Controller load pressure detection system

Abstract

The utility model relates to the technical field of brushless motor controllers, and discloses a controller load pressure detection system, which comprises a DC power supply, a controller to be detected, an instrument box, a motor dragging jig and a load resistance box, the instrument box, the motor dragging jig and the load resistance box are connected in sequence, and the DC power supply, the controller to be tested and the motor dragging jig are connected in sequence. A controller is connected to test equipment, the controller to be tested is started to enable an active motor (a brushless motor I) to start rotating, an operator operates a load resistance box according to an operation instruction to control the access of a load resistor, different loads are applied to a controller-motor system, and three indicating instruments of current, rotating speed and positive and negative rotation are observed to judge whether a product is qualified or not; and the instrument box, the motor dragging jig and the load resistance box of the detection system are integrated and independent from one another, so that the station movement of a production line and the replacement of the controller to be detected are facilitated, and the overall utilization rate of equipment is improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to brushless motor controller technical field especially, relates to the load pressure test field of brushless motor controller, concretely is a kind of controller load pressure detection system. BACKGROUND

[0002] Brushless motor controller is used to control the device of brushless motor operation, brushless motor has no carbon brush and commutator, controller detects motor rotor position sensor (such as hall sensor) signal, to determine rotor position, again switch the conduction and shutdown of power switch device (such as MOSFET, IGBT etc.) in inverter in order, DC power is inverted into AC power, for motor stator winding power supply, realize the continuous rotation of motor.

[0003] The purpose of load pressure test of brushless motor controller is: detect the working performance, stability and reliability of brushless motor controller under different load conditions, verify whether it can operate normally under various working conditions, provide basis for optimizing design and improving performance.

[0004] Current controller load pressure detection system does not have the ability to accurately adjust load, cannot accurately simulate actual load condition, and each test component in the system is not convenient to separate after connection, that is, it is not convenient to replace the product to be tested, therefore we need to propose a kind of controller load pressure detection system. UTILITY MODEL CONTENT

[0005] The utility model aims at providing a kind of controller load pressure detection system, connects test equipment to controller, starts the motor (brushless motor one) to rotate by the controller to be measured, operator operates load resistance box control load resistance access according to job instruction, applies different load to controller-motor system, and observes current, speed, positive and negative rotation three indicating instruments, judges whether product is qualified;And the instrument box of this detection system, motor pair drag fixture, load resistance box trinity and independent of each other, facilitate production line mobile station and replacement controller to be measured, improve the utilization of equipment as a whole;To solve the problems raised in the above background technology.

[0006] To achieve the above object, the utility model provides the following technical scheme: a kind of controller load pressure detection system, comprising:

[0007] DC power supply can display voltage and current, and provide stable DC power supply for detection system;

[0008] By controlling brushless motor operation, test the controller to be measured under different conditions on brushless motor control ability;

[0009] Instrument box for accurately measuring the speed of brushless motor and judging the rotation direction of brushless motor;

[0010] Motor pair drag tool for simulating the operation and load condition of brushless motor under actual working condition, and providing a test environment for the to-be-tested controller;

[0011] Load resistance box for simulating the load state of brushless motor under different working conditions, and testing the performance of brushless motor and the to-be-tested controller under different loads;

[0012] The instrument box, the motor pair drag tool and the load resistance box are sequentially connected, and the DC power supply, the to-be-tested controller and the motor pair drag tool are sequentially connected.

[0013] Preferably, the motor pair drag tool comprises two brushless motors connected through a shaft coupling, and the two brushless motors comprise a brushless motor one connected with the to-be-tested controller and a brushless motor two connected with the load resistance box.

[0014] Preferably, the load resistance box comprises a three-phase rectifier bridge connected with the brushless motor two, and the three-phase rectifier bridge is connected with load resistance one, load resistance two, load resistance three and load resistance four arranged in parallel, one end of the load resistance one is connected with a switch SW1, one end of the load resistance two is connected with a switch SW2, one end of the load resistance three is connected with a switch SW3, and one end of the load resistance four is connected with a switch SW4.

[0015] Preferably, the instrument box comprises a tachometer, a forward-reverse detection meter and a rotating speed probe installed on the motor pair drag tool, and the tachometer and the forward-reverse detection meter are connected with the rotating speed probe.

