A monitoring and protection device for preventing motor failures

Abstract

This utility model relates to the field of motor monitoring technology, specifically to a monitoring and protection device for preventing motor faults. It includes an overload protection module, a temperature detection module, a speed detection module, an overvoltage protection module, an overcurrent protection module, an no-load protection module, a short-circuit protection module, a central processing unit, a communication module, and a human-machine interface module. This device can achieve real-time monitoring of motor parameters such as temperature, voltage, power, current, and speed. Furthermore, when the motor is in an abnormal state, the device can take measures to cut off power and issue an alarm, protecting the motor and alerting the operator. This utility model solves the technical problem of existing technologies that mostly rely on single parameters such as current or temperature, failing to integrate multi-dimensional data such as speed, voltage, and power, leading to a high rate of missed fault detection.

Description

Technical Field

[0001] This utility model relates to the field of motor monitoring technology, and more specifically, to a measurement and control protection device for preventing motor failures. Background Technology

[0002] Electric motors are core devices that convert electrical energy into mechanical energy, and are widely used in industrial manufacturing (such as machine tools and pumps), transportation (electric vehicles and rail transit), and household appliances (air conditioners and washing machines). As a crucial component of power systems, the reliable operation of electric motors directly affects production efficiency, equipment lifespan, and personal safety. Faults (such as overload, short circuit, and overheating) can lead to anything from production and operational stoppages to fires or mechanical damage. Therefore, as a core component of industrial power systems, the stable operation of electric motors directly impacts production safety and efficiency.

[0003] Currently, motor protection technology mainly relies on manual inspection and the following two types of solutions: traditional electromechanical protection: such as thermal relays that detect overload through the thermal deformation of bimetallic strips, and fuses that achieve short-circuit protection by melting the fuse element; electronic protection devices: using microcontrollers to collect current and voltage signals and trigger protection through threshold comparison. Some of these solutions introduce temperature sensors, but they are mostly limited to single-parameter judgment and lack the ability to coordinate and analyze multiple physical quantities and adapt.

[0004] Despite some progress in existing technologies, some significant shortcomings remain. Most importantly, the monitoring dimensions are limited: most current technologies rely on single parameters such as current or temperature, failing to integrate multi-dimensional data such as speed, voltage, and power, resulting in a high rate of missed fault detections. Summary of the Invention

[0005] The purpose of this application is to provide a measurement and control protection device for preventing motor faults, which solves the technical problem that most existing technologies rely on single parameters such as current or temperature and cannot integrate multi-dimensional data such as speed, voltage, and power, resulting in a high rate of missed fault detection.

[0006] To solve the above-mentioned technical problems, the solution adopted in this application is as follows:

[0007] A monitoring and protection device for preventing motor failures, characterized in that it includes an overload protection module, a temperature detection module, a speed detection module, an overvoltage protection module, an overcurrent and no-load protection module, a short-circuit protection module, and a central processing unit.

[0008] Preferably, the signal output terminals of the overload protection module, temperature detection module, speed detection module, overvoltage protection module, overcurrent and no-load protection module, and short-circuit protection module are connected to the general peripheral interface of the central processing unit.

[0009] Preferably, the signal output terminal SPEED of the speed detection module is connected to a general-purpose input pin of the central processing unit, which is configured as a digital input; the output terminal OUT of the overload protection circuit is connected to a general-purpose input pin of the central processing unit, which is configured as a digital input; and the output terminal OUT of the short-circuit protection circuit is connected to a general-purpose input pin of the central processing unit, which is configured as a digital input.

[0010] Preferably, the output terminal of the temperature detection module is connected to the analog input pin (ADC pin) of the central processing unit, and the central processing unit acquires the analog signal output by the temperature detection module through the ADC; the current detection signal output terminal of the overcurrent protection module is connected to the analog input pin (ADC pin) of the central processing unit, and the central processing unit acquires the current signal through the ADC.

[0011] Preferably, the speed detection module adopts a motor speed monitoring circuit. The motor speed monitoring circuit includes a photoelectric sensor U3, resistors R10, R11, R12, R13, and R14, a capacitor C5, and a comparator U2.1.

[0012] Specifically, the photoelectric sensor U3 is used to monitor the motor speed. When a rotating part of the motor (such as a turntable or gear) passes through the photoelectric sensor U3, it blocks or reflects light, thereby changing the resistance of the photodiode inside the photoelectric sensor U3. The change in resistance is converted into an electrical signal output, and the output electrical signal is proportional to the motor speed.

[0013] Specifically, the output terminal of the photoelectric sensor U3 is connected to the non-inverting input terminal 3 of the comparator U2.1. This connection allows the electrical signal output by the photoelectric sensor U3 to be directly transmitted to the comparator U2.1. The non-inverting input terminal 3 of the comparator U2.1 receives the signal output by the photoelectric sensor U3 and compares it with a reference voltage, thereby outputting a level signal indicating the motor's speed status.

