Direct-current brushless motor driving module single-board testing device

Abstract

A single-board testing device for a direct-current brushless motor driving module belongs to the field of brushless motor testing devices and is characterized by comprising a processor control unit, a control signal conditioning unit, a sensor acquisition unit, an external communication interface unit, a man-machine interaction unit and a power supply unit. Through the combined arrangement of the processor control unit, the control signal conditioning unit, the sensor acquisition unit, the external communication interface unit, the man-machine interaction unit and the power supply unit, the full-function test can be completed in the single board state of the control board and the efficiency board, and the abnormal single board problem can be exposed in advance. The problem that the single plates cannot be repaired after problems are found after butt welding is avoided, so that the yield of finished products is improved, tedious wiring during conventional testing is effectively solved, various testing equipment instruments are omitted, and the batch production efficiency is improved; and meanwhile, test data can be stored and a test report can be formed, so that later archiving and viewing are facilitated.

Description

Technical Field

[0001] The utility model belongs to the field of brushless motor testing devices, in particular to a single-board testing device for a DC brushless motor drive module. Background Art

[0002] With the advantages of small size, light weight and high integration, brushless DC motors are increasingly used in various fields of national economic life, showing broad application prospects.

[0003] Currently, due to size limitations in various applications, brushless DC motor drive modules primarily consist of two boards: a control board and a power board. These boards are welded together in a housing. The control board receives external control commands, feedback commands, enable signals, Hall effect signals, and other information. After calculations, it generates commutation control signals for the brushless DC motor and sends them to the power board, which then drives the brushless DC motor for commutation. The power board also detects the motor's current during operation and sends it to the control board for calculation. In the event of overcurrent or short circuit, the control board shuts off the control signal to the power board, implementing overcurrent protection.

[0004] Due to the small size, high integration, and multiple interactive signals of this type of drive module, during production debugging, the control board and power board must be welded before a complete functional test can be performed. If any abnormalities in functions or performance indicators occur, rework and repair are extremely difficult, posing a major challenge to the mass production of this module. Summary of the Invention

[0005] The utility model aims to solve the above problems and provides a single-board testing device for a brushless DC motor drive module, which can test a control board and a power board respectively before the control board and the power board are butt-welded.

[0006] The single-board test device for the brushless DC motor drive module of the utility model includes a processor control unit, a control signal conditioning unit, a sensor acquisition unit, an external communication interface unit, a human-computer interaction unit and a power supply unit;

[0007] The processor control unit, control signal conditioning unit, sensor acquisition unit, external communication interface unit and human-computer interaction unit are all electrically connected to the power supply unit;

[0008] The control signal conditioning unit, the sensor acquisition unit, the external communication interface unit and the human-computer interaction unit are all electrically connected to the aforementioned processor control unit.

[0009] Furthermore, in the single-board test device for a brushless DC motor drive module described in the present invention, the processor control unit includes an MCU controller, a drive circuit, and peripheral circuits; the drive circuit and peripheral circuits are electrically connected to the MCU controller. The MCU controller is used to generate control signals and control sampling for the control board and power board, thereby confirming whether the control signals sent to the control board and power board are normal; monitoring whether the control board and power board are in normal state during testing; performing human-computer interaction functions; and realizing data exchange functions through an external communication interface. The drive circuit is used to expand the MCU controller's IO port and is used to drive certain circuits such as indicator lights and buzzers; and the peripheral circuit is used to build a minimum working system for the MCU controller.

[0010] Furthermore, in the single-board test device for the brushless DC motor drive module of the present invention, the control signal conditioning unit includes a signal isolation circuit, a DAC circuit, an op amp conversion circuit, and a level conversion circuit; the op amp conversion circuit is electrically connected to the isolation circuit via the DAC circuit; the level conversion circuit is electrically connected to the isolation circuit; and the isolation circuit is electrically connected to the aforementioned MCU controller. The level conversion circuit and op amp conversion circuit are both electrically connected to the single board under test; under the control of the aforementioned MCU controller, the DAC circuit generates the analog signal required for control board testing and generates a Hall signal for detecting the rotor position of the brushless DC motor, which is converted into a level signal that matches the control board under test through the level conversion circuit. At the same time, the MCU controller samples the power supply and control signals transmitted by the test device from the single board under test, as well as the relevant signals output by the single board under test in response to the control signal. The MCU controller compares all sampled signals with normal signals to determine whether the functional performance of the single board under test is normal.

