Multi-channel intelligent motor control system

Abstract

The application relates to the technical field of motor control, in particular to a multi-path intelligent motor control system. The system comprises a master station, a slave station, intelligent motors, a communication module and a power supply unit; the master station is the core of system control, is used for sending control instructions, receiving feedback data and managing system operation states, and a configuration state display screen is used for displaying system operation parameters and fault information; the slave station is in communication connection with the master station, is used for forwarding the control instructions of the master station to the intelligent motors, and collecting the operation data and fault parameter feedback of the intelligent motors to the master station; the application has the beneficial effects that: the control capacity is large and expandable; through the hierarchical architecture of the master station and the slave station, the centralized control of a maximum of 16 slave stations and 512 intelligent motors is supported, the multi-stage cascade can further expand the control quantity, and the demand of a multi-electric field scene is met; the control precision is high, and the synchronization is good; the intelligent motor is configured with a 2048-line magnetic encoder and a maximum 256-subdivision driving structure, and is combined with the 0-bit calibration function of the slave station.

Description

Technical Field

[0001] This invention relates to the field of motor control technology, and in particular to a multi-channel intelligent motor control system. Background Technology

[0002] Existing motor control systems often suffer from limitations such as a limited number of controlled motors, poor synchronization, insufficient control precision, limited operation methods, and a wide range of impacts from malfunctions. In scenarios such as advertising screen driving, robot joint control, and automated production lines in smart factories, precise synchronous control of multiple motors is required simultaneously, along with support for remote operation and independent fault feedback. Traditional control systems struggle to meet these multi-dimensional demands. For example, double-sided rotating advertising screens require multiple motors to coordinate screen switching, and existing systems are prone to issues like asynchronous switching and inaccurate angle control. The joint movements of multi-motor robots require high coordination, and communication delays in traditional control systems can lead to motion stuttering. Furthermore, multi-stage motor control in smart factories places high demands on system scalability and remote management capabilities.

[0003] Therefore, a control system that can achieve precise synchronous control of multiple motors, support multiple operating modes, and has high reliability is needed. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-channel intelligent motor control system to solve the problems of limited number of motors to be controlled, poor synchronization, single operation mode and wide range of fault impact in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a multi-channel intelligent motor control system, comprising a master station, slave stations, intelligent motors, a communication module, and a power supply unit; the master station is the system control core, used to send control commands, receive feedback data, and manage the system's operating status, and is configured with a status display screen to display system operating parameters and fault information; the slave stations are communicatively connected to the master station, used to forward master station control commands to the intelligent motors, and collect intelligent motor operating data and fault parameters to feed back to the master station; each slave station can connect to up to 32 intelligent motors, and the system supports up to 16 slave stations. The intelligent motor is a stepper or servo closed-loop intelligent motor with CAN / RS485 bus communication, equipped with a 2048-line magnetic encoder and a drive structure with a maximum of 256 microsteps, used to achieve precise control of angle and speed, and has an independent fault feedback function; the communication module includes an RS485 communication unit, a CAN bus communication unit, a USB local communication unit, and a 4G remote communication unit, which respectively realize communication connections between the master station and the slave station, the slave station and the intelligent motor, the local device and the master station, and the master station and the cloud; the power supply unit provides a stable DC24V power supply for all components of the system.

[0006] As a further aspect of the present invention, the master station and slave stations establish a connection through an RS485 communication unit, setting up 16 communication nodes. The master station sends control data using a broadcast packet method, with each packet containing valid data covering the corresponding intelligent motor control parameters of all slave stations. Calculated at 2 bytes per motor, the number of valid data bytes per packet is 1024 bytes. After including auxiliary bytes, the data per packet is calculated as 1200 bytes. Combined with a baud rate of 19200bps, the data transmission latency is low, ensuring synchronous operation of multiple motors with no noticeable asynchrony perceived by the human eye. After sending the broadcast data, the master station waits for responses from each slave station, with a data update frequency of 2 seconds.

[0007] As a further embodiment of the present invention, the slave station and the intelligent motor are connected through a CAN bus communication unit or an RS485 communication unit, with 32 communication nodes set up. The maximum data packet size is 16 bytes, ensuring strong real-time performance. The slave station stores the calibration 0-position angle value of the corresponding 32 intelligent motors. The intelligent motors adjust their rotation angle based on the 0-position angle value to ensure control accuracy.

[0008] As a further embodiment of the present invention, the USB local communication unit is located at the main station and can be connected to a computer host computer to realize functions such as timed angle setting, calibrated angle adjustment, fault monitoring feedback, real-time time calibration and timed setting; at the same time, it can be connected to a wireless adapter module to support wireless control through devices such as computers and mobile phones.

[0009] As a further embodiment of the present invention, the 4G remote communication unit adopts a 4G, CAT1 module to establish a communication connection between the main station and the cloud. Users can log in to the cloud through any networked device (computer, mobile phone, etc.) to achieve remote control, and the operation effect is the same as that of local operation.

