Electromechanical actuation system and redundancy management method

Abstract

The application provides an electromechanical actuating system and a redundancy management method. The electromechanical actuating system comprises a filtering module, a secondary power conversion module, a bus interface, a main control module, a power drive module and an actuator, wherein the filtering module comprises EMI filter 1, EMI filter 2, EMI filter 3 and EMI filter 4; the secondary power conversion module comprises secondary power conversion module 1 and secondary power conversion module 2; the main control module comprises main control module 1 and main control module 2; the power drive module comprises power drive module 1 and power drive module 2; and the actuator comprises motor winding 1, motor winding 2, a motor position sensor, a speed reducer, an actuator position sensor and a ball screw.

Description

Technical Field

[0001] This invention belongs to the field of redundant electromechanical actuator servo system control technology, specifically relating to an electromechanical actuator system and a redundancy management method. Background Technology

[0002] Existing dual-redundant control electromechanical actuators generally only use master-slave switching, which may mean that the master channel or a single winding of the master-redundant motor is always working. If a single winding fails, switching is necessary, and the switching time will lead to low product efficiency, low reliability, and affect product safety. For products that achieve redundancy switching by adding or removing monitoring modules, from a control perspective, this increases the complexity of product control. At the same time, if the monitoring module fails, the product will lose the function of switching between dual redundancies. Summary of the Invention

[0003] This application provides an electromechanical actuation system and a redundancy management method, which can solve the problem of high complexity in switching between dual redundancies.

[0004] In a first aspect, this application provides an electromechanical actuation system, which includes a filtering module, a secondary power conversion module, a bus interface, a main control module, a power drive module, and an actuator, wherein:

[0005] The filtering module includes EMI filter 1, EMI filter 2, EMI filter 3, and EMI filter 4. The secondary power conversion module includes secondary power conversion module 1 and secondary power conversion module 2; The main control module includes main control module 1 and main control module 2; The power drive module includes power drive module 1 and power drive module 2; The actuator includes motor winding 1, motor winding 2, motor position sensor, reducer, actuator position sensor, and ball screw.

[0006] Specifically, the bus interface is located on the main control module and uses the bus control module that comes with the digital signal processor. The input of the bus interface is connected to the upper-level system via a communication cable, and the output of the bus interface is connected to the digital signal processor.

[0007] Specifically, EMI filter 3, EMI filter 4, secondary power conversion module 1, and secondary power conversion module 2 are connected to the machine via power cables. The inputs of EMI filter 3 and EMI filter 4 are connected to the two 28V power supplies on the machine. The outputs of EMI filter 3 and EMI filter 4 are connected to secondary power conversion module 1 and secondary power conversion module 2. The secondary power conversion modules are connected to the main control board, driver board, interface circuit, sensors, etc., to provide them with power.

[0008] Specifically, EMI filter 1 and EMI filter 2 are connected to the two 400V power supplies on the machine via power cables, and the outputs of the filter modules are connected to power drive module 1 and power drive module 2.

[0009] Specifically, the main control module and the drive module are connected via an inter-board connector, and the drive module and the motor are connected via cables. The motor integrates a temperature sensor, a brake, and a motor position sensor. The motor and the reducer are connected by a gear shaft and secured with screws. The reducer and the actuator position sensor are connected by a gear shaft and secured with screws. The reducer and the lead screw are connected by a gear shaft and secured with screws. Secondly, this application provides a redundancy management method, applied to the aforementioned electromechanical actuation system, the method comprising: Step 1: After the electromechanical actuation system is powered on, it enters signal monitoring and judges the validity of the servo monitoring signals. If all servo monitoring signals are valid, the electromechanical actuation system enters normal operation mode; if any servo monitoring signal is invalid, the electromechanical actuation system enters fault handling mode. Step 2: After the system enters normal working mode, it checks the enable signal. If the enable signal is valid, it enters the main channel for normal operation. If the enable signal is invalid, it does not work and waits for the enable signal. Step 3: When the system enters the main channel for normal operation, if any drive module signal is invalid, any motor winding signal is invalid, any motor position sensor signal is invalid, or any actuator position sensor signal is invalid, then the system enters the main channel one-time fault operation mode. Step 4: When the system is in the main channel first-failure working mode, if a second failure occurs, it will enter the backup channel working mode. Step 5: When the system enters the backup channel for normal operation, if any drive module signal is invalid, any motor winding signal is invalid, any motor position sensor signal is invalid, or any actuator position sensor signal is invalid, then the system enters the backup channel one-time fault operation mode. Step 6: If a secondary fault occurs while the system is operating under backup channel failure, it will enter fail-safe mode.

