A brushless direct current motor driving control method, system, device and medium

Abstract

The application provides a brushless direct-current electric scissors driving control method, system, device and medium, and relates to the technical field of electric scissors control. The brushless direct-current electric scissors driving control method comprises the following steps: collecting multi-dimensional data of the brushless direct-current electric scissors and calling preset control parameters; after detecting a trigger signal of a trigger, identifying a preheating operation mode according to a battery temperature and two-stage preheating temperature thresholds, outputting a heating current to a motor winding through a driving bridge arm and dynamically adjusting a heating parameter, entering an allowed starting state after meeting an exit condition; fitting a battery equivalent internal resistance in a starting transient window, calculating an aging factor and adjusting a peak current upper limit, and executing a two-stage under-voltage protection in combination with two-stage under-voltage thresholds; calculating a battery health degree and an equivalent remaining cutting frequency, outputting state information and updating an operation record. The application can realize low-temperature preheating, aging self-adaptive adjustment and two-stage under-voltage protection, improve low-temperature starting reliability and reduce false shutdown.

Description

Technical Field

[0001] This invention relates to the field of electric shears control technology, and more specifically, to a brushless DC electric shears drive control method, system, device, and medium. Background Technology

[0002] As the application scenarios of lithium-ion handheld tools continue to expand, brushless DC electric shears, with their advantages of portability and work efficiency, are widely used in fields such as sheet metal processing and garden pruning. Existing brushless DC electric shears' battery drive systems typically only have basic overvoltage, overcurrent, overtemperature, and undervoltage hardware protection circuits, relying on fixed thresholds for battery safety management. To address the difficulty of starting at low temperatures, some solutions use an external heating film to raise the battery temperature, thereby improving discharge capacity in low-temperature environments.

[0003] However, in existing technologies, the peak current limit and undervoltage protection threshold are mostly fixed values, which cannot distinguish between transient voltage collapse caused by battery cycle aging and insufficient actual capacity. Under heavy load conditions, undervoltage protection is prone to frequent false triggering, resulting in situations where the battery still has remaining capacity but cannot complete the cutting operation. External heating film solutions require additional components and wiring, which will damage the sealed structure of the battery compartment, increasing hardware costs and structural design complexity. At the same time, conventional solutions only show users the remaining power percentage, which cannot reflect the true health status of the battery and the actual remaining working capacity, making users prone to battery power loss during operation. Summary of the Invention

[0004] The problem addressed by this invention is how to improve the efficiency of brushless DC electric shear drive control.

[0005] To address the aforementioned problems, this invention provides a brushless DC electric shear drive control method, system, device, and medium.

[0006] In a first aspect, the present invention provides a brushless DC scissor drive control method, comprising: The system collects data on the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and retrieves preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. After the trigger signal is detected, the system identifies whether to enter the preheating operation mode based on the cell temperature and the two-stage preheating temperature thresholds. In the preheating operation mode, the system outputs heating current to the motor windings through the drive bridge arm and adjusts the heating parameters with the set temperature rise rate as the target. After the preheating exit condition is met, the system enters the start-up allowed state. During the transient window of the brushless DC electric shear startup process in the allowed startup state, the bus voltage and the bus current are fitted to obtain the battery equivalent internal resistance; the aging factor is calculated based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, and the upper limit of the peak current is adjusted according to the aging factor; and graded undervoltage protection is performed based on the relationship between the bus voltage and the two-level undervoltage threshold. Based on the battery's equivalent internal resistance, remaining battery capacity, and battery lifespan determination threshold, calculate battery health and equivalent remaining shear cycles; output battery status information and update operation records; upon detecting a shutdown or completion of operation, enter standby loop process.

[0007] Optionally, after detecting the trigger signal, the preheating operation mode is identified and preheating control is initiated based on the cell temperature and the two-stage preheating temperature thresholds, including: When the trigger signal is detected, the cell temperature is compared with the preheating entry threshold in the two-stage preheating temperature threshold. If the cell temperature is lower than the preheating entry threshold, it is identified as entering the preheating operation mode and the preheating control is started. If the cell temperature is not lower than the preheating entry threshold, it directly enters the normal start-up process.

[0008] Optionally, in the preheating operation mode, outputting heating current to the motor windings through the drive bridge arm and adjusting the heating parameters with the set temperature rise rate as the target includes: In the preheating operation mode, the motor commutation logic is not executed. Two phases of the motor winding are selected, and the drive bridge arm switching transistors of the corresponding phases are controlled to conduct in a pulse manner, so that the heating current flows through the selected two phases of the motor winding to generate Joule heat. The energized winding phase combination is periodically rotated, and each energized phase maintains the energized phase rotation duration. When switching, all drive bridge arms are turned off first, and then the phase switching is performed. The duty cycle of the heating pulse is fed back with the real-time cell temperature rise rate, tracks the set temperature rise rate, and uses the winding temperature rise rate limit as the limiting condition.

[0009] Optionally, the step of fitting the bus voltage and the bus current to obtain the battery's equivalent internal resistance within the transient window of the brushless DC electric shears startup process includes: After entering the start-up allowed state, the brushless DC electric shears start up, and the bus current gradually increases from zero. During the transient window of the start-up process, multiple sets of corresponding sample points of the bus voltage and the bus current are continuously collected. The least squares method is used to linearly fit the bus voltage and the bus current to obtain the battery's equivalent internal resistance.

