Motor controller failure monitoring device and motor controller
Patent Information
- Application Number
- CN202521993780.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-16
- Publication Date
- 2026-09-11
- Estimated Expiration
- 2035-09-16
AI Technical Summary
[0006]有鉴于此，本实用新型提供了一种电机控制器故障监测装置以及电机控制器，以解决现有技术中针对控制器的故障处理措施不够完善的问题
[0006] In view of this, the present invention provides a motor controller fault monitoring device and a motor controller to solve the problem that the fault handling measures for controllers in the prior art are not perfect.
Smart Images
Figure CN224745315U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of motor control technology, specifically to a motor controller fault monitoring device and a motor controller. Background Technology
[0002] With the rapid development of automotive intelligence and electrification technologies, new energy vehicles are equipped with an increasing number of controllers and various electronic components. The safety and reliability requirements for these electronic components are also constantly rising to cope with increasingly complex and diverse driving conditions and environmental challenges. According to the international standard ISO 26262 (Functional Safety Standard), motor controller systems are classified as safety-related electronic systems, requiring stringent safety requirements in their design and implementation, including safety analysis of both hardware and software, and fault diagnosis and handling capabilities.
[0003] In motor controller systems, the System Basis Chip (SBC) is a highly integrated circuit chip used to manage and regulate power supply. The SBC plays a key role in ensuring system stability, optimizing energy utilization, and protecting system safety, and is an indispensable part of the motor control system.
[0004] Currently, the application of SBC in ASIL D level motor controllers involves the combined use of the SBC and the main control chip (Microcontroller Unit, MCU) to achieve the ASIL D safety level. The main control chip typically uses an ARM Cortex-M processor, which processes the acquired and received signals according to a preset algorithm to ultimately control the drive circuit. The SBC's main functions are to provide various protection features, such as overvoltage protection, undervoltage protection, SBC over-temperature protection, and overcurrent protection, and it periodically checks for faults during system operation.
[0005] However, the traditional SBC and main control chip combined solution is not perfect in terms of fault handling measures and lacks methods for detecting and handling other faults, which leads to a reduction in the safety of the motor controller. Utility Model Content
[0006] In view of this, the present invention provides a motor controller fault monitoring device and a motor controller to solve the problem that the fault handling measures for controllers in the prior art are not perfect.
[0007] In a first aspect, this utility model provides a motor controller fault monitoring device, the motor controller fault monitoring device comprising:
[0008] A power supply module, which is used to supply power to the main controller;
[0009] A data acquisition module is connected to the power supply module and is used to acquire the operating parameters of the power supply module, convert the operating parameters into digital signals, and output them.
[0010] A fault detection module is connected to the acquisition module and the main controller respectively. The fault detection module is used to perform fault detection on itself and the main controller during startup and confirm the fault information during startup. After startup, it receives the digital signal and confirms the fault information of the digital signal and acquires the fault information of the main controller. It is also used to output the fault protection signal corresponding to the fault information.
[0011] The motor controller fault monitoring device provided by this utility model performs fault detection on itself and the main controller during startup through a fault detection module. Upon detecting a fault during startup, it confirms the fault information and outputs a corresponding fault protection signal to implement protective measures. After startup, it receives digital signals, confirms fault information in the digital signals, and outputs a corresponding fault protection signal to implement protective measures. The fault detection module also collects fault information sent by the main controller, which needs to be detected by external devices. After collecting the fault information sent by the main controller, the fault detection module outputs a corresponding fault protection signal to implement protective measures. Compared to the traditional method using an SBC and control chip, this method, by detecting faults in the motor control device and controller during startup, and performing periodic fault detection after startup, automatically entering a safety mode to protect critical components, greatly improves the completeness of fault handling.
[0012] In one optional implementation, the main controller includes a security unit, and the fault detection module includes:
[0013] A fault self-test module is connected to the acquisition module and is used to receive the digital signal, confirm the fault information of the digital signal, and output the fault protection signal corresponding to the fault information.
[0014] The monitoring module is connected to the safety unit and is used to collect fault information of the main controller and output fault protection signals corresponding to the fault information.
[0015] In one optional embodiment, the motor controller fault monitoring device further includes:
[0016] A reset control module is connected to both the fault self-test module and the main controller, and is used to output a reset control signal to the main controller.
[0017] In one optional implementation, the fault self-test module is connected to the safety pin of the motor controller and is also used to output a safety control signal to the safety pin.
