CN102307033A - Integrated driving motor without position sensor - Google Patents
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Abstract
The invention relates to the motor technology field, more particularly to an integrated driving motor without a position sensor. The driving motor is provided with a motor; and the motor is composed of a stator, an external rotor, a rotor spindle, and an end cover. The driving motor is characterized in that: a driver is arranged in the motor and is fixedly connected with the end cover; the end cover and the stator of the motor are mutually connected to form an integral body so as to strengthen heat radiation capability of a module; the driver is composed of a power plate and a control plate; the power plate is provided with a major loop, an inlet wire open-phase detection circuit, a bus current detection circuit, an under-voltage and over-voltage detection circuit, a counter-electromotive force detection circuit and a switch power supply circuit; and the control plate is provided with a DSP control system circuit and a communication module circuit. According to the invention, on the basis of the above-mentioned structure, the driving motor has advantages of compact structure, high-density power, high efficiency, low noise, high integrated level, and low cost and the like.
Description
Technical Field
The invention relates to the technical field of motors, in particular to an integrated position-sensorless driving motor.
Background
At present, a Brushless DC Motor (BLDC) is developed internationally by virtue of its characteristics of high reliability, high efficiency, convenient speed regulation, long service life, etc., and in some developed countries, the Brushless DC Motor will become a leading Motor in the coming years and gradually replace other types of motors.
The BLDC drive control method is classified into a position sensor type and a non-position sensor type. In the control method with the position sensor, the existence of the position sensor brings many defects and inconveniences to the application of the brushless motor: first, the position sensor increases the size and cost of the motor; secondly, the reliability of the motor operation can be reduced by connecting a plurality of position sensors, and even if the Hall sensor which is most widely applied at present has a certain magnetic insensitive area; again, in certain harsh operating environments, such as in a sealed air conditioning compressor, conventional position sensors cannot be used at all due to the strong corrosiveness of the refrigerant. In addition, the installation accuracy of the sensor also influences the running performance of the motor, the production process difficulty is increased, and especially when the size of the motor is small to a certain degree, the defect of using the position sensor is gradually obvious.
In the position-sensor-free square wave control, the two-to-two conduction mode is most commonly adopted for control. However, the control mode has the problem that the follow current is too long due to overlarge current, and further commutation failure is caused, which is a main technical difficulty influencing the application of the position-sensor-free control mode in the high-power field.
The traditional starting mode of the brushless direct current motor without the position sensor is three-section starting, and belongs to an open-loop starting mode. The starting circuit has strict requirements on starting environment, can generate reverse rotation phenomenon, has weak adaptability to load change during starting, can generate the problem of starting failure, and has larger starting current ratio.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides an integrated position-sensorless driving motor which is novel in structure, low in cost, small in size and convenient to mount.
The technical scheme adopted by the invention for solving the technical problems is as follows:
an integrated drive motor without position sensor is composed of motor consisting of stator, external rotor, rotor shaft and end cover, and features that a driver is arranged in motor and is fixed to end cover, the end cover is connected to stator of motor to increase the heat radiating power of module, the driver is composed of power board with main loop, phase-off detecting circuit, bus current detecting circuit, under-voltage and over-voltage detecting circuit, counter-potential detecting circuit and switching power supply circuit, and control board with DSP control system and communication module,
wherein:
an incoming line EMI filter and a piezoresistor are arranged in a main loop for protection, an X capacitor, a Y capacitor and a three-phase common-mode filter are used for inhibiting differential mode and common-mode interference, a rectifier bridge and an inverter bridge are integrated in a power module, and the power module is high in integration level and small in occupied area by adopting a chip SEMIKRON; the DC bus has an LC structure to realize Power Factor Correction (PFC),
the incoming line open-phase detection circuit is characterized in that three-phase electricity sent to the power module is processed by a detection circuit consisting of a resistor, a diode and an optocoupler and then sent to a DSP chip for reading, the duty ratio of output digital signals LHP1 and LHP2 of the open-phase detection circuit is read to judge whether open-phase exists or not, and the incoming line open-phase detection circuit has the functions of incoming line open-phase alarm, overload and overheat alarm, overcurrent and overvoltage alarm, power factor correction and the like,
the bus current detection circuit is characterized in that a very small current detection resistor is connected in series on a bus, voltage signals at two ends of the resistor are isolated and amplified through a linear optical coupler, and the signals are processed into a range which can be received by a control chip through a conditioning circuit, so that the current of the motor is fed back and monitored,
the undervoltage and overvoltage detection circuit adopts a large-resistance isolation method, and converts the bus voltage into an analog signal input by a control chip through a simple operational amplifier circuit to realize undervoltage and overvoltage detection, the input of the operational amplifier is the bus voltage, the input resistance is very large, the feedback resistance is very small, so that the input voltage of the actual operational amplifier pin is not very large, the flowing current is very small, the isolation effect is realized, and the voltage detection is also realized,
the back electromotive force detection circuit is a low-pass filter, the sensorless control is realized by adopting a 'terminal voltage method', the voltage to earth of three phases UVW of the motor is processed, a rotor position signal is generated by a DSP processor, the terminal voltage is divided into a back electromotive force signal and a current follow current interference signal, the three-phase voltage of the motor firstly filters a high-frequency interference signal and reduces the voltage by the low-pass filter, then a direct current part is removed by a capacitor, the processed signal is compared with a virtual neutral point voltage constructed by the three phases, the phase and the amplitude of the two signals are calculated to obtain the phase advance angle of the rotor position signal caused by the current follow current, the offset angle of the current follow current influence is determined by detecting the current, the rotating speed, the duty ratio, the bus voltage and the motor parameter to compensate, so that the zero crossing point signal of the back electromotive force is obtained, and the phase change time is close, ensures the correct commutation, greatly expands the application range of the brushless DC motor without a position sensor,
the switching power supply circuit adopts a flyback converter, the input is bus voltage, 3 isolated direct current voltages are output and are respectively used for a DSP control system circuit and a communication module circuit,
the control core chip of the DSP control system circuit is a DSP and is provided with 6 paths of analog signal inputs, 3 pairs of PWM outputs,
the communication module circuit comprises two one-step serial communication modes of RS232 and RS485, wherein RS232 is used for maintaining programs and other operations, RS485 is used for industrial control, RS232 and RS485 bus communication input and an analog quantity speed setting circuit can be carried out, the analog quantity speed setting circuit adjusts the rotating speed of the motor by inputting voltage to the controller,
the end cover is provided with wiring holes, the control panel is provided with terminal row interfaces which are respectively a three-phase power inlet interface, a driver alarm output interface, a serial port RS232, a serial port RS485 and an analog quantity given interface, and the terminal row interfaces on the control panel respectively penetrate through the wiring holes on the end cover to connect communication and analog quantity speed regulation, protection alarm and three-phase alternating current input.