[0010] Optionally, the step of performing graded undervoltage protection based on the relationship between the bus voltage and the two undervoltage thresholds includes: During operation, the bus voltage is monitored in real time and compared with the two-level undervoltage thresholds to implement two-level undervoltage protection: when the bus voltage is lower than the soft undervoltage threshold, the peak current upper limit is lowered, and no shutdown is performed, maintaining operational continuity by reducing power; when the bus voltage is lower than the hard undervoltage threshold and the duration reaches the undervoltage determination time, shutdown protection is triggered; the soft undervoltage threshold is greater than the hard undervoltage threshold.

[0011] Optionally, the step of calculating battery health and equivalent remaining shear cycles based on the battery's equivalent internal resistance, the battery's remaining capacity, and the battery lifespan determination threshold includes: The full-charge open-circuit voltage and available peak value coefficient are retrieved from the preset control parameters. Using the full-charge open-circuit voltage as the reference voltage, and combining the percentage of the increase in the battery's equivalent internal resistance relative to the baseline internal resistance of the new battery at room temperature, the battery health is calculated. Using the remaining battery capacity as the basis for available capacity, and combining the battery health and the available peak value coefficient, the equivalent remaining shear cycles are calculated. The battery's equivalent internal resistance is compared with the battery life determination threshold to determine the corresponding battery health level.

[0012] Optionally, the output battery status information and update the operation record; upon detecting a shutdown or completion of the operation, a standby loop process is entered, including: The battery health level and the equivalent remaining shear count are output to the user via indicator lights or a display screen; if the aging factor exceeds the battery life judgment threshold, the battery replacement prompt signal is output simultaneously; the battery equivalent internal resistance, peak current upper limit and undervoltage trigger event record obtained during this operation are updated simultaneously and stored in the operation record of the main control microcontroller storage unit; If a hard undervoltage shutdown is triggered during operation, the operation record is updated and the system enters standby mode. If the shearing operation is completed normally and there is no new trigger signal, the system returns to standby mode and waits for the next trigger. In standby mode, the parameter acquisition and status monitoring process is executed cyclically.

[0013] In a second aspect, the present invention provides a brushless DC electric shear drive control system, comprising: The parameter acquisition and configuration module is used to acquire the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and to retrieve preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. The low-temperature preheating start-up module is used to detect the trigger signal and, based on the cell temperature and the two-stage preheating temperature thresholds, identify whether to enter the preheating operation mode; in the preheating operation mode, it outputs heating current to the motor windings through the drive bridge arm and adjusts the heating parameters with the set temperature rise rate as the target; after the preheating exit condition is met, it enters the start-up allowed state; The internal resistance identification and protection module is used to fit the bus voltage and the bus current within the transient window of the brushless DC electric shear startup process under the allowed startup state to obtain the battery equivalent internal resistance; calculate the aging factor based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, adjust the upper limit of the peak current according to the aging factor; and perform graded undervoltage protection according to the relationship between the bus voltage and the two-level undervoltage threshold. The health assessment and management module is used to calculate the battery health and equivalent remaining shear count based on the battery's equivalent internal resistance, remaining battery capacity, and battery life determination threshold; output battery status information and update the operation record; and enter the standby loop process when a shutdown or operation is completed.

[0014] Thirdly, the present invention provides an electronic device, including a memory and a processor; The memory is used to store computer programs; The processor is configured to implement the brushless DC scissor drive control method as described in the first aspect when executing the computer program.

[0015] Fourthly, the present invention provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the brushless DC scissor drive control method as described in the first aspect.