[0016] Preferably, the tachometer is used for displaying the rotating speed information of the brushless motor in real time, the forward-reverse detection meter is used for judging the rotating direction of the brushless motor, and the rotating speed probe is used for detecting the rotating speed of the brushless motor.

[0017] Preferably, the brushless motor one is a driving motor, the brushless motor two is a load motor, the to-be-tested controller drives the brushless motor one to run through a motor driving module, and the motor driving module comprises a three-phase inverter bridge circuit, a current sampling circuit, a voltage sampling circuit and a Hall encoder driving circuit electrically connected with the three-phase inverter bridge circuit.

[0018] Compared with the prior art, the utility model has the advantages that:

[0019] 1、The utility model discloses a controller is connected to the test equipment, starts the to-be-tested controller and makes the initiative motor (brushless motor one) begin to rotate, and the operator operates the load resistance box according to the operation instruction book and controls the load resistance to be connected, and different loads are applied to the controller-motor system, and three indicating instruments of current, rotating speed and forward-reverse rotation are observed, and whether the product is qualified is judged.

[0020] 2, the utility model discloses instrument box, motor pair drag fixture, load resistance box trinity and each other independent, facilitate production line mobile station and replacement measured controller, improve the utilization of equipment whole. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 It is system block diagram of the utility model;

[0022] Figure 2 It is structure diagram of the utility model instrument box;

[0023] Figure 3 It is structure diagram of the utility model motor pair drag fixture;

[0024] Figure 4 It is structure diagram of the utility model load resistance box;

[0025] Figure 5 It is structure diagram of the utility model three-phase inverter bridge circuit;

[0026] Figure 6 It is structure diagram of the utility model current sampling circuit;

[0027] Figure 7 It is structure diagram of the utility model voltage sampling circuit;

[0028] Figure 8 It is structure diagram of the utility model hall encoder drive circuit. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the utility model will be clearly and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the utility model.

[0030] Please refer to Figures 1-8 The utility model provides a kind of controller load pressure detection system, comprising:

[0031] DC power supply can display voltage and current, and provide stable DC power supply for detection system;

[0032] Test the measured controller of the control ability of brushless motor under different conditions by controlling brushless motor operation;

[0033] Instrument box for accurately measuring the rotation speed of brushless motor and judging the rotation direction of brushless motor;

[0034] The instrument box comprises a tachometer, a forward-reverse detection meter and a rotating speed probe installed on an electrode pair drag fixture, wherein the tachometer and the forward-reverse detection meter are connected with the rotating speed probe.

[0035] The tachometer is used for displaying the rotating speed information of the brushless motor in real time, the forward-reverse detection meter is used for judging the rotating direction of the brushless motor, and the rotating speed probe is used for detecting the rotating speed of the brushless motor.

[0036] The motor pair drag fixture simulates the running and load conditions of the brushless motor under actual working conditions to provide a test environment for the to-be-tested controller.

[0037] The motor pair drag fixture comprises two brushless motors connected through a shaft coupling, wherein the two brushless motors comprise a brushless motor one connected with the to-be-tested controller and a brushless motor two connected with a load resistance box. The brushless motor one is a driving motor, and the brushless motor two is a load motor.

[0038] The load resistance box simulates the load state of the brushless motor under different working conditions to test the performance of the brushless motor and the to-be-tested controller under different loads.

[0039] The load resistance box comprises a three-phase rectifier bridge connected with the brushless motor two, wherein the three-phase rectifier bridge is connected with a load resistance one, a load resistance two, a load resistance three and a load resistance four arranged in parallel, one end of the load resistance one is connected with a switch SW1, one end of the load resistance two is connected with a switch SW2, one end of the load resistance three is connected with a switch SW3, and one end of the load resistance four is connected with a switch SW4.

[0040] The instrument box, the motor pair drag fixture and the load resistance box are sequentially connected, and the DC power supply, the to-be-tested controller and the motor pair drag fixture are sequentially connected.

[0041] The DC power supply provides DC power for the whole system and displays the voltage and current values of the output, so as to monitor the power supply state in real time and ensure the stable power supply and normal parameters of the system.

[0042] The to-be-tested controller is the brushless motor controller to be tested, and its performance is the core object of the test. The to-be-tested controller controls the operation of the brushless motor to test the control ability and stability of the brushless motor under different conditions.

[0043] The instrument box is internally provided with a tachometer and a forward-reverse detection meter. The tachometer is used for accurately measuring the rotating speed of the brushless motor, and the forward-reverse detection meter is used for judging the rotating direction of the motor to provide data for analyzing the running state of the motor.