The ceramic coating is arranged on the shaft body of the rotor shaft, so that the influence of axial current on the electromagnetic performance of the motor can be prevented, the ceramic coating comprises a front ceramic coating and a rear ceramic coating, and the front ceramic coating and the rear ceramic coating respectively correspond to the mounting positions of the bearings, so that the axial current generated by the high-speed operation of the motor can be prevented.
In the invention, each phase winding can be inserted into the hole of the stator core by one winding in a staggered way to form the winding series connection of four coils, so as to reduce the inductance of the stator and better match with a driver for speed regulation.
The invention can install the heat dissipation disc between the end cover and the motor stator, so as to be beneficial to heat dissipation of the power board and the control board.
The invention can arrange a lug boss contacting with the driver module in the end cover, and arrange a radiating fin outside the end cover, so that the module on the driver is tightly connected with the end cover, and the radiating capacity of the module is increased.
The invention can isolate the driving circuit and the ground wire of the main loop from the ground wire of the control circuit, thereby increasing the stability of the system.
The temperature detection circuit is arranged on the driving plate and consists of a common resistor, a capacitor, a thermistor and an operational amplifier, and is used for detecting the temperatures of the rectification and inversion module, the power plate and the motor in real time, so that unstable and abnormal working conditions caused by overhigh or overlow temperature are prevented.
The outer rotor is composed of a shell body and flange mounting surfaces at the end parts of the shell body, the shell body and the flange mounting surfaces are formed in a one-step stretching mode, the flange mounting surfaces do not need to be manufactured independently, the secondary welding process is omitted, the number of production parts is reduced, the production efficiency of the motor is improved, the cost is reduced, the production efficiency is improved, the stability of the motor structure is enhanced, and the concentricity is guaranteed.
The stator core straight notch is formed by laminating the stator punching sheets in a straight slot mode, and is perpendicular to the end faces of the stator punching sheets, so that the press-fitting structure of the stator core is simplified, the production procedures are simplified, and the effects of simple laminating process, high production efficiency, high qualification rate and low production cost are achieved.
The periphery of the rotor shaft body is provided with an annular groove corresponding to the bearing, and the front ceramic coating and the rear ceramic coating are respectively arranged in the grooves, so that the processing is convenient, and the overall strength of the rotor shaft is improved.
The inner circle space of the gap between the magnetic shoes is smaller than the outer circle space, and the spring piece is clamped in the gap between the magnetic shoes, so that the spring piece achieves the radial limiting effect, and the spring piece is effectively prevented from overflowing from the gap.
The cross section of the gap between the magnetic shoes can be trapezoidal, so that the radial and axial stability of the magnetic shoes is ensured, and the matching tension of the magnetic shoes and the rotor shell is increased.
The compensation calculation method of the back electromotive force detection circuit comprises the following specific steps: in order to analyze the phase shift phenomenon of the position detection signal when the motor is subjected to heavy load, the terminal voltage under the heavy load is analyzed as follows:
since the back emf detection circuit is a low pass filter, the high frequency components will be filtered out by the detection circuit, so the following simplification can be made:
1) because the PWM modulation frequency is far greater than the cut-off frequency of the low-pass filter of the counter electromotive force detection circuit, the high-frequency PWM chopped voltage can be approximated by the average value of the voltage;
2) similarly, the voltage fluctuation of the neutral point of the motor is also filtered out and can be approximated by the average value of the voltage fluctuation;
3) the reverse electromotive force is a PWM wave with 120 degrees flat top width and the equivalent amplitude is bus voltage;
when the upper arm modulation is adopted, the terminal voltage at the time of the lower arm conduction mode (PWM-ON) can be simplified into a model as shown in fig. 8, wherein,
is the sum of the ideal line back emf and the voltage at the ideal neutral point,
voltage distortion for current freewheelingIs equal to
And
to sum, i.e.
