Efficient and accurate control system for new energy commercial truck based on DSP redundancy

Abstract

The utility model discloses an efficient and accurate control system for a new energy commercial truck based on DSP redundancy. According to the utility model, the dual-core DSP is adopted to improve the system performance. One core focuses on wave sending processing, voltage, current and temperature sampling work, operation control algorithm and communication functions; and the other core is used for detection and protection, fault processing, a self-learning algorithm and a fault pre-judgment algorithm. Meanwhile, the CAL coprocessor is used for sharing a signal calculation processing task, remarkably reducing CPU load and improving the overall operation efficiency of the system, and two groups of power modules are mutually backed up, so that when one group of power supply fails, the other group of power supply can be quickly switched, stable power supply of the system is ensured, system shutdown caused by power supply failure is effectively avoided, and the service life of the system is prolonged. Precise detection of three-phase current is achieved through a hardware addition circuit, three sets of data are displayed at the same time and verified mutually, data misjudgment caused by faults of a single collection point is prevented, and therefore reliable data support is provided for precise control of a system.

Description

Technical Field

[0001] This utility model belongs to the field of new energy truck control technology, specifically a high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy. Background Technology

[0002] In new energy vehicles, the motor drive controller plays a crucial role in operating and protecting the motor. With the increasingly complex operating environment of new energy commercial trucks, the motor drive control system faces unprecedented challenges. As vehicle intelligence increases, more auxiliary functions, such as autonomous driving assistance and vehicle-to-everything (V2X) communication, interact with the motor drive system, further increasing the processing burden on traditional single-DSP control systems. Simultaneously, stringent regulations require vehicles to ensure safe operation under various extreme conditions. Traditional solutions face severe tests of stability and reliability when dealing with harsh environments such as low temperatures, high temperatures, high humidity, and strong electromagnetic interference. For example, in high-temperature environments, the heat dissipation problem of a single DSP chip intensifies, easily leading to performance degradation or even system crashes, seriously affecting normal vehicle operation. Moreover, existing solutions rely heavily on simple threshold judgments for fault diagnosis, making it difficult to accurately detect intermittent or latent faults. This not only increases the difficulty of vehicle maintenance but also poses potential safety hazards. In the motor drive control system of new energy commercial trucks, with the continuous improvement of vehicle performance and stringent safety requirements...

[0003] However, traditional single-DSP control systems are no longer sufficient to meet the high reliability requirements under complex operating conditions. On the one hand, a single DSP is prone to performance bottlenecks due to excessive load when handling complex functions such as wave generation, sampling, control algorithms, and communication. On the other hand, insufficient reliability of the power supply module and inadequate fault detection and protection mechanisms mean that the system cannot respond promptly and effectively to sudden failures, potentially leading to secondary failures and major safety accidents. Furthermore, there are shortcomings in the recording and analysis of fault data, which hinders subsequent research, development, optimization, and upgrade efforts. Summary of the Invention

[0004] The purpose of this invention is to provide a high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy in order to solve the problems mentioned above.

[0005] The technical solution adopted in this utility model is as follows: A high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy, comprising:

[0006] The dual-core DSP main circuit is used to execute motor drive control algorithms and fault detection and protection, and includes core 1 and core 2.

[0007] The redundant power supply circuit module provides stable power to the system through a dual-power switching mechanism.

[0008] Multi-point sampling and verification circuit is used to collect IGBT bus voltage, three-phase current and temperature data and perform hardware-level redundancy verification.

[0009] The black box storage circuit is independent of the main control circuit and cyclically stores key data before and after the fault.

[0010] Independent safety chip monitoring module, based on automotive-grade safety chip, directly controls PWM blocking and relay shutdown;

[0011] The dual-core DSP main circuit, redundant power supply circuit, multi-point sampling and verification circuit, black box storage circuit, and independent security chip monitoring communicate with each other via CAN bus, SPI interface, and shared memory.

