A brushless motor control system
The brushless motor control system with dual MCU architecture, combined with various encoders and sensors, achieves efficient motor control, solves the problems of slow response and poor stability in traditional systems, improves the system's reliability and adaptability, and is suitable for industrial control systems.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANGSU DIGITAL INTELLIGENCE TECHNOLOGY CO LTD
- Filing Date
- 2025-06-19
- Publication Date
- 2026-05-26
AI Technical Summary
Traditional brushless DC motor control systems suffer from problems such as slow response, interface conflicts, poor stability, high cost, and insufficient security in multi-task systems, especially in terms of multiple motors, redundant design, and real-time protection.
It adopts a dual MCU architecture with a main controller and a co-controller. The main controller is responsible for high-performance DSP functions and motor control, while the co-controller assists in monitoring the motor status and performing emergency braking. Combined with various encoders, sensors and driver chips, it realizes multi-level redundant power supply and rich interfaces, supports multiple communication methods, and enhances the system's adaptability and environmental monitoring capabilities.
It improves control precision and stability, reduces costs, enhances system scalability and reliability, and features a multi-level redundant power supply design to meet the complex needs of industrial control systems.
Smart Images
Figure CN224289650U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of motor control technology, specifically a brushless motor control system. Background Technology
[0002] Currently, motor drive systems used for actuator control, especially in intelligent robots, industrial automation, and high-precision actuators, commonly employ brushless DC motors (BLDC) or permanent magnet synchronous motors (PMSM) for vector control to achieve high-performance dynamic response and precise control. Traditional motor control systems mostly use single-chip controllers to implement FOC (Field-Oriented Control) algorithms. However, limited by controller resource constraints, they suffer from significant shortcomings in supporting multiple motors, redundant design, real-time protection, and compatibility with various interfaces.
[0003] Especially in multi-tasking systems, such as multi-joint robots or high-precision multi-axis positioning platforms, control systems often exhibit problems such as slow response, interface conflicts, and poor stability when faced with complex control logic and real-time requirements. Furthermore, traditional control systems often use a single MCU with a high pin count and high functional integration as the main control device, which is not only costly but also reduces system stability and maintainability to some extent.
[0004] In addition, commercially available motor drive systems do not pay enough attention to interface protection, current sampling accuracy, temperature monitoring mechanisms, and power management methods. Overheating, false triggering, and driver damage are likely to occur during long-term use, which seriously affects the service life and reliability of the equipment. Utility Model Content
[0005] The purpose of this invention is to provide a brushless motor control system that effectively improves control precision, stability and reliability, has rich interfaces, strong expandability, effectively reduces costs, has a multi-level redundant power supply design, enhances adaptability, communication capabilities, environmental monitoring and thermal protection capabilities, and is compatible with industrial control systems.
[0006] This utility model is implemented as follows:
[0007] A brushless motor control system includes a main controller and a co-controller. The main controller is communicatively connected to the co-controller. The main controller is connected to multiple encoder modules for transmitting position information and closed-loop control. Each encoder module is connected to a corresponding motor. The main controller is also connected to multiple drive modules. The main controller is connected to a current sampling module and a voltage sampling module via multiple ADC channels. Each drive module is connected to a corresponding current sampling module, and all drive modules are connected to the voltage sampling module. Each drive module is connected to a corresponding motor. All drive modules are connected to the co-controller. The co-controller is connected to a temperature detection module for temperature detection and an environmental detection module for environmental monitoring.
[0008] Furthermore, any one of the encoder modules includes an ABZ quadrature encoder for position information acquisition, a HALL encoder for motor commutation and coarse position feedback, and an encoder for... 2 IIC encoders that communicate data via the C bus.
[0009] Furthermore, the drive module includes a drive chip with an internally integrated buck buck module.
[0010] Furthermore, the current sampling module includes a current sensor one for acquiring the A-phase current of the corresponding connected motor and a current sensor two for acquiring the B-phase current of the corresponding connected motor. The voltage sampling module includes a voltage sensor for acquiring the bus voltage of multiple motors.
[0011] Furthermore, the temperature detection module includes a motor temperature sensor for monitoring the motor thermocouple and an onboard temperature sensor for monitoring the MOSFET temperature. The motor temperature sensor is connected to the corresponding motor, and the onboard temperature sensor is connected to the corresponding motor board. The environmental detection module includes a pressure sensor for monitoring air tightness and a humidity sensor for monitoring water tightness.