=
+
(the voltage reference point is the negative of the bus);
terminal voltage in FIG. 8Can be divided into 6 states, which are respectively:
1）
andtime: the phase lower bridge arm is conducted and the terminal voltage is
And
equal, the bus bar negative voltage, labeled 0,
is also 0, at this timeThe detection of the position signal is not influenced;
2）
time period: the motor is phase-changed, the current flows through the upper bridge arm anti-parallel diode, the voltage is clamped to the bus voltage，Rises linearly with increasing counter electromotive force;
is composed ofAnd
a difference of
；
3）Time period: the phase is suspended, and the voltage at the phase end is the sum of the opposite electromotive force and the neutral point voltage. The neutral point voltage is DC bias, the back electromotive force rises linearly, and the terminal voltage
And
linearly increasing;0, not functioning;
4）
time period: the phase upper bridge arm is modulated and the duty ratio is adjusted
And bus voltage
Product of andin a relationship of
Terminal voltage
Is equal to
Is provided with
；
0, does not affect the detection of the position signal;
5）time period: the motor is phase-changed, the current flows through the lower bridge arm anti-parallel diode, the terminal voltage is clamped to be the bus ground voltage 0,
linearly decreases with a decrease in the back emf,
is composed of
Anda difference of
；
6）
Time period: the phase is suspended, the voltage of the phase end is the sum of the counter electromotive force and the voltage of the neutral point, the voltage of the neutral point is DC bias, the counter electromotive force is linearly reduced, and the voltage of the end is
And
the linear decrease is carried out, and the linear decrease,0, does not affect the detection of the position signal;
by means of the decomposition of the terminal voltage,the same as in light and heavy loads, and
there is a great difference that at light load, the current is small,
and
the length of the short-circuit wire is very short,
has a short action time, a small volt-second product, of(
=
,
) Therefore, only weak influence is caused on the detection of the position signal and can be ignored; when the load is heavy, the current is large,
and
for a longer time, volt-second product
It is not negligible, its influence on the position detection signal is serious, the generated phase lead angle is too large, fig. 10 is terminal voltage
And voltage of its decomposition
And
the generated signal after passing through the low-pass filter, the follow current interference signal leads the back electromotive force signal, so that the superimposed and synthesized terminal voltage signal leads the back electromotive force signal, the amplitude of the follow current interference signal is larger, the leading angle of the terminal voltage signal is larger, the terminal voltage phase lead leads the zero crossing point moment of the terminal voltage to come forward, the detected zero crossing point deviates from the real back electromotive force zero crossing point, when the phase leading angle is increased along with the increase of the load current, and when the leading angle is too large, the phase change situation becomes worse, the current distortion is caused, and the terminal voltage wave is adversely affectedShape and position detection signals, causing further deterioration of commutation, eventually leading to commutation failure;
through the establishment of the model and the decomposition analysis of the end-to-end voltage, the phase relation of the back electromotive force detection signals during light load and heavy load can be obtainedAnd+
due to the phase relationship of
And
the same period, the phase angle lag through the low pass filter is equal, so the difference between the phase angles of the position signals under light and heavy loads depends on
And
the included angle and the amplitude value of the phase compensation under the heavy load are obtained by the method:
under the step voltage, the zero state response calculation formula of the low-pass filter is as follows
Wherein
，
、
And
as shown in fig. 7. Voltage across low pass filter
And the voltage of the simulated neutral point
Comparing to obtain zero crossing point of back electromotive force, neglecting fluctuation of neutral point voltage
Is composed of
Is therefore only considered
Of an alternating current component of
In the back electromotive force detection circuit shown in fig. 7, appropriate resistances and capacitances are selected so that
To obtain
Will be provided with
Carrying out approximately equivalent step signal processing, and obtaining by the formula (3)
AC amplitude of output voltage after passing through low pass filter
Is provided with
Wherein,for follow current angle, is the current follow current time
The electrical angle of the conversion is calculated,
is the frequency of the back emf of the motor,
to modify the scale factor, take=1，
In the same way
AC amplitude of output voltage after passing through low pass filter
Is provided with
(6)
And satisfy
，
Is non-linear and computationally complex, but because of
The fluctuation range is small, and the method of engineering approximation is adopted, so that the method can be regarded as constant value approximation calculation
According to the formulas (4) and (5), as shown in FIG. 9,
andphase angle of
Satisfy the requirement of
(7)
When in use
When taking 20 degrees, can obtain
In the formula:
in order to compensate for the angle, the angle is adjusted,
the microprocessor can be used for easily processing and calculating the phase advance angle deduced by the formula, so that after the relation between the current follow current angle and the current magnitude is measured, the controller can determine the phase advance angle in real time only by detecting the phase current of the motor, and the phase angle advance commutation is favorable for reducing the torque pulsation of the brushless direct current motor, so that the phase angle compensation can be properly carried out according to the current magnitude and the rotating speed, and the motor can reach the optimal running state.
The invention adopts the structure, integrates the motor and the driver into a whole, so that the permanent magnet brushless motor replaces the traditional alternating current asynchronous motor, the efficiency is greatly improved, the energy consumption is reduced, the outer rotor structure is adopted, the motor and the impeller can be directly connected, the volume is reduced, the power density ratio of the system is improved, the cost is reduced, the phase change problem under heavy load is solved, the driver integrates the main circuit and the control circuit into a whole, the anti-electromagnetic interference capability is enhanced, and the permanent magnet brushless motor has the advantages of compact structure, high power density, high efficiency, low noise, high integration level, low cost and the like.
Drawings
Fig. 1 is a schematic structural view of the present invention.
Fig. 2 is a schematic block diagram of the present invention.
Fig. 3 is a schematic view of the structure of the rotor shaft in the present invention.