[0010] Specifically, the servo monitoring valid signal is valid when the main control module 1 and main control module 2 detect that the bus interface circuit signal, the self-monitoring signal of main control module 1, the self-monitoring signal of main control module 2, the monitoring signal of power drive module 1, the monitoring signal of power drive module 2, and the actuator monitoring signal are all valid. Invalid servo monitoring signal includes: if any one of the bus interface circuit signal, main control module 1 self-monitoring signal, main control module 2 self-monitoring signal, power drive module 1 monitoring signal, power drive module 2 monitoring signal, or actuator monitoring signal is invalid, then the servo monitoring signal is invalid.

[0011] Specifically, normal working mode: The control signal of the main working channel is enabled by default, and the control signal of the backup working channel is disabled. At this time, the enable signal of the main working channel is enabled, and the main working channel is working. At this time, the main control module 1 is working, the power drive module 1 and the power drive module 2 are working at the same time, the motor winding 1 and the motor winding 2 are working at the same time, and each motor winding outputs half of the rated load and the rated speed.

[0012] Specifically, the main channel's single-failure operating mode: For the main working channel, if any drive module signal is invalid, a single drive module ensures the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed. If any motor winding signal is invalid, a single motor winding ensures the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed. If the motor position sensor signal is invalid, the actuator position sensor is used for contactless control to ensure the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed. If the actuator position sensor signal is invalid, the actuator position is calculated using the motor position sensor for electromechanical actuation system control, ensuring the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed.

[0013] Specifically, the backup channel operating mode: For the standby channel, when the main control module 2 monitors the bus interface circuit monitoring signal, the main control module 2 self-monitoring signal, the power drive module 1 monitoring signal, the power drive module 2 monitoring signal, and the actuator monitoring signal, all of which are valid, the servo monitoring signal is valid and the standby channel is working. When the main control module 2 is working, the power drive module 1 and the power drive module 2 work simultaneously, and the motor winding 1 and the motor winding 2 work simultaneously. Each motor winding outputs half of the rated load and the rated speed.

[0014] In summary, this application provides an electromechanical actuation system and a redundancy management method, enabling the actuator servo control circuit to still output rated load and rated speed even in the event of a single fault, ensuring normal product operation and improving the reliability and safety of the actuator. Even with a single main control module, a single power drive module, or a single motor winding failure, rated load and rated speed can still be output, ensuring normal product operation. This application firstly avoids prolonged operation of single windings and single power drive modules, extending product lifespan. Secondly, in the event of a single winding or single power drive module failure, only the faulty power drive module needs to be disconnected, while the other continues to operate normally, ensuring that the output force and average operating speed of the electromechanical actuation system remain unchanged, allowing the product to operate normally and improving its efficiency and reliability. Attached Figure Description

[0015] Figure 1 A schematic diagram of an electromechanical actuation system provided by the present invention; Figure 2 This is a schematic diagram of an electromechanical actuation system and redundancy management method provided by the present invention. Detailed Implementation

[0016] Example 1 like Figure 1 As shown, the present invention provides an electromechanical actuation system including a filtering module, a secondary power conversion module, a bus interface, a main control module, a power drive module, and an actuator, wherein: The filtering module includes EMI filter 1, EMI filter 2, EMI filter 3, and EMI filter 4. The secondary power conversion module includes secondary power conversion module 1 and secondary power conversion module 2; The main control module includes main control module 1 and main control module 2; The power drive module includes power drive module 1 and power drive module 2; The actuator includes motor winding 1, motor winding 2, motor position sensor, reducer, actuator position sensor, and ball screw.