[0016] The beneficial effects of the brushless DC electric shear drive control method, device, equipment, and medium of the present invention are as follows: It collects the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shear; retrieves preset control parameters; clarifies the hardware architecture of the motor windings and drive bridge arm; and provides a unified data input and configuration basis for the entire process drive control. All operating status quantities are collected synchronously, and control parameters are retrieved uniformly. The sampling path of existing protection circuits can be directly reused without adding additional hardware acquisition modules, thus reducing hardware costs and structural design complexity. Upon detecting the trigger signal, the preheating operation mode is identified based on the cell temperature and the two-stage preheating temperature thresholds, and preheating control is initiated. In the preheating operation mode, a heating current is output to the motor windings via the drive bridge arm, and the heating parameters are adjusted with the set temperature rise rate as the target. After meeting the preheating exit conditions, the system enters the start-up allowed state. Under low-temperature conditions, the cell temperature can be raised by utilizing the heat generated by the motor windings themselves, eliminating the need for an external heating film and associated wiring, and preventing damage to the sealed structure of the battery compartment. The heating power is adjusted in a closed loop with the set temperature rise rate as the target, while also taking into account the winding temperature rise limit. This allows for rapid increase in battery temperature without overheating damage to components, solving the problem of start-up failure caused by increased cell internal resistance and insufficient discharge rate at low temperatures, and improving start-up reliability in low-temperature environments. Within the transient window of the brushless DC electric shears startup process, the equivalent internal resistance of the battery is obtained by fitting the bus voltage and the bus current. An aging factor is calculated based on the battery's equivalent internal resistance and the baseline of the new battery's room-temperature internal resistance. The upper limit of the peak current is adjusted according to the aging factor. Then, graded undervoltage protection is implemented based on the relationship between the bus voltage and the two-stage undervoltage thresholds. Internal resistance identification is completed using the window of natural current rise during startup, eliminating the need for actively injecting additional test pulses and preventing delays in normal startup response speed. The upper limit of the peak current is dynamically adjusted based on the real-time identified battery aging state, adapting to the discharge capacity of batteries with different aging levels and avoiding premature triggering of undervoltage protection under heavy loads. A two-stage progressive undervoltage protection mechanism is adopted: first, power reduction is used to maintain operational continuity, and then a shutdown is triggered as a fallback based on the duration of the shutdown. This effectively distinguishes between transient load fluctuations and actual capacity insufficiency, reducing false shutdowns under heavy load conditions and lowering the rate of meaningless fault repairs.Based on the battery's equivalent internal resistance, remaining battery capacity, and battery lifespan threshold, the battery health and equivalent remaining shear cycles are calculated. Battery status information is output and operation records are updated. Upon detecting a shutdown or completion of work, a standby loop is initiated. Instead of simply displaying a single remaining capacity percentage, the actual number of equivalent shear cycles that can be completed is calculated based on the battery's health degradation status, intuitively reflecting the battery's true operational capability. This allows users to plan their work schedule in advance and avoid work interruptions due to insufficient battery capacity. Synchronous updates to operational data and event records enable traceability analysis of battery status and faults. The standby loop mechanism continuously maintains parameter acquisition and status monitoring, ensuring a complete closed loop for the entire control process. This invention achieves adaptive drive control of lithium batteries across all operating conditions and the entire lifespan through the coordinated linkage of low-temperature preheating adaptive control, transient internal resistance identification during startup, graded undervoltage progressive protection, and quantitative assessment of health status. This improves low-temperature startup capability and the operational endurance of aging batteries, while ensuring power supply safety and user experience. Furthermore, no additional hardware is required, resulting in a low-cost and highly compatible solution. Attached Figure Description

[0017] Figure 1 This is a flowchart illustrating a brushless DC electric shear drive control method according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the structure of a brushless DC electric shear drive control system according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of an electronic device according to an embodiment of the present invention. Detailed Implementation

[0018] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Although some embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the accompanying drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0019] It should be understood that the various steps described in the method embodiments of the present invention may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this respect.

[0020] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this invention are used only to distinguish different devices, modules, or units, and are not intended to limit the order of functions performed by these devices, modules, or units or their interdependencies.

[0021] It should be noted that the terms "a" and "a plurality of" used in this invention are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0022] The names of the messages or information exchanged between the multiple devices in the embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of these messages or information.

[0023] In related technologies, the drive control parameters of existing brushless DC electric shears are mostly fixed values ​​that are factory-set. These values ​​cannot adapt to dynamic changes in battery temperature and aging cycles, resulting in a mismatch between low-temperature start-up performance, load-bearing capacity, and safety protection levels, leading to overall low operating efficiency. For example, under low-temperature conditions, the internal resistance of the battery cell increases and the discharge rate drops sharply. The fixed undervoltage protection threshold will frequently trigger shutdown due to the aggravated drop in bus voltage, making it impossible to start operation normally after pressing the trigger. If the protection threshold is relaxed to adapt to low temperatures, the over-discharge protection function will be lost, posing a safety hazard of damaging the battery cell.

[0024] To address the problems existing in the aforementioned related technologies, this embodiment provides a brushless DC electric shear drive control method, device, equipment, and medium.

[0025] like Figure 1 As shown in the figure, an embodiment of the present invention provides a brushless DC electric shear drive control method, comprising: S1, collect the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and retrieve preset control parameters; the brushless DC electric shears include motor windings and drive bridge arms; the preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time.

[0026] It should be noted that the existing battery sampling and parameter configuration of brushless DC electric shears are only used to implement basic overvoltage, overcurrent, overtemperature, and undervoltage hardware protection. The sampling dimension and parameter granularity are insufficient to support fine-grained adaptive control such as low-temperature preheating, online internal resistance identification, and graded undervoltage protection. This embodiment simultaneously collects all operating status parameters and retrieves preset control thresholds, clarifying the hardware composition and parameter structure, and providing a unified data input foundation for subsequent full-process drive control.

[0027] Optionally, the cell temperature, bus voltage, bus current, remaining battery charge, and trigger signal of the brushless DC electric shears are collected, and preset control parameters are retrieved, including: The temperature of the battery cells of the brushless DC electric scissors is collected by a temperature sensor built into the battery pack; the bus current of the brushless DC electric scissors is collected by a bus-series sampling resistor; the bus voltage of the brushless DC electric scissors is collected by a resistor voltage divider acquisition circuit; the remaining battery power of the brushless DC electric scissors is collected; the user's trigger signal is collected through the trigger interface; and preset control parameters are retrieved from the main control microcontroller's storage unit.

[0028] The brushless DC electric scissors include a motor winding and a drive bridge arm, the drive bridge arm being used to control the energization state of the motor winding.