[0018] In one optional embodiment, the main controller includes a communication unit, and the motor controller fault monitoring device includes:
[0019] A communication module is connected to the communication unit, the acquisition module, and the fault detection module, respectively. It is used to receive fault judgment configuration information sent by the main controller and then send it to the fault detection module, as well as to send fault information and the operating parameters of the power supply module to the main controller.
[0020] In an optional implementation, the fault self-test module is further configured to, upon startup and when the detection configuration flag is not a set value, confirm the fault information during startup and output the fault protection signal corresponding to the fault information.
[0021] In one optional embodiment, the fault self-test module is connected to the reset control module. The fault self-test module is also used to send reset control information to the reset control module during startup, so that the reset control module sends a trigger signal to the reset pin. When a fault is detected in the reset path, the fault information during startup is confirmed and a fault protection signal corresponding to the fault information is output.
[0022] In one optional implementation, the fault self-test module is connected to the safety pin of the motor controller. The fault self-test module is also used to send a trigger signal to the safety pin during startup, and when a fault is detected in the safety control path, to confirm the fault information during startup and output the fault protection signal corresponding to the fault information.
[0023] This utility model also provides a motor controller, which includes the motor controller fault monitoring device and main controller as described above.
[0024] In one optional implementation, the main controller is further configured to confirm the fault level corresponding to the fault information and output the protective measures corresponding to the fault level. Attached Figure Description
[0025] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0026] Figure 1 This is a structural diagram of a motor controller fault monitoring device according to an embodiment of the present utility model;
[0027] Figure 2 This is a schematic diagram of fault classification and corresponding fault handling methods in a motor controller fault monitoring device according to an embodiment of the present utility model;
[0028] Figure 3 This is a flowchart of the initialization process of a motor controller fault monitoring device according to an embodiment of the present utility model;
[0029] Figure 4 This is a flowchart of the fault handling process of another motor controller fault monitoring device according to an embodiment of the present utility model. Detailed Implementation
[0030] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0031] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0032] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can also refer to the internal connection of two components; and they can refer to a wireless connection or a wired connection. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0033] Furthermore, the technical features involved in the different embodiments of this utility model described below can be combined with each other as long as they do not conflict with each other.
[0034] With the rapid development of automotive intelligence and electrification technologies, new energy vehicles are equipped with an increasing number of controllers and various electronic components. The safety and reliability requirements for these electronic components are also constantly rising to cope with increasingly complex and diverse driving conditions and environmental challenges. According to the international standard ISO 26262 (Functional Safety Standard), motor controller systems are classified as safety-related electronic systems, requiring stringent safety requirements in their design and implementation, including safety analysis of both hardware and software, and fault diagnosis and handling capabilities.
[0035] In motor controller systems, the System Basis Chip (SBC) is a highly integrated circuit chip used to manage and regulate power supply. The SBC plays a key role in ensuring system stability, optimizing energy utilization, and protecting system safety, and is an indispensable part of the motor control system.
[0036] Currently, there are two main application schemes for SBCs in ASIL D level motor controllers. The first scheme involves using the SBC in conjunction with a main control chip (Microcontroller Unit, MCU) to achieve the ASIL D safety level. The main control chip typically uses an ARM Cortex-M processor, which processes the acquired and received signals according to a preset algorithm to ultimately control the drive circuit. The SBC's main function is to provide various protection features, such as overvoltage protection, undervoltage protection, SBC over-temperature protection, and overcurrent protection. During system operation, it periodically checks for faults. The second scheme involves designing an application circuit for an ARM core microprocessor, sampling and verifying power and control signals to implement a multi-level checking mechanism, thereby achieving an ASIL-D integrated motor controller system design.
[0037] However, the traditional SBC and main control chip combined solution lacks comprehensive fault handling measures, and the corresponding inspection methods during the controller initialization phase are simple and limited, lacking methods for detecting and handling other faults, leading to reduced safety of the motor controller. High-performance ARM core microprocessor chips are typically more complex in design, integrating more functions and performance optimizations, and are therefore relatively more expensive.
[0038] In response, this embodiment provides a motor controller fault monitoring device, such as... Figure 1 As shown, the motor controller fault monitoring device is connected to the main controller, and the motor controller fault monitoring device includes:
[0039] Power supply module 10, which is used to supply power to the main controller;
[0040] A data acquisition module 20 is connected to the power supply module 10 and is used to acquire the operating parameters of the power supply module 10 and output the operating parameters.