[0011] The signal isolation circuit is used to electrically isolate the control signal sent by the MCU controller to the single board under test and the signal sampled back by the MCU from the single board under test, so as to avoid the loss of electrical isolation due to the association of the MCU control system, which leads to the control and power parts of the single board under test sharing the same ground.

[0012] The DAC circuit is driven by the digital signal output by the MCU controller through the signal isolation circuit, generates the analog control signal required by the tested board, and transmits it to the tested board for control.

[0013] The operational amplifier conversion circuit is used to perform operational conversion on the power supply voltage, analog signal and differential signal collected from the tested single board, and send them to the MCU controller for detection after being processed by the signal isolation circuit.

[0014] The level conversion circuit is used to convert the level of digital signals. The digital control signals sent by the MCU controller to the board under test are first isolated by the signal isolation circuit, then converted by the level conversion circuit before being sent to the board under test. Simultaneously, digital signals collected from the board under test are converted, then isolated by the signal isolation circuit before being sent to the MCU controller for testing.

[0015] Furthermore, in the single-board testing device for the brushless DC motor drive module of the present invention, the sensor acquisition unit includes a voltage acquisition circuit, a current acquisition circuit, a temperature acquisition circuit, and an ADC conversion circuit; the voltage acquisition circuit, the current acquisition circuit, and the temperature acquisition circuit are all electrically connected to the aforementioned operational amplifier conversion circuit; the operational amplifier conversion circuit is electrically connected to the isolation circuit via the ADC conversion circuit; the voltage acquisition circuit, the current acquisition circuit, and the temperature acquisition circuit are all electrically connected to the single board under test; the voltage acquisition circuit is used to acquire the power supply voltage at the single board under test, and the sampled voltage first undergoes signal conversion through the operational amplifier conversion circuit, and then the ADC conversion circuit converts the analog voltage signal into a digital signal, and the digital signal is isolated by the signal isolation circuit and sent to the MCU controller for detection.

[0016] The current acquisition circuit is used to collect the power supply current provided to the single board under test, convert the current signal into a voltage signal by the sampling resistor, perform signal conversion through the operational amplifier conversion circuit, and then convert the analog voltage signal into a digital signal by the ADC conversion circuit. The digital signal is isolated by the signal isolation circuit and then sent to the MCU controller for detection.

[0017] The temperature acquisition circuit is used to collect the operating temperature of the single board under test, convert the temperature change into a change in the resistance value through the thermistor, and then perform signal conversion through the operational amplifier conversion circuit. The ADC conversion circuit converts the analog voltage signal into a digital signal. The digital signal is isolated by the signal isolation circuit and then sent to the MCU controller for detection.

[0018] The ADC conversion circuit is used to convert the voltage signal converted by the operational amplifier conversion circuit into a digital signal.

[0019] The signal isolation circuit is used to isolate the digital signal output by the ADC conversion circuit and send it to the MCU controller for processing.

[0020] Furthermore, in the single-board testing device for the brushless DC motor drive module of the present invention, the power supply unit includes an external power supply interface, a surge suppression circuit, an anti-reverse connection circuit, a short-circuit and overcurrent protection circuit, a DC-DC conversion circuit, and an LDO conversion circuit; the external power supply interface, the anti-reverse connection circuit, the surge suppression circuit, and the short-circuit and overcurrent protection circuit are electrically connected in sequence; the short-circuit and overcurrent protection circuit is electrically connected to the LDO conversion circuit via the DC-DC conversion circuit; the LDO conversion circuit is electrically connected to the aforementioned processor control unit, control signal conditioning unit, sensor acquisition unit, external communication interface unit, and human-computer interaction unit, respectively; and the DC-DC conversion circuit is electrically connected to the single board under test.