[0014] It should be noted that the non-inverting input terminal 3 of the comparator U2.1 receives the signal output by the photoelectric sensor U3, and the negative-inverting input terminal 2 receives the reference voltage. The comparator U2.1 compares the signals received at the non-inverting input terminal 3 and the negative-inverting input terminal 2. If the signal voltage output by the sensor U3 is higher than the reference voltage, the output terminal 1 of the comparator U2.1 outputs a high level; if the signal voltage output by the sensor U3 is lower than the reference voltage, the output terminal 1 of the comparator U2.1 outputs a low level. This converts the analog signal output by the sensor into a digital signal, facilitating further processing by subsequent circuits and the control system.

[0015] It should be noted that capacitor C5, resistors R10, R11, R12, R13, and R14 are connected to the photoelectric sensor U3 and the comparator U2.1, serving as bias, filter, and voltage regulators in the circuit to ensure its stability and accuracy. Specifically, resistor R10 acts as a bias resistor, connected between the power supply terminal and ground of the photoelectric sensor U3 to provide a suitable operating point for it. Capacitor C5 acts as a filter capacitor, connected between the output terminal 4 of the photoelectric sensor U3 and ground, and between the non-inverting input terminal 3 of the comparator U2.1 and ground, to remove noise and interference from the signal. Resistors R11 and R12 act as voltage regulators, connected to the circuit's power supply line to ensure stable operation even under voltage fluctuations.

[0016] It should be noted that the SPEED signal output terminal of the speed detection module is connected to the general-purpose input pin of the central processing unit (CPU). This pin is configured in digital input mode. When the CPU receives a level signal indicating the motor speed status, it determines whether the motor speed is abnormal based on changes in this level signal. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor speed status to the communication module. The communication module then transmits this motor speed data to the human-machine interface (HMI) module for real-time display. The CPU's general-purpose output pin is connected to the signal input terminal of the communication module, and the communication module's signal output terminal is connected to the signal receiving terminal of the HMI module.

[0017] Preferably, the overload protection module adopts an overload protection circuit; the overload protection circuit includes resistors R1, R2, R3, R4, R5, and R6, capacitors C1 and C2, comparator U1.1, and overload indicator D1.

[0018] Specifically, resistors R3 and R4 form a voltage divider reference circuit, which sets a threshold voltage. Resistor R5, connected in series with capacitor C2, filters the signal from the voltage divider reference circuit to obtain a cleaner threshold voltage signal. This threshold voltage signal is input to the inverting input terminal 2 of comparator U1.1. The motor is connected to the signal input terminal of the overload protection circuit. The motor and resistor R1 form a voltage divider circuit, and resistor R2 and capacitor C1 form a filter circuit. One end of resistor R1 is connected to the non-inverting input terminal 3 of comparator U1.1.

[0019] Specifically, when the motor is overloaded, the current flowing through the circuit is higher than the current during normal operation. Therefore, we use a comparator to set a threshold so that when the motor is operating normally, the comparator U1.1 does not issue an overload signal; when the motor is overloaded and exceeds this threshold, the comparator U1.1 outputs an overload signal. The non-inverting input 3 of the comparator U1.1 is a simple current-to-voltage conversion circuit, which detects the current flowing through the motor through the voltage across resistor R1. When the motor is operating normally, the voltage at point B is less than the voltage at point A, the comparator U1.1 outputs a low level, and the overload indicator D1 is off. When the motor is overloaded, the current flowing through resistor R1 increases, the voltage drop across R51 increases, the voltage at point B rises, and when it exceeds the voltage at point A, the comparator U1.1 outputs a high level, and the overload indicator D1 illuminates.

[0020] It should be noted that the comparator U1.1 is an open-circuit gate output, and the resistor R2 is an external pull-up resistor, which is also the current-limiting resistor for the overload indicator D1.

[0021] It should be noted that the output terminal OUT of the overload protection circuit is connected to the general-purpose input pin of the central processing unit (CPU). This pin is configured in digital input mode. When the CPU receives a level signal indicating whether the motor is overloaded, it determines whether the motor power is abnormal based on the change in this level signal. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor power status to the communication module. The communication module transmits this motor power data to the human-machine interface (HMI) module for real-time display. The CPU's general-purpose output pin is connected to the signal input terminal of the communication module, and the communication module's signal output terminal is connected to the signal receiving terminal of the HMI module.

[0022] Preferably, the short-circuit protection module adopts a short-circuit protection circuit; the short-circuit protection circuit includes resistors R7, R8, and R9, capacitors C3 and C4, transistor Q1, and transistor Q2.