[0029] The preset control parameters include two-level preheating temperature thresholds, a baseline for the internal resistance of the new battery at room temperature, two-level undervoltage thresholds, a battery life determination threshold, a set temperature rise rate, a full-charge open-circuit voltage, an available peak value coefficient, a winding temperature rise rate limit, a energized phase switching duration, and an undervoltage determination duration. The two-level preheating temperature thresholds include a preheating entry threshold and a preheating exit threshold. The two-level undervoltage thresholds include a soft undervoltage threshold and a hard undervoltage threshold, wherein the soft undervoltage threshold is higher than the hard undervoltage threshold, and the two constitute a progressive protection hierarchy: the soft undervoltage threshold is a power reduction warning threshold, and the hard undervoltage threshold is a shutdown protection fallback threshold. The winding temperature rise rate limit is the maximum allowable temperature rise rate of the winding during the preheating stage, the energized phase switching duration is the duration of each energized winding phase, and the undervoltage determination duration is the continuous triggering duration of the hard undervoltage protection.

[0030] In this optional embodiment, by completing the collection and retrieval of all input data at once, a unified data foundation is provided for subsequent preheating operation mode identification, heating parameter adjustment, peak current adaptive adjustment, and battery health estimation. This can be achieved by reusing the sampling path of the existing protection circuit without the need for additional hardware acquisition modules.

[0031] S2, after detecting the trigger signal, identify whether to enter the preheating operation mode based on the cell temperature and the two-stage preheating temperature threshold; in the preheating operation mode, output heating current to the motor winding through the drive bridge arm, and adjust the heating parameters with the set temperature rise rate as the target; after the preheating exit condition is met, enter the start-up allowed state.

[0032] It should be noted that existing brushless DC electric scissors suffer from increased cell internal resistance and a sharp drop in discharge rate at low temperatures, making it prone to failure to start or triggering undervoltage protection shutdown after the trigger is pressed. Solutions using external heating films require additional components and wiring, which can damage the battery compartment's sealing structure, increasing cost and structural complexity. This embodiment uses a trigger signal as the starting condition, identifies the preheating mode based on cell temperature and preheating threshold, outputs heating current to the motor windings via the drive bridge arm, and dynamically adjusts heating parameters, achieving low-temperature preheating start-up without adding any hardware components.

[0033] Optionally, after detecting the trigger signal, based on the cell temperature and the two-stage preheating temperature thresholds, the preheating operation mode is identified and preheating control is initiated, including: When the trigger signal is detected, the cell temperature is compared with the preheating entry threshold in the two-stage preheating temperature threshold. If the cell temperature is lower than the preheating entry threshold, it is identified as entering the preheating operation mode and the preheating control is started. If the cell temperature is not lower than the preheating entry threshold, it directly enters the normal start-up process.

[0034] In this optional embodiment, the preheating operation mode recognition is linked by the trigger signal, which not only ensures the preheating start-up capability in low temperature environment, but also avoids ineffective energy consumption in non-operation state, and the control logic fits the actual use scenario.

[0035] Optionally, in the preheating operation mode, a heating current is output to the motor winding through the drive bridge arm, and the heating parameters are adjusted with the set temperature rise rate as the target, including: In the preheating operation mode, the motor commutation logic is not executed. Two phases of the motor winding are selected, and the drive bridge arm switch of the corresponding phase is controlled to be turned on in a pulse manner, so that the heating current flows through the selected two phases of the motor winding to generate Joule heat. The heat is conducted to the battery compartment heating cell through the motor housing and bracket.

[0036] The current path is as follows: positive terminal of the bus, upper bridge arm switch of phase A, motor winding of phase A, motor winding of phase B, lower bridge arm switch of phase B, sampling resistor, and negative terminal of the bus.

[0037] Throughout the entire control process, the constraint that the upper and lower bridge arm switches of the same phase must not be turned on at the same time is strictly followed; the energized winding phase combinations are periodically rotated, with the rotation sequence being AB, BC, CA. Each energized phase maintains the rotation duration of the energized phase. When switching, all drive bridge arms are turned off first before the phase switching is performed.

[0038] The duty cycle of the heating pulse is adjusted using a temperature closed-loop control: the real-time cell temperature rise rate is used as feedback to track the set temperature rise rate, while the winding temperature rise rate limit is used as the limiting condition; the lower the cell temperature, the higher the initial heating duty cycle.

[0039] The cell temperature rise rate is the change in cell temperature per unit time, which can reflect the cell temperature rise speed under the current heating power in real time and serve as a feedback basis for dynamic adjustment of the duty cycle.

[0040] It should be noted that by using a two-phase series pulse energizing method, heating current can be generated without rotating the motor rotor, thus avoiding malfunctions of the machine during the preheating stage; alternating energized phases can ensure uniform heating of the motor windings as a whole, avoiding local overheating; and closed-loop regulation with the set temperature rise rate as the target can balance heating speed and device reliability.

[0041] In another embodiment, the heating current is applied in the following manner: a low-frequency square wave is applied to two selected phases to periodically reverse the current direction; a spatially symmetrical three-phase pulse is applied to the three-phase winding to make the sum of the instantaneous currents of the three phases zero; heating is achieved by using a small commutation current of pulse chopping; all of the above application methods must comply with the constraint that the upper and lower bridge arms of the same phase cannot be turned on at the same time.

[0042] In another embodiment, temperature acquisition is achieved by using a positive temperature coefficient thermistor or a digital temperature sensor to acquire the cell temperature; or by indirectly estimating the cell temperature through the mapping relationship between the battery's internal resistance and temperature, thus eliminating the need for a separate temperature sensor.

