construct equally spaced flow rate and pressure ratio matrices based on the flow rate and pressure ratio parameter ranges in the air compressor MAP matrix, and combine them with the adiabatic efficiency conversion function to determine the suitable operating condition point corresponding to the maximum adiabatic efficiency in each preset direction. The function fitting module is used to obtain the air compressor pressure ratio working function and air compressor flow working function by interpolation fitting based on the adapted operating point and its corresponding speed. The load calculation module is used to calculate and output the target load torque based on the load torque optimization algorithm, according to the input speed, air compressor pressure ratio working function and flow working function.

3. The model-based high-speed motor control frame for fuel cell air compressors according to claim 1, characterized in that, The rapid prototyping controller for the motor adopts a modular architecture, including: The power board is used to provide compatible operating power to the various boards inside the controller. A simulated CPU board, connected to the host computer, is used to receive and compile the user-defined air compressor control algorithm; A communication board is used for data communication with the host computer and the three-phase two-level motor driver. An ADC board is used to acquire analog signals from drivers and motors. The DIDO board is used to receive status signals from the driver and output control commands. A PWM board is used to generate pulse width modulation signals to control the three-phase two-level motor driver.

4. The model-based high-speed motor control frame for fuel cell air compressors according to claim 1, characterized in that, The signal acquisition and encoding unit includes: A 2048-line sine and cosine encoder is coaxially connected to the output shaft of the permanent magnet synchronous motor to collect the angular displacement and speed information of the motor and output sine and cosine signals. A sine-cosine incremental pulse generator, connected to the 2048-line sine-cosine encoder, is used to convert sine and cosine signals into A, B, and Z three-phase incremental pulse signals. An incremental signal decoding card, connected to the sine-cosine incremental pulse generator, is used to decode the incremental pulse signal into rotational speed and angular position information, and convert it into a standardized AIAO signal.

5. The model-based high-speed motor control frame for fuel cell air compressors according to claim 1, characterized in that, Also includes: The test bench mechanical structure includes a vibration-damping cast iron platform, a reference horizontal platform surface set on the vibration-damping cast iron platform, a motor bracket for mounting and fixing the permanent magnet synchronous motor, and vibration-damping springs set below the vibration-damping cast iron platform for vibration reduction. A protective cover is provided over the coupling area between the permanent magnet synchronous motor and the eddy current brake. An eddy current brake temperature controller is used to control the operating temperature of the eddy current brake. An air-cooled radiator is used to dissipate heat from the permanent magnet synchronous motor. An overvoltage protector is connected in series in the power supply circuit to provide overvoltage protection.

6. A model-based high-speed motor control method for a fuel cell air compressor, applied to the control frame as described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Based on the air compressor MAP data and load torque optimization algorithm, construct a load control model for the high-speed motor of the air compressor; S2: Download the user-defined air compressor control algorithm to the motor rapid prototyping controller via the host computer; S3: The motor rapid prototyping controller compiles the air compressor control algorithm, automatically generates control code, and loads it into the three-phase two-level motor driver; S4: Start the control console. The high-speed motor load control model of the air compressor calculates the target load torque based on arbitrary speed information and controls the electric eddy current brake to apply the corresponding simulated load. S5: The three-phase two-level motor driver drives the permanent magnet synchronous motor to run according to the control code, and at the same time, the motor running status is fed back in real time through the signal acquisition and encoding unit to realize the closed-loop verification of the air compressor control algorithm.

7. The model-based high-speed motor control method for fuel cell air compressors according to claim 6, characterized in that, In step S1, a load control model for the high-speed motor of the air compressor is constructed, specifically including: S11: Obtain the air compressor MAP matrix, which contains speed, flow rate, pressure ratio, adiabatic efficiency, and power data for multiple test points; S12: Based on MAP matrix data, establish adiabatic efficiency conversion function, rotational speed conversion function, and power conversion function; S13: Determine the upper and lower limits of flow rate and pressure ratio based on MAP data, and construct equally spaced flow rate and pressure ratio matrices; S14: Combine the adiabatic efficiency conversion function to determine the sequence of suitable operating points with the highest adiabatic efficiency on the flow-pressure ratio plane; S15: Based on the adapted operating point sequence and its corresponding speed, the air compressor pressure ratio working function and air compressor flow working function are obtained by interpolation fitting; S16: Establish a load torque optimization algorithm so that for any input speed, the target load torque at the corresponding highest adiabatic efficiency operating point can be calculated based on the pressure ratio operating function and the flow rate operating function.

8. The model-based high-speed motor control method for fuel cell air compressors according to claim 7, characterized in that, The target load torque T r The calculation formula is: Where, ω r f3 is the power conversion function, f4 is the air compressor pressure ratio function, and f5 is the air compressor flow rate function.

9. The model-based high-speed motor control method for fuel cell air compressors according to claim 6, characterized in that, In step S4, the simulated load applied to the eddy current brake is controlled using a closed-loop control method, specifically including: The target load torque is compared with the actual load torque detected by the torque sensor to obtain a torque error signal; The excitation current controller adjusts the excitation current of the eddy current brake according to the torque error signal, so that the actual load torque tracks the target load torque.

10. The model-based high-speed motor control method for fuel cell air compressors according to claim 6, characterized in that, The control method also includes, during the closed-loop verification process, evaluating the dynamic response performance, stability, and tracking accuracy of the air compressor control algorithm under different speed step changes or load changes through the host computer.

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