Fig. 4 is a schematic structural view of an outer rotor in the present invention.
Fig. 5 is a schematic view of the structure of the stator winding in the present invention.
Fig. 6 is a schematic view of the structure of the stator core in the present invention.
Fig. 7 is a counter electromotive force detection circuit in the present invention.
Fig. 8 is a terminal voltage and its exploded view in the present invention.
Fig. 9 is a diagram for analyzing the phase relationship between voltages.
Fig. 10 is a graph showing the terminal voltage after passing through the low-pass filter and its decomposition.
Fig. 11 is a schematic view of the inner structure of the outer rotor in the present invention.
Fig. 12 is an enlarged view of B in fig. 11.
Fig. 13 is a signal interface diagram of the present invention.
Reference numerals: the device comprises a power board 1, a control board 2, an EMI filter 3, a rectifier bridge 4, an inverter bridge 5, a power module 6, a detection circuit 7, a switching power supply circuit 8, a communication module circuit 9, an analog quantity speed setting circuit 10, a control circuit 11, a three-phase alternating current input 12, an upper computer 13, a counter electromotive force detection circuit 14, a potentiometer 15, a motor 16, a power factor correction 17, a drive circuit 18, a stator 22, an outer rotor 24, a rotor shaft 25, an end cover 26, a bearing 27, a driver 28, a heat dissipation disc 29, a ceramic plating layer 30, a shell 31, flange mounting surfaces 32, 33, U-phase windings U1-U2, 34, V-phase windings V1-V2, 3, W-phase windings W1-W2, 35 and a stator core straight notch, 36. stator punching, 37, follow current interference signal, 38, terminal voltage signal, 39, opposite electromotive force signal, 40, magnetic shoe, 41, spring leaf.
Detailed Description
The invention is further described below with reference to the accompanying drawings:
an integrated drive motor without position sensor is provided with a motor 16, the motor 16 is composed of a stator 22, an outer rotor 24, a rotor shaft 25, a bearing 27 and an end cover 26, the stator is installed in an iron core wire slot by a multi-phase winding, the connection relation between the stator 22 and the outer rotor 24 is the same as that of the prior art, which is not described again, the outer rotor 24 is fixedly connected with the end cover 26 through a labyrinth spigot, a driver 28 is arranged in the motor 16, the driver 28 is fixedly connected with the end cover 26, the end cover 26 is connected with the stator 22 of the motor 16 to form a whole so as to increase the heat dissipation capability of the module, the driver 28 is composed of a power board 1 and a control board 2, the control board 2 is fixed on the power board 1, the power board 1 is provided with a main loop, an incoming line open-phase detection circuit, a bus current detection circuit, an under-voltage and over-voltage detection circuit, a DSP control system circuit and a communication module circuit 9 are arranged on the control panel 2,
wherein:
an incoming line EMI filter 3 and a piezoresistor are arranged in a main loop for protection, an X capacitor, a Y capacitor and a three-phase common mode filter are used for inhibiting differential mode and common mode interference, a rectifier bridge 4 and an inverter bridge 5 are integrated in a power module 6, the power module 6 is high in integration level and small in occupied area by adopting a chip SEMIKRON; an LC structure is arranged on the direct current bus, Power Factor Correction (PFC) 17 is realized,
the incoming line open-phase detection circuit is characterized in that three-phase electricity sent to the power module is processed by a detection circuit 7 consisting of a resistor, a diode and an optocoupler and then sent to a DSP chip for reading, the duty ratio of output digital signals LHP1 and LHP2 of the open-phase detection circuit is read to judge whether open-phase exists or not, and the incoming line open-phase detection circuit has the functions of incoming line open-phase alarm, overload and overheat alarm, overcurrent and overvoltage alarm, power factor correction and the like,
the bus current detection circuit is characterized in that a very small current detection resistor is connected in series on a bus, voltage signals at two ends of the resistor are isolated and amplified through a linear optical coupler, and the signals are processed into a range which can be received by a control chip through a conditioning circuit, so that the current of the motor is fed back and monitored,
the undervoltage and overvoltage detection circuit adopts a large-resistance isolation method, and converts the bus voltage into an analog signal input by a control chip through a simple operational amplifier circuit to realize undervoltage and overvoltage detection, the input of the operational amplifier is the bus voltage, the input resistance is very large, the feedback resistance is very small, so that the input voltage of the actual operational amplifier pin is not very large, the flowing current is very small, the isolation effect is realized, and the voltage detection is also realized,
the counter electromotive force detection circuit 14 is a low pass filter, the sensorless control is realized by adopting a 'terminal voltage method', a rotor position signal is obtained by processing the voltage to earth of three phases UVW of the motor, the three-phase voltage of the motor firstly filters a high-frequency interference signal and reduces the voltage through the low pass filter, then a direct current part is removed through a capacitor, the processed signal is compared with a virtual neutral point voltage constructed by the three phases, so that a counter electromotive force zero crossing point signal is obtained, the offset angle of current follow current influence is determined by detecting current, rotating speed, duty ratio, bus voltage and motor parameters for compensation, the phase change moment is close to the optimal phase change moment, the correct implementation of commutation is ensured, and the application range of the sensorless brushless direct current motor is greatly expanded,
the switch power supply circuit 8 adopts a flyback converter, inputs bus voltage, outputs 3 isolated direct current voltages, and is respectively used for a DSP control system circuit, a communication module circuit and an analog speed setting circuit, the invention preferably adopts a path of 5V output to supply power to DSP, a path of 15V output is output, then 5V is rectified to provide power for chips of a power part, a path of 15V output is output, then 10V and 5V are rectified to provide power for communication and speed simulation setting,
the control core chip of the DSP control system circuit is a DSP and is provided with 6 paths of analog signal inputs, 3 pairs of PWM outputs,
the communication module circuit 9 comprises two one-step serial communication modes of RS232 and RS485, wherein RS232 is used for operations such as maintenance of programs, RS485 is used for industrial control, RS232 and RS485 bus communication and input of an analog quantity speed setting circuit 10 can be carried out, the analog quantity speed setting circuit 10 adjusts the rotating speed of the motor by inputting voltage to a control circuit 11,
the terminal row interfaces are arranged on the control panel 2 and are respectively a three-phase power incoming line interface, a driver alarm output interface, a serial port RS232, a serial port RS485 and an analog quantity given interface, wiring holes are formed in the end cover 8, and the terminal row interfaces on the control panel 2 respectively penetrate through the wiring holes formed in the end cover 8 to connect communication, analog quantity speed regulation, protection alarm and three-phase alternating current input.
