Hall detection type dual-redundancy multi-turn motion servo mechanism

Abstract

The application belongs to the technical field of servo mechanisms, and specifically discloses a Hall detection type double-redundancy multi-turn motion servo mechanism. The Hall detection type double-redundancy multi-turn motion servo mechanism comprises a drive control box and an executing mechanism; the executing mechanism comprises a motor and a speed reduction mechanism; the drive control box and the motor are designed in a double-redundancy mode to form two independent working channels; during working, the double redundancies work simultaneously, and the redundancy where a fault occurs exits the working after the fault occurs. The scheme solves the technical problem of cooperative control between position measurement and redundancy of the double-redundancy multi-turn motion servo mechanism.

Description

Technical Field

[0001] This invention belongs to the technical field of servo mechanisms, specifically relating to a Hall-detection type dual-redundant multi-turn motion servo mechanism and its control method. Background Technology

[0002] With the rapid development of electric servo technology, the types and application scenarios of electric servo products have become increasingly diverse, widely used in aerospace, shipbuilding, automotive, robotics, industrial automation, and other fields. This article describes a valve motion control scenario where a servo mechanism is used to control the opening and closing of a valve. This allows the valve to be pushed into position within a specified time under different load conditions, and then promptly stopped and locked upon arrival to prevent overtravel. To improve reliability, the servo mechanism driving the valve employs a dual-redundancy design. Both redundancies operate simultaneously without electrical interconnection and work independently. Upon receiving a command from the host computer, both redundancies work simultaneously, controlling the servo mechanism to rotate multiple times to drive the valve into position. Once the host computer detects that the valve has reached its designated position, it controls the servo mechanism to stop operating via a command.

[0003] Common dual-redundant servo mechanisms have the following main disadvantages: 1) Based on absolute position detection, it is impossible to complete multi-loop motion detection and control; 2) The redundancy is used for primary and backup purposes, and cannot give full play to the full effectiveness of dual redundancy; 3) The separate output detection stage increases system complexity and cost. Summary of the Invention

[0004] The purpose of this invention is to provide a Hall effect detection-based dual-redundant multi-turn motion servo mechanism and control method to solve the technical problem of coordinated control between position measurement and redundancy in dual-redundant multi-turn motion servo mechanisms.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A Hall effect detection-type dual-redundant multi-turn motion servo mechanism includes: a drive control box and an actuator; the actuator includes a motor and a reduction mechanism; the drive control box and the motor adopt a dual-redundant design to form two independent working channels; during operation, the dual redundancies work simultaneously, and the redundancy where the fault occurs stops working after a fault occurs.

[0006] Preferably, the drive control box includes a DC-DC power module and a signal processing circuit. The DC-DC power module and the signal processing circuit are divided into two groups, one main and one backup. The two power supplies of the control system are respectively connected to the main and backup DC-DC power modules, and the two RS422 buses of the control system are respectively connected to the main and backup signal processing circuits.

[0007] Preferably, the drive control box further includes a motor driver, which is divided into two groups: a main group and a backup group. The main and backup groups of motor drivers are respectively connected to the main and backup groups of motors of the actuator. The main and backup groups of motor drivers are respectively connected to the main and backup groups of DC-DC power modules and the main and backup groups of signal processing circuits.

[0008] Preferably, the actuator includes two sets of brushless DC motors (main and backup) and a single-redundant reduction mechanism. Both the main and backup brushless DC motors are connected to the reduction mechanism via motor locks.

[0009] Preferably, each power supply of the control system is divided into two paths: one path is connected to a DC-DC power module for conversion and power supply to other circuits, and the other path is connected to the motor driver for power supply.

[0010] Preferably, the motion control signal sent by the host computer is connected to the signal processing circuit via an RS422 bus signal. After being analyzed by the signal processing circuit and processed by the logic processing circuit, the unlock signal and control signal are output to the motor driver in sequence. After passing through the motor driver, the motor is unlocked and rotated.

[0011] Preferably, the rotational motion of the motor is transmitted and converted into the rotational motion of the output shaft through the reduction mechanism. After the motor rotates, the Hall sensor detects the position information of the motor and outputs it to the signal processing circuit. The signal processing circuit analyzes and processes the Hall signal to obtain the number of rotations and the rotational speed, and outputs the control signal of the motor driver to adjust the motor speed and direction.

[0012] Preferably, after the motor has moved to the correct position, the signal processing circuit cuts off its output, the motor stops, and the motor lock engages, thus achieving position locking.

[0013] Preferably, the logic processing circuit receives instructions from the host computer and converts them into forward / reverse signals, unlock signals, enable signals, or motor speed signals.