[0043] In this optional embodiment, the heating current is generated by controlling the on / off state of the motor windings through the drive bridge arm. This eliminates the need for additional heating films, temperature control circuits, or other devices, and does not damage the sealed structure of the battery compartment. The low-temperature preheating function is achieved with zero additional hardware cost.

[0044] Optionally, after the preheating exit conditions are met, the system enters the start-up permitted state, including: The preheating exit condition is determined to be met when the following condition is met: the cell temperature rises to a level not lower than the preheating exit threshold among the two-stage preheating temperature thresholds. After the preheating exit condition is met, the heating current output stops, and the system enters the start-up allowed state.

[0045] It should be noted that using cell temperature as the basis for determining preheating termination directly reflects the current temperature state of the battery. The determination logic is simple and reliable, and it is suitable for the rapid start-up requirements of electric scissors.

[0046] In this optional embodiment, the preheating exit mechanism based on temperature threshold determination not only ensures the preheating effect in low-temperature environments but also matches the start-up timing with the actual discharge capacity of the battery, thereby improving the reliability of low-temperature start-up.

[0047] S3, during the transient window of the brushless DC electric shear startup process in the allowed startup state, the bus voltage and the bus current are fitted to obtain the battery equivalent internal resistance; the aging factor is calculated based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, and the upper limit of the peak current is adjusted according to the aging factor; and graded undervoltage protection is performed according to the relationship between the bus voltage and the two-level undervoltage threshold.

[0048] It should be noted that existing brushless DC electric shears use fixed peak current thresholds and fixed undervoltage protection thresholds, which cannot distinguish between transient voltage collapse caused by battery aging and actual battery depletion. Under heavy load conditions such as shearing coarse branches, undervoltage protection is frequently triggered falsely, resulting in situations where the battery still has remaining capacity but the shearing operation cannot be completed, and this is easily misjudged as a fault requiring repair. This embodiment obtains the battery's equivalent internal resistance by fitting it within the startup transient window, calculates the aging factor based on this, and dynamically adjusts the peak current upper limit. Simultaneously, it combines two levels of undervoltage thresholds to implement graded protection, adapting to the power capacity of aging batteries to reduce false shutdowns while retaining the protection function of hard undervoltage protection.

[0049] Optionally, during the transient window of the brushless DC electric shears startup process, the bus voltage and the bus current are fitted to obtain the battery's equivalent internal resistance, including: After entering the start-up allowed state, the brushless DC electric shears start up, and the bus current gradually increases from zero. During the transient window of the start-up process, multiple sets of corresponding sample points of the bus voltage and the bus current are continuously collected, and the least squares method is used for linear fitting to obtain the battery equivalent internal resistance.

[0050] It should be noted that during the startup process, the current naturally rises from zero, covering a range of currents from small to large, without the need for additional active injection of test pulses, and will not cause delays in normal startup; the internal resistance is identified by utilizing the natural current change during startup transients, which is suitable for the frequent start-stop operation characteristics of brushless DC electric shears.

[0051] In another embodiment, the internal resistance identification is achieved as follows: at the end of each shearing and the transient when the current drops from large to zero, the equivalent internal resistance of the battery can be obtained by fitting the ratio of the voltage change to the current change, without affecting the startup response; or the battery pulse impedance method is used, and a small current pulse is actively injected during the standby interval to measure the response and obtain the equivalent internal resistance of the battery.

[0052] In this optional embodiment, the internal resistance is identified online by fitting voltage and current samples during the transient window. No dedicated impedance testing circuit is required. The internal resistance is automatically updated each time the battery is started, which can reflect the current aging state and temperature characteristics of the battery in real time.

[0053] Optionally, an aging factor is calculated based on the battery's equivalent internal resistance and the baseline of the new battery's room-temperature internal resistance, and the upper limit of the peak current is adjusted according to the aging factor, including: The ratio of the battery's equivalent internal resistance to the baseline internal resistance of the new battery at room temperature is used as the battery aging factor.

[0054] The maximum allowable peak current is dynamically adjusted based on the aging factor; the larger the aging factor value, the lower the maximum peak current setting; when the aging factor exceeds the battery life determination threshold, a battery replacement prompt signal is generated.

[0055] In another embodiment, the peak current limit adjustment is achieved by maintaining the peak value but increasing the commutation acceleration slope to limit the current rise rate; or by reducing the pulse duty cycle limit; or by limiting the stall duration, all of which can achieve the purpose of preventing bus voltage collapse.

[0056] In this optional embodiment, the peak current upper limit is adjusted by linkage with the aging factor, so that the drive control can adaptively match the current health status of the battery, extend the usable cycle of the aging battery, and reduce unnecessary repairs caused by false protection.

[0057] Optionally, based on the relationship between the bus voltage and the two-level undervoltage thresholds, graded undervoltage protection is implemented, including: During operation, the bus voltage is monitored in real time and compared with the two-level undervoltage thresholds to implement two-level undervoltage protection: when the bus voltage is lower than the soft undervoltage threshold of the two-level undervoltage thresholds, the upper limit of the peak current is reduced, and no shutdown is performed, maintaining the continuity of operation by reducing power; when the bus voltage is lower than the hard undervoltage threshold of the two-level undervoltage thresholds and the duration reaches the undervoltage judgment duration, shutdown protection is triggered.