The present invention can isolate the drive circuit 18 from the "ground" of the main circuit and the "ground" of the control circuit 11 to increase the stability of the system.
The invention can be provided with a temperature detection circuit on the driving board 1, the temperature detection circuit consists of a resistor, a capacitor, a thermistor and an operational amplifier, and is used for detecting the temperature of the rectification and inversion module, the power board and the motor in real time, preventing the unstable work and abnormal conditions caused by overhigh or overlow temperature,
the present invention may incorporate a heat sink plate 29 between the end cap 26 and the motor stator 22 to facilitate heat dissipation from the power and control boards.
The present invention may have bosses in the end cap 26 that contact the driver 28 modules and cooling fins on the outside to allow the modules on the driver 28 to be tightly attached to the end cap 26, increasing the heat dissipation capacity of the modules.
The ceramic coating 30 is arranged on the shaft body of the rotor shaft 25, so that the influence of axial current on the electromagnetic performance of the motor can be prevented, the ceramic coating 30 comprises a front ceramic coating and a rear ceramic coating, and the front ceramic coating and the rear ceramic coating respectively correspond to the mounting positions of the bearings, so that the axial current generated by high-speed operation of the motor can be prevented.
The periphery of the rotor shaft 25 shaft body is provided with the annular groove, and the front ceramic coating and the rear ceramic coating are respectively arranged in the groove, so that the processing is convenient, and the integral strength of the rotor shaft is improved.
In the invention, each phase winding can be penetrated into the hole of the stator core 35 by one winding in a staggered way, so that the windings of four coils are connected in series, the inductance of the stator is reduced, the speed of the stator is better regulated by matching with a driver, and the invention has the advantages of simple production process, high production efficiency, high qualification rate and low motor cost.
The outer rotor 24 in the invention is composed of a shell 31 and a flange mounting surface 32 at the end part of the shell, and the shell 31 and the flange mounting surface 32 are formed by one-time stretching, so that the flange mounting surface is not required to be manufactured independently, the secondary welding procedure is omitted, the number of production parts is reduced, the production efficiency of the motor is improved, the cost is reduced, the production efficiency is improved, the stability of the motor structure is enhanced, and the concentricity is ensured.
The stator 22 body is provided with the stator core straight notch at the periphery, the stator core straight notch is formed by laminating the stator punching sheets in a straight slot mode, and the stator core straight notch is vertical to the end face of the stator core 36, so that the press mounting structure of the stator core 36 is simplified, the production process is simplified, and the effects of simple laminating process, high production efficiency, high qualification rate and low production cost are achieved.
The inner circle distance of the gap between the magnetic shoe 40 and the magnetic shoe 40 is smaller than the outer circle distance, and the spring piece 41 is clamped in the gap between the magnetic shoe 40 and the magnetic shoe 40, so that the spring piece 41 achieves the radial limiting effect, and the spring piece 41 is effectively prevented from overflowing from the gap.
The cross section of the gap between the magnetic shoe 40 and the magnetic shoe 40 can be trapezoidal, so that the radial and axial stability of the magnetic shoe 40 is ensured, and the matching tension of the magnetic shoe 40 and the rotor shell body 31 is increased.
The invention realizes communication with the upper computer 13 through RS232, when the upper computer 13 is used for control, the running state of the motor 16 can be detected, or a speed is given to the driver through the rheostatic potentiometer 15, the motor speed can be adjusted freely in a set range by the upper computer 13 or the potentiometer 15, when the motor is started, the starting rotating speed is started by adopting a method of injecting current pulse, the starting rotating speed is usually in a range of 50-80r/min, the offset angle of current follow current influence is determined by detecting the alternating action of a voltage vector and an accelerating voltage vector on the motor, the current, the rotating speed, the duty ratio, the bus voltage and the motor parameter, the three-phase terminal voltage is detected through the back electromotive force detection circuit 14, the three-phase terminal voltage is compared with a simulated neutral point after deep filtering through a filter circuit, a rotor position signal is generated through a DSP processor, and the terminal voltage is divided into a, the phase and amplitude of the two signals are calculated to obtain the phase lead angle of the rotor position signal caused by current follow current, and the phase lead angle is compensated, wherein the specific compensation calculation method comprises the following steps: in order to analyze the phase shift phenomenon of the position detection signal when the motor is subjected to heavy load, the terminal voltage under the heavy load is analyzed as follows:
the compensation calculation method of the back electromotive force detection circuit can be realized by the following specific steps: in order to analyze the phase shift phenomenon of the position detection signal when the motor is subjected to heavy load, the terminal voltage under the heavy load is analyzed as follows:
since the back emf detection circuit is a low pass filter, the high frequency components will be filtered out by the detection circuit, so the following simplification can be made:
1) because the PWM modulation frequency is far greater than the cut-off frequency of the low-pass filter of the counter electromotive force detection circuit, the high-frequency PWM chopped voltage can be approximated by the average value of the voltage;
2) similarly, the voltage fluctuation of the neutral point of the motor is also filtered out and can be approximated by the average value of the voltage fluctuation;
3) the reverse electromotive force is a PWM wave with 120 degrees flat top width and the equivalent amplitude is bus voltage;
when the upper arm modulation is adopted, the terminal voltage at the time of the lower arm conduction mode (PWM-ON) can be simplified into a model as shown in fig. 8, wherein,
is the sum of the ideal line back emf and the voltage at the ideal neutral point,
voltage distortion for current freewheeling
Is equal toAnd
to sum, i.e.