[0012] In a preferred embodiment, the dual-core DSP main circuit internally includes:

[0013] Core 1 connects to the IGBT driver circuit via the SPI interface and is responsible for generating PWM signals, executing the FOC algorithm, and acquiring voltage, current, and temperature data in real time.

[0014] Core 2 communicates with an independent security chip via the CAN bus to monitor fault signals in real time and execute protection algorithms;

[0015] Core 1 and Core 2 synchronize status data through shared memory, allowing for seamless switching of control in the event of a failure.

[0016] In a preferred embodiment, the redundant power supply circuit adopts a dual-power supply design using the LM2596S chip, and monitors the input voltage in real time through a voltage comparator;

[0017] When the main power supply fails, it switches to the backup power supply via a MOSFET switch, with a switching time of <1ms;

[0018] The output power supply is connected to the dual-core DSP main circuit and peripheral circuits through a multi-stage filtering circuit.

[0019] In a preferred embodiment, the multi-point sampling and verification circuit is used to acquire three-phase current signals through an isolation operational amplifier circuit and connect to a hardware adder circuit for redundancy verification.

[0020] Temperature data is acquired through a thermistor voltage divider circuit and redundantly distributed across the DSP chip, IGBT module, and power module.

[0021] The acquired data is converted by the ADC and then transmitted to the dual-core DSP main circuit via the SPI interface.

[0022] In a preferred embodiment, the black box storage circuit uses W25Q128 SPI Flash and AT24C256 EEPROM chips, and is isolated from the main circuit through an independent SPI / I2C interface;

[0023] The storage module inside the black box storage circuit is independently powered and physically spaced more than 10cm from the main control board. It cyclically stores voltage, current, and temperature data for 10 seconds before and after a fault.

[0024] In a preferred embodiment, the independent security chip monitoring module is based on the N32A455 automotive-grade MCU and directly acquires bus voltage, IGBT temperature and current signals through an independent ADC channel;

[0025] When overcurrent or overtemperature is detected, the PWM output and relay are directly shut off via the GPIO interface, with a response time of <1ms.

[0026] It communicates with Core 2 via the CAN bus, has a higher priority than the main control DSP, and triggers an emergency braking signal to the vehicle's braking system.

[0027] In a preferred embodiment, the switching logic of the redundant power supply circuit includes intelligent load distribution: when the main power supply temperature exceeds a threshold, the backup power supply is automatically activated to share the load, and a power status alarm is sent to the dual-core DSP main circuit via the CAN bus.

[0028] In a preferred embodiment, the black box storage circuit integrates the AES-128 encryption algorithm, and the encrypted data is remotely transmitted to the cloud platform via a wireless communication module (such as 4G / LoRa) for fault analysis.

[0029] In a preferred embodiment, the independent security chip monitors a built-in self-diagnostic function, periodically checking the status of the chip's internal ADC, comparator, and communication interface. In case of a fault, a redundant security chip takes over the protection function.

[0030] The independent safety chip monitors and links with the vehicle steering system. When a motor failure causes abnormal torque, it sends a speed limit command to the steering controller via the CAN bus to prevent the vehicle from losing control.

[0031] In a preferred embodiment, the hardware addition circuit of the multi-point sampling and verification circuit adopts a three-group redundant design. By cross-comparing the three-phase current values, abnormal data is eliminated and the redundant acquisition channels are triggered to resample.

[0032] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0033] 1. In this invention, a dual-core DSP (such as DSP28337) is used to improve system performance. One core focuses on processing wave generation, voltage, current, and temperature sampling, running control algorithms, and communication functions; the other core is used for detection and protection, fault handling, self-learning algorithms, and fault prediction algorithms. Simultaneously, the CAL coprocessor is used to offload signal calculation and processing tasks, significantly reducing the CPU load and improving the overall system operating efficiency.

[0034] 2. This utility model designs a dual-power switching protection mechanism for the easily damaged low-voltage power supply module in the motor drive system of new energy commercial trucks. By backing up the two sets of power supply modules, when one power supply fails, it can quickly switch to the other, ensuring stable power supply to the system and effectively avoiding system downtime due to power failure.