[0058] Since the soft undervoltage threshold is higher than the hard undervoltage threshold, when the load fluctuates, the bus voltage will first reach the soft undervoltage threshold to perform power reduction backoff. Only when the voltage continues to drop and exceeds the hard undervoltage threshold will the shutdown be triggered, thus avoiding false shutdown caused by instantaneous large load.

[0059] In this optional embodiment, a two-level undervoltage protection mechanism is used to retain the safety fallback function of undervoltage protection while avoiding frequent false shutdowns caused by transient load fluctuations, thus balancing battery safety and operating efficiency.

[0060] S4. Calculate the battery health and equivalent remaining shear count based on the battery's equivalent internal resistance, remaining battery capacity, and battery life determination threshold; output battery status information and update the operation record; enter the standby loop process when a shutdown or operation is detected.

[0061] It should be noted that existing brushless DC electric shears only display the remaining battery percentage to the user, failing to reflect battery health and actual available peak power. Users cannot predict the remaining working capacity, making sudden power outages during operation a common occurrence. This embodiment calculates battery health and equivalent remaining shearing counts based on the battery's equivalent internal resistance, remaining battery capacity, and a lifespan determination threshold. It outputs visualized status information and updates the operation record. Upon shutdown or completion of the operation, it enters a standby cycle, making battery lifespan and remaining working capacity readily perceptible.

[0062] Optionally, based on the battery's equivalent internal resistance, the battery's remaining capacity, and the battery lifespan determination threshold, the battery health and equivalent remaining shear cycles are calculated, including: The full-charge open-circuit voltage and available peak value coefficient are retrieved from the preset control parameters. Using the full-charge open-circuit voltage as the reference voltage, and combining the percentage of the increase in the battery's equivalent internal resistance relative to the baseline internal resistance of the new battery at room temperature, the battery health is calculated. Using the remaining battery capacity as the basis for available capacity, and combining the battery health and the available peak value coefficient, the equivalent remaining shear cycles are calculated. The battery's equivalent internal resistance is compared with the battery life determination threshold to determine the corresponding battery health level.

[0063] In this optional embodiment, the battery health status is converted into the remaining shear cycles and health level that users can intuitively understand, realizing the visualization of battery life and remaining capacity, which makes it easier for users to plan their work and replace batteries in advance, and avoid sudden power loss during the operation.

[0064] Optionally, output battery status information and update the running log, including: The battery health level and the equivalent remaining shear cycles are output to the user via indicator lights or a display screen; if the aging factor exceeds the battery life determination threshold, a battery replacement reminder signal is output simultaneously. The battery equivalent internal resistance, peak current upper limit, and undervoltage trigger event records obtained during this operation are simultaneously updated and stored in the operation record of the main control microcontroller's storage unit.

[0065] In another embodiment, the health status output is implemented in the following ways: by using a buzzer to provide graded prompts, or by transmitting the data to a mobile app via Bluetooth for display.

[0066] In this optional embodiment, the user can monitor the battery status in real time through hierarchical visualization output and operation record updates, while accumulating operation data to provide a basis for subsequent battery status assessment.

[0067] Optionally, upon detecting a shutdown or the completion of an operation, a standby loop process is initiated, including: If a hard undervoltage shutdown is triggered during operation, the operation record is updated and the system enters standby mode. If the shearing operation is completed normally and there is no new trigger signal, the system returns to standby mode and waits for the next trigger. In standby mode, the parameter acquisition and status monitoring process is executed cyclically.

[0068] In this optional embodiment, a complete closed-loop operation of acquisition-control-feedback-standby is formed through a standby cycle mechanism, which not only realizes the core functions of low-temperature start-up, aging adaptation and lifespan perception, but also maintains the simplicity of the system architecture and engineering feasibility.

[0069] like Figure 2 As shown, an embodiment of the present invention provides a brushless DC electric shear drive control system 200, comprising: The parameter acquisition and configuration module 210 is used to acquire the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and to retrieve preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. The low-temperature preheating start-up module 220 is used to detect the trigger signal and, based on the cell temperature and the two-stage preheating temperature thresholds, identify whether to enter the preheating operation mode; in the preheating operation mode, it outputs heating current to the motor winding through the drive bridge arm and adjusts the heating parameters with the set temperature rise rate as the target; after the preheating exit condition is met, it enters the start-up allowed state; The internal resistance identification and protection module 230 is used to fit the bus voltage and the bus current within the transient window of the brushless DC electric shear startup process under the allowed startup state to obtain the battery equivalent internal resistance; calculate the aging factor based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance; adjust the upper limit of the peak current according to the aging factor; and perform graded undervoltage protection according to the relationship between the bus voltage and the two-level undervoltage threshold. The health assessment and management module 240 is used to calculate the battery health and equivalent remaining shear count based on the battery's equivalent internal resistance, the battery's remaining capacity, and the battery life determination threshold; output battery status information and update the operation record; and enter the standby loop process when a shutdown or operation is completed.

[0070] like Figure 3 As shown, an electronic device 300 provided in this embodiment of the invention includes a memory 310 and a processor 320; the memory 310 is used to store a computer program; the processor 320 is used to implement the brushless DC scissor drive control method as described above when the computer program is executed.