[0021] The external power supply interface is used to connect an external DC adapter to supply power to the system.

[0022] The surge suppression circuit is used to filter out interference such as surges and spikes in the external input power supply.

[0023] The anti-reverse connection circuit is used to prevent damage to the subsequent circuit when the positive and negative poles of the external adapter are connected in reverse.

[0024] The short-circuit and over-current protection circuit is used to cut off the power supply when an over-current or short-circuit fault occurs in the circuit of the test device, so as to prevent the circuit and components from being damaged by impact.

[0025] The DC-DC conversion circuit is used to convert the voltage input from the outside. The converted voltage provides the required working voltage for the control signal conditioning system, external communication interface, human-computer interaction system, control board and power board.

[0026] The LDO conversion circuit is used to convert the voltage output by the DC-DC conversion circuit. The converted voltage provides the operating voltage required for the processor control system, sensor acquisition system, external communication interface system, human-computer interaction system and other parts.

[0027] Furthermore, in the single-board testing device for the brushless DC motor drive module of the present invention, the DC-DC conversion circuit adopts an isolated DC-DC conversion circuit.

[0028] Furthermore, in the single-board testing device for the brushless DC motor drive module of the present invention, the external communication interface unit includes an Ethernet interface, a USB interface, an RS232 interface, and a TF card interface; the Ethernet interface, USB interface, RS232 interface, and TF card interface are all electrically connected to the aforementioned MCU controller.

[0029] The Ethernet interface is used for data exchange between the test device and the host computer. The MCU controller sends real-time data during the test to the host computer for display. At the same time, the host computer can configure parameters through the Ethernet interface and send control instructions to the MCU controller for execution.

[0030] The USB interface is used for program upgrades of the MCU controller and can also be used for data exchange between the test device and the host computer, achieving the same function as the Ethernet interface. The RS232 interface is a reserved communication interface. The TF card interface is used to place a TF card. When the test device is working alone, the MCU controller saves the test data to the TF card.

[0031] Furthermore, in the single-board testing device for the brushless DC motor drive module of the present invention, the human-computer interaction unit includes a button, a display screen, an indicator light, a buzzer and a host computer; the indicator light and the buzzer are electrically connected to the MCU via the aforementioned drive circuit; the button, display screen, and host computer are electrically connected to the aforementioned MCU.

[0032] The buttons are used to operate the test device to perform relevant tests and set test device control signal parameters. The display screen is used to display the test device menu selection, as well as the test results of relevant test items during the test process and whether the tested board has passed the final test. The indicator lights are used to indicate the operating status of the test device and the test results of the tested board. The buzzer is used to indicate the operating status of the test device and whether the tested board has passed the test. The host computer is used to configure test device parameters, control tests, and display the test results of each test item during the test process.

[0033] The single-board testing device for a brushless DC motor drive module of the present invention can complete full-function testing when the control board and the efficiency board are in a single-board state by combining and arranging a processor control unit, a control signal conditioning unit, a sensor acquisition unit, an external communication interface unit, a human-computer interaction unit, and a power supply unit. This can expose abnormal single-board problems in advance, and avoid the problem of being unable to repair problems found after the single board is welded, thereby improving the yield rate of finished products, effectively solving the tedious wiring during conventional testing, and eliminating various testing equipment and instruments, thereby improving batch production efficiency. At the same time, the test data can be stored and a test report can be generated, which is convenient for later archiving and viewing. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a schematic block diagram of the structure of the single-board testing device for the brushless DC motor drive module according to this embodiment;

[0035] Figure 2 This is a schematic diagram of the structure of the control signal conditioning unit according to this embodiment;

[0036] Figure 3 This is a structural diagram of the sensor acquisition unit described in this embodiment;

[0037] Figure 4 This is a schematic diagram of the structure of the power supply unit described in this embodiment. DETAILED DESCRIPTION

[0038] The following describes in detail the DC brushless motor drive module single board testing device of the present invention through the accompanying drawings and embodiments.