[0023] Specifically, the input terminal IN of the short-circuit protection circuit is connected to the motor; the input terminal IN of the short-circuit protection circuit is connected to the emitter of transistor Q1; the collector of transistor Q1 is connected to one end of resistor R7 and then to ground through resistor R7; the base of transistor Q1 is connected to one end of resistor R8 and the other end of resistor R8 is connected to ground through resistor R9; the emitter of transistor Q1 is connected to the negative terminal of capacitor C4 and the base of transistor Q2; the collector of transistor Q2 is connected to the intermediate node of resistors R8 and R9, and this node is used as the signal output node OUT of the short-circuit protection circuit; the input terminal IN of the short-circuit protection circuit is connected to capacitor C3, capacitor C4, and the collector of transistor Q2, respectively.

[0024] Specifically, when the motor is short-circuited, transistor Q2 is pulled low, and transistor Q1 conducts, forming a self-locking effect. This forces transistor Q2 to turn off, and transistor Q3 has no output after turning off. The current at the signal output node OUT of the short-circuit protection circuit is zero, the entire circuit is open, and no current flows through the motor, thus effectively protecting the motor from burnout. When the circuit is restarted, because the voltage across capacitors C3 and C4 cannot change abruptly, capacitor C3 keeps the base of transistor Q1 at a high level at the moment of power-on, thus preventing transistor Q1 from conducting; capacitor C4 keeps the base of transistor Q2 at a low level at the moment of power-on, causing transistor Q2 to conduct. The signal output node OUT of the short-circuit protection circuit has an output voltage, making one end of resistor R9 high and the other end connected to ground, locking the conduction.

[0025] It should be noted that the output terminal OUT of the short-circuit protection circuit is connected to the general-purpose input pin of the central processing unit (CPU). This pin is configured in digital input mode. When the CPU receives a level signal indicating whether the motor is short-circuited, it determines whether the motor's current state is abnormal based on the change in this level signal. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor current state to the communication module. The communication module then transmits this motor current data to the human-machine interface (HMI) module for real-time display. The CPU's general-purpose output pin is connected to the signal input terminal of the communication module, and the communication module's signal output terminal is connected to the signal receiving terminal of the HMI module.

[0026] Preferably, the overvoltage protection module includes an overvoltage protection circuit; the overvoltage protection circuit includes resistors R15, R16, R17, and R18, transistor Q4, and PMOS transistor Q3; resistor R15 is connected to the voltage input terminal VIN, resistor R15 is connected to ground through Zener diode D2, one end of resistor R16 is connected to the midpoint between resistor R15 and Zener diode D2, and the other end is connected to the base of transistor Q4, the emitter of transistor Q4 is connected to the voltage input terminal VIN of the circuit, the collector of transistor Q4 is connected to one end of resistor R17, the other end of resistor R17 is connected to the voltage input terminal VIN of the circuit, resistors R17 and R18 are connected in series, the drain of PMOS transistor Q3 is connected to one end of resistor R18 and connected to the motor, the gate of PMOS transistor Q3 is connected in series with resistor R18, and the source of PMOS transistor Q3 is connected to the voltage input terminal VIN of the circuit.

[0027] Specifically, when the voltage input terminal VIN is at normal input voltage, the Zener diode D2 does not break down in reverse, and almost no current flows through resistors R15 and R16. The transistor Q4 is not conducting, and the voltage drop V across the gate and source of the PMOS transistor Q3 is... gsThe voltage division by resistors R17 and R18 determines whether PMOS transistor Q3 is turned on, allowing the power supply to normally power the motor. When the input voltage VIN is greater than the normal voltage, Zener diode D2 breaks down, and transistor Q4 turns on. The voltage drop across the collector and emitter of transistor Q4 is approximately zero. Consequently, the voltage drop V across the gate and source of PMOS transistor Q3 is V0. gs When the voltage is approximately equal to 0, the PMOS transistor Q3 is turned on, the circuit is broken, and thus overvoltage protection for the motor can be achieved.

[0028] Preferably, the temperature detection module is a DS18B20 temperature detection module. This module monitors the motor's temperature status in real time. When the motor temperature rises abnormally, it transmits the temperature data to the central processing unit (CPU) for processing. The CPU then issues a command to cut off the circuit and sends an alarm signal to prevent the motor from being damaged due to overheating.

[0029] Specifically, the output of the temperature detection module is connected to the analog input pin (ADC pin) of the central processing unit (CPU). The CPU acquires the analog signal output by the temperature detection module through the ADC, converts it into a digital signal, and then calculates the temperature value. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor temperature status to the communication module. The communication module then transmits this motor temperature data to the human-machine interface module for real-time display.

[0030] It should be noted that the temperature monitoring function of the DS18B20 temperature detection module is existing technology, which can be understood by those skilled in the art, and will not be elaborated further here.