[0071] Alternatively, an electronic device 300 includes a memory 310 and a processor 320 coupled to the memory 310; the memory 310 is configured to store a computer program; and the processor 320 is configured to perform the following operations when the computer program is executed: The system collects data on the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and retrieves preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. After the trigger signal is detected, the system identifies whether to enter the preheating operation mode based on the cell temperature and the two-stage preheating temperature thresholds. In the preheating operation mode, the system outputs heating current to the motor windings through the drive bridge arm and adjusts the heating parameters with the set temperature rise rate as the target. After the preheating exit condition is met, the system enters the start-up allowed state. During the transient window of the brushless DC electric shear startup process in the allowed startup state, the bus voltage and the bus current are fitted to obtain the battery equivalent internal resistance; the aging factor is calculated based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, and the upper limit of the peak current is adjusted according to the aging factor; and graded undervoltage protection is performed based on the relationship between the bus voltage and the two-level undervoltage threshold. Based on the battery's equivalent internal resistance, remaining battery capacity, and battery lifespan determination threshold, calculate battery health and equivalent remaining shear cycles; output battery status information and update operation records; upon detecting a shutdown or completion of operation, enter standby loop process.

[0072] This invention provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it implements the brushless DC scissor drive control method described above.

[0073] Alternatively, a non-volatile computer-readable storage medium storing a computer program that, when executed by a processor, causes the processor to perform the following operations: The system collects data on the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and retrieves preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. After the trigger signal is detected, the system identifies whether to enter the preheating operation mode based on the cell temperature and the two-stage preheating temperature thresholds. In the preheating operation mode, the system outputs heating current to the motor windings through the drive bridge arm and adjusts the heating parameters with the set temperature rise rate as the target. After the preheating exit condition is met, the system enters the start-up allowed state. During the transient window of the brushless DC electric shear startup process in the allowed startup state, the bus voltage and the bus current are fitted to obtain the battery equivalent internal resistance; the aging factor is calculated based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, and the upper limit of the peak current is adjusted according to the aging factor; and graded undervoltage protection is performed based on the relationship between the bus voltage and the two-level undervoltage threshold. Based on the battery's equivalent internal resistance, remaining battery capacity, and battery lifespan determination threshold, calculate battery health and equivalent remaining shear cycles; output battery status information and update operation records; upon detecting a shutdown or completion of operation, enter standby loop process.

[0074] The present invention will now be described an electronic device 300 that can serve as a server or client of the present invention, which is an example of a hardware device that can be applied to various aspects of the present invention. Electronic device 300 is intended to represent various forms of digital electronic computer devices, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. Electronic device 300 can also represent various forms of mobile devices, such as personal digital processors, cellular phones, smartphones, wearable devices, and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the invention described and / or claimed herein.

[0075] Electronic device 300 includes a computing unit that can perform various appropriate actions and processes based on a computer program stored in read-only memory (ROM) or a computer program loaded from a storage unit into random access memory (RAM). The RAM may also store various programs and data required for device operation. The computing unit, ROM, and RAM are interconnected via a bus. Input / output (I / O) interfaces are also connected to the bus.

[0076] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. The storage medium can be a magnetic disk, optical disk, read-only memory (ROM), or random access memory (RAM), etc. In this application, the units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments of the present invention according to actual needs. Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated units can be implemented in hardware or as software functional units.

[0077] While the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A brushless DC electric shear drive control method, characterized in that, include: The system collects data on the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and retrieves preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. After the trigger signal is detected, the system identifies whether to enter the preheating operation mode based on the cell temperature and the two-stage preheating temperature thresholds. In the preheating operation mode, the system outputs heating current to the motor windings through the drive bridge arm and adjusts the heating parameters with the set temperature rise rate as the target. After the preheating exit condition is met, the system enters the start-up allowed state. During the transient window of the brushless DC electric shear startup process in the allowed startup state, the bus voltage and the bus current are fitted to obtain the battery equivalent internal resistance; the aging factor is calculated based on the battery equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, and the upper limit of the peak current is adjusted according to the aging factor; and graded undervoltage protection is performed based on the relationship between the bus voltage and the two-level undervoltage threshold. Based on the battery's equivalent internal resistance, remaining battery capacity, and battery lifespan determination threshold, calculate battery health and equivalent remaining shear cycles; output battery status information and update operation records; upon detecting a shutdown or completion of operation, enter standby loop process.

2. The brushless DC electric shear drive control method according to claim 1, characterized in that, After detecting the trigger signal, the system identifies whether to enter the preheating operation mode based on the cell temperature and the two-stage preheating temperature thresholds, including: When the trigger signal is detected, the cell temperature is compared with the preheating entry threshold in the two-stage preheating temperature threshold. If the cell temperature is lower than the preheating entry threshold, it is identified as entering the preheating operation mode and the preheating control is started. If the cell temperature is not lower than the preheating entry threshold, it directly enters the normal start-up process.