[0039] This embodiment discloses a single-board test device for a brushless DC motor drive module. Figure 1 As shown, it includes a processor control unit, a control signal conditioning unit, a sensor acquisition unit, an external communication interface unit, a human-computer interaction unit and a power supply unit; the processor control unit, the control signal conditioning unit, the sensor acquisition unit, the external communication interface unit and the human-computer interaction unit are all electrically connected to the aforementioned power supply unit; the control signal conditioning unit, the sensor acquisition unit, the external communication interface unit and the human-computer interaction unit are all electrically connected to the aforementioned processor control unit.

[0040] In the disclosed embodiment, the processor control unit includes an MCU controller, a drive circuit, and peripheral circuits; the drive circuit and peripheral circuits are all electrically connected to the MCU controller. The MCU controller is used to generate control signals and control sampling for the control board and power board, thereby confirming whether the control signals sent to the control board and power board are normal; monitoring whether the control board and power board are in normal state during testing; completing human-computer interaction functions; and realizing data exchange functions through external communication interfaces. The drive circuit is used to realize MCU controller IO port expansion, which is used to drive some circuits such as indicator lights and buzzers; and the peripheral circuit is used to build a minimum working system for the MCU controller.

[0041] In the embodiment of the present disclosure, Figure 2 As shown, the control signal conditioning unit includes a signal isolation circuit, a DAC circuit, an op amp conversion circuit and a level conversion circuit; the op amp conversion circuit is electrically connected to the isolation circuit via the DAC circuit; the level conversion circuit is electrically connected to the isolation circuit; the isolation circuit is electrically connected to the aforementioned MCU controller; the level conversion circuit and the op amp conversion circuit are both electrically connected to the board under test.

[0042] like Figure 3 As shown, the sensor acquisition unit includes a voltage acquisition circuit, a current acquisition circuit, a temperature acquisition circuit, and an ADC conversion circuit; the voltage acquisition circuit, the current acquisition circuit, and the temperature acquisition circuit are all electrically connected to the operational amplifier conversion circuit; the operational amplifier conversion circuit is electrically connected to the isolation circuit via the ADC conversion circuit; the voltage acquisition circuit, the current acquisition circuit, and the temperature acquisition circuit are all electrically connected to the board under test.

[0043] like Figure 4 As shown, the power supply unit includes an external power supply interface, a surge suppression circuit, an anti-reverse connection circuit, a short-circuit and overcurrent protection circuit, a DC-DC conversion circuit, and an LDO conversion circuit; the external power supply interface, the anti-reverse connection circuit, the surge suppression circuit, and the short-circuit and overcurrent protection circuit are electrically connected in sequence; the short-circuit and overcurrent protection circuit is electrically connected to the LDO conversion circuit via the DC-DC conversion circuit; the LDO conversion circuit is electrically connected to the aforementioned processor control unit, control signal conditioning unit, sensor acquisition unit, external communication interface unit, and human-computer interaction unit respectively; and the DC-DC conversion circuit is electrically connected to the board under test.

[0044] In the disclosed embodiment, the DC-DC conversion circuit uses an isolated DC-DC conversion circuit. The external communication interface unit includes an Ethernet interface, a USB interface, an RS232 interface, and a TF card interface; the Ethernet interface, USB interface, RS232 interface, and TF card interface are all electrically connected to the aforementioned MCU controller. The human-computer interaction unit includes a button, a display, an indicator light, a buzzer, and a host computer; the indicator light and buzzer are electrically connected to the MCU via the aforementioned drive circuit; the button, display, and host computer are electrically connected to the aforementioned MCU.