[0031] Preferably, the overcurrent and no-load protection module is used to monitor the current status of the motor in real time. When the current exceeds or falls below the set threshold, measures are taken to cut off the motor power supply and trigger an alarm to prevent the motor from being damaged due to overcurrent and ensure the safe operation of the motor.

[0032] Specifically, the overcurrent and no-load protection module uses a Hall current sensor, which is installed on the current path of the motor to monitor the current flowing through the motor in real time and transmit the current data to the central processing unit for processing. When the current exceeds the threshold voltage for normal operation of the motor, the central processing unit issues a command to cut off the circuit and issues an alarm signal to prevent the motor from being damaged due to overcurrent.

[0033] More specifically, the current detection signal output terminal of the overcurrent protection module is connected to the analog input pin (ADC pin) of the central processing unit (CPU). The CPU acquires the current signal through the ADC, converts it into a digital signal, and then calculates the current value for real-time monitoring of the current magnitude. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor current status to the communication module, which then transmits this motor temperature data to the human-machine interface module for real-time display.

[0034] Preferably, when the motor enters an unloaded state, the current will suddenly drop to near zero. When the Hall current sensor detects that the current flowing through the motor is close to zero, the central processing unit issues a command to cut off the circuit and issues an alarm signal to prevent the motor from being damaged due to no-load. This enables the monitoring of whether the motor is unloaded and the taking of measures and issuing an alarm when the motor is unloaded.

[0035] It should be noted that the Hall current sensor used in this solution is model ACS712ELCTR-05B-T. Monitoring current using the ACS712ELCTR-05B Hall current sensor is existing technology, which can be understood by those skilled in the art, and will not be elaborated further here.

[0036] Preferably, the motor fault prevention and control protection device includes a communication module and a human-machine interaction module; the signal output terminal of the central processing unit is connected to the signal input terminal of the communication module, and the signal output terminal of the communication module is connected to the signal receiving terminal of the human-machine interaction module; the communication module is used to transmit the data output by the central processing unit to the human-machine interaction module for real-time display.

[0037] Therefore, this motor fault prevention and control protection device, through the above-mentioned modules and connection methods, can achieve real-time monitoring of the motor's temperature, voltage, power, current, and speed. Furthermore, in the event of an abnormal motor condition, this device can take measures to cut off power and trigger an alarm, protecting the motor and alerting the operator.

[0038] The technical solution of this application has at least the following advantages and beneficial effects:

[0039] 1. This utility model integrates an overload protection module, a temperature detection module, a speed detection module, an overvoltage protection module, an overcurrent and no-load protection module, and a short-circuit protection module, achieving comprehensive monitoring of multi-dimensional data such as motor temperature, voltage, power, current, and speed. It overcomes the limitations of single-parameter monitoring in traditional solutions, enabling more accurate judgment of the motor's operating status and effectively reducing the rate of missed fault detection. The device provides comprehensive protection against various fault states that the motor may experience, such as overload, short circuit, overheating, overcurrent, and no-load, ensuring the motor operates in a safe state. Upon detecting a fault, the device can quickly cut off the power supply to prevent motor damage, protect equipment and personnel safety, and provide strong assurance for the safe operation of the motor.

[0040] 2. This utility model integrates multiple protection functions into one device, improving the system's integration level. At the same time, each module functions independently, allowing for modular expansion or upgrades according to actual needs, meeting the requirements of different application scenarios, and improving the device's flexibility and scalability. Attached Figure Description

[0041] Figure 1 This invention relates to a motor speed monitoring circuit.

[0042] Figure 2 This is the short-circuit protection circuit of this utility model;

[0043] Figure 3 This is the overload protection circuit of this utility model;

[0044] Figure 4 This is the overvoltage protection circuit of this utility model;

[0045] Figure 5 This is a topological diagram of the present invention. Detailed Implementation

[0046] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0047] It should be noted that similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. The terms "center," "upper," "lower," "inner," and "outer," indicating orientation or positional relationships based on the orientation or positional relationships shown in the figures, or the orientation or positional relationships commonly used when the product is in use, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed or operated in a specific orientation, and therefore should not be construed as a limitation on this application. It should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0048] Example 1

[0049] Please refer to Figures 1-5 This utility model provides a measurement and control protection device for preventing motor failures, including an overload protection module, a temperature detection module, a speed detection module, an overvoltage protection module, an overcurrent and no-load protection module, a short circuit protection module, a human-machine interaction module, a communication module, and a central processing unit.