=
+
(the voltage reference point is the negative of the bus);
terminal voltage in FIG. 8
Can be divided into 6 states, which are respectively:
1）
andtime: the phase lower bridge arm is conducted and the terminal voltage is
And
equal, the bus bar negative voltage, labeled 0,
is also 0, at this time
The detection of the position signal is not influenced;
2）
time period: the motor is phase-changed, the current flows through the upper bridge arm anti-parallel diode, the voltage is clamped to the bus voltage
，
Rises linearly with increasing counter electromotive force;is composed of
And
a difference of
；
3）
Time period: the phase is suspended, and the voltage at the phase end is the sum of the opposite electromotive force and the neutral point voltage. The neutral point voltage is DC bias, the back electromotive force rises linearly, and the terminal voltageAnd
linearly increasing;
0, not functioning;
4）
time period: the phase upper bridge arm is modulated and the duty ratio is adjusted
And bus voltageProduct of and
in a relationship of
Terminal voltageIs equal to
Is provided with
；
0, does not affect the detection of the position signal;
5）
time period: the motor is phase-changed, the current flows through the lower bridge arm anti-parallel diode, the terminal voltage is clamped to be the bus ground voltage 0,
linearly decreases with a decrease in the back emf,
is composed of
Anda difference of
；
6）
Time period: the phase is suspended, the voltage of the phase end is the sum of the counter electromotive force and the voltage of the neutral point, the voltage of the neutral point is DC bias, the counter electromotive force is linearly reduced, and the voltage of the end is
And
the linear decrease is carried out, and the linear decrease,
0, does not affect the detection of the position signal;
by means of the decomposition of the terminal voltage,
the same as in light and heavy loads, and
there is a great difference that at light load, the current is small,andthe length of the short-circuit wire is very short,
has a short action time, a small volt-second product, of
(
=
,
) Therefore, only weak influence is caused on the detection of the position signal and can be ignored; when the load is heavy, the current is large,
andfor a longer time, volt-second product
It is not negligible, its influence on the position detection signal is serious, the generated phase lead angle is too large, fig. 10 is terminal voltage
And voltage of its decomposition
And
the generated signal after passing through the low-pass filter, the follow current interference signal leads the back electromotive force signal, so that the superimposed and synthesized terminal voltage signal leads the back electromotive force signal, the amplitude of the follow current interference signal is larger, the leading angle of the terminal voltage signal is larger, the phase advance of the terminal voltage leads the zero crossing point moment of the terminal voltage to come, the detected zero crossing point deviates from the real back electromotive force zero crossing point, when the phase advance angle is increased along with the increase of the load current, and when the leading angle is too large, the phase change situation becomes worse, the current distortion is caused, the waveform and the position detection signal of the terminal voltage are adversely influenced, and the phase change is causedFurther deterioration of the phase, eventually leading to a phase commutation failure;
through the establishment of the model and the decomposition analysis of the end-to-end voltage, the phase relation of the back electromotive force detection signals during light load and heavy load can be obtained
And
+
due to the phase relationship of
And
the same period, the phase angle lag through the low pass filter is equal, so the difference between the phase angles of the position signals under light and heavy loads depends on
And
the included angle and the amplitude value of the phase compensation under the heavy load are obtained by the method:
under the step voltage, the zero state response calculation formula of the low-pass filter is as follows
Wherein
，、
And
as shown in fig. 7, the voltage passing through the low pass filter
And the voltage of the simulated neutral point
Comparing to obtain zero crossing point of back electromotive force, neglecting fluctuation of neutral point voltageIs composed of
Is therefore only considered
Of an alternating current component of
In the back electromotive force detection circuit shown in fig. 7, appropriate resistances and capacitances are selected so that
To obtain
Will be provided with
Carrying out approximately equivalent step signal processing, and obtaining by the formula (3)
AC amplitude of output voltage after passing through low pass filter
Is provided with
Wherein,
for follow current angle, is the current follow current time
The electrical angle of the conversion is calculated,
is the frequency of the back emf of the motor,
to modify the scale factor, take
=1，
In the same wayAC amplitude of output voltage after passing through low pass filterIs provided with
(6)
And satisfy
，
The solution of (a) is non-linear,the calculation is complicated but because
The fluctuation range is small, and the method of engineering approximation is adopted, so that the method can be regarded as constant value approximation calculation
According to the formulas (4) and (5), as shown in FIG. 9,
and
phase angle of
Satisfy the requirement of
(7)
When in use
When taking 20 degrees, can obtain
In the formula:
in order to compensate for the angle, the angle is adjusted,
the microprocessor can be used for easily processing and calculating the phase advance angle deduced by the formula, so that after the relation between the current follow current angle and the current magnitude is measured, the controller can determine the phase advance angle in real time only by detecting the phase current of the motor after the relation between the current follow current angle and the current magnitude is measured, and since the phase angle advance commutation is favorable for reducing the torque pulsation of the brushless direct current motor, the phase angle compensation can be properly carried out according to the current magnitude and the rotating speed, so that the motor can reach the optimal running state.