[0045] When testing a brushless DC motor driver module board, the board under test is connected to the test equipment. The MCU controller controls the DAC circuit to generate the analog signals required for board testing. It also generates Hall effect signals for detecting the DC motor's rotor position. The level conversion circuit converts these signals into voltage levels that match the board under test.

[0046] The signal isolation circuit electrically isolates the control signal sent by the MCU controller to the board under test from the signal sampled by the MCU from the board under test, so as to avoid the loss of electrical isolation due to the common ground of the control and power parts of the board under test caused by the association of the MCU control system.

[0047] The DAC circuit is driven by the digital signal output by the MCU controller through the signal isolation circuit, generates the analog control signal required by the board under test, and transmits it to the board under test for control.

[0048] The voltage acquisition circuit collects the power supply voltage at the board under test. The sampled voltage first undergoes signal conversion via the op amp conversion circuit. The ADC conversion circuit then converts the analog voltage signal into a digital signal. The digital signal is isolated by the signal isolation circuit and sent to the MCU controller for detection. The current acquisition circuit collects the power supply current supplied to the board under test. A sampling resistor converts the current signal into a voltage signal. The op amp conversion circuit performs signal conversion. The ADC conversion circuit then converts the analog voltage signal into a digital signal. The digital signal is isolated by the signal isolation circuit and sent to the MCU controller for detection. The temperature acquisition circuit collects the operating temperature of the board under test. A thermistor converts temperature changes into resistor changes. The op amp conversion circuit performs signal conversion. The ADC conversion circuit then converts the analog voltage signal into a digital signal. The digital signal is isolated by the signal isolation circuit and sent to the MCU controller for detection.

[0049] The ADC conversion circuit converts the voltage signal converted by the op amp conversion circuit into a digital signal. The signal isolation circuit isolates the digital signal output by the ADC conversion circuit and sends it to the MCU controller for processing. The op amp conversion circuit performs computational conversion on the power supply voltage, analog signal, and differential signal collected from the board under test. After processing through the signal isolation circuit, it is sent to the MCU controller for testing.

[0050] The level shifter circuit is used to convert the digital signal level. The digital control signal sent by the MCU controller to the board under test is first isolated by the signal isolation circuit, then converted by the level shifter circuit before being sent to the board under test. Simultaneously, the digital signal collected from the board under test is converted, then isolated by the signal isolation circuit, and sent to the MCU controller for testing.

[0051] During testing, connect an external DC adapter to the external power supply port to power the system. A surge suppression circuit filters out surges, spikes, and other interference from the external input power. A reverse polarity protection circuit prevents damage to downstream circuitry caused by reverse polarity connection of the external adapter. Short-circuit and overcurrent protection circuits cut off power if an overcurrent or short-circuit fault occurs in the test device circuit, preventing damage to the circuit and components.

[0052] The DC-DC conversion circuit converts the external input voltage, and the converted voltage provides the required operating voltage for the control signal conditioning system, external communication interface, human-computer interaction system, control board and power board.

[0053] The LDO conversion circuit converts the voltage output by the DC-DC conversion circuit. The converted voltage provides the required working voltage for the processor control system, sensor acquisition system, external communication interface system, human-computer interaction system and other parts.

[0054] The MCU controller samples the power supply and control signals transmitted by the test device from the tested board, as well as the relevant signals output by the tested board in response to the control signals. The MCU controller compares all sampled signals with normal signals to determine whether the functional performance of the tested board is normal.

[0055] During testing, the test device is operated by keystrokes to execute relevant tests and set control signal parameters. The display screen displays the test device's menu selections, test results for relevant test items, and whether the board under test passes the final test. Indicator lights indicate the test device's operating status and the test results of the board under test. A buzzer indicates the test device's operating status and whether the board under test passes the test. Simultaneously, the host computer configures test device parameters, controls the test, and displays the test results of each test item during the test.

