Intelligent controller of brushless direct current motor

Abstract

The utility model discloses an intelligent controller for a brushless direct current motor, which comprises a control module, the control module comprises a single chip microcomputer control unit, the signal input end of the single chip microcomputer control unit is connected with a signal acquisition unit, and the signal output end of the single chip microcomputer control unit is connected with a signal output unit. The signal acquisition unit is used for acquiring a control signal and a motor rotating speed feedback square wave signal; the signal output unit is used for inputting a control signal of the single-chip microcomputer control unit to the execution motor. The signal acquisition unit comprises a local control signal acquisition subunit and a remote control signal acquisition subunit. According to the utility model, inching, self-locking, time delay and time delay with emergency stop control can be carried out on the motor, the DC brushless motor DC 12V / 24V can be controlled, the maximum power is 120W, and the maximum load is 10A. A speed regulation mode adopts a PWM signal to control the rotating speed of the motor, a motor rotating speed feedback square wave signal is collected, the maximum frequency is 200Hz, and the rotating speed of the motor is accurately stabilized at a set target rotating speed by adopting PID closed-loop control.

Description

TECHNICAL FIELD

[0001] The utility model relates to a controller, concretely relates to a brushless DC motor intelligent controller. BACKGROUND

[0002] The output rotation of a motor serves as a widely used power source and plays a crucial role in various mechanical devices and systems. In order to make more effective use of this power source, accurate control of the motor is particularly important. Generally, through a controller, the rotation direction and speed of the motor can be adjusted to meet different power requirements and improve the operating efficiency and performance of the equipment.

[0003] However, traditional motor controllers are relatively single in control mode, mostly using single point operation mode. Although this control mode can achieve the start-stop and simple speed regulation of the motor to some extent, it is limited in control when facing complex and variable power control requirements of the execution equipment. Specifically, the single point operation mode lacks sufficient flexibility and accuracy, making it difficult to achieve fine control of the motor rotation, thereby limiting the potential of the motor in more application scenarios. SUMMARY

[0004] Therefore, in order to solve the above problems, the utility model provides a brushless DC motor intelligent controller, which can control the motor to point, self-lock, delay and delay with emergency stop control. The controller can control the DC brushless motor DC12V / 24V, the maximum power is 120W, and the maximum load is 10A. The speed regulation mode uses PWM signal to control the motor speed, and collects the motor speed feedback square wave signal with a maximum frequency of 200Hz, and uses PID closed loop control to accurately stabilize the motor speed at the set target speed,

[0005] Specifically, a brushless DC motor intelligent controller includes a control module, which includes a single-chip microcomputer control unit, a signal acquisition unit connected to the signal input end of the single-chip microcomputer control unit, and a signal output unit connected to the signal output end of the single-chip microcomputer control unit,

[0006] The signal acquisition unit is used to acquire control signals and motor speed feedback square wave signals.

[0007] The signal output unit is used to input the control signals of the single-chip microcomputer control unit to the execution motor.

[0008] The signal acquisition unit includes a local control signal acquisition subunit and a remote control signal acquisition subunit.

[0009] Optionally, the brushless DC motor intelligent controller further includes a protection module for acquiring motor under-voltage and blocked rotor over-current signals.

[0010] Optionally, an alarm module is also included.

[0011] Optionally, the signal acquisition unit further includes several single signal interfaces.

[0012] Optionally, the device further comprises a base and a shell mounted on the base, wherein the control module is mounted on the base and located inside the shell;

[0013] A button connected to the control module is provided on the housing.

[0014] Optionally, the base is provided with a mounting groove, and a locking plate is provided on one side of the mounting groove.

[0015] Optionally, the base is provided with a lock slot located on one side of the mounting slot, and the lock plate is slidably mounted in the lock slot;

[0016] One end of the lock plate is a flat lock tongue, and a locking claw is arranged on the lock plate.

[0017] Optionally, the brushless DC motor intelligent controller further includes a mounting track, which is mounted in the mounting slot. When the lock plate is in a locked state, the lock tongue is pressed against the track (there is a snap-fitting area at the end of the lock tongue, which is adapted to the edge of the track).

[0018] The utility model has the following advantages:

[0019] This utility model is an intelligent brushless DC motor controller capable of controlling 12V / 24V DC brushless DC motors with a maximum power of 120W and a maximum load of 10A. The controller uses a PWM signal to control the motor speed and collects a square wave speed feedback signal with a maximum frequency of 200Hz. It employs PID closed-loop control to precisely stabilize the motor speed at the set target speed. Speed ​​setting supports both local and remote control. Local control utilizes keypad buttons for speed regulation; remote control utilizes an external analog 1-10V input for speed regulation.