[0035] 3. In this invention, the bus voltage, current, and temperature of all IGBTs are comprehensively collected, abandoning the traditional approach of only collecting a single bus voltage, two-phase current, and one temperature. A hardware addition circuit is used to achieve accurate detection of the three-phase current, and all three sets of data are displayed simultaneously and cross-checked to prevent data misinterpretation due to a single data collection point failure, thus providing reliable data support for precise system control.

[0036] 4. This utility model incorporates a black box-like storage circuit, employing an external Flash or EEPROM module to continuously and cyclically store data before and after a fault. This module is kept at a certain distance from the main control board, effectively protecting the stored data from damage in the event of system failure, system crash, or overcurrent, providing strong evidence for tracing and analyzing the cause of the accident, while reducing primary damage to the module during an accident and secondary damage to the main storage unit during disassembly.

[0037] 5. This utility model introduces a safety chip based on the National Technology automotive-grade MCU N32A455, which independently undertakes the monitoring tasks of critical faults such as voltage, current, temperature, and speed, in addition to the main control DSP. This safety chip has the ability to directly control the motor's waveform generation and the closing of the main control relay or bus relay. It can quickly take measures when a fault is detected to avoid secondary faults, effectively protect critical components such as IGBTs from damage, and ensure vehicle operation safety. Attached Figure Description

[0038] Figure 1 This is the overall circuit diagram of the control system of this utility model;

[0039] Figure 2 This is the power supply circuit diagram based on LM2596 in this utility model;

[0040] Figure 3This is a schematic diagram of the redundant power supply circuit in this utility model;

[0041] Figure 4 This is a circuit diagram of the three-phase current acquisition circuit in this utility model;

[0042] Figure 5 This is a circuit diagram of the redundant three-phase current adding method in this utility model;

[0043] Figure 6 This is a circuit diagram for temperature, current, and voltage acquisition in this utility model;

[0044] Figure 7 This is a diagram of the redundant temperature acquisition circuit in this utility model;

[0045] Figure 8 This is a diagram of the redundant storage circuit in this utility model;

[0046] Figure 9 This is a circuit diagram of the independent security chip monitoring circuit in this utility model; Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this utility model and are not intended to limit this utility model. Example:

[0048] Reference Figure 1-9 A high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy, comprising:

[0049] Main circuit based on dual-core DSP

[0050] Power redundancy circuit

[0051] Multi-point sampling and verification circuit

[0052] Black box storage circuit

[0053] Independent security chip monitoring

[0054] Based on the DSP28337, this solution uses the DSP28337 as the core to build the overall hardware architecture. It possesses high-performance processing capabilities and rich peripheral interfaces, meeting the complex requirements of the motor drive control system for new energy commercial trucks. The dual-core architecture allows for the rational allocation of different functional modules to different cores. Adding redundant power supply and sampling circuitry improves system stability and fault tolerance under complex operating conditions, enabling the system to handle unexpected failures. Adding redundant storage circuitry facilitates subsequent upgrades and improvements by R&D personnel, allowing for rapid fault location. Adding redundant circuitry for the safety monitoring chip increases the failure rate, extends system lifespan, and prevents secondary accidents.

[0055] The dual-core DSP main circuit uses TI's TMS320F28337 dual-core processor with a main frequency of 200MHz, and integrates FPU and CLA coprocessor.

[0056] The DSP-based control circuit mainly includes: power supply 1 (3.3V, 3.0V, 1.2V, etc.), redundant power supply 2; storage circuit based on Flash and EEPROM, redundant EEPROM storage circuit; isolated gate drive circuit, ADC sampling circuit based on isolated operational amplifier, monitoring and protection circuit based on comparator, redundant sampling circuit for temperature, voltage, and current; communication circuits such as CAN, SPI, and USB, communication circuit for speed and angle reading of resolver or magnetic encoder; IGBT or SiC drive circuit.