[0041] The fault detection module 30 is connected to the acquisition module 20 and the main controller respectively. The fault detection module 30 is used to perform fault detection on itself and the main controller during startup, and confirm the fault information during startup. After startup, it receives the digital signal, confirms the fault information of the digital signal, and acquires the fault information of the main controller. It is also used to output the fault protection signal corresponding to the fault information.
[0042] Specifically, the motor controller fault monitoring device is a fault detection and processing device for the low-voltage power supply system in a new energy vehicle motor controller. The main controller is the main control chip, and the motor controller includes a controller and a power module. The controller includes a main controller and a pre-driver chip, which drives the power module. The power supply module 10 provides power to the core of the main controller, the ADC (Analog to Digital Converter) module, and Flash (a type of memory device).
[0043] Specifically, the acquisition module 20 periodically acquires the operating parameters of the power supply module 10, including information such as output voltages and device temperature. The acquisition module 20 converts the output voltages and device temperature into digital signals and outputs them to the fault detection module 30. Optionally, the acquisition module 20 can be an analog multiplexer (AMUX) signal acquisition device.
[0044] Specifically, the fault detection module 30 performs fault detection on itself and the main controller during startup. Upon detecting a fault during startup, it confirms the fault information and outputs a corresponding fault protection signal to implement protective measures. After startup, it receives digital signals, confirms fault information in those signals, and outputs a corresponding fault protection signal to implement protective measures. The fault detection module 30 also collects fault information sent by the main controller. This fault information needs to be detected by external devices. After collecting the fault information sent by the main controller, the fault detection module 30 outputs a corresponding fault protection signal to implement protective measures. Compared to the traditional method using an SBC and control chip, this approach, which detects faults in the motor control device and controller during startup, and performs periodic fault detection after startup, automatically entering a safe mode to protect critical components, significantly improves the completeness of fault handling.
[0045] In some alternative implementations, such as Figure 1 As shown, the main controller includes a safety unit, and the fault detection module 30 includes:
[0046] The fault self-test module 31 is connected to the acquisition module 20 and is used to receive the digital signal, confirm the fault information of the digital signal, and output the fault protection signal corresponding to the fault information.
[0047] Specifically, the fault self-test module 31 is used to receive digital information and determine whether the motor controller fault monitoring device itself has faults such as overvoltage, undervoltage, overcurrent, and overtemperature based on the digital information. The fault information includes overvoltage, undervoltage, overcurrent, and overtemperature.
[0048] The monitoring module 32 is connected to the safety unit and is used to collect fault information of the main controller and output the fault protection signal corresponding to the fault information.
[0049] Specifically, the monitoring module 32 is used to collect fault information from the main controller, for reference. Figure 1 The monitoring module 32 reads the alarm signal from the safety unit, which is a safety signal. Thus, the monitoring module 32 detects whether a fault has occurred in the main controller. When the main controller's safety unit detects a fault, it transmits the fault information to the monitoring module 32 via pin level. The monitoring module 32 can also be connected to the fault self-test module 31 and / or the reset control module 40. In this case, the monitoring module 32 sends fault information to the fault self-test module 31, which pulls down the safety pin level, and / or, when the fault is severe, sends fault information to the reset control module 40, causing the reset control module 40 to control the main controller to reset.
[0050] In some alternative implementations, such as Figure 1 As shown, the motor controller fault monitoring device further includes:
[0051] A reset control module 40 is connected to the fault self-test module 31 and the main controller, respectively, and is used to output a reset control signal to the main controller.
[0052] Specifically, the reset control module 40 is connected to the reset pin of the main controller.
[0053] In some alternative implementations, such as Figure 1 As shown, the fault self-test module 31 is connected to the safety pin of the motor controller and is also used to output a safety control signal to the safety pin.
[0054] Specifically, the motor controller includes a pre-drive chip, and the fault self-test module 31 outputs a safety control signal to the safety pin, thereby controlling the pre-drive chip to shut down the power module.
[0055] In some alternative implementations, such as Figure 1 As shown, the main controller includes a communication unit, and the motor controller fault monitoring device includes:
[0056] The communication module 50 is connected to the communication unit, the acquisition module 20 and the fault detection module 30 respectively. It is used to receive fault judgment configuration information sent by the main controller and send it to the fault detection module 30, and to send fault information and the working parameters of the power supply module to the main controller.
[0057] Specifically, the communication module 50 provides a communication interface to the main controller, enabling the main controller to write required configurations to the motor controller fault monitoring device or read output signals from the motor controller fault monitoring device, such as writing fault thresholds, output voltage, temperature, and other signals. After the motor controller completes power-on initialization, the main control chip can periodically read the configuration register values of the motor controller fault monitoring device and obtain information such as the output voltage and temperature configured by the motor controller fault monitoring device, as well as fault level information.