[0017] Specifically, the bus interface is located on the main control module and uses the bus control module built into the digital signal processor. The input of the bus interface is connected to the upper-level system via a communication cable, and the output of the bus interface is connected to the digital signal processor. Specifically, there are EMI filters 3 and 4, secondary power conversion module 1, and secondary power conversion module 2. The inputs of EMI filters 3 and 4 are connected to two 28V power supplies on the machine via power cables. The outputs of EMI filters 3 and 4 are connected to secondary power conversion module 1 and secondary power conversion module 2. The secondary power conversion modules are connected to the main control board, driver board, interface circuits, sensors, etc., to provide them with power. Specifically, EMI filter 1 and EMI filter 2. The inputs of EMI filter 1 and EMI filter 2 are connected to two 400V power supplies on the machine via power cables, and the outputs of the filter modules are connected to power drive module 1 and power drive module 2. The main control module and the drive module are connected via an inter-board connector. The drive module and the motor are connected via a cable. The motor integrates a temperature sensor, a brake, and a motor position sensor. The motor and the reducer are connected via a gear shaft and fastened with screws. The reducer and the actuator position sensor are connected via a gear shaft and fastened with screws. The reducer and the lead screw are connected via a gear shaft and fastened with screws.

[0018] Specifically, the core parameters are: (1) Dual power supply voltage Control power: DC28V (range: DC17~30V); Power supply: DC400V (range: DC300~415V output capacity not less than rated; DC240~300V output capacity not less than 80% of rated).

[0019] (2) Power Rated power supply per circuit: 1000W; Peak power supply per circuit: 2000W (1-2S); Dual-circuit rated power supply: 2000W; Dual-circuit peak power supply: 4000W (1-2S); Single-circuit rated control power: 30W; Dual-circuit rated control power: 40W.

[0020] (3) Main parameters of the motor a) Redundancy: Double redundancy; b) Rated power supply: 400VDC (240~415VDC, 300~415VDC output capacity not less than the rated, 240~300VDC output capacity not less than 80% of the rated). c) Number of pole pairs: 5; d) Rated speed (per winding): 5100 rpm; e) Rated torque (per winding): ≥1.58 N•m; j) Back EMF waveform: Sine wave; k) Rated efficiency: ≥85%.

[0021] It should be noted that the electromechanical actuation system of this application adopts a dual-redundant (dual control + dual drive) hot-hot backup architecture. It can realize dual-redundant control and main power drive.

[0022] a) The actuator is powered by two independent 400V high-voltage power supplies and two independent 28V low-voltage power supplies. When one power supply fails, the actuator must be kept running normally, the output force remains unchanged, and the average running speed remains unchanged (without degradation). b) Dual-channel CAN communication: When one channel fails, the actuator must be kept running normally, the output force must remain unchanged, and the average running speed must remain unchanged (without degradation). c) During normal operation, the main control module 1 controls the power drive module 1 and the power drive module 2, and drives the motor winding 1 and the motor winding 2 to work simultaneously, outputting the rated load (each winding outputs half of the rated load) and the rated speed. d) Two main control modules, main control module 1 and main control module 2 communicate with each other through CCDL. When main control module 1 fails, it switches to main control module 2 to work. It is necessary to ensure that the actuator is running normally, the output force remains unchanged, and the average running speed remains unchanged (without degradation). e) Two sets of windings and two power drive modules. When one motor winding / power drive module fails, the main control module 1 does not need to switch. It only needs to cut off the PWM wave of the faulty winding / power drive module to ensure that the other winding operates normally, the output force remains unchanged, and the average running speed is not less than 50% of the rated average speed.