[0057] The specific function allocation is as follows:

[0058] Core 1: Primarily responsible for waveform control, achieving efficient motor drive through precise PWM signal generation and execution of the FOC drive algorithm; it also undertakes the task of sampling key parameters such as voltage, current, and temperature to acquire real-time system operating status data; it runs the control algorithm to dynamically adjust motor operating parameters based on the sampled data to achieve precise control; in addition, it is responsible for the communication function between the system and external devices to ensure real-time data transmission and interaction.

[0059] Core 2: Focuses on system detection and protection, monitors fault signals during system operation in real time, responds quickly and handles various faults, and monitors fault signals (overcurrent, overtemperature, voltage abnormality) in real time; runs a self-learning algorithm to continuously optimize control strategies through analysis and learning of system operation data, and learns basic motor parameters by driving motor rotation; executes a fault pre-judgment algorithm (based on historical data trend analysis) to provide early warning of potential fault risks, thus ensuring the stable operation of the system.

[0060] Optimized design: The CLA coprocessor is responsible for calculations in the FOC algorithm, PID algorithm, and filtering algorithm. With the help of the CAL coprocessor, complex signal calculations and processing are performed, effectively distributing the load of the core, improving the overall system performance, and reducing CPU utilization.

[0061] Redundancy mechanism: Core 1 and Core 2 synchronize status data through shared memory, and seamlessly switch control in the event of a failure.

[0062] Redundant power supply circuit modules, such as Figure 2 As shown, based on the LM2596S chip as the step-down module, an input voltage monitoring and feedback circuit is added. The V-5V potential feedback signal in the diagram is divided by two resistors, with the sampling point potential at 2.5V. This circuit can monitor changes in the input voltage in real time and feed the information back to the monitoring and management chip. The circuit composed of D2 and Q1 can achieve input voltage undervoltage lockout. By monitoring the input voltage, it ensures that the system stops working when the voltage is insufficient, avoiding abnormal operation or damage to devices. When the input voltage is lower than the set threshold, UVLO forces the system to shut down or enter sleep mode, ensuring the device is in a controllable state. This suppresses the impact of transient power supply drops (such as voltage fluctuations during vehicle startup) on the system, avoiding frequent restarts. When the input voltage fluctuations far exceed the normal range, the monitoring and management chip will disable some chips, cut off some circuits, and trigger an alarm. Simultaneously, to improve the power module's anti-interference capability, a multi-stage filtering circuit is added to the circuit. The capacitors and resistors in the diagram can refer to multiple capacitors and resistors, effectively filtering out high-frequency noise and electromagnetic interference in the power input, ensuring the purity of the power output.

[0063] For commonly used 3.3V power supplies or power supplies with severe heat generation: Based on two sets of identical redundant designs, a power status monitoring and intelligent switching algorithm is introduced. By monitoring the output voltage, current, temperature, and other parameters of each power supply in real time, the voltage comparator triggers a MOSFET to switch the power supply path when a change in the power supply status is detected. When an anomaly is detected in one power supply (such as low voltage, excessive current, or excessive temperature), the intelligent switching algorithm quickly activates, seamlessly switching the load to another normal power supply while simultaneously issuing a fault alarm. Furthermore, to reduce the heat generation of the power module, a high-efficiency parallel structure design is adopted. For example, if the load capacity of power supply 1 is detected to be too high, resulting in excessive temperature rise, but it is still operating normally, by turning on the MOS switch of power supply 2, power supply 2 can share the current pressure, reduce localized heat generation, and alleviate the workload of power supply 1, ensuring the stability of the power module under long-term high-load operation.

[0064] like Figure 4As shown, the multi-point sampling and verification circuit uses a FET (Field-Effect Transistor) operational amplifier for two-stage amplification, then a protection circuit, and finally an ADC for acquisition. The motor control circuit uses three sets of phase current sampling and a redundant hardware adder circuit to obtain the other current. Compared to traditional circuits that only sample two phase currents and calculate the other phase current using software based on the current relationship ib = -(ia + ic), this patent redundantly designs a set of current sampling and hardware current adder circuits. Figure 5 This method allows for data verification to obtain accurate current data and can detect abnormal current fluctuations in a particular phase caused by poor contact. It effectively identifies and eliminates erroneous data caused by interference, sampling circuit failures, and other factors, thereby ensuring the accuracy and reliability of the acquired current data. This provides solid data support for the efficient and precise control of the motor, greatly improving the stability and reliability of the system operation.