[0014] Preferably, the signal output by the logic processing circuit is transmitted to the motor driver through a level conversion circuit, wherein the level conversion circuit is used to convert between signals of different voltage levels.

[0015] In this invention, a dual-redundancy design is adopted for the drive control box and motor, forming two independent working channels. During operation, both redundancies work simultaneously. In the event of a fault, the redundancy where the fault occurred exits operation, thereby realizing a Hall-effect detection-type dual-redundancy multi-turn motion servo mechanism and control. This achieves coordinated control between the two redundancies, ensuring stable operation even without electrical interconnection. The coordinated operation of the two redundancies maximizes the system's efficiency. In the event of a fault, the faulty redundancy exits operation, releasing its control authority, while the normal redundancy continues to operate. This improves the product's task reliability and solves the technical problems of position measurement and coordinated control between redundancies in a dual-redundancy multi-turn motion servo mechanism, achieving the technical effect of improving the operational reliability of the servo mechanism. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of a Hall-detection dual-redundant multi-turn motion servo mechanism in an embodiment of the present invention.

[0017] Figure 2 This is a schematic diagram of a redundant design scheme for a Hall-detection type dual-redundant multi-turn motion servo mechanism in an embodiment of the present invention.

[0018] Figure 3 This is a schematic diagram of a Hall-detection type dual-redundant multi-turn motion servo mechanism according to an embodiment of the present invention.

[0019] Figure 4 This is a block diagram of the drive control box in an embodiment of the present invention.

[0020] Figure 5 This is a block diagram of the power supply circuit in an embodiment of the present invention.

[0021] Figure 6 This is a schematic diagram of the power supply circuit in an embodiment of the present invention.

[0022] Figure 7 This is a schematic diagram of the logic processing circuit in an embodiment of the present invention.

[0023] Figure 8 This is a schematic diagram of the level conversion circuit in an embodiment of the present invention.

[0024] Figure 9 This is a schematic diagram of the RS422 communication circuit in an embodiment of the present invention.

[0025] Figure 10 This is a schematic diagram of the unlocking circuit in an embodiment of the present invention.

[0026] Figure 11 This is a schematic diagram of the power supply unlocking circuit in an embodiment of the present invention.

[0027] Figure 12 This is a block diagram of the motor driver principle in an embodiment of the present invention.

[0028] Figure 13 This is a schematic diagram of the P-tube on / off control circuit in an embodiment of the present invention.

[0029] Figure 14 This is a schematic diagram of the optical coupling circuit in an embodiment of the present invention.

[0030] Figure 15 This is a schematic diagram of the logic processing circuit in an embodiment of the present invention.

[0031] Figure 16 This is a schematic diagram of the gate driving circuit in an embodiment of the present invention.

[0032] Figure 17 This is a schematic diagram of the current limiting circuit in an embodiment of the present invention.

[0033] Figure 18 This is a schematic diagram of a three-phase power inverter circuit in an embodiment of the present invention.

[0034] Figure 19 This is a schematic diagram of the Hall detection circuit in an embodiment of the present invention.

[0035] Figure 20 This is a schematic diagram of a full-bridge two-by-two conducting circuit in an embodiment of the present invention.

[0036] Figure 21 This is a block diagram of the motor drive module in an embodiment of the present invention.

[0037] Figure 22 This is a schematic diagram of the control logic processing circuit in an embodiment of the present invention. Detailed Implementation

[0038] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of the present invention will become clearer from the following description and claims. It should be noted that the drawings are all in a very simplified form and are not to a precise scale, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0039] It should be noted that, in order to clearly illustrate the content of this invention, several embodiments are provided to further explain different implementations of the invention. These embodiments are enumerated rather than exhaustive. Furthermore, for the sake of brevity, content mentioned in the preceding embodiments is often omitted in the following embodiments. Therefore, content not mentioned in the later embodiments can be referred to in the preceding embodiments.

[0040] Example 1 A Hall effect detection type dual-redundant multi-turn motion servo mechanism, such as Figure 1 As shown, it includes: a drive control box and an actuator; the actuator includes a motor and a reduction gear mechanism; The drive control box and motor adopt a dual-redundancy design, forming two independent working channels. During operation, both redundancies work simultaneously, and the redundancy where the fault occurs stops working after a fault occurs.

[0041] Optionally, such as Figure 1 As shown, the servo mechanism consists of a drive control box and an actuator. The drive box mainly comprises a logic processing circuit and a motor drive circuit, while the actuator mainly comprises a motor (including a motor lock) and a reduction mechanism. Both the drive control box and the motor employ a dual-redundancy design, with the motor lock being single-redundant and the reduction mechanism also being single-redundant. Redundancy design schemes are not limited to... Figure 2 As shown. During operation, both redundancies work simultaneously. In the event of a fault, the redundancy where the fault occurred stops working.