[0050] The signal output terminals of the overload protection module, temperature detection module, speed detection module, overvoltage protection module, overcurrent and no-load protection module, and short-circuit protection module are connected to the general-purpose peripheral interface of the central processing unit (CPU). The SPEED signal output terminal of the speed detection module is connected to the CPU's general-purpose input pin, configured for digital input mode. The OUT output terminal of the overload protection circuit is also connected to the CPU's general-purpose input pin, configured for digital input mode. The OUT output terminal of the short-circuit protection circuit is connected to the CPU's general-purpose input pin, configured for digital input mode. The output terminal of the temperature detection module is connected to the CPU's analog input pin (ADC pin), allowing the CPU to acquire the analog signal output from the temperature detection module. The current detection signal output terminal of the overcurrent and no-load protection module is connected to the CPU's analog input pin (ADC pin), allowing the CPU to acquire the current signal. The CPU's signal output terminals are connected to the signal input terminals of the communication module, and the communication module's signal output terminals are connected to the signal receiving terminals of the human-machine interface module. The communication module transmits data output from the CPU to the human-machine interface module for real-time display.

[0051] Furthermore, such as Figure 1 As shown, the speed detection module uses a motor speed monitoring circuit. The motor speed monitoring circuit includes a photoelectric sensor U3, resistors R10, R11, R12, R13, and R14, a capacitor C5, and a comparator U2.1.

[0052] Specifically, the photoelectric sensor U3 is used to monitor the motor speed. When a rotating part of the motor (such as a turntable or gear) passes through the photoelectric sensor U3, it blocks or reflects light, thereby changing the resistance of the photodiode inside the photoelectric sensor U3. The change in resistance is converted into an electrical signal output, and the output electrical signal is proportional to the motor speed.

[0053] Specifically, the output terminal of the photoelectric sensor U3 is connected to the non-inverting input terminal 3 of the comparator U2.1. This connection allows the electrical signal output by the photoelectric sensor U3 to be directly transmitted to the comparator U2.1. The non-inverting input terminal 3 of the comparator U2.1 receives the signal output by the photoelectric sensor U3, compares it with a reference voltage, and thus outputs a level signal indicating the motor's speed status.

[0054] It should be noted that the non-inverting input 3 of comparator U2.1 receives the signal output from photoelectric sensor U3, while the negative input 2 receives a reference voltage. Comparator U2.1 compares the signals received at the non-inverting input 3 and the negative input 2. If the signal voltage output by sensor U3 is higher than the reference voltage, output 1 of comparator U2.1 outputs a high level; if the signal voltage output by sensor U3 is lower than the reference voltage, output 1 of comparator U2.1 outputs a low level. This converts the analog signal output by the sensor into a digital signal, facilitating further processing by subsequent circuits and the control system.

[0055] It should be noted that capacitor C5, resistors R10, R11, R12, R13, and R14 are connected to photoelectric sensor U3 and comparator U2.1, serving as bias resistors, filters, and voltage regulators to ensure circuit stability and accuracy. Specifically, resistor R10 acts as a bias resistor, connected between the power supply terminal and ground of photoelectric sensor U3 to provide a suitable operating point. Capacitor C5 acts as a filter capacitor, connected between the output terminal 4 of photoelectric sensor U3 and ground, and between the non-inverting input terminal 3 of comparator U2.1 and ground, to remove noise and interference from the signal. Resistors R11 and R12 act as voltage regulator resistors, connected to the circuit's power supply line to ensure stable operation even under voltage fluctuations.

[0056] It should be noted that the SPEED signal output terminal of the speed detection module is connected to the general-purpose input pin of the central processing unit (CPU). This pin is configured in digital input mode. When the CPU receives a level signal indicating the motor speed status, it determines whether the motor speed is abnormal based on changes in this signal. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor speed status to the communication module. The communication module then transmits this motor speed data to the human-machine interface (HMI) module for real-time display. The CPU's general-purpose output pin is connected to the signal input terminal of the communication module, and the communication module's signal output terminal is connected to the signal receiving terminal of the HMI module.

[0057] Furthermore, such as Figure 2 As shown, the overload protection module uses an overload protection circuit. The overload protection circuit includes resistors R1, R2, R3, R4, R5, and R6, capacitors C1 and C2, comparator U1.1, and overload indicator D1.

[0058] Specifically, resistors R3 and R4 form a voltage divider reference circuit, which sets a threshold voltage. Resistor R5, in series with capacitor C2, filters the signal from the voltage divider reference circuit to obtain a cleaner threshold voltage signal. This threshold voltage signal is input to the inverting input terminal 2 of comparator U1.1. The motor is connected to the signal input terminal of the overload protection circuit. The motor and resistor R1 form a voltage divider circuit, and resistor R2 and capacitor C1 form a filter circuit. One end of resistor R1 is connected to the non-inverting input terminal 3 of comparator U1.1.