[0044] The motor pair drag fixture is composed of the brushless motor one and the brushless motor two, simulates the running and load conditions of the motor under actual working conditions, and provides a test environment for the to-be-tested controller.

[0045] When the brushless motor one rotates, it drives the brushless motor two to rotate synchronously through the coupling. The brushless motor two generates a reverse resistance torque under the action of the load resistance box, simulating the load condition of the motor under actual working conditions.

[0046] The tachometer in the instrument box monitors the speed of the motor in real time, and the forward and reverse detection meter determines the rotation direction of the brushless motor. By changing the control parameters of the controller to be tested and the load size of the load resistance box, the performance of the brushless motor under different working conditions can be tested.

[0047] The three-phase rectifier bridge in the load resistance box converts the alternating current generated by the brushless motor into direct current, and the load resistance provides different sizes of load for the brushless motor, simulating the load state of the brushless motor under various working conditions, helping to test the performance of the brushless motor and the controller to be tested under different loads.

[0048] The controller to be tested drives the brushless motor one to run through the motor drive module, which includes a three-phase inverter bridge circuit, a current sampling circuit electrically connected to the three-phase inverter bridge circuit, a voltage sampling circuit, and a Hall encoder drive circuit.

[0049] In use, connect the DC power supply to the system to power the entire test equipment and ensure that it can display voltage and current stably, connect the controller to be tested to the corresponding position of the test equipment to establish an electrical connection with the system, and ensure that the brushless motor one and the brushless motor two are connected to ensure the stability of mechanical transmission, turn on the controller to be tested to drive the brushless motor one as the driving motor to start rotating. At this time, the rotation information of the brushless motor one will be transmitted to the instrument box.

[0050] The operator operates the load resistance box according to the operation instruction manual. By controlling the connection of the four load resistances, the three-phase rectifier bridge converts the alternating current generated by the brushless motor into direct current to apply to the load resistance. Different load resistance combinations can simulate different loads, thereby applying different degrees of load pressure to the controller-motor system.

[0051] During the load application process, continuously observe the three indicating instruments in the instrument box:

[0052] Tachometer: Real-time acquisition of the speed information of the brushless motor, understanding the change of the speed of the brushless motor under different loads, and analyzing the control ability of the controller to be tested on the speed of the brushless motor and the speed variation characteristics of the brushless motor.

[0053] Forward and reverse detection meter: Determine whether the rotation direction of the brushless motor meets the expectation, and judge the accuracy of the brushless motor rotation control of the controller to be tested.

[0054] Current indication (DC power display voltage current can assist in determining the current situation): monitor the current size of the controller-motor system, find the overcurrent protection point / limiting working point of the system under different load pressure conditions, and determine whether the performance of the controller to be tested in the current protection is normal.

[0055] According to the observed current, speed, and forward and reverse rotation data, whether the brushless motor controller is qualified is determined according to the pre-set qualified standard. If all indicators are within the qualified range, the product is qualified; if there is current abnormality, unstable speed, and incorrect rotation, etc., it can be judged that the product has poor electrical performance or characteristic degradation, and it will be screened out.

[0056] The three-phase inverter bridge circuit comprises a chip U2, a MOS tube Q1 and a MOS tube Q2, a resistor R9 is connected to the 2-pin of the chip U2, a resistor R10 is connected to the 3-pin of the chip U2, the 6-pin of the chip U2 is connected to the connection end of the source electrode of the MOS tube Q1 and the drain electrode of the MOS tube Q2, a resistor R14 is connected between the 5-pin of the chip U2 and the gate electrode of the MOS tube Q2, the resistor R14 is connected in parallel with a resistor R13 and a diode D6 connected in series, a resistor R6 is connected between the 7-pin of the chip U2 and the gate electrode of the MOS tube Q1, and the resistor R6 is connected in parallel with a resistor R3 and a diode D1 connected in series.

[0057] The current sampling circuit comprises a comparator U7B, a resistor R46 is connected between the 6-pin and the 7-pin of the comparator U7B, a resistor R53 and a resistor R54 are connected in series to the 5-pin of the comparator U7B, a resistor R48 and a resistor R49 are connected in series to the 6-pin of the comparator U7B, a capacitor C27 is connected between the connection end of the resistor R48 and the resistor R49 and the connection end of the resistor R53 and the resistor R54, a resistor R56 is connected to the 5-pin of the comparator U7B, and a resistor R52 and a capacitor C29 connected in series are connected to the 7-pin of the comparator U7B.