[0042] The redundant design scheme in this application embodiment has the following characteristics: 1) The system has no output position detection step, resulting in a simple system structure and low overall cost; 2) Redundancy design at the main and backup channel levels, single-axis output; 3) The system has low complexity and high reliability. There is no electrical cross-linking between the main and backup redundancies. Hardware faults between channels can be completely isolated, which can effectively prevent cross short circuits. The redundancy design is highly effective. 4) The primary and backup redundancies work simultaneously, and the system can continue to operate without performance degradation even if a single redundancy fails. 5) Low logical complexity, simple debugging and verification, and short cycle; 6) Redundancy failure mode: Both the primary and backup channels experience single-point failures.

[0043] As an optional implementation, the drive control box includes a DC-DC power module and a signal processing circuit. The DC-DC power module and the signal processing circuit are divided into two groups, one main and one backup. The two power supplies of the control system are respectively connected to the main and backup DC-DC power modules, and the two RS422 buses of the control system are respectively connected to the main and backup signal processing circuits.

[0044] As an optional implementation, the drive control box also includes a motor driver, which is divided into two groups: a main group and a backup group. The main and backup groups of motor drivers are respectively connected to the main and backup motors of the actuator. The main and backup groups of motor drivers are respectively connected to the main and backup DC-DC power modules and the main and backup signal processing circuits.

[0045] As an optional implementation, the actuator includes two sets of brushless DC motors (main and backup) and a single-redundant reduction mechanism. Both the main and backup brushless DC motors are connected to the reduction mechanism via motor locks.

[0046] Alternatively, the principle of the servo mechanism is not limited to such as Figure 3As shown, the drive control box consists of two sets of DC-DC power modules (main and backup), a signal processing circuit, and a motor driver. The actuator consists of a dual-redundant brushless DC motor (including an electromagnetic motor lock) and a single-redundant reduction mechanism. The servo mechanism uses a dual-redundant design to form two independent channels; if one channel fails, the other continues to operate. The control system provides two sets of 28V power supplies and two sets of RS422 buses to the main and backup channels of the servo mechanism, respectively. The main and backup channels of the servo mechanism are isolated from each other and operate simultaneously.

[0047] As an optional implementation, each power supply of the control system is divided into two paths: one path is connected to a DC-DC power module for conversion to power other circuits, and the other path is connected to the motor driver for power supply.

[0048] As an optional implementation, the motion control signal sent by the host computer is connected to the signal processing circuit via an RS422 bus signal. After being parsed by the signal processing circuit and processed by the logic processing circuit, the unlock signal and control signal are output to the motor driver in sequence. After passing through the motor driver, the motor is unlocked and rotated.

[0049] As an optional implementation, the rotational motion of the motor is transmitted through a reduction mechanism and converted into the rotational motion of the output shaft. After the motor rotates, the Hall sensor detects the position information of the motor and outputs it to the signal processing circuit. The signal processing circuit analyzes and processes the Hall signal to obtain the number of rotations and the rotational speed, and outputs the control signal of the motor driver to adjust the motor speed and direction.

[0050] As an optional implementation, after the motor has moved to the correct position, the signal processing circuit cuts off its output, the motor stops, and the motor lock engages, thus achieving position locking.

[0051] Optionally, for a single redundancy, the 28V power supply is divided into two paths after being connected to the driver. One path is connected to a DC-DC power module, which outputs three power supplies after DC-DC conversion, respectively serving as the power supply for the signal processing circuit, the logic synthesis circuit (gate circuit, etc.), and the unlocking circuit. The other path is connected to the motor driver as the power supply for driving the motor to rotate. The motion control signal sent by the host computer is input to the signal processing circuit via RS422 bus. After being parsed and logically combined by the signal processing circuit, the unlock signal (LOCK) and control signals (including pulse width modulation (PWM), forward / reverse (FR), and enable (EN) signals) are output to the motor driver in a certain timing sequence. After passing through the motor driver, the motor is unlocked and rotated. The rotational motion of the motor is transmitted through the reduction mechanism and finally converted into the rotational motion of the output shaft. After the motor rotates, the Hall sensor detects the position information of the motor and outputs it to the signal processing circuit. The signal processing circuit analyzes and processes the Hall signal to obtain the number of rotations and the rotational speed, which is provided to the CPU to further correct the control signal output to the motor driver, adjusting the motor speed and direction. After the motion is in place, the host computer stops sending motion commands, the signal processing circuit cuts off the output, the motor stops rotating, and the motor lock is engaged, realizing the position locking.