[0012] Furthermore, the main controller is connected to a USB virtual serial port and multiple CAN interfaces, and the co-controller is connected to a CAN interface.
[0013] Furthermore, it also includes a USB power supply and a main power supply for powering the system. The USB power supply is connected to the main controller and the co-controller. The main power supply is connected to the drive module. The drive module is connected to the LDO voltage regulator module. The LDO voltage regulator module is connected to the main controller and the co-controller.
[0014] Furthermore, the co-controller is connected to an LCD display screen for displaying system status and parameter information.
[0015] Compared with the prior art, the beneficial effects of this utility model are:
[0016] In practical applications, the main controller is an STM32G474, which has high-performance DSP functions. It adopts a 6PWM drive mode and complementary output of TIM1 / TIM8 advanced timers, which can control two motors at the same time, improving system control efficiency and response speed.
[0017] By introducing a co-controller to replace the high-pin main controller, the main controller specification requirements are reduced, thereby reducing costs.
[0018] The co-controller communicates bidirectionally with the main controller via USART1, assisting in the issuance of control commands and alarm reporting. It forms a dual MCU architecture with the main controller. The co-controller can independently monitor the motor status and execute the emergency braking strategy (Dynamic Braking). It also communicates with the main controller via SPI and USART to achieve task separation and fault tolerance.
[0019] The main controller supports multiple encoder inputs, including IIC encoders, ABZ encoders, and HALL encoders. The ABZ encoder provides orthogonal A, B, and Z channels for high-resolution position information acquisition. The HALL encoder outputs discrete position signals based on the Hall effect for motor commutation and coarse position feedback. The IIC encoder... 2 Digital encoders that use the C-bus for data communication are small in size, have simple wiring, and are suitable for scenarios where multiple devices share a communication bus;
[0020] The main controller receives the bus voltage VBUS signal monitored by the voltage sensor, as well as the A-phase current signals of the two motors monitored by two current sensors and the B-phase current signals of the two motors monitored by two current sensors through multiple ADC channels.
[0021] The main controller communicates with the CAN module through CAN interfaces FDCAN1 and FDCAN2 respectively, supporting host computer control and data interaction. It also supports Bootloader program upgrades and debugging data uploads through a USB virtual serial port. All interfaces are ESD protected and offer multiple communication methods to meet various application scenarios such as industrial automation, robot control, and remote monitoring.
[0022] The coprocessor connects to two motor temperature sensors via two ADC channels to monitor two motor thermocouples, connects to two onboard temperature sensors via two ADC channels to monitor the temperature of two MOSFETs, connects to a barometric pressure sensor and a humidity sensor via an IIC interface to monitor the airtightness and watertightness of the environment, and connects to an LCD display via SPI. The coprocessor has real-time temperature display and overheat alarm functions.
[0023] The driver chip is model DRV8301. The driver chip independently drives the corresponding connected motor. The driver chip integrates a buck converter module, eliminating the need for an external DC-DC converter, saving the number of components and further reducing costs.
[0024] The system automatically switches between USB power and main power. When the main power is not connected, the system automatically draws power from the USB power. When the main power is connected, the system switches to the internal step-down power supply of the DRV8301 and uses a Schottky diode to prevent current backflow.
[0025] This invention effectively improves control precision, stability, and reliability, features rich interfaces and strong expandability, effectively reduces costs, has a multi-level redundant power supply design, enhances adaptability, communication capabilities, environmental monitoring and thermal protection capabilities, and is compatible with industrial control systems. Attached Figure Description
[0026] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.
[0027] Figure 1 This is a circuit block diagram of this utility model;
[0028] Figure 2 This is the overall circuit schematic diagram of this utility model;
[0029] Figure 3 This is the circuit schematic diagram of the main controller of this utility model;
[0030] Figure 4 This is the circuit schematic diagram of the co-controller of this utility model;
[0031] Figure 5 This is a circuit schematic diagram of the driving module of this utility model;
[0032] Figure 6 This is another circuit schematic diagram of the drive module of this utility model;
[0033] Figure 7 This is a circuit diagram of the USB power supply and main power supply of this utility model;
[0034] Figure 8 This is a circuit diagram of the sensor and peripheral circuit of this utility model;
[0035] Figure 9This is a schematic diagram of a three-phase full-bridge inverter circuit for a motor according to this utility model. Detailed Implementation
[0036] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model. Therefore, the following detailed description of the embodiments of this utility model provided in the accompanying drawings is not intended to limit the scope of the claimed utility model, but merely represents selected embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.