[0059] Specifically, when the motor is overloaded, the current flowing through the circuit is higher than the current during normal operation. Therefore, we use a comparator to set a threshold so that when the motor is operating normally, comparator U1.1 does not issue an overload signal; when the motor is overloaded and exceeds this threshold, comparator U1.1 outputs an overload signal. The non-inverting input 3 of comparator U1.1 is a simple current-to-voltage conversion circuit, detecting the current flowing through the motor through the voltage across resistor R1. When the motor is operating normally, the voltage at point B is less than the voltage at point A, comparator U1.1 outputs a low level, and the overload indicator D1 is off. When the motor is overloaded, the current flowing through resistor R1 increases, the voltage drop across R51 increases, the voltage at point B rises, and when it exceeds the voltage at point A, comparator U1.1 outputs a high level, and the overload indicator D1 illuminates.

[0060] It should be noted that comparator U1.1 is an open-collector (OC) gate output, and resistor R2 is an external pull-up resistor, which also serves as the current-limiting resistor for the overload indicator D1.

[0061] It should be noted that the output terminal OUT of the overload protection circuit is connected to the general-purpose input pin of the central processing unit (CPU). This pin is configured in digital input mode. When the CPU receives a level signal indicating whether the motor is overloaded, it determines whether the motor power is abnormal based on the change in this level signal. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor power status to the communication module. The communication module then transmits this motor power data to the human-machine interface (HMI) module for real-time display. The CPU's general-purpose output pin is connected to the signal input terminal of the communication module, and the communication module's signal output terminal is connected to the signal receiving terminal of the HMI module.

[0062] Furthermore, the short-circuit protection module employs a short-circuit protection circuit. This circuit includes resistors R7, R8, and R9, capacitors C3 and C4, and transistors Q1 and Q2. The input terminal IN of the short-circuit protection circuit is connected to the motor to monitor the current flowing through it in real time. The input terminal IN is connected to the emitter of transistor Q1. The collector of transistor Q1 is connected to one end of resistor R7 and then to ground through resistor R7. The base of transistor Q1 is connected to one end of resistor R8, and the other end of resistor R8 is connected to ground through resistor R9. The emitter of transistor Q1 is connected to the negative terminal of capacitor C4 and the base of transistor Q2. The collector of transistor Q2 is connected to the intermediate node between resistors R8 and R9, and this node serves as the signal output node OUT of the short-circuit protection circuit. The input terminal IN is connected to capacitors C3 and C4, and the collector of transistor Q2.

[0063] Specifically, when the motor is short-circuited, transistor Q2 is pulled low, and transistor Q1 conducts, forming a latch-up that forces transistor Q2 to turn off. After transistor Q3 turns off, there is no output, and the current at the signal output node OUT of the short-circuit protection circuit is zero. The entire circuit is open, and no current flows through the motor, thus effectively protecting the motor from burnout. When the circuit restarts, because the voltage across capacitors C3 and C4 cannot change abruptly, capacitor C3 keeps the base of transistor Q1 at a high level at the moment of power-on, thus preventing transistor Q1 from conducting. Capacitor C4 keeps the base of transistor Q2 at a low level at the moment of power-on, causing transistor Q2 to conduct. The signal output node OUT of the short-circuit protection circuit has an output voltage, making one end of resistor R9 high and the other end connected to ground, locking the conduction.

[0064] It should be noted that the output terminal OUT of the short-circuit protection circuit is connected to the general-purpose input pin of the central processing unit (CPU). This pin is configured in digital input mode. When the CPU receives a voltage level signal indicating whether the motor is short-circuited, it determines whether the motor's current state is abnormal based on the change in this signal. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor current state to the communication module. The communication module then transmits this motor current data to the human-machine interface (HMI) module for real-time display. The CPU's general-purpose output pin is connected to the signal input terminal of the communication module, and the communication module's signal output terminal is connected to the signal receiving terminal of the HMI module.

[0065] Furthermore, the overvoltage protection module employs an overvoltage protection circuit. This circuit includes resistors R15, R16, R17, and R18, a transistor Q4, and a PMOS transistor Q3. The voltage input terminal VIN is connected to resistor R15, which is connected to ground via a Zener diode D2. One end of resistor R16 is connected to the midpoint between resistor R15 and Zener diode D2, and the other end is connected to the base of transistor Q4. The emitter of transistor Q4 is connected to the circuit's voltage input terminal VIN. The collector of transistor Q4 is connected to one end of resistor R17, and the other end of resistor R17 is connected to the circuit's voltage input terminal VIN. Resistors R17 and R18 are connected in series. The drain of PMOS transistor Q3 is connected to one end of resistor R18 and then to the motor. The gate of PMOS transistor Q3 is connected in series with resistor R18, and the source of PMOS transistor Q3 is connected to the circuit's voltage input terminal VIN.