[0020] The controller can realize various motor functions such as forward and reverse rotation, reciprocating cycle, limit, delay, speed regulation, and emergency stop. It also provides undervoltage, stalled rotor and overcurrent protection for the motor. The intelligent controller drives the motor in four main operating modes: inching, self-locking, delay control, and delay with emergency stop.

[0021] The brushless DC motor driven by this utility model can be widely used in production processes and process industrial automation control in industries such as automobiles, electronics, energy, medical care, and home appliances, making production more efficient, flexible, low-carbon, and green, and helping to build efficient smart factories. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1The brushless DC motor intelligent controller of the present invention is a systematic block diagram;

[0023] Figure 2 This is the control main circuit diagram of the brushless DC motor intelligent controller of the utility model;

[0024] Figure 3 It is the power supply and output circuit diagram of the utility model;

[0025] Figure 4 This is the human-machine interface circuit diagram of the brushless DC motor intelligent controller;

[0026] Figure 5 1 is a schematic diagram of terminal definitions of the brushless DC motor intelligent controller;

[0027] Figure 6 is a structural diagram of the brushless DC motor intelligent controller;

[0028] Figure 7 2 is a schematic structural diagram of the brushless DC motor intelligent controller from another perspective;

[0029] Figure 8 Schematic diagram of the combination of the base and the guide rail;

[0030] Figure 9 This is a schematic diagram of the structure of the brushless DC motor intelligent controller after the housing is removed;

[0031] Figure 10 is a schematic diagram of the combination of the locking plate and the track;

[0032] In the figure: 101, single-chip microcomputer control unit; 102, signal acquisition unit; 103, protection module; 104, alarm module; 105, signal output unit; 201, base; 202, housing; 203, button; 204, lock plate; 2041, engaging area; 2042, locking claw; 205, track; 2051, edge. DETAILED DESCRIPTION

[0033] The following describes in detail embodiments of the present application, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present application, and should not be construed as limiting the present application.

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

[0035] As mentioned in the background, however, traditional motor controllers have a relatively simple control approach, often operating in a single-moment mode. While this control mode can achieve motor start / stop and simple speed regulation to a certain extent, it is limited when faced with the complex and ever-changing power control requirements of actuators. Specifically, the single-moment mode lacks sufficient flexibility and precision, making it difficult to achieve fine-grained control of motor rotation, thus limiting the potential of motors in a wider range of application scenarios.

[0036] Based on the above reasons, this embodiment provides a brushless DC motor intelligent controller, such as Figure 1-Figure 5 As shown, the brushless DC motor intelligent controller includes a control module, which includes a single-chip control unit 101. The signal input end of the single-chip control unit is connected to a signal acquisition unit 102, and the signal output end of the single-chip control unit is connected to a signal output unit 105.

[0037] The signal acquisition unit is used to collect control signals and motor speed feedback square wave signals;

[0038] The signal output unit is used to input the control signal of the single chip control unit to the execution motor;

[0039] The signal acquisition unit includes a local control signal acquisition subunit and a remote control signal acquisition subunit.

[0040] For example, the single-chip microcomputer control unit adopts an STM32F103RCT6 single-chip microcomputer; the parameters of the controller are shown in Table 1:

[0041] Table 1: Controller parameters

[0042]

[0043] The above technical features can control a DC12V / 24V brushless DC motor with a maximum power of 120W and a maximum load of 10A. The controller uses a PWM signal to control the motor speed and collects the motor speed feedback square wave signal with a maximum frequency of 200Hz. It uses a PID closed-loop control to accurately stabilize the motor speed at the set target speed. The speed setting supports both local control and remote control. Local control uses the operation panel buttons to adjust the speed; remote control uses an external analog value of 1~10V to adjust the speed. The controller can realize various motor functions such as forward and reverse rotation, reciprocating cycle, limit, delay, speed regulation, and emergency stop.

[0044] In one embodiment, the signal acquisition unit further includes several single signal interfaces, such as Figure 5 As shown, it has four signal interfaces: IN1, IN2, IN3 and IN4. When controlling the motor, in order to realize the control modes of jog, self-locking, delay control and delay with emergency stop, the control can be as follows:

[0045] Jog mode

[0046] When signal IN1 is given, the motor rotates forward, and when signal IN1 is disconnected, the motor stops.

[0047] When signal IN2 is given, the motor reverses, and when signal IN2 is disconnected, the motor stops.

[0048] When signal IN3 is given, the motor stops at the forward limit position, and when signal IN4 is given, the motor stops at the reverse limit position.

[0049] Self-locking mode

[0050] When signal IN1 is given, the motor continues to rotate forward, and when signal IN1 is given again, the motor stops.

[0051] When signal IN2 is given, the motor continues to reverse, and when signal IN2 is given again, the motor stops.

[0052] When signal IN3 is given, the motor stops at the forward limit position, and when signal IN4 is given, the motor stops at the reverse limit position.