[0037] Please see Figures 1 to 9 A brushless motor control system includes a main controller and a co-controller. The main controller is communicatively connected to the co-controller. The main controller is connected to multiple encoder modules for transmitting position information and closed-loop control. Each encoder module is connected to a corresponding motor. The main controller is also connected to multiple drive modules. The main controller is connected to a current sampling module and a voltage sampling module via multiple ADC channels. Each drive module is connected to a corresponding current sampling module, and all drive modules are connected to the voltage sampling module. Each drive module is connected to a corresponding motor. All drive modules are connected to the co-controller. The co-controller is connected to a temperature detection module for temperature detection and an environmental detection module for environmental detection.
[0038] Any of the encoder modules includes an ABZ quadrature encoder for position information acquisition, a HALL encoder for motor commutation and coarse position feedback, and an encoder for... 2 IIC encoders that communicate data via the C bus.
[0039] The drive module includes a drive chip with an integrated buck converter.
[0040] The current sampling module includes a current sensor one for acquiring the A-phase current of the corresponding connected motor and a current sensor two for acquiring the B-phase current of the corresponding connected motor. The voltage sampling module includes a voltage sensor for acquiring the bus voltage of multiple motors.
[0041] The temperature detection module includes a motor temperature sensor for monitoring the motor thermocouple and an onboard temperature sensor for monitoring the MOSFET temperature. The motor temperature sensor is connected to the corresponding motor, and the onboard temperature sensor is connected to the corresponding motor board. The environmental detection module includes a pressure sensor for monitoring air tightness and a humidity sensor for monitoring water tightness.
[0042] The main controller is connected to a USB virtual serial port and multiple CAN interfaces, and the co-controller is connected to a CAN interface.
[0043] It also includes a USB power supply and a main power supply for powering the system. The USB power supply is connected to the main controller and the co-controller. The main power supply is connected to the driver module. The driver module is connected to the LDO voltage regulator module. The LDO voltage regulator module is connected to the main controller and the co-controller.
[0044] The co-controller is connected to an LCD screen for displaying system status and parameter information.
[0045] In practical applications, please refer to Figures 1 to 9 The encoder module collects the position information of the motor and feeds it back to the main controller. The FOC algorithm on the main controller calculates and processes the signal and outputs a PWM signal to multiple drive modules. The drive modules control the operation of the motors connected to them.
[0046] The motor feeds back current and voltage signals to the main controller through corresponding connected current and voltage sensors. The main controller dynamically adjusts the PWM duty cycle based on the current and voltage signals sampled through the ADC channel to achieve closed-loop control.
[0047] The motor feeds back the motor and onboard temperature signals, as well as the motor environment signals, to the co-controller through the temperature detection module and the environmental detection module. The drive module feeds back the operation error signals and fault signals to the co-controller. The co-controller dynamically brakes and controls the motor based on the received motor and onboard temperature signals, motor environment signals, operation error signals, and fault signals, and displays the results on the indicator lights and LCD screen. At the same time, it feeds back abnormal situations to the main controller through USART1, and the main controller executes the corresponding emergency strategy.
[0048] The host computer connects to the CAN bus and communicates with the main controller through the FDCAN channel. The co-controller processes the information and displays it on the LCD screen connected by SPI.
[0049] The main controller uses an STM32G474RETx chip, responsible for the entire system's vector control (FOC) algorithm calculation, current and voltage data acquisition, execution of control logic for two motors, and bus communication. It receives position information from ABZ quadrature encoders, HALL encoders, and IIC encoders for closed-loop control. It receives current detection signals and bus voltage VBUS signals through the ADC channel to assess motor operating status; it also receives control data and alarm information sent by the co-controller via USART1. It outputs 6-channel PWM signals to control two DRV8301 driver chips, driving motors M1 and M2 respectively. It sends operating status information to the co-controller. It communicates with the CAN module through CAN interfaces FDCAN1 and FDCAN2, supporting host computer control and data interaction. It supports bootloader program upgrades and debug data uploads via a USB virtual serial port. It connects to a debugger via SWD. It supports STLink V3E emulator debugging.