[0052] Alternatively, the principle of the drive control box is not limited to that of... Figure 4 As shown, the drive control box adopts a dual-redundant channel design with primary and backup channels, and the two channels are completely identical. Each channel includes a power supply circuit, a signal processing circuit, an unlocking circuit, and a motor drive circuit.

[0053] Furthermore, the power supply principle is as follows: Figure 5 As shown, the circuit is as follows Figure 6 As shown, the power supply circuit uses an isolated DC / DC converter with an input voltage range of 18 to 36V. The power supply circuit converts the input 28V power supply into two +5V power supplies, one for the signal processing circuit and the other as a signal isolation power supply.

[0054] Optionally, the signal processing circuit includes a logic processing circuit and a level conversion circuit, an RS422 communication circuit, an unlock control circuit, and an unlock power supply circuit.

[0055] As an optional implementation, the logic processing circuit receives instructions from the host computer and converts them into forward / reverse signals, unlock signals, enable signals, or motor speed signals.

[0056] Alternatively, the logic processing circuit is not limited to, for example Figure 7As shown, the logic processing circuit mainly receives commands from the host computer and converts them into forward / reverse signals (F / R), unlock signals (JS), enable signals (EN), and motor speed signals (PWM). This part of the hardware circuit is implemented by the JS32F103CB microcontroller and peripheral circuits. The microcontroller is a 48-pin package with a cross-section of 9mm × 9mm. It integrates 3 UART serial ports (communication rate up to 4.5Mbps), 37 multiplexed GPIOs (which can be used for GPIO, ADC, PWM, etc.), and 7 timers, which can meet the requirements of communicating with the host computer, outputting control signals, and detecting voltage and current.

[0057] As an optional implementation, the signal output by the logic processing circuit is transmitted to the motor driver through a level conversion circuit, wherein the level conversion circuit is used to convert between signals of different voltage levels.

[0058] Optionally, the signal output from the logic processing circuit ultimately needs to be transmitted to the motor drive circuit. Directly outputting through the microcontroller's GPIO pins has drawbacks such as insufficient drive capability and small level error tolerance. Therefore, level conversion is used to enhance drive capability and improve level error tolerance. Level conversion circuits are not limited to... Figure 8 As shown, the GKI164245TS is a 16-bit level converter with tri-state output. The direction of the input and output signals is determined by the DIR pin. This driver chip realizes the mutual conversion between 3.3V and 5V level signals, and the external driving capability can reach ±24mA. It is stable and reliable in operation.

[0059] Optionally, the circuit for RS422 communication between the signal processing circuit and the host computer is not limited to, for example, Figure 9 As shown, the GKI2682S is an isolated RS422 transceiver with a maximum transmission rate of 16Mbps and integrated over-temperature and over-current protection mechanisms. Considering electrostatic discharge (ESD) protection and electromagnetic compatibility, an ESD protection diode was added to the bus, providing ±30KV contact discharge ESD protection.

[0060] Optionally, the unlocking control circuit controls the opening and closing of the brake according to the signal from the logic processing circuit; the brake is a common circuit part of two sets of drivers, and the unlocking or locking signal of one or more drivers can make the brake respond, and one or more power supply systems can provide working power to the unlocking circuit and the brake.

[0061] The unlocking circuit is a common part of the two channel circuits. When the OR gate receives an unlock / lock signal from either channel, it controls the MOSFET to open, releasing the brake. After the MOSFET opens, the voltage across the resistor is compared with the preset voltage value of the comparator, and a brake feedback signal is output to the logic processing circuit. The brake will only lock when both unlock / lock signals are low. If one channel is not powered, the unlock / lock signal of that channel will be low. The components of the brake and unlocking circuit are powered by two sources. In actual operation, the higher voltage source provides power. When the higher voltage source is cut off, the power supply switches to the lower voltage source. This design is to avoid the dynamic situation where the voltages of the two sources are high and low when both sources are powered simultaneously, which may cause fluctuations in the operation of the brake and unlocking circuit, resulting in unstable operation.

[0062] The principle of unlocking control circuit is not limited to, for example Figure 10 As shown, the unlock / lock signals of the two channels are isolated by optocouplers and then controlled by an OR gate to turn the field-effect transistor QJS1 on and off. When one or more unlock / lock signals are high, the OR gate outputs a high level, the field-effect transistor turns on, and the current of JSGD-28V flows through the brake, the field-effect transistor, and the sampling resistor R223 in sequence. The brake is unlocked as current flows through it, and the voltage drop across the sampling resistor R223 is approximately 3V. The comparator outputs a high-level unlock feedback signal to the digital circuit. When both unlock / lock signals of the two channels are low, the field-effect transistor turns off, and the brake locks.