[0053] Delay control mode

[0054] When signal IN1 is given, the motor will rotate forward for A seconds (set parameters) and then stop.

[0055] Give signal IN2, the motor will reverse for B seconds (set parameters) and then stop.

[0056] When signal IN3 is given, the motor stops at the forward limit position, and when signal IN4 is given, the motor stops at the reverse limit position.

[0057] Extension belt emergency stop control mode

[0058] When signal IN1 is given, the motor will rotate forward for A seconds (set parameters) and then stop when it encounters the forward limit signal IN3.

[0059] Give signal IN1 again, the motor will reverse for B seconds (set parameters) and then stop when it encounters reverse limit signal IN4.

[0060] Give signal IN2 to stop the motor urgently.

[0061] The above four modes can each be set individually with the following 8 groups of parameters:

[0062] (1) SA: soft start time, 0-100 seconds;

[0063] (2) SP: soft stop time, 0-100 seconds;

[0064] (3) PF: forward speed, 1-999 rpm;

[0065] (4) OP: reverse speed, 1-999 rpm;

[0066] (5) CD: Current alarm delay time, 0.01s-9.99s;

[0067] (6) CF: Forward current alarm value, 0.01A-9.99A;

[0068] (7) CE: Reverse current alarm value, 0.01A-9.99A;

[0069] (8) DE: Mode working time, 1 second to 999 minutes, 0 means unlimited time;

[0070] In order to protect the motor, in one embodiment, the brushless DC motor intelligent controller further includes a protection module 103 and an alarm module 104 for obtaining motor undervoltage and stalled rotor overcurrent signals. The protection module can provide undervoltage and stalled rotor overcurrent protection functions for the motor. Figure 3 The circuit shown in the figure uses the Hall sensor CI5930-20A to monitor current, overcurrent and overload monitoring and protection

[0071] In order to achieve the protection of the control module and the installation of the entire controller, such as Figures 6-10 As shown, in one embodiment, it further includes a base 201 and a shell 202 mounted on the base, and the control module is mounted on the base and located in the shell;

[0072] A button 203 connected to the control module is provided on the housing.

[0073] The base has a mounting slot, with a locking plate 204 on one side. The base also has a locking slot located on one side of the mounting slot, into which the locking plate is slidably mounted. One end of the locking plate 204 is a flat locking tongue, on which a locking claw 2042 is disposed. A track 205 is mounted on the locking slot, and when the locking plate is locked, the locking tongue presses against the track. The end of the locking tongue has an engaging area 2041 that mates with an edge 2051 of the track. Preferably, the track is a 35mm DIN track.

[0074] The above technical features can realize the protection of the control module and the quick installation of the controller; during installation, the lock slot is engaged with the track, and then the lock plate is pushed in so that the lock tongue of the lock plate is pressed against the track; during this process, the locking claw is pressed against the bottom surface of the base, increasing the friction of the lock plate and reducing the risk of the lock tongue being separated from the edge of the track due to the retraction of the lock plate.

[0075] The above description of the disclosed embodiments will enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A brushless DC motor intelligent controller, characterized by: The control module includes a single chip microcomputer control unit, the signal input end of the single chip microcomputer control unit is connected to the signal acquisition unit, and the signal output end of the single chip microcomputer control unit is connected to the signal output unit. The signal acquisition unit is used to collect control signals and motor speed feedback square wave signals; The signal output unit is used to input the control signal of the single chip control unit to the execution motor; The signal acquisition unit includes a local control signal acquisition subunit and a remote control signal acquisition subunit.

2. The brushless DC motor intelligent controller according to claim 1, characterized in that: It also includes a protection module for obtaining motor undervoltage and stall overcurrent signals.

3. The brushless DC motor intelligent controller according to claim 1, characterized in that: Also includes an alarm module.

4. The brushless DC motor intelligent controller according to claim 1, characterized in that: The signal acquisition unit further includes several single signal interfaces.

5. The brushless DC motor intelligent controller according to any one of claims 1 to 4, characterized in that: It also includes a base and a shell mounted on the base, wherein the control module is mounted on the base and located in the shell; A button connected to the control module is provided on the housing.

6. The brushless DC motor intelligent controller according to claim 5, characterized in that: The base is provided with a mounting groove, and a locking plate is provided on one side of the mounting groove.

7. The brushless DC motor intelligent controller according to claim 6, characterized in that: The base is provided with a lock slot located on one side of the mounting slot, and the lock plate is slidably mounted in the lock slot; One end of the lock plate is a flat lock tongue, and a locking claw is arranged on the lock plate.

8. The brushless DC motor intelligent controller according to claim 7, characterized in that: It also includes a mounting track, which is mounted on the mounting groove. When the lock plate is in a locked state, the lock tongue is pressed against the track.

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