[0065] Figure 6 Temperature, current, and voltage sampling are performed in the motor control circuit. Temperature sampling includes the motor, IGBT drive module, and main control circuit board; current sampling includes bus current, three-phase current, and low-voltage power supply current; voltage sampling includes low-voltage power supply voltage, 12V, 5V, 3.3V, 1.2V, bus voltage, IGBT gate voltage, and the voltage between the IGBT collector and emitter.

[0066] Figure 7 This is a simple redundant temperature detection structure that uses a thermistor for sampling. As the temperature changes, the voltage across the thermistor changes, and the current temperature is obtained by reading the voltage value. The redundant sampling circuit in this patent refers to:

[0067] 1. Place thermistors in multiple locations on the main control board to collect temperature changes, such as the DSP chip (the internal temperature value of the chip can be used), the DCDC power supply with a large current load (5V, 12V), and the ambient temperature of the main control board; collect the temperature of each IGBT. If a single circuit board integrates 3 groups of IGBTs, more than two thermistors should be placed and redundant comparison circuits should be implemented.

[0068] 2. Redundant bus voltage acquisition: Compared with the traditional method of acquiring the bus voltage of only one IGBT, redundant bus voltage sampling requires taking three sets of voltages and performing a comparison circuit to obtain the maximum bus voltage.

[0069] 3. Redundant current sampling circuits are used to collect the current at the front end and the current at the back end, compare the current magnitudes, and prevent erroneous readings.

[0070] Redundant current sampling can accurately identify faults in individual IGBTs and power supplies, ensuring that the failure of a single IGBT does not affect adjacent IGBTs. In the multi-point acquisition circuit, in addition to comprehensively acquiring the bus voltage, current, and temperature of all IGBTs and using hardware addition circuitry to achieve accurate three-phase current detection, a data preprocessing and anomaly detection module is added. After data acquisition, this module first performs preprocessing operations such as filtering and amplification to improve data accuracy and stability. Then, through a built-in anomaly detection algorithm, the acquired data is analyzed in real time to determine if there are any data anomalies, such as sudden data changes or data exceeding the normal range. If abnormal data is detected, the redundant acquisition channel is immediately activated to re-acquire data, and the abnormal data is marked and recorded, providing a basis for subsequent fault diagnosis.

[0071] The black box storage circuit, based on the continuous cyclic storage of data before and after a fault using an external Flash or EEPROM module, adds data encryption and accident analysis functions. The redundant storage circuit is designed in a relatively suitable space away from the accident source, and can be designed as a separate module connected to the periphery of the main control circuit board to prevent secondary damage caused by an accident, thus preventing the chip from being read. Data encryption algorithms are used to encrypt the data stored in the module, ensuring data security and integrity and preventing unauthorized tampering or theft. Simultaneously, a wireless communication module can be used to achieve remote transmission of black box data. When a vehicle malfunctions or data analysis is required, maintenance personnel or managers can read the data from the black box for convenient fault diagnosis and vehicle performance evaluation. Furthermore, to further improve the reliability of data storage, a data verification and repair mechanism is added to the black box storage circuit. The stored data is periodically verified, and if data errors or corruption are found, it is repaired promptly to ensure the accuracy of the stored data.

[0072] Redundant storage chip selection: W25Q128SPIFlash, capacity 16MB, erase / write cycles 100,000, data retention period 20 years; AT24C256IICEEPROM, capacity 256kb, erase / write cycles 1,000,000, data retention period 100 years.

[0073] Anti-interference design: The storage module is physically isolated from the main control board (spacing > 10cm).

[0074] The power supply is independent to prevent data loss due to main power failure.

[0075] Data Management: Circular Storage Strategy: System status data (voltage, current, temperature, speed) is written every 100ms, and data for 10 seconds before and after a fault is retained.