[0058] In some alternative implementations, such as Figure 3 As shown, the fault self-test module 31 is also used to confirm the fault information during startup and output the fault protection signal corresponding to the fault information when the detection configuration flag bit is not a set value during startup.
[0059] Specifically, after power-on, the motor controller fault monitoring device performs detection during the startup process to determine whether the functions of the motor controller fault monitoring device and each controller are complete. The fault self-test module 31 detects whether the configuration flag bit is a set value. When it detects that the configuration flag bit is a set value instead of a default value, it confirms the fault information during startup and outputs the corresponding fault protection signal.
[0060] In some alternative implementations, such as Figure 3 As shown, the fault self-test module 31 is connected to the reset control module 40. The fault self-test module 31 is also used to send reset control information to the reset control module 40 during startup, so that the reset control module 40 sends a trigger signal to the reset pin. When a fault is detected in the reset path, the fault information during startup is confirmed and the fault protection signal corresponding to the fault information is output.
[0061] Specifically, the fault self-test module 31 checks the validity of the main controller's reset pin. The fault self-test module 31 sends reset control information to the reset control module 40, thereby changing the main controller's reset pin from a high level to a low level. The fault self-test module 31 checks whether the reset path is normal, thereby detecting whether the main controller's reset function is normal.
[0062] In some alternative implementations, such as Figure 3 As shown, the fault self-test module 31 is connected to the safety pin of the motor controller. The fault self-test module 31 is also used to send a trigger signal to the safety pin during startup, and when a fault is detected in the safety control path, to confirm the fault information during startup and output the fault protection signal corresponding to the fault information.
[0063] Specifically, the fault self-test module 31 performs a safety pin validity check. After controlling the level state of the safety pin, it checks whether the current level state and the set level state are the same. If they are not the same, it confirms that the safety pin is faulty. Then, it confirms the fault information during startup and outputs the fault protection signal corresponding to the fault information.
[0064] refer to Figure 3 The power-on initialization process of the fault self-built module 31 is as follows:
[0065] Step 1: Check if the configuration flag is set. If the configuration flag is the default value, proceed to the next initialization step. If the configuration flag is set, proceed to another initialization step.
[0066] Step 2: Configure the functions. This part mainly sets the voltage monitoring thresholds for each power rail in the motor controller fault monitoring device and the corresponding fault handling measures.
[0067] Step 3: Perform an RSTB validity check, also known as a reset validity check. The motor controller fault monitoring device actively changes the RSTB pin from high to low to check if the RSTB path is normal. If the RSTB pin is active, the main control chip will be reset and the initialization program will be re-executed. If the RSTB path fails, the device will initialize the flag and activate the safety pin.
[0068] Step 4: After the reboot is complete, the initialization process will check the configuration flag value again. If the configuration flag value is set, the next initialization step will be executed. If the configuration flag value is not set, the process will return to Step 1 and re-initialize.
[0069] Step 5: Check if the configuration meets expectations. If they are the same, proceed to the next initialization step. If they are different, reset the device initialization flag position.
[0070] Step 6: Safety pin validity check. Control the safety pin level and check whether the set level is the same. If they are the same, proceed to the next initialization step. If they are different, reset the device initialization flag position.
[0071] refer to Figure 2 If an initialization fault exists, the motor controller fault monitoring device sends the fault information to the main controller. The main controller then disables the power module and reports the fault information to the vehicle controller. If a watchdog fault exists (i.e., a periodic communication failure between the main controller and the motor controller fault monitoring device), the RSTB pin is pulled low to reset the main control chip. If an abnormal fault is detected in the main control chip, the motor controller fault monitoring device controls the safety pin of the motor controller, thereby shutting down the power module.
[0072] This embodiment also provides a motor controller, which includes a motor controller fault monitoring device and a main controller. Compared with the traditional method of using an SBC and a control chip, this method detects faults in the motor control device and controller during startup. At the same time, it performs periodic fault detection after startup and automatically enters a safe mode to protect critical components, thereby greatly improving the integrity of fault handling.
[0073] This utility model provides a motor controller fault monitoring device that generates corresponding fault signals upon detecting faults and implements corresponding handling strategies based on the fault level to ensure the system remains in a safe state. Using this device, effective safety protection for the motor controller system can be guaranteed, reducing the risk of actuator errors due to the failure of the motor controller system's safety functions. Furthermore, the initialization process and corresponding fault handling measures involved in the device's initialization phase ensure the safe startup of the motor controller system. In case of emergencies or the detection of potential hazards, the device's periodic tasks can ensure the system automatically enters a safe mode, limiting the power output of the low-voltage system and protecting critical components.