[0066] Specifically, when the voltage input terminal VIN is at normal input voltage, the Zener diode D2 does not break down in reverse, and almost no current flows through resistors R15 and R16. Transistor Q4 is not conducting, and the voltage drop V across the gate and source of PMOS transistor Q3 is... gs The voltage division by resistors R17 and R18 determines whether PMOS transistor Q3 is turned on, allowing the power supply to normally power the motor. When the input voltage VIN is greater than the normal voltage, Zener diode D2 breaks down, and transistor Q4 turns on. The voltage drop across the collector and emitter of transistor Q4 is approximately zero. Consequently, the voltage drop V across the gate and source of PMOS transistor Q3 is also zero. gs When the voltage is approximately equal to 0, PMOS transistor Q3 does not conduct, and the circuit is open, thus achieving overvoltage protection for the motor.

[0067] Furthermore, the temperature detection module adopts the DS18B20 temperature detection module. This module monitors the motor's temperature status in real time. When the motor temperature rises abnormally, it transmits the temperature data to the central processing unit (CPU) for processing. The CPU then issues a command to cut off the circuit and sends an alarm signal to prevent the motor from being damaged due to overheating.

[0068] It should be noted that the output of the temperature detection module is connected to the analog input pin (ADC pin) of the central processing unit (CPU). The CPU acquires the analog signal output by the temperature detection module through the ADC, converts it into a digital signal, and then calculates the temperature value. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor temperature status to the communication module, which then transmits this motor temperature data to the human-machine interface module for real-time display.

[0069] It should be noted that using the DS18B20 temperature detection module to monitor temperature is existing technology, which can be understood by those skilled in the art, and will not be elaborated further here.

[0070] Furthermore, the overcurrent and no-load protection module is used to monitor the current status of the motor in real time. When the current exceeds or falls below the set threshold, measures are taken to cut off the motor power supply and trigger an alarm to prevent the motor from being damaged due to overcurrent and ensure the safe operation of the motor.

[0071] Specifically, the overcurrent and no-load protection module uses a Hall current sensor, which is installed on the current path of the motor to monitor the current flowing through the motor in real time and transmit the current data to the central processing unit for processing. When the current exceeds the threshold voltage for normal operation of the motor, the central processing unit issues a command to cut off the circuit and issues an alarm signal to prevent the motor from being damaged due to overcurrent.

[0072] It should be noted that the current detection signal output terminal of the overcurrent protection module is connected to the analog input pin (ADC pin) of the central processing unit (CPU). The CPU acquires the current signal through the ADC, converts it into a digital signal, and then calculates the current value for real-time monitoring of the current magnitude. Simultaneously, the CPU's general-purpose output pin outputs data indicating the motor current status to the communication module, which then transmits this motor temperature data to the human-machine interface module for real-time display.

[0073] Furthermore, when the motor enters an unloaded state, the current suddenly drops to near zero. When the Hall current sensor detects that the current flowing through the motor is close to zero, the central processing unit issues a command to cut off the circuit and issue an alarm signal to prevent the motor from being damaged due to no-load. This enables the monitoring of whether the motor is unloaded and the taking of measures and issuing an alarm when the motor is unloaded.

[0074] It should be noted that the Hall current sensor used in this solution is model ACS712ELCTR-05B-T. Monitoring current using the ACS712ELCTR-05B Hall current sensor is existing technology, which can be understood by those skilled in the art, and will not be elaborated further here.

[0075] Furthermore, this motor fault prevention and control protection device includes a communication module and a human-machine interface module. The signal output terminal of the central processing unit is connected to the signal input terminal of the communication module, and the signal output terminal of the communication module is connected to the signal receiving terminal of the human-machine interface module. The communication module is used to transmit the data output by the central processing unit to the human-machine interface module for real-time display.

[0076] Therefore, this motor fault prevention and control protection device, through the above-mentioned modules and connection methods, can achieve real-time monitoring of the motor's temperature, power, current, and speed. Furthermore, in the event of an abnormal motor condition, this device can take measures to cut off power and trigger an alarm, protecting the motor and alerting the operator.

[0077] It should be noted that all the electronic devices mentioned in the above embodiments are available in domestic and international markets.

[0078] The various embodiments of this utility model have now been described in detail. To avoid obscuring the concept of this utility model, some details known in the art have not been described. Those skilled in the art will fully understand how to implement the technical solution of this utility model based on the above description. The scope of this utility model is defined by the appended claims.