[0063] Alternatively, the unlocking power supply circuit is not limited to, for example, Figure 11 As shown, UA1 and UA2 are DC / DC power modules with an input voltage range of 15V to 50V and an output voltage of 28V. This DC / DC ensures that the output voltage remains constant at 28V when the input voltage changes, providing a stable voltage for the brake. The output of UA1 passes through diode V19 to obtain power VP1-JS, and the output of UA2 passes through diodes V21 and V20 to obtain power VP2-JS. VP1-JS and VP2-JS are shorted to provide power to the brake. Since the voltage of VP1-JS is higher than that of VP2-JS, and the voltage of 12V-JSGD1 is higher than that of 12V-JSGD2, when both channels are working normally at the same time, only VP1-JS and 12V-JSGD1 in channel 1 provide power to the unlocking circuit.

[0064] The principle of brushless DC motor drivers is not limited to, for example Figure 12As shown, the bus voltage VP passes through the P-tube on / off control circuit and then through the bus filter energy storage capacitor to supply the three-phase power inverter circuit. This voltage is simultaneously converted to 12V to power the Hall signal processing circuit, gate drive circuit, current limiting circuit, and motor Hall effect sensor. The optocoupler receives the PWM signal, F / R signal, and enable signal. The PWM signal and F / R signal are isolated and output to the logic processing circuit, and the enable signal is isolated and output to the P-tube on / off control circuit. The Hall signal processing circuit comprehensively processes the motor Hall signal, forward / reverse signal, and current limiting signal, and outputs six control signals to the gate drive circuit. The gate drive circuit performs bootstrapping and push-pull outputs of the control signals of the upper bridge arm and push-pull outputs of the control signals of the lower bridge arm. The three-phase power inverter circuit sequentially switches the six MOSFETs on and off according to the six switching signals of the gate drive, transmitting power to the brushless DC motor and driving it to run.

[0065] Furthermore, the principle of the P-transistor on / off control circuit is not limited to, for example... Figure 13 As shown, when the enable signal EN' is high, the N-channel MOSFET QB1 turns on, and subsequently the P-channel MOSFET QB2 turns on, and the bus voltage VP is sent to the subsequent circuit after passing through the P-channel MOSFET; when the enable signal EN' is low, both QB1 and QB2 are turned off, and the power supply to the subsequent circuit is cut off.

[0066] Optical isolation circuits are not limited to, for example Figure 14 As shown, the PWM signal, F / R signal, and enable signal EN in the digital circuit are isolated and output, as follows: Figure 14 As shown, the isolation circuit for the PWM1 signal, F / R1 signal and enable signal EN1 in channel 1, the isolated PWM1' signal and F / R1' signal are sent to the logic processing circuit, and EN1' is sent to the P-tube on / off control circuit; through optocoupler isolation, the ground lines of the digital circuit and the driver can be separated to prevent fluctuations in the driver ground line from affecting the normal operation of the digital circuit.

[0067] The control logic processing circuit performs logical operations on the three-phase Hall signals (HA, HB, HC), speed control signal (PWM'), steering control signal (F / R'), and current limiting protection signal (XL'), and then outputs three-phase six-state control signals M1 to M6. The logic processing circuit for channel one is not limited to... Figure 15 As shown.

[0068] Gate drive circuits are not limited to, for example Figure 16As shown, the system mainly consists of a driver chip, a bootstrap circuit, and upper and lower bridge arm driver circuits. 1V1 (bootstrap diode) and 1C4 (bootstrap capacitor) constitute the bootstrap circuit, the parameters of which are related to factors such as switching frequency, duty cycle, and MOSFET gate capacitor charging time. 1R11, 1R12, 1V4 and 1R13, 1R14, 1V5 constitute the turn-on (turn-off) circuits for the upper and lower bridge arms, respectively. The drive resistor during turn-on is 1R11 (1R13); the drive resistor during turn-off is 1R11∥1R12 (1R13∥1R14). By adjusting the resistance values ​​of the drive resistors, the drive signal of the same bridge arm conforms to the principle of "turn-off first, turn-on later," avoiding shoot-through between the upper and lower bridge arms and burning out the power MOSFETs. The drive resistor values ​​are adjusted and improved according to the actual system requirements.

[0069] Current limiting circuits are not limited to, for example Figure 17 As shown, the sampling voltage XL1 in the three-phase power inverter circuit is compared with the set voltage value, and a protection feedback signal XL1' is output. The XL1' signal is ANDed with the PWM' signal to participate in the PWM modulation. The current limiting circuit has a hysteresis comparison function. When XL1' is high, there is a high current limiting value, and when XL1' is low, there is a low current limiting value.