[0056] The test device and the host computer exchange data via the Ethernet interface. The MCU controller sends real-time test data to the host computer for display. At the same time, the host computer uses the Ethernet interface to configure parameters and send control instructions to the MCU controller for execution. The MCU controller program can also be upgraded via the USB interface. At the same time, data can also be exchanged between the test device and the host computer, achieving the same functions as the Ethernet interface. The RS232 interface is a reserved communication interface. The TF card interface is used to hold a TF card. When the test device is working alone, the MCU controller saves the test data to the TF card.

[0057] The testing device described in this embodiment significantly improves mass production efficiency and product yield by separately testing the full functionality and performance of the control and power boards before welding them. Once these tests are complete, they are transferred to the back-end for welding. Furthermore, test data and records can be directly saved to a local storage card or uploaded to a server via a computer, facilitating data organization and subsequent review.

Claims

1. A single-board test device for a brushless DC motor drive module, characterized by: It includes a processor control unit, a control signal conditioning unit, a sensor acquisition unit, an external communication interface unit, a human-computer interaction unit and a power supply unit; The processor control unit, control signal conditioning unit, sensor acquisition unit, external communication interface unit and human-computer interaction unit are all electrically connected to the power supply unit; The control signal conditioning unit, the sensor acquisition unit, the external communication interface unit and the human-computer interaction unit are all electrically connected to the aforementioned processor control unit.

2. The single-board test device for a brushless DC motor drive module according to claim 1, characterized in that: The processor control unit includes an MCU controller, a drive circuit and a peripheral circuit; the drive circuit and the peripheral circuit are both electrically connected to the MCU controller.

3. The single-board testing device for a brushless DC motor drive module according to claim 2, characterized in that: The control signal conditioning unit includes a signal isolation circuit, a DAC circuit, an operational amplifier conversion circuit and a level conversion circuit; The operational amplifier conversion circuit is electrically connected to the isolation circuit via the DAC circuit; The level conversion circuit is electrically connected to the isolation circuit; The isolation circuit is electrically connected to the aforementioned MCU controller.

4. The single-board testing device for a brushless DC motor drive module according to claim 3, characterized in that: The sensor acquisition unit includes a voltage acquisition circuit, a current acquisition circuit, a temperature acquisition circuit, and an ADC conversion circuit; The voltage acquisition circuit, current acquisition circuit, and temperature acquisition circuit are all electrically connected to the aforementioned operational amplifier conversion circuit; The operational amplifier conversion circuit is electrically connected to the isolation circuit via the ADC conversion circuit.

5. The single-board testing device for a brushless DC motor drive module according to claim 4, characterized in that: The power supply unit includes an external power supply interface, a surge suppression circuit, an anti-reverse connection circuit, a short circuit and overcurrent protection circuit, a DC-DC conversion circuit and an LDO conversion circuit; The external power supply interface, anti-reverse connection circuit, surge suppression circuit and short circuit and overcurrent protection circuit are electrically connected in sequence; The short circuit and overcurrent protection circuit is electrically connected to the LDO conversion circuit via the DC-DC conversion circuit; The LDO conversion circuit is electrically connected to the aforementioned processor control unit, control signal conditioning unit, sensor acquisition unit, external communication interface unit and human-computer interaction unit respectively.

6. The single-board testing device for a brushless DC motor drive module according to claim 5, characterized in that: The DC-DC conversion circuit adopts an isolated DC-DC conversion circuit.

7. The single-board testing device for a brushless DC motor drive module according to claim 5 or 6, characterized in that: The external communication interface unit includes an Ethernet interface, a USB interface, an RS232 interface, and a TF card interface; the Ethernet interface, USB interface, RS232 interface, and TF card interface are all electrically connected to the aforementioned MCU controller.

8. The single-board testing device for a brushless DC motor drive module according to claim 7, characterized in that: The human-computer interaction unit includes a button, a display screen, an indicator light, a buzzer and a host computer; the indicator light and the buzzer are electrically connected to the MCU via the aforementioned drive circuit; the button, display screen, host computer and the aforementioned MCU are electrically connected.

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