[0074] In some alternative implementations, the main controller of the motor controller is also used to confirm the fault level corresponding to the fault information and output the protective measures corresponding to the fault level.
[0075] Specifically, refer to Figure 2 The main controller receives voltage, temperature and other information sent by the motor controller fault monitoring device, and determines the fault level based on the voltage, temperature and other information.
[0076] For example, power supply faults can include two levels of faults, and over-temperature faults can also include two levels of faults. After receiving voltage information, the main controller determines that a level-two fault is occurring and reports the fault information to the vehicle controller. In the case of a level-one fault, the main controller shuts down the power module. Similarly, after receiving temperature information, the main controller determines that a level-two fault is occurring and reports the fault information to the vehicle controller. In the case of a level-one fault, the main controller shuts down the power module. It should be noted that the level-one and level-two fault thresholds can be set by the main controller through the communication unit to the communication module of the motor controller fault monitoring device.
[0077] refer to Figure 4 The following steps are the procedures for handling a motor controller malfunction.
[0078] Step S1: Fault occurs;
[0079] Step S2: When the motor controller fault monitoring device detects a fault, it generates a fault signal;
[0080] Step S3: Send the fault signal to the main control chip through the communication module;
[0081] Step S4: The main control chip takes corresponding fault handling measures according to the fault type and level;
[0082] Step S5: The system enters a safe state.
[0083] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.
Claims
1. A motor controller fault monitoring device, characterized in that, The motor controller fault monitoring device includes: A power supply module, which is used to supply power to the main controller; A data acquisition module is connected to the power supply module and is used to acquire the operating parameters of the power supply module, convert the operating parameters into digital signals, and output them. A fault detection module is connected to the acquisition module and the main controller respectively. The fault detection module is used to perform fault detection on itself and the main controller during startup and confirm the fault information during startup. After startup, it receives the digital signal and confirms the fault information of the digital signal and acquires the fault information of the main controller. It is also used to output the fault protection signal corresponding to the fault information.
2. The motor controller fault monitoring apparatus of claim 1, wherein, The main controller includes a security unit, and the fault detection module includes: A fault self-test module is connected to the acquisition module and is used to receive the digital signal, confirm the fault information of the digital signal, and output the fault protection signal corresponding to the fault information. The monitoring module is connected to the safety unit and is used to collect fault information of the main controller and output fault protection signals corresponding to the fault information.
3. The motor controller fault monitoring device according to claim 2, characterized in that, The motor controller fault monitoring device also includes: A reset control module is connected to both the fault self-test module and the main controller, and is used to output a reset control signal to the main controller.
4. The motor controller fault monitoring device according to claim 3, characterized in that, The fault self-test module is connected to the safety pin of the motor controller and is also used to output a safety control signal to the safety pin.
5. The motor controller fault monitoring device according to claim 4, characterized in that, The main controller includes a communication unit, and the motor controller fault monitoring device includes: A communication module is connected to the communication unit, the acquisition module, and the fault detection module, respectively. It is used to receive fault judgment configuration information sent by the main controller and then send it to the fault detection module, as well as to send fault information and the operating parameters of the power supply module to the main controller.
6. The motor controller fault monitoring device according to claim 5, characterized in that, The fault self-test module is also used to confirm fault information during startup and output the fault protection signal corresponding to the fault information when the detection configuration flag bit is not a set value.
7. An electric machine controller fault monitoring apparatus according to claim 6, characterised in that, The fault self-test module is connected to the reset control module. The fault self-test module is also used to send reset control information to the reset control module during startup, so that the reset control module sends a trigger signal to the reset pin. When a fault is detected in the reset path, the fault information during startup is confirmed and the fault protection signal corresponding to the fault information is output.
8. The motor controller fault monitoring device according to claim 7, characterized in that, The fault self-test module is connected to the safety pin of the motor controller. The fault self-test module is also used to send a trigger signal to the safety pin during startup, and when a fault is detected in the safety control path, to confirm the fault information during startup and output the fault protection signal corresponding to the fault information.
9. An electric machine controller characterized by The motor controller includes a motor controller fault monitoring device and a main controller as described in any one of claims 1 to 8.
10. The motor controller of claim 9, wherein, The main controller is also used to confirm the fault level corresponding to the fault information and output the protection measures corresponding to the fault level.