[0070] The three-phase power bridge inverter circuit and sampling resistors are power-generating devices for the driver. To ensure good heat dissipation, they are designed onto an aluminum-based printed circuit board. The circuitry is not limited to... Figure 18 As shown, Q1 to Q6 are power MOSFETs, and their conduction sequence is: Q1Q2→Q2Q3→Q3Q4→Q4Q5→Q5Q6→Q6Q1→Q1Q2→……. When the switching signal is changed, the conduction sequence is reversed.

[0071] The Hall effect detection circuit outputs the three-phase Hall signals from the motor to the detection terminal of the signal processing circuit after voltage division and optocoupler isolation, providing a basis for motor position and speed detection. The circuit principle is not limited to this. Figure 19 As shown.

[0072] Furthermore, for the aforementioned Hall-detection dual-redundant multi-turn motion servo mechanism, servo control is not limited to the corresponding control methods.

[0073] The key to controlling a servo mechanism lies in solving the problems of position and speed detection based on Hall effect sensors, dual-redundancy collaborative operation, and fault diagnosis and handling during operation. Then, by combining the classic PID position loop and speed loop control methods, the control of the servo mechanism can be realized.

[0074] For Hall position and speed detection, the motor is designed as a dual-redundant three-phase six-pole eighteen-slot brushless DC motor. The three-phase Hall sensors are evenly distributed around the output shaft, and the commutation system is a two-phase conducting three-phase six-state system. The circuit principle is as follows: Figure 20As shown.

[0075] At any given moment, two power switches (MOSFETs or IGBTs) are on, commutating every 60° electrical angle, with one power switch commutating each time. Each power switch conducts for 120° electrical angle. Therefore, there are two conduction sequences: Conduction sequence 1 is: Q1Q2→Q2Q3→Q3Q4→Q4Q5→Q5Q6→Q6Q1→Q1Q2→……. Conduction sequence 2 is: Q2Q1→Q1Q6→Q6Q5→Q5Q4→Q4Q3→Q3Q2→Q2Q1→……. For ease of description, the state changes of the three-phase Hall effect sensors A, B, and C during clockwise rotation are: 001 → 011 → 010 → 110 → 100 → 101 → 001, corresponding to conduction sequence 1. During counterclockwise rotation, the changes are: 001 → 101 → 100 → 110 → 010 → 011 → 001, corresponding to conduction sequence 2.

[0076] During one revolution of the motor in one direction, the six states of the three-phase Hall sensor repeat three times. Therefore, the Hall sensor signal can detect 18 state changes. After acquiring the three-phase Hall signals, the motor's position can be measured according to the state change patterns in both clockwise and counterclockwise directions. The measurement resolution of the Hall sensor is [insert resolution here]. Corresponding angle Therefore, it can be seen that when the motor runs to any position within the range of [N, N+20)° (N∈[0, 360)°), the sampled position is the same value, thus exhibiting a discontinuity in position. Since speed is the ratio of position increment to the time to reach that increment, speed also exhibits a discontinuity.

[0077] The fundamental reason for the discontinuity in position and speed lies in the insufficient resolution of the Hall sensor itself. The angle data of the motor during the Hall state change process is discarded due to insufficient resolution, similar to the "truncation" operation in the process of converting floating-point numbers to integers. At high speeds, the impact is lower because the base number is large, but at low speeds, the impact is greater because the base number is small. Therefore, finding a suitable method to reconnect the lost "tail" in this process can reduce the fluctuations caused by the insufficient resolution of the Hall sensor. Considering that the motor can be regarded as a second-order inertial element with continuously differentiable velocity, the motor position can be predicted based on existing motion data within a short time period. The closer the predicted value is to the actual value, the better the accuracy of the obtained speed, and the higher the control quality of the control loop.

[0078] Considering factors such as prediction accuracy, computational load, and system control margin, the servo mechanism uses a weighted moving average filter to process the motor speed. The processing procedure is as follows: a) Select a time window n, and record the velocity values ​​within the first n-1 calculation cycles, denoted as . ; b) If the Hall state changes during the current calculation cycle, then calculate the velocity value for the current velocity calculation cycle (denoted as...). This is used as the speed value for the current calculation cycle; c) If the Hall state remains unchanged during the current calculation period, the average rate of change of velocity is calculated using the least squares method and denoted as... In the formula, T is the time window for velocity calculation, which is the time window from the previous velocity calculation value. Based on this, the product of the average rate of change of velocity and the calculation window time is added to obtain the velocity prediction value for the current calculation period, i.e. ; d) Remove the oldest speed record and add the latest speed record, updating the calculated speed values ​​in chronological order; e) After weighted filtering, the final calculated value is determined, i.e. K is the sliding filter factor. The smaller K is, the smoother the speed, but the smaller K is, the greater the phase delay of the control loop. f) Repeat process a) ~ e).