[0023] Example 2 This application provides a detailed description of the working process of an electromechanical actuation system: When the electromechanical actuation system is working normally, after the power is turned on, the system first performs system initialization and power-on bit. When everything is normal, the electromechanical actuation system enters the standby state. When the communication bus control module of the digital signal processor in the controller receives the instruction from the upper-level system, the main control module integrates the instruction with the information from the actuator position sensor and the motor position sensor, and outputs the corresponding PWM waveform through the power drive module to control the two windings of the motor to output a certain speed and torque. The speed is converted into low-speed, high-torque motion by the reducer, and the ball screw nut pair converts the low-speed, high-torque motion into linear displacement, speed and output force.

[0024] like Figure 2 As shown, the present invention provides a redundancy management method for an electromechanical actuation system, comprising: Step 1: After the electromechanical actuation system is powered on, it enters signal monitoring and judges the validity of the servo monitoring signals. If all servo monitoring signals are valid, the electromechanical actuation system enters normal operation mode; if any servo monitoring signal is invalid, the electromechanical actuation system enters fault handling mode. Step 2: After the system enters normal working mode, it checks the enable signal. If the enable signal is valid, it enters the main channel for normal operation. If the enable signal is invalid, it does not work and waits for the enable signal. Step 3: When the system enters the main channel for normal operation, if any drive module signal is invalid, any motor winding signal is invalid, any motor position sensor signal is invalid, or any actuator position sensor signal is invalid, then the system enters the main channel one-time fault operation mode. Step 4: When the system is in the main channel first-failure working mode, if a second failure occurs, it will enter the backup channel working mode. Step 5: When the system enters the backup channel for normal operation, if any drive module signal is invalid, any motor winding signal is invalid, any motor position sensor signal is invalid, or any actuator position sensor signal is invalid, then the system enters the backup channel one-time fault operation mode. Step 6: If a secondary fault occurs while the system is operating under backup channel failure, it will enter fail-safe mode.

[0025] Specifically, valid servo monitoring signals include: When the main control module 1 and main control module 2 detect that the bus interface circuit signal, the self-monitoring signal of main control module 1, the self-monitoring signal of main control module 2, the monitoring signal of power drive module 1, the monitoring signal of power drive module 2, and the actuator monitoring signal are all valid, then the servo monitoring valid signal is valid.

[0026] Specifically, invalid servo monitoring signals include: If any one of the bus interface circuit signal, main control module 1 self-monitoring signal, main control module 2 self-monitoring signal, power drive module 1 monitoring signal, power drive module 2 monitoring signal, or actuator monitoring signal is invalid, then the servo monitoring signal is invalid.

[0027] The actuator monitoring signals include motor position sensor monitoring signals and actuator position sensor monitoring signals.

[0028] (1) Normal working (main channel) mode: The control signal of the main working channel is enabled by default, and the control signal of the backup working channel is disabled. At this time, the enable signal of the main working channel is enabled, and the main working channel is working. At this time, the main control module 1 is working, the power drive module 1 and the power drive module 2 are working at the same time, the motor winding 1 and the motor winding 2 are working at the same time, and each motor winding outputs half of the rated load and the rated speed.

[0029] (2) Main channel single-failure working mode: For the main working channel, if any drive module signal is invalid, a single drive module ensures the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed. If any motor winding signal is invalid, a single motor winding ensures the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed. If the motor position sensor signal is invalid, the actuator position sensor is used for contactless control to ensure the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed. If the actuator position sensor signal is invalid, the actuator position is calculated using the motor position sensor for electromechanical actuation system control, ensuring the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed.