[0010] As a further aspect of the present invention, the system also includes an account management module, which sets up multi-level operation permission accounts, including manufacturer accounts, user administrator accounts, and user operator accounts; the manufacturer account has the highest permissions and can remotely turn the device off, on, and lock its operation; the user administrator account and the user operator account perform corresponding operations according to preset permissions to ensure the security of system use.

[0011] As a further aspect of the present invention, the fault parameters of the intelligent motor are fed back to the slave station via CAN bus or RS485 communication, and then fed back to the master station by the slave station, so as to realize real-time fault reporting; when a single intelligent motor fails, it does not affect the operation of other intelligent motors and the overall system, thereby improving system reliability.

[0012] The beneficial effects of this invention are as follows:

[0013] Large and scalable control capacity: Through a hierarchical architecture of master station and slave station, it supports centralized control of up to 16 slave stations and 512 smart motors. Multi-level cascading can further expand the number of controls to meet the needs of multi-motor scenarios.

[0014] High control precision and good synchronization: The intelligent motor is equipped with a 2048-line magnetic encoder and a drive structure with a maximum of 256 microsteps. Combined with the slave station 0-position calibration function, it can achieve precise control of angle and speed. The master station broadcast packet communication method, combined with low-latency transmission, ensures that multiple motors operate synchronously, and the human eye can not perceive any obvious asynchrony.

[0015] Flexible operation: Supports USB local wired control, wireless adapter control and 4G remote cloud control to meet the operation needs of different scenarios, and is convenient and efficient to operate;

[0016] High reliability: Individual intelligent motor failures are reported independently without affecting the overall system operation; multi-level account access management ensures system security, and the manufacturer's account can remotely control the equipment, improving the convenience of operation and maintenance;

[0017] It has a wide range of applications: it can be adapted to various scenarios such as double-sided flip advertising screens, multi-motor robots, and intelligent factory automated production lines, and can realize multiple functions such as programmed control, timing control, and synchronous control of motors, making it highly practical.

[0018] Obviously, based on the above description of the present invention, and according to common technical knowledge and conventional methods in the field, various other modifications, substitutions or alterations can be made without departing from the basic technical concept of the present invention.

[0019] The following detailed embodiments further illustrate the above-described content of the present invention. However, this should not be construed as limiting the scope of the present invention to the following examples. All technologies implemented based on the above-described content of the present invention fall within the scope of the present invention. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the present invention.

[0021] Appendix Label Reference Table:

[0022] 1. Master station; 2. Slave station; 3. Status display screen; 4. RS485 communication unit; 5. CAN bus communication unit; 6. USB local communication unit; 7. 4G remote communication unit; 8. Power supply unit; 9. Intelligent motor. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] To address the technical problems in the background section, the following multi-channel intelligent motor control system is proposed:

[0025] Combination Figure 1 As shown, the multi-channel intelligent motor control system provided by the present invention is characterized by comprising a master station 1, slave stations 2, intelligent motors 9, a communication module, and a power supply unit 8; the master station 1 is communicatively connected to at least one slave station 2, and the master station 1 and slave stations 2 establish a connection through an RS485 communication unit 4, setting 16 communication nodes; the master station 1 sends control data to all slave stations 2 using a broadcast packet method, with a single packet containing 1024 bytes of effective data, and after including auxiliary bytes, the data per packet is calculated as 1200 bytes; the data update frequency is 2 seconds; each slave station 2 is connected to at least one intelligent motor 9. The motor 9 is connected via communication; the communication module includes an RS485 communication unit 4, a CAN bus communication unit 5, a USB local communication unit 6, and a 4G remote communication unit 7. The slave station 2 establishes a connection with the intelligent motor 9 through the CAN bus communication unit 5 or the RS485 communication unit 4, setting up 32 communication nodes, with a maximum single packet data size of 16 bytes; the intelligent motor 9 is a stepper or servo closed-loop intelligent motor 9 with CAN / RS485 bus communication, configured with a 2048-line magnetic encoder and a maximum 256 microstepping drive structure, and the slave station 2 stores the corresponding mounted data. The system includes 32 intelligent motors 9 with calibrated 0-position angle values, which are used to adjust the rotation angle of the intelligent motors 9. The power supply unit 8 provides DC24V power to all components of the system. The USB local communication unit 6 is located at the master station 1 and is used to connect to a computer or wireless adapter module to realize functions such as timed angle setting, calibrated angle adjustment, fault monitoring feedback, real-time time calibration, and timed setting. The 4G remote communication unit 7 is a 4G / CAT1 module used to establish a communication connection between the master station 1 and the cloud, supporting remote execution of control commands consistent with local operation via networked devices. The system also includes an account management module, which sets up multi-level operation permission accounts, including manufacturer accounts, user administrator accounts, and user operator accounts. The manufacturer account has the authority to remotely close, open, and lock the device. The intelligent motors 9 are equipped with fault feedback units, which sequentially feed back fault parameters to slave stations 2 and master stations 1 via CAN bus or RS485 communication. A fault in a single intelligent motor 9 does not affect the normal operation of other components. The master station 1 is equipped with a status display screen 3 to display the system operating status, motor operating parameters, and fault information.