[0079] For dual-redundancy coordinated control, the lack of coordination in dual-redundancy operation mainly manifests as a lack of coordination in motor control, which is reflected in two aspects: One issue is the coordination problem, with two typical operating conditions: one is that the motor uses a dual-redundant slotted cross-winding method. Therefore, during operation, the electromagnetic forces generated by each dual-redundant winding act on the motor output shaft. When the dual-redundant windings are working simultaneously, the motor output shaft moves along the direction of the electromagnetic resultant force of the dual-redundant windings. If the electromagnetic resultant force of the dual-redundant windings is 0, that is, the electromagnetic forces of the two sets of windings cancel each other out, the motor cannot rotate normally. The other is that when one set of windings is working normally, the other set of windings is not energized but any two phases are short-circuited. At this time, due to the phase-to-phase short circuit, a large induced magnetic field will be generated. During the commutation process of the normally operating winding, when the direction of the induced magnetic field is inconsistent with the direction of the magnetic field of the short-circuited winding, the induced magnetic field will generate a large braking torque on the motor output shaft, eventually causing the motor to stop.

[0080] On the other hand, there is the issue of speed coordination. A typical working condition is that the motion commands sent by the host computer to the servo mechanism are different. Assuming that the primary redundancy receives the command first and acts first, while the backup redundancy receives the command later, since the output of the motor's dual windings is coaxial, the motor output shaft has already started moving or even moving at a relatively high speed. In this case, the backup redundancy will interfere with the primary redundancy by controlling it according to the zero starting state after receiving the command, resulting in unstable motor movement.

[0081] From the working principle of the servo mechanism, the information processing circuit collects the Hall sensor signal, receives the host computer instruction and decides to control the direction and speed of the motor. The signal to control the motor is first sent to the drive module, amplified by the drive module and then output to the motor. Therefore, the motor speed and direction are logically controlled by the signal processing circuit, and behaviorally controlled by the motor drive module.

[0082] The working principle of the motor drive module is not limited to, for example Figure 21 As shown, the module receives pulse width modulation (PWM) control signals and forward / reverse control signals (F / R) from an external controller. It then performs logic operations based on the three-phase position Hall signals (Sa, Sb, and Sc) output by the brushless DC motor to output three-phase six-state control signals. These signals control the alternating conduction of six power switches (MOSFETs or IGBTs) in the subsequent stage, thereby controlling the brushless DC motor to rotate at different speeds and in different directions according to the externally supplied PWM and F / R signals.

[0083] from Figure 21 It can be seen that the control logic processing circuit is the core component for controlling the motor speed and direction. Therefore, it is necessary to further analyze the working principle of the control logic processing circuit, and not limited to... Figure 22 As shown. From Figure 22 It can be seen that the PWM signal and the current limiting signal DL are ANDed together with the output signal after being synthesized by the front-end F / R and HA', HB', HC' logic. When the PWM signal is high, the power transistor is turned on; when the PWM signal is low, the power transistor is turned off. Therefore, the PWM signal only determines the turn-on time of the power transistor, but does not determine which group of power transistors is turned on. As can be seen from the analysis in Section 3.1.1, the core factor determining the direction of motor rotation is the conduction sequence of the power transistors. Therefore, a core conclusion of the drive module control can be drawn: the direction of motor rotation is determined by the F / R signal, and the speed of motor rotation is determined by the duty cycle of the PWM signal.

[0084] In summary, to achieve coordinated control of a dual-redundant motor, it is only necessary to coordinate the F / R signals and the three-phase Hall signals. The three-phase Hall signals are determined by the installation method of the motor's Hall sensors. Therefore, during motor production, it is crucial to strictly ensure the synchronization of the Hall signals corresponding to the same windings in both redundancies. Specifically, the primary redundant Hall signal HA and the backup redundant Hall signal HA should be output synchronously; the primary Hall signal HB and the backup Hall signal HB should be output synchronously; and the primary Hall signal HC and the backup Hall signal HC should be output synchronously. This ensures the synchronization of the Hall signals. The F / R signal is determined by the host computer signal. When the host computer requests clockwise movement, the F / R signal outputs a high level; when it requests counter-clockwise movement, the F / R signal outputs a low level. The signal processing circuit can receive the host computer command and output the F / R signal as required. This solves the problem of coordinated movement direction of the dual-redundant motor.

[0085] To address the issue of speed incoordination between the two redundancies, considering that although the motor adopts a dual-winding, dual-Hall design, the output shaft is coaxial, once one redundancy starts working, the other redundancy can detect the movement position and speed of the motor output shaft. Therefore, during the period when one redundancy has received a command and started moving, but the other redundancy has not yet received a command, the redundancy that has not received a command will be controlled in a follow-up mode. That is, even though no command has been received from the host computer, once the other redundancy is detected to have started moving and its speed is stable, it will operate as if it has received a command from the host computer. In this way, after receiving a command from the host computer, the two redundancy control loops can achieve speed coordination.