[0030] (3) Backup channel working mode: For the standby channel, when the main control module 2 monitors the bus interface circuit monitoring signal, the main control module 2 self-monitoring signal, the power drive module 1 monitoring signal, the power drive module 2 monitoring signal, and the actuator monitoring signal (motor position sensor monitoring signal and actuator position sensor monitoring signal) as valid, the servo monitoring signal is valid and the standby channel is working; when the main control module 2 is working, the power drive module 1 and the power drive module 2 work simultaneously, and the motor winding 1 and the motor winding 2 work simultaneously, with each motor winding outputting half of the rated load and the rated speed.

[0031] (4) Backup channel failure working mode: For the standby working channel, if any drive module signal is invalid, a single drive module ensures the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed; if any motor winding signal is invalid, a single motor winding ensures the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed; if the motor position sensor signal is invalid, the actuator position sensor is used for contactless control to ensure the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed; if the actuator position sensor signal is invalid, the motor position sensor is used to calculate the actuator position for electromechanical actuation system control to ensure the normal operation of the electromechanical actuation system, maintaining constant output force and average operating speed.

[0032] (5) Fail-safe mode: The servo monitoring signals for the main working channel and the backup working channel are invalid, so neither the main working channel nor the backup working channel is working, and the system remains in the current position.

[0033] In summary, this application proposes a dual-redundant control and main-main-power-driven operating mode to achieve servo control. This ensures that the output force and average operating speed of the electromechanical actuation system's servo control loop remain constant even in the event of a single fault. The dual-redundant control and main-main-power-driven operating mode improves the reliability and safety of the electromechanical actuation system. It also proposes simultaneous operation of both windings of the dual-redundant motor, avoiding prolonged operation of a single winding and improving the motor's reliability and lifespan. Furthermore, it proposes a control method where the motor position sensor and actuator position sensor are mutually redundant. When the motor position sensor fails, the electromechanical actuation system uses the actuator position sensor for contactless control; when the actuator position sensor fails, the motor position sensor is used to calculate the actuator position for electromechanical actuation system control, further improving the reliability and safety of the electromechanical actuation system.

Claims

1. An electromechanical actuation system, characterized in that, The electromechanical actuation system includes a filtering module, a secondary power conversion module, a bus interface, a main control module, a power drive module, and an actuator, wherein: The filtering module includes EMI filter 1, EMI filter 2, EMI filter 3, and EMI filter 4. The secondary power conversion module includes secondary power conversion module 1 and secondary power conversion module 2; The main control module includes main control module 1 and main control module 2; The power drive module includes power drive module 1 and power drive module 2; The actuator includes motor winding 1, motor winding 2, motor position sensor, reducer, actuator position sensor, and ball screw.

2. The electromechanical actuation system according to claim 1, characterized in that, The bus interface is located on the main control module and uses the bus control module that comes with the digital signal processor. The input of the bus interface is connected to the upper-level system via a communication cable, and the output of the bus interface is connected to the digital signal processor.

3. The electromechanical actuation system according to claim 1, characterized in that, EMI filter 3, EMI filter 4, secondary power conversion module 1, and secondary power conversion module 2; the inputs of EMI filter 3 and EMI filter 4 are connected to two 28V power supplies on the machine via power cables, and the outputs of EMI filter 3 and EMI filter 4 are connected to secondary power conversion module 1 and secondary power conversion module 2. The secondary power conversion modules are connected to the main control board, driver board, interface circuit, sensors, etc., to provide them with power.

4. The electromechanical actuation system according to claim 1, characterized in that, EMI Filter 1 and EMI Filter 2 are connected to the machine's two 400V power supplies via power cables. The outputs of the filter modules are connected to Power Drive Module 1 and Power Drive Module 2.

5. The electromechanical actuation system according to claim 1, characterized in that, The main control module and the drive module are connected via an inter-board connector. The drive module and the motor are connected via a cable. The motor integrates a temperature sensor, a brake, and a motor position sensor. The motor and the reducer are connected via a gear shaft and fastened with screws. The reducer and the actuator position sensor are connected via a gear shaft and fastened with screws. The reducer and the lead screw are connected via a gear shaft and fastened with screws.