[0076] Data encryption: Stored using AES-128 encryption algorithm to prevent tampering.

[0077] The independent safety chip monitoring module is an automotive-grade MCU with an operating temperature range of -40℃ to 125℃, conforming to the ISO26262ASIL-B standard. It incorporates a safety chip based on the National Technology automotive-grade MCU N32A455, which operates independently of the main control DSP and possesses powerful monitoring and protection functions. Through CAN and SPI communication interfaces, the safety chip can directly read key data such as temperature, current, voltage, and speed, while simultaneously monitoring the resolver encoder in real time. Utilizing its internal ADC and comparator, it achieves accurate system detection and safety protection. Upon detecting a fault, the safety chip has higher priority and can directly perform PWM blocking, shutting down some relays, controlling vehicle deceleration or cutting off output to stop vehicle operation. This effectively protects critical components such as IGBTs from damage and avoids high-risk situations, such as engine failure, caused by main control DSP malfunctions.

[0078] The independent safety chip monitoring module, in addition to its robust monitoring and protection functions, adds integration capabilities with other vehicle safety systems. For example, when the safety chip detects a serious motor malfunction that could lead to loss of vehicle control, it immediately sends a signal to the vehicle's braking system, initiating an emergency braking procedure to ensure the vehicle stops safely. Simultaneously, the safety chip communicates with the vehicle's steering system, intervening when necessary to prevent dangerous steering maneuvers due to motor failure. Furthermore, the safety chip possesses a self-diagnostic function, periodically testing its internal modules to ensure it remains in normal working order. If a malfunction is detected, it promptly activates redundant safety chips (if applicable) or sends fault information to the main control DSP, ensuring system safety and reliability.

[0079] As can be seen from the above, the DSP-based redundant control hardware solution for new energy commercial trucks can meet the complex requirements of the motor drive control system for new energy commercial trucks. The dual-core architecture allows the system to rationally allocate different functional modules to different cores. Redundancy in power supply, sampling, storage, and safety monitoring circuits can improve the stability and reliability of the system, and enhance its fault tolerance under complex operating conditions.

[0080] From the above, we can conclude that:

[0081] In this invention, a dual-core DSP (such as the DSP28337) is used to improve system performance. One core focuses on handling waveform generation, voltage, current, and temperature sampling, running control algorithms, and communication functions; the other core is used for detection and protection, fault handling, self-learning algorithms, and fault prediction algorithms. Simultaneously, a CAL coprocessor is used to offload signal processing tasks, significantly reducing the CPU load and improving the overall system efficiency.

[0082] This invention addresses the vulnerability of low-voltage power modules in the motor drive system of new energy commercial trucks by designing a dual-power switching protection mechanism. Through mutual backup of two sets of power modules, when one power supply fails, it can quickly switch to the other, ensuring stable power supply to the system and effectively preventing system downtime due to power failure.

[0083] This invention comprehensively collects the bus voltage, current, and temperature of all IGBTs, abandoning the traditional approach of only collecting a single bus voltage, two-phase current, and one temperature. A hardware addition circuit achieves accurate detection of the three-phase current, and all three sets of data are displayed simultaneously and cross-checked to prevent misjudgment due to a single data collection point failure, thus providing reliable data support for precise system control.

[0084] This invention designs a black box-like storage circuit, employing an external Flash or EEPROM module to continuously and cyclically store data before and after a fault. This module is kept at a certain distance from the main control board, effectively protecting the stored data from damage in the event of system failure, system crash, or overcurrent, providing strong evidence for tracing and analyzing the cause of the accident, while reducing primary damage to the module during an accident and secondary damage to the main storage unit during disassembly.

[0085] This invention introduces a safety chip based on the National Technology automotive-grade MCU N32A455, which independently undertakes the monitoring of critical faults such as voltage, current, temperature, and speed, in addition to the main control DSP. This safety chip has the ability to directly control motor waveform generation and the closing of main control relays or bus relays. It can quickly take measures upon detecting a fault to prevent secondary faults, effectively protect critical components such as IGBTs from damage, and ensure vehicle operational safety.