Claims

1. A kind of anti-motor fault measurement and control protection device, it is characterized by: It includes an overload protection module, a temperature detection module, a speed detection module, an overvoltage protection module, an overcurrent and no-load protection module, a short-circuit protection module, and a central processing unit; The signal output terminals of the overload protection module, temperature detection module, speed detection module, overvoltage protection module, overcurrent and no-load protection module, and short-circuit protection module are connected to the general peripheral interface of the central processing unit. The SPEED signal output terminal of the speed detection module is connected to the general-purpose input pin of the central processing unit, which is configured as a digital input mode; the OUT output terminal of the overload protection circuit is connected to the general-purpose input pin of the central processing unit, which is configured as a digital input mode; the OUT output terminal of the short-circuit protection circuit is connected to the general-purpose input pin of the central processing unit, which is configured as a digital input mode. The output of the temperature detection module is connected to the analog input pin of the central processing unit (CPU), and the CPU acquires the analog signal output by the temperature detection module through an ADC. The current detection signal output of the overcurrent and no-load protection module is connected to the analog input pin of the CPU, and the CPU acquires the current signal through an ADC.

2. The kind of protection device of preventing motor fault of claim 1, its characterized in that, The speed detection module adopts a motor speed monitoring circuit; the motor speed monitoring circuit is equipped with a photoelectric sensor U3 and a comparator U2.1 for monitoring the motor speed; the output terminal of the photoelectric sensor U3 is connected to the non-inverting input terminal of the comparator.

3. The monitoring and protection device for preventing motor failure according to claim 2, characterized in that, The motor speed monitoring circuit includes a bias resistor R10 connected between the power supply terminal and ground of the photoelectric sensor U3; and a filter capacitor C5 connected between the output terminal and ground of the photoelectric sensor U3, and between the non-inverting input terminal of the comparator U2.1 and ground.

4. The monitoring and protection device for preventing motor failure according to claim 1, characterized in that, The overload protection module adopts an overload protection circuit; the overload protection circuit includes resistors R3, R4, and R5, capacitor C2, and comparator U1.

1.

5. The monitoring and protection device for preventing motor failure according to claim 4, characterized in that, Resistors R3 and R4 form a voltage divider reference circuit, through which a threshold voltage is set. Resistor R5, in series with capacitor C2, forms a filter circuit. The output of the voltage divider reference circuit is connected to the input of the filter circuit to filter the signal of the voltage divider reference circuit and obtain the threshold voltage signal. The output of the filter circuit is connected to the inverting input of comparator U1.1 to input the threshold voltage signal to comparator U1.

1.

6. The monitoring and protection device for preventing motor failure according to claim 1, characterized in that, The short-circuit protection module adopts a short-circuit protection circuit; the short-circuit protection circuit includes resistors R7, R8, and R9, capacitors C3 and C4, transistor Q1, and transistor Q2.

7. The monitoring and protection device for preventing motor failure according to claim 6, characterized in that, The input terminal IN of the short-circuit protection circuit is connected to the motor; the input terminal IN of the short-circuit protection circuit is connected to the emitter of transistor Q1; the collector of transistor Q1 is connected to one end of resistor R7 and then to ground through resistor R7; the base of transistor Q1 is connected to one end of resistor R8 and the other end of resistor R8 is connected to ground through resistor R9; the emitter of transistor Q1 is connected to the negative terminal of capacitor C4 and the base of transistor Q2; the collector of transistor Q2 is connected to the intermediate node of resistors R8 and R9, and this node is used as the signal output node OUT of the short-circuit protection circuit; the input terminal IN of the short-circuit protection circuit is connected to capacitor C3, capacitor C4, and the collector of transistor Q2 respectively.

8. The monitoring and protection device for preventing motor failure according to claim 1, characterized in that, The overvoltage protection module employs an overvoltage protection circuit. This circuit includes resistors R15, R16, R17, and R18, a transistor Q4, and a PMOS transistor Q3. Resistor R15 is connected to the voltage input terminal VIN and is connected to ground via a Zener diode D2. One end of resistor R16 is connected to the midpoint between resistor R15 and Zener diode D2, and the other end is connected to the base of transistor Q4. The emitter of transistor Q4 is connected to the circuit's voltage input terminal VIN. The collector of transistor Q4 is connected to one end of resistor R17, and the other end of resistor R17 is connected to the circuit's voltage input terminal VIN. Resistors R17 and R18 are connected in series. The drain of PMOS transistor Q3 is connected to one end of resistor R18 and is connected to the motor. The gate of PMOS transistor Q3 is connected in series with resistor R18, and the source of PMOS transistor Q3 is connected to the circuit's voltage input terminal VIN.

9. The monitoring and protection device for preventing motor failure according to claim 1, characterized in that, The motor fault prevention and control protection device includes a communication module and a human-machine interaction module; the signal output terminal of the central processing unit is connected to the signal input terminal of the communication module, and the signal output terminal of the communication module is connected to the signal receiving terminal of the human-machine interaction module; the communication module is used to transmit the data output by the central processing unit to the human-machine interaction module for real-time display.

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