6. A redundancy management method, characterized in that, The method is applied to the electromechanical actuation system of claim 1, the method comprising: Step 1: After the electromechanical actuation system is powered on, it enters signal monitoring and judges the validity of the servo monitoring signals. If all servo monitoring signals are valid, the electromechanical actuation system enters normal operation mode; if any servo monitoring signal is invalid, the electromechanical actuation system enters fault handling mode. Step 2: After the system enters normal working mode, it checks the enable signal. If the enable signal is valid, it enters the main channel for normal operation. If the enable signal is invalid, it does not work and waits for the enable signal. Step 3: When the system enters the main channel for normal operation, if any drive module signal is invalid, any motor winding signal is invalid, any motor position sensor signal is invalid, or any actuator position sensor signal is invalid, then the system enters the main channel one-time fault operation mode. Step 4: When the system is in the main channel first-failure working mode, if a second failure occurs, it will enter the backup channel working mode. Step 5: When the system enters the backup channel for normal operation, if any drive module signal is invalid, any motor winding signal is invalid, any motor position sensor signal is invalid, or any actuator position sensor signal is invalid, then the system enters the backup channel one-time fault operation mode. Step 6: If a secondary fault occurs while the system is operating under backup channel failure, it will enter fail-safe mode.

7. The method according to claim 6, characterized in that, The servo monitoring signal is valid when the main control module 1 and main control module 2 detect that the bus interface circuit signal, the self-monitoring signal of main control module 1, the self-monitoring signal of main control module 2, the monitoring signal of power drive module 1, the monitoring signal of power drive module 2, and the actuator monitoring signal are all valid. Invalid servo monitoring signal includes: if any one of the bus interface circuit signal, main control module 1 self-monitoring signal, main control module 2 self-monitoring signal, power drive module 1 monitoring signal, power drive module 2 monitoring signal, or actuator monitoring signal is invalid, then the servo monitoring signal is invalid.

8. The method according to claim 7, characterized in that, Normal working mode: By default, the control signal for the main working channel is enabled, and the control signal for the standby working channel is disabled. At this time, the enable signal for the main working channel is enabled, and the main working channel is working. At this time, the main control module 1 is working, the power drive module 1 and the power drive module 2 are working simultaneously, the motor winding 1 and the motor winding 2 are working simultaneously, and each motor winding outputs half of the rated load and the rated speed.

9. The method according to claim 7, characterized in that, Main channel single-failure operating mode: For the main working channel, if any drive module signal is invalid, a single drive module ensures the normal operation of the electromechanical actuation system, with the output force and average running speed remaining unchanged; if any motor winding signal is invalid, a single motor winding ensures the normal operation of the electromechanical actuation system, with the output force and average running speed remaining unchanged. If the motor position sensor signal is invalid, the actuator position sensor is used for contactless control to ensure the normal operation of the electromechanical actuation system, with the output force and average running speed remaining unchanged. If the actuator position sensor signal is invalid, the actuator position is calculated using the motor position sensor to control the electromechanical actuation system, ensuring the normal operation of the electromechanical actuation system, maintaining constant output force and average running speed.

10. The method according to claim 7, characterized in that, Backup channel working mode: For the standby channel, when the main control module 2 monitors the bus interface circuit monitoring signal, the main control module 2 self-monitoring signal, the power drive module 1 monitoring signal, the power drive module 2 monitoring signal, and the actuator monitoring signal, all of which are valid, the servo monitoring signal is valid and the standby channel is working. When the main control module 2 is working, the power drive module 1 and the power drive module 2 work simultaneously, and the motor winding 1 and the motor winding 2 work simultaneously. Each motor winding outputs half of the rated load and the rated speed.

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