[0086] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the term "comprising" or any other variations thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0087] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy, characterized in that... ,include: The dual-core DSP main circuit is used to execute motor drive control algorithms and fault detection and protection, and includes core 1 and core 2. The redundant power supply circuit module provides stable power to the system through a dual-power switching mechanism. Multi-point sampling and verification circuit is used to collect IGBT bus voltage, three-phase current and temperature data and perform hardware-level redundancy verification. The black box storage circuit is independent of the main control circuit and cyclically stores key data before and after the fault. Independent safety chip monitoring module, based on automotive-grade safety chip, directly controls PWM blocking and relay shutdown; The dual-core DSP main circuit, redundant power supply circuit, multi-point sampling and verification circuit, black box storage circuit, and independent security chip monitoring communicate with each other via CAN bus, SPI interface, and shared memory.

2. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The dual-core DSP main circuit is internally equipped with: Core 1 connects to the IGBT driver circuit via the SPI interface and is responsible for generating PWM signals, executing the FOC algorithm, and acquiring voltage, current, and temperature data in real time. Core 2 communicates with an independent security chip via the CAN bus to monitor fault signals in real time and execute protection algorithms; Core 1 and Core 2 synchronize status data through shared memory, allowing for seamless switching of control in the event of a failure.

3. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The redundant power supply circuit adopts a dual-power supply design using the LM2596S chip, and monitors the input voltage in real time through a voltage comparator. When the main power supply fails, it switches to the backup power supply via a MOSFET switch, with a switching time of <1ms; The output power supply is connected to the dual-core DSP main circuit and peripheral circuits through a multi-stage filtering circuit.

4. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The multi-point sampling and verification circuit is used to acquire three-phase current signals through an isolation operational amplifier circuit and connect to a hardware adder circuit for redundancy verification. Temperature data is acquired through a thermistor voltage divider circuit and redundantly distributed across the DSP chip, IGBT module, and power module. The acquired data is converted by the ADC and then transmitted to the dual-core DSP main circuit via the SPI interface.

5. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The black box storage circuit uses W25Q128 SPI Flash and AT24C256 EEPROM chips, and is isolated from the main circuit through an independent SPI / I2C interface; The storage module inside the black box storage circuit is independently powered and physically spaced more than 10cm from the main control board. It cyclically stores voltage, current, and temperature data for 10 seconds before and after a fault.

6. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The independent security chip monitoring module is based on the N32A455 automotive-grade MCU and directly acquires bus voltage, IGBT temperature and current signals through an independent ADC channel. When overcurrent or overtemperature is detected, the PWM output and relay are directly shut off via the GPIO interface, with a response time of <1ms. It communicates with Core 2 via the CAN bus, has a higher priority than the main control DSP, and triggers an emergency braking signal to the vehicle's braking system.

7. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The switching logic of the redundant power supply circuit includes intelligent load distribution: when the main power supply temperature exceeds the threshold, the backup power supply is automatically started to share the load, and a power status alarm is sent to the dual-core DSP main circuit via the CAN bus.

8. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The black box storage circuit integrates the AES-128 encryption algorithm, and the encrypted data is remotely transmitted to the cloud platform via a wireless communication module for fault analysis.

9. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The independent security chip monitors the built-in self-diagnostic function, periodically checking the status of the chip's internal ADC, comparator, and communication interface. In case of a fault, the redundant security chip takes over the protection function. The independent safety chip monitors and links with the vehicle steering system. When a motor failure causes abnormal torque, it sends a speed limit command to the steering controller via the CAN bus to prevent the vehicle from losing control.

10. The high-efficiency and precise control system for new energy commercial trucks based on DSP redundancy as described in claim 1, characterized in that: The hardware addition circuit of the multi-point sampling and verification circuit adopts a three-group redundancy design. By cross-comparing the three-phase current values, abnormal data is eliminated and the redundant acquisition channels are triggered to resample.

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