[0086] For fault diagnosis and handling, the main purpose of fault handling is to promptly and effectively isolate the faulty channel or component in the system after a fault occurs, reconstruct the remaining usable system resources, form a new working mode to continue working, maximize the redundancy characteristics, and improve the system's task reliability and operational reliability.

[0087] The drive unit features a channel-level redundancy design. If any channel experiences a single point of failure, that channel will be unable to continue operating. Therefore, in order for the drive unit to continue operating normally, it is necessary to block the faulty channel when any fault occurs.

[0088] In this embodiment, the Hall effect detection-based dual-redundant multi-turn motion servo mechanism and control method achieve coordinated control between the two redundancies, ensuring smooth operation even without electrical interconnection. It also allows for high-speed and low-speed adjustment of the servo motor's operating speed as needed, accommodating both rapid start-up and rapid stop characteristics. Under normal conditions, the two redundancies operate collaboratively, maximizing system efficiency. In the event of a fault, the faulty redundancy exits operation, releasing control authority, while the normal redundancy continues operation, improving the product's task reliability and maximizing the efficiency of the redundant servo mechanism. The solution is simple, feasible, highly reliable, technically superior, and cost-effective. Example

[0089] In another aspect, the present invention provides an electronic device for implementing the above-described servo control method. This electronic device is not limited to a terminal device or server in a system. The electronic device includes, but is not limited to, a memory and a processor. The memory stores a computer program, and the processor is configured to execute the steps of any of the above-described method embodiments via the computer program. Example

[0090] In another aspect, a computer program product or computer program is provided, comprising computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the methods provided in various optional embodiments of the above-described servo control method. The computer program is configured to execute the steps of any of the above-described method embodiments during runtime.

Claims

1. A Hall effect detection type dual-redundant multi-turn motion servo mechanism, characterized in that, include: A drive control box and an actuator; the actuator includes a motor and a reduction gear mechanism; The drive control box and the motor adopt a dual-redundancy design, forming two independent working channels; during operation, both redundancies work simultaneously, and the redundancy where the fault occurs stops working after a fault occurs.

2. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 1, characterized in that, The drive control box includes a DC-DC power module and a signal processing circuit. The DC-DC power module and the signal processing circuit are divided into two groups: a main group and a backup group. The two power supplies of the control system are respectively connected to the main group and the backup group of DC-DC power modules. The two RS422 buses of the control system are respectively connected to the main group and the backup group of signal processing circuits.

3. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 2, characterized in that, The drive control box also includes a motor driver, which is divided into two groups: a main group and a backup group. The main and backup groups of motor drivers are respectively connected to the main and backup groups of motors of the actuator. The main and backup groups of motor drivers are respectively connected to the main and backup groups of DC-DC power modules and the main and backup groups of signal processing circuits.

4. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 1, characterized in that, The actuator includes two sets of brushless DC motors (main and backup) and a single-redundant reduction mechanism. Both sets of brushless DC motors are connected to the reduction mechanism via motor locks.

5. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 2, characterized in that, Each power supply of the control system is divided into two paths: one path is connected to a DC-DC power module for conversion and power supply to other circuits, and the other path is connected to the motor driver for power supply.

6. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 2, characterized in that, The motion control signal sent by the host computer is connected to the signal processing circuit via the RS422 bus. After being analyzed by the signal processing circuit and processed by the logic processing circuit, the unlock signal and control signal are output to the motor driver in sequence. After passing through the motor driver, the motor is unlocked and rotated.

7. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 6, characterized in that, The rotational motion of the motor is transmitted through the reduction mechanism and converted into the rotational motion of the output shaft. After the motor rotates, the Hall sensor detects the position information of the motor and outputs it to the signal processing circuit. The signal processing circuit analyzes and processes the Hall signal to obtain the number of rotations and the rotational speed, and outputs the control signal of the motor driver to adjust the motor speed and direction.

8. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 6, characterized in that, After the motor reaches its designated position, the signal processing circuit cuts off its output, the motor stops, and the motor lock engages, thus achieving position locking.

9. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 6, characterized in that, The logic processing circuit receives instructions from the host computer and converts them into forward / reverse signals, unlock signals, enable signals, or motor speed signals.

10. The Hall-detection type dual-redundant multi-turn motion servo mechanism as described in claim 6, characterized in that, The signal output by the logic processing circuit is transmitted to the motor driver through a level conversion circuit, wherein the level conversion circuit is used to convert between signals of different voltage levels.

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