When starting, the motor 16 firstly determines the initial relative position relationship between the stator 22 and the outer rotor 24, divides an electrical angle period of the stator and the rotor into 6 parts, and determines to conduct two bridge arms therein by adopting a square wave driving two-by-two conduction mode, in the process of motor operation, because the starting of the traditional brushless DC motor without a position sensor adopts 'three-section type' starting, which belongs to open-loop starting, the starting mode has large current and is easy to cause step loss, but the invention adopts a new closed-loop starting mode of starting the brushless DC motor with the outer rotor: according to the characteristic that the inductance values of the three-phase inductance of the brushless direct current motor with the surface magnet at different electrical angles are different, pulse voltage is injected into the motor, under the same volt-second product, the current obtained by the motor rotor 23 and the stator 22 at different relative positions is different due to the difference of the inductance values, the relation of the inductance values can be judged according to the current values, so that the relative position of the outer rotor 24 and the stator 22, namely the position information of the outer rotor 24 is determined, the position information of the outer rotor 24 is continuously detected, then a correct starting voltage vector is added, the motor can correctly select a conducting phase as a position sensor, the motor 16 does not generate reverse rotation, loading starting can be realized, when the rotating speed of the motor 16 is enough to enable a counter electromotive force detection circuit to normally work, the starting state is switched to a self-synchronous state, after the automatic synchronous operation, the control is carried out by adopting a PI controller, so that the non-overshoot and stable rising to the given speed are realized.
The invention adopts the structure, so that the driver is embedded into the motor, the integration of the driver and the motor is realized, a circuit for connecting the motor and the driver is saved, the system efficiency is greatly improved, the energy consumption is reduced, the external rotor structure is adopted, the volume is reduced, the power density ratio of the system is improved, the cost is reduced, the phase change problem under heavy load is solved, the driver integrates the main circuit and the control circuit, the anti-electromagnetic interference capability is enhanced, and the invention has the advantages of compact structure, high power density, high efficiency, low noise, high integration level, low cost, convenient maintenance, easy operation and movement and the like.
Claims (10)
1. An integrated drive motor without position sensor is composed of motor consisting of stator, external rotor, rotor shaft and end cover, and features that a driver is arranged in motor and is fixed to end cover, the end cover is connected to stator of motor to form a whole, the driver is composed of power board with main loop, incoming line open-phase detection circuit, bus current detection circuit, under-voltage and over-voltage detection circuit, counter-potential detection circuit and switching power supply circuit, and control board with DSP control system circuit and communication module circuit,
wherein:
the main circuit is provided with an incoming EMI filter and a piezoresistor for protection, an X capacitor, a Y capacitor and a three-phase common mode filter are used for inhibiting differential mode and common mode interference, a rectifier bridge and an inverter bridge are integrated in a power module, a DC bus is provided with an LC structure for realizing Power Factor Correction (PFC),
the incoming line open-phase detection circuit is characterized in that three-phase electricity sent to the power module is processed by a detection circuit consisting of a resistor, a diode and an optocoupler and then sent to a DSP chip for reading, the duty ratio of output digital signals LHP1 and LHP2 of the open-phase detection circuit is read to judge whether open-phase exists or not, and the incoming line open-phase detection circuit has the functions of incoming line open-phase alarm, overload and overheat alarm, overcurrent and overvoltage alarm, power factor correction and the like,
the bus current detection circuit is characterized in that a current detection resistor is connected in series on a bus, voltage signals at two ends of the resistor are isolated and amplified through a linear optical coupler, and the signals are processed into a range which can be received by a control chip through a conditioning circuit, so that the current of the motor is fed back and monitored,
the undervoltage and overvoltage detection circuit adopts a large-resistance isolation method, and converts the bus voltage into an analog signal input by a control chip through a simple operational amplifier circuit to realize undervoltage and overvoltage detection, the input of the operational amplifier is the bus voltage, the input resistance is very large, the feedback resistance is very small, so that the input voltage of the actual operational amplifier pin is not very large, the flowing current is very small, the isolation effect is realized, and the voltage detection is also realized,
the back electromotive force detection circuit is a low-pass filter, the sensorless control is realized by adopting a 'terminal voltage method', the rotor position signal is generated by processing the voltage to earth of three phases of UVW of the motor through a DSP processor, the terminal voltage is divided into a back electromotive force signal and a current follow current interference signal, the three-phase voltage of the motor firstly filters a high-frequency interference signal and reduces the voltage through the low-pass filter, then a direct current part is removed through a capacitor, then the processed signal is compared with a virtual neutral point voltage constructed by the three phases, the phase and the amplitude of the two signals are calculated to obtain the phase advance angle of the rotor position signal caused by the current follow current, the offset angle of the current follow current influence is determined by detecting the current, the rotating speed, the duty ratio, the bus voltage and the motor parameter to compensate, and the signal of the back electromotive force zero crossing point,
the switching power supply circuit adopts a flyback converter, the input is bus voltage, 3 isolated direct current voltages are output and are respectively used for a DSP control system circuit and a communication module circuit,
the control core chip of the DSP control system circuit is provided with 6 paths of analog signal inputs, 3 pairs of PWM outputs,
the communication module circuit comprises two one-step serial communication modes of RS232 and RS485, wherein RS232 is used for maintaining programs and other operations, RS485 is used for industrial control, RS232 and RS485 bus communication input and an analog quantity speed setting circuit can be carried out, the analog quantity speed setting circuit adjusts the rotating speed of the motor by inputting voltage to the controller,
the terminal strip interface is arranged on the control panel, the wiring holes are arranged on the end cover and are respectively a three-phase power incoming line interface, a driver alarm output interface, a serial port RS232, a serial port RS485 and an analog quantity given interface, and the terminal strip interface on the control panel respectively penetrates through the wiring holes arranged on the end cover to connect communication and analog quantity speed regulation, protection alarm and three-phase alternating current input.