3. The brushless DC electric shear drive control method according to claim 1, characterized in that, In the preheating operation mode, the heating current is output to the motor winding through the drive bridge arm, and the heating parameters are adjusted with the set temperature rise rate as the target, including: In the preheating operation mode, the motor commutation logic is not executed. Two phases of the motor winding are selected, and the drive bridge arm switching transistors of the corresponding phases are controlled to conduct in a pulse manner, so that the heating current flows through the selected two phases of the motor winding to generate Joule heat. The energized winding phase combination is periodically rotated, and each energized phase maintains the energized phase rotation duration. When switching, all drive bridge arms are turned off first, and then the phase switching is performed. The duty cycle of the heating pulse is fed back with the real-time cell temperature rise rate, tracks the set temperature rise rate, and uses the winding temperature rise rate limit as the limiting condition.

4. The brushless DC electric shear drive control method according to claim 1, characterized in that, Within the transient window of the brushless DC electric shear start-up process under the allowed start-up state, the bus voltage and bus current are fitted to obtain the battery's equivalent internal resistance, including: After entering the start-up allowed state, the brushless DC electric shears start up, and the bus current gradually increases from zero. During the transient window of the start-up process, multiple sets of corresponding sample points of the bus voltage and the bus current are continuously collected. The least squares method is used to linearly fit the bus voltage and the bus current to obtain the battery's equivalent internal resistance.

5. The brushless DC electric shear drive control method according to claim 1, characterized in that, The step of performing graded undervoltage protection based on the relationship between the bus voltage and the two-level undervoltage thresholds includes: During operation, the bus voltage is monitored in real time and compared with the two-level undervoltage thresholds to implement two-level undervoltage protection: when the bus voltage is lower than the soft undervoltage threshold, the peak current upper limit is lowered, and no shutdown is performed, maintaining operational continuity by reducing power; when the bus voltage is lower than the hard undervoltage threshold and the duration reaches the undervoltage determination time, shutdown protection is triggered; the soft undervoltage threshold is greater than the hard undervoltage threshold.

6. The brushless DC electric shear drive control method according to claim 1, characterized in that, The step of calculating battery health and equivalent remaining shear cycles based on the battery's equivalent internal resistance, remaining battery capacity, and battery lifespan determination threshold includes: The full-charge open-circuit voltage and available peak value coefficient are retrieved from the preset control parameters. Using the full-charge open-circuit voltage as the reference voltage, and combining the percentage of the increase in the battery's equivalent internal resistance relative to the baseline internal resistance of the new battery at room temperature, the battery health is calculated. Using the remaining battery capacity as the basis for available capacity, and combining the battery health and the available peak value coefficient, the equivalent remaining shear cycles are calculated. The battery's equivalent internal resistance is compared with the battery life determination threshold to determine the corresponding battery health level.

7. The brushless DC electric shear drive control method according to claim 1, characterized in that, The system outputs battery status information and updates the operation record; upon detecting a shutdown or completion of an operation, it enters a standby loop process, including: The battery health level and the equivalent remaining shear count are output to the user via indicator lights or a display screen; if the aging factor exceeds the battery life judgment threshold, the battery replacement prompt signal is output simultaneously; the battery equivalent internal resistance, peak current upper limit and undervoltage trigger event record obtained during this operation are updated simultaneously and stored in the operation record of the main control microcontroller storage unit; If a hard undervoltage shutdown is triggered during operation, the operation record is updated and the system enters standby mode. If the shearing operation is completed normally and there is no new trigger signal, the system returns to standby mode and waits for the next trigger. In standby mode, the parameter acquisition and status monitoring process is executed cyclically.

8. A brushless DC electric shear drive control system, characterized in that, include: The parameter acquisition and configuration module is used to acquire the cell temperature, bus voltage, bus current, remaining battery power, and trigger signal of the brushless DC electric shears, and to retrieve preset control parameters. The brushless DC electric shears include motor windings and drive bridge arms. The preset control parameters include two-stage preheating temperature thresholds, baseline internal resistance of the new battery at room temperature, two-stage undervoltage thresholds, battery life judgment thresholds, set temperature rise rate, full-charge open-circuit voltage, available peak value coefficient, winding temperature rise rate limit, energized phase switching time, and undervoltage judgment time. The low-temperature preheating start-up module is used to detect the trigger signal, identify the preheating operation mode and start preheating control according to the cell temperature and the two-stage preheating temperature threshold; in the preheating operation mode, the heating current is output to the motor winding through the drive bridge arm, and the heating parameters are adjusted with the set temperature rise rate as the target; after the preheating exit condition is met, it enters the start-up allowed state; The internal resistance identification and protection module is used to fit the bus voltage and the bus current during the transient window of the brushless DC electric shear startup process to obtain the battery's equivalent internal resistance; calculate the aging factor based on the battery's equivalent internal resistance and the baseline of the new battery's room temperature internal resistance, adjust the upper limit of the peak current according to the aging factor; and perform graded undervoltage protection based on the relationship between the bus voltage and the two-level undervoltage thresholds. The health assessment and management module is used to calculate the battery health and equivalent remaining shear count based on the battery's equivalent internal resistance, the battery's remaining capacity, and the battery life determination threshold. Output battery status information and update operation records; if a shutdown or operation is detected, enter the standby cycle.

9. An electronic device, characterized in that, Including memory and processor; The memory is used to store computer programs; The processor is configured to implement the brushless DC scissor drive control method as described in any one of claims 1 to 7 when executing the computer program.

10. A computer-readable storage medium, characterized in that, The storage medium stores a computer program, which, when executed by a processor, implements the brushless DC electric shear drive control method as described in any one of claims 1 to 7.

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