[0026] Working principle and usage process of this invention:

[0027] The system's operation process is divided into five core stages, each logically connected and operating in a closed loop, as detailed below:

[0028] System initialization phase: After the DC24V power supply is connected, the master station and slave station will sequentially self-check the hardware (such as 4G module, communication interface) and motor connection status, and a fault pop-up window will be displayed in real time.

[0029] Control parameter setting stage: Access the parameter module locally (USB / wireless connection) or remotely (4G cloud), select the control mode (programmed / timed / synchronous speed change), configure parameters such as angle, speed, and time, and store and feed back the data from the slave station after sending it down, and synchronize the status with the cloud.

[0030] Motor operation control phase: Supports manual control (temporary operation of single / group / all motors), automatic control (operation according to preset timing / program parameters, synchronization delay ≤0.2 seconds), and sensor linkage control (automatic execution of actions when trigger conditions are met), with the motor providing feedback on its position status after the action.

[0031] Operation monitoring and fault handling phase: Real-time monitoring of motor angle / speed (out of range is marked in red) and communication status (interruption prompt), data is synchronized to the local screen and the cloud; in case of fault (motor stall / slave station failure, etc.), the faulty motor is independently reported and stopped without affecting other equipment, the master station pop-up window + remote notification, non-fatal faults of the master station can be operated locally, and the slave station is in standby for repair in case of fatal faults.

[0032] System shutdown phase: can be manually (emergency / normal shutdown), timed (automatic and smooth shutdown at the designated time), or remotely (manufacturer / administrator privilege operation). Emergency shutdown cuts off power instantly, normal shutdown decelerates according to the procedure, and locked shutdown requires unlocking by the manufacturer.

[0033] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0035] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

[0036] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-channel intelligent motor control system, characterized in that, The system includes a master station (1), slave stations (2), intelligent motors (9), a communication module, and a power supply unit (8). The master station (1) is connected to at least one slave station (2), and each slave station (2) is connected to at least one intelligent motor (9). The communication module includes an RS485 communication unit (4), a CAN bus communication unit (5), a USB local communication unit (6), and a 4G remote communication unit (7). The power supply unit (8) provides DC24V power to each component of the system.

2. The multi-channel intelligent motor control system according to claim 1, characterized in that, The master station (1) and the slave station (2) establish a connection through the RS485 communication unit (4), and set up 16 communication nodes. The master station (1) sends control data to all slave stations (2) in the form of broadcast packets. The effective data bytes of a single packet are 1024 bytes. After the auxiliary bytes are included, the data of a single packet is calculated as 1200 bytes. The data update frequency is 2 seconds.

3. The multi-channel intelligent motor control system according to claim 2, characterized in that, The slave station (2) and the intelligent motor (9) establish a connection through the CAN bus communication unit (5) or the RS485 communication unit (4), with 32 communication nodes set up and a maximum single packet data of 16 bytes; the intelligent motor (9) is a stepper or servo closed-loop intelligent motor (9) with CAN / RS485 bus communication, configured with a 2048-line magnetic encoder and a maximum 256 microstepping drive structure.

4. The multi-channel intelligent motor control system according to claim 3, characterized in that, The slave station (2) stores the calibration 0-position angle values ​​of the 32 smart motors (9) attached to it, and adjusts the rotation angle of the smart motors (9) based on the 0-position angle values.

5. The multi-channel intelligent motor control system according to claim 1, characterized in that, The USB local communication unit (6) is located at the main station (1) and is used to connect to a computer host computer or a wireless adapter module to realize the functions of timing angle setting, calibration angle adjustment, fault monitoring feedback, real-time time calibration and timing time setting.

6. The multi-channel intelligent motor control system according to claim 5, characterized in that, The 4G remote communication unit (7) is a 4G-CAT1 module, used to establish a communication connection between the main station (1) and the cloud, and supports remote execution of control commands consistent with local operation through networked devices.

7. The multi-channel intelligent motor control system according to claim 1, characterized in that, It also includes an account management module, which sets up multi-level operation permission accounts, including manufacturer accounts, user administrator accounts, and user operator accounts. The manufacturer account has the authority to remotely shut down, open, and lock the device.

8. The multi-channel intelligent motor control system according to claim 1, characterized in that, The intelligent motor (9) is equipped with a fault feedback unit, which feeds back the fault parameters to the slave station (2) and the master station (1) in sequence via CAN bus or RS485 communication. The fault of a single intelligent motor (9) does not affect the normal operation of other components.

9. The multi-channel intelligent motor control system according to claim 8, characterized in that, The main station (1) is equipped with a status display screen (3) to display the system operating status, motor operating parameters and fault information.

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