[0050] The co-controller, model STM32F103C8T6, is responsible for system auxiliary tasks, data display, safety protection, and handling of abnormal motor conditions, assisting the main controller in achieving high-reliability operation. It communicates bidirectionally with the main controller via USART1, assisting in issuing control commands and reporting alarms. In case of an anomaly, it executes a dynamic braking strategy to quickly stop the motor. It controls two DRV8301 driver chips via SPI2, configuring their internal registers and switching the control chip select (CS) signal. It connects to an LCD color display via SPI1 to display system status and parameter information; the screen can be disconnected or used for other SPI peripheral expansion. It acquires four temperature signals (two MOS temperature signals and two thermocouple motor temperature signals) via ADC. It connects to environmental sensors or other peripherals via the IIC interface. It receives error signals from the gate driver (overcurrent, fault, etc.) and indicates them via LEDs.
[0051] The system supports a dual power supply scheme: USB power supply (5V) and mains power supply (6V~65V). When no mains power is available, the USB circuit directly powers G4 and F1. When mains power is available, 5V is obtained from the buck circuit integrated within the DRV8301 driver chip, and then regulated to 3.3V by an LDO regulator module for the MCU. To prevent reverse current flow, low-dropout Schottky diodes are used for freewheeling in both the USB and mains power supplies. While VDDA (analog power) and VDD (digital power) are not isolated, they are connected to an ultra-low noise LDO via a ferrite bead to reduce analog circuit noise interference.
[0052] The system controls two three-phase brushless motors (M1 and M2), using two DRV8301 chips as independent driver chips. The main controller outputs 6-channel complementary PWM signals via TIM1 and TIM8, respectively connected to H1 and H2, to achieve independent control of the two circuits. Current sampling of each driver chip is performed differentially using alloy resistors, and the signals are fed back to the ADC of the main controller. Each driver chip has an error indication function, with its status displayed visually via LEDs. H1 is configured with a 3.3V output; H2 is configured with a 5V output to meet the power supply requirements of different modules.
[0053] The co-controller connects to an LCD display via SPI for parameter display during debugging. An onboard temperature sensor, combined with a motor temperature sensor, monitors the temperatures of the drive MOS and the motor body, respectively. Error and fault information from the drive chip is transmitted to the co-controller via GPIO, providing intuitive error status feedback.
[0054] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.
Claims
1. A brushless motor control system, characterized in that: The system includes a main controller and a co-controller. The main controller is communicatively connected to the co-controller. The main controller is connected to multiple encoder modules for transmitting position information and closed-loop control. Each encoder module is connected to a corresponding motor. The main controller is also connected to multiple drive modules. The main controller is connected to current sampling modules and voltage sampling modules via multiple ADC channels. Each drive module is connected to a corresponding current sampling module, and all drive modules are connected to the voltage sampling modules. Each drive module is connected to a corresponding motor, and all drive modules are connected to the co-controller. The co-controller is connected to a temperature detection module for temperature detection and an environmental detection module for environmental monitoring.
2. The brushless motor control system according to claim 1, characterized in that, Any of the encoder modules includes an ABZ quadrature encoder for position information acquisition, a HALL encoder for motor commutation and coarse position feedback, and an encoder for... 2 IIC encoders that communicate data via the C bus.
3. The brushless motor control system according to claim 1, characterized in that, The drive module includes a drive chip with an integrated buck converter.
4. The brushless motor control system according to claim 1, characterized in that, The current sampling module includes a current sensor one for acquiring the A-phase current of the corresponding connected motor and a current sensor two for acquiring the B-phase current of the corresponding connected motor. The voltage sampling module includes a voltage sensor for acquiring the bus voltage of multiple motors.
5. A brushless motor control system according to claim 1, characterized in that, The temperature detection module includes a motor temperature sensor for monitoring the motor thermocouple and an onboard temperature sensor for monitoring the MOSFET temperature. The motor temperature sensor is connected to the corresponding motor, and the onboard temperature sensor is connected to the corresponding motor board. The environmental detection module includes a pressure sensor for monitoring air tightness and a humidity sensor for monitoring water tightness.
6. The brushless motor control system according to claim 1, characterized in that, The main controller is connected to a USB virtual serial port and multiple CAN interfaces, and the co-controller is connected to a CAN interface.
7. A brushless motor control system according to claim 1, characterized in that, It also includes a USB power supply and a main power supply for powering the system. The USB power supply is connected to the main controller and the co-controller. The main power supply is connected to the driver module. The driver module is connected to the LDO voltage regulator module. The LDO voltage regulator module is connected to the main controller and the co-controller.
8. A brushless motor control system according to claim 1, characterized in that, The co-controller is connected to an LCD screen for displaying system status and parameter information.