[0058] The voltage sampling circuit comprises a comparator U8B, a resistor R73 is connected between the 6-pin and the 7-pin of the comparator U8B, a resistor R79 and a resistor R80 are connected in series to the 5-pin of the comparator U8B, a resistor R76 and a resistor R77 are connected in series to the 6-pin of the comparator U8B, a capacitor C36 is connected between the connection end of the resistor R48 and the resistor R49 and the connection end of the resistor R53 and the resistor R54, a resistor R83 is connected to the 5-pin of the comparator U8B, and a resistor R78 and a capacitor C37 connected in series are connected to the 7-pin of the comparator U8B.

[0059] The Hall encoder drive circuit comprises a connector P2, a pin 1 of the connector P2 is connected with a 5V voltage and connected with a capacitor C13, a pin 2 of the connector P2 is connected with a resistor R20, a pin 3 of the connector P2 is connected with a resistor R22, and a pin 4 of the connector P2 is connected with a resistor R25;

[0060] One end of the resistor R20 is connected with a resistor R16 and a capacitor C17 respectively, one end of the resistor R22 is connected with a resistor R17 and a capacitor C18 respectively, one end of the resistor R25 is connected with a resistor R21 and a capacitor C19 respectively, one end of the resistor R16, the resistor R17 and the resistor R21 is connected with 3.3V, and one end of the capacitor C17, the capacitor C18 and the capacitor C19 is connected with ground.

[0061] The system can configure the host computer to read the meter to reduce the demand for worker skills, and the host computer cooperates with the electronic load to flexibly adjust the load value and record the load voltage, current and power; the host computer cooperates with the barcode system to realize data binding and product traceability; the resistance load with grid-connected energy recovery function can be used to greatly save energy compared with the power resistance heat dissipation mode of the existing scheme; the customized generator can be used as the load end instead of the same motor as the active motor used at present to reduce noise and vibration.

[0062] Although the embodiments of the utility model have been shown and described, it can be understood by those skilled in the art that various changes, modifications, replacements and variations can be made to these embodiments without departing from the principles and spirits of the utility model, and the scope of the utility model is defined by the appended claims and their equivalents.

Claims

1. A controller load pressure detection system characterized by, The utility model relates to a test system for testing the performance of brushless motor controller, comprising: DC power supply for displaying voltage and current and providing stable DC power for the test system; Test the performance of brushless motor controller by controlling brushless motor running under different conditions; Instrument box for accurately measuring the speed of brushless motor and judging the rotating direction of brushless motor; Motor pair drag tool for simulating the running and load conditions of brushless motor under actual working conditions and providing test environment for the tested controller; Load resistance box for simulating the load state of brushless motor under different working conditions and testing the performance of brushless motor and the tested controller under different loads; The instrument box, motor pair drag tool and load resistance box are connected in sequence, and the DC power supply, tested controller and motor pair drag tool are connected in sequence.

2. The controller load pressure detection system of claim 1, wherein: The motor pair drag tool comprises two brushless motors connected through a shaft coupling, and the two brushless motors comprise a brushless motor one connected with the tested controller and a brushless motor two connected with the load resistance box.

3. The controller load pressure detection system of claim 1, wherein: The load resistance box comprises a three-phase rectifier bridge connected with the brushless motor two, and the three-phase rectifier bridge is connected with load resistance one, load resistance two, load resistance three and load resistance four arranged in parallel, one end of the load resistance one is connected with switch SW1, one end of the load resistance two is connected with switch SW2, one end of the load resistance three is connected with switch SW3, and one end of the load resistance four is connected with switch SW4.

4. The controller load pressure detection system of claim 1, wherein: The instrument box comprises a tachometer, a forward-reverse detection meter and a speed probe installed on the motor pair drag tool, and the tachometer and forward-reverse detection meter are connected with the speed probe.

5. The controller load pressure detection system of claim 2, wherein: The brushless motor one is a driving motor, the brushless motor two is a load motor, the tested controller drives the brushless motor one to run through a motor drive module, and the motor drive module comprises a three-phase inverter bridge circuit, a current sampling circuit, a voltage sampling circuit and a Hall encoder drive circuit electrically connected with the three-phase inverter bridge circuit.

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