2. The integrated brushless dc motor according to claim 1, wherein the compensation calculation method of the back electromotive force detection circuit comprises the following steps: in order to analyze the phase shift phenomenon of the position detection signal when the motor is subjected to heavy load, the terminal voltage under the heavy load is analyzed as follows:
since the back emf detection circuit is a low pass filter, the high frequency components will be filtered out by the detection circuit, so the following simplification can be made:
1) because the PWM modulation frequency is far greater than the cut-off frequency of the low-pass filter of the counter electromotive force detection circuit, the high-frequency PWM chopped voltage can be approximated by the average value of the voltage;
2) similarly, the voltage fluctuation of the neutral point of the motor is also filtered out and can be approximated by the average value of the voltage fluctuation;
3) the reverse electromotive force is a PWM wave with 120 degrees flat top width and the equivalent amplitude is bus voltage;
when the upper arm modulation is adopted, the terminal voltage at the time of the lower arm conduction mode (PWM-ON) can be simplified into a model as shown in fig. 8, wherein,
is the sum of the ideal line back emf and the voltage at the ideal neutral point,
voltage distortion for current freewheelingIs equal to
And
to sum, i.e.
=
+
(the voltage reference point is the negative of the bus);
terminal voltage in FIG. 8
Can be divided into 6 states, which are respectively:
1）
and
time: the phase lower bridge arm is conducted and the terminal voltage is
Andequal, the bus bar negative voltage, labeled 0,
is also 0, at this time
The detection of the position signal is not influenced;
2）
time period: the motor is phase-changed, the current flows through the upper bridge arm anti-parallel diode, the voltage is clamped to the bus voltage
，
Rises linearly with increasing counter electromotive force;
is composed of
And
a difference of
；
3）
Time period: the phase is suspended, the voltage of the phase end is the sum of the counter electromotive force and the voltage of the neutral point, the voltage of the neutral point is DC bias, the counter electromotive force rises linearly, and the voltage of the end is
Andlinearly increasing;0, not functioning;
4）
time period: the phase upper bridge arm is modulated and the duty ratio is adjusted
And bus voltage
Product of andin a relationship of
Terminal voltageIs equal to
Is provided with
；0, does not affect the detection of the position signal;
5）
time period: the motor is phase-changed, the current flows through the lower bridge arm anti-parallel diode, the terminal voltage is clamped to be the bus ground voltage 0,
linearly decreases with a decrease in the back emf,
is composed of
And
a difference of
；
6）
Time period: the phase is suspended, the voltage of the phase end is the sum of the counter electromotive force and the voltage of the neutral point, the voltage of the neutral point is DC bias, the counter electromotive force is linearly reduced, and the voltage of the end is
And
linearityThe temperature of the molten steel falls down,
0, does not affect the detection of the position signal;
by means of the decomposition of the terminal voltage,the same as in light and heavy loads, and
there is a great difference that at light load, the current is small,
and
the length of the short-circuit wire is very short,
has a short action time, a small volt-second product, of
(
=
,
) Therefore, only weak influence is caused on the detection of the position signal and can be ignored; when the load is heavy, the current is large,
andfor a longer time, volt-second product
It is not negligible, its influence on the position detection signal is serious, the generated phase lead angle is too large, fig. 10 is terminal voltageAnd voltage of its decomposition
And
the generated signal after passing through the low-pass filter leads the back electromotive force signal by the follow current interference signal, so that the superimposed and synthesized terminal voltage signal leads the back electromotive force signal, the amplitude of the follow current interference signal is larger, the leading angle of the terminal voltage signal is larger, the phase advance of the terminal voltage leads the zero crossing point moment of the terminal voltage to come forward, the detected zero crossing point deviates from the real back electromotive force zero crossing point, when the phase leading angle is increased along with the increase of the load current, and when the leading angle is too large, the phase change situation becomes worse, the current distortion is caused, the waveform of the terminal voltage and the position detection signal are adversely affected, the further deterioration of the phase change is caused, and finally the phase change failure is caused;
through the establishment of the model and the decomposition analysis of the end-to-end voltage, the phase relation of the back electromotive force detection signals during light load and heavy load can be obtained
And+
phase ofRelationship due to
And
the same period, the phase angle lag through the low pass filter is equal, so the difference between the phase angles of the position signals under light and heavy loads depends on
And
the included angle and the amplitude value of the phase compensation under the heavy load are obtained by the method:
under the step voltage, the zero state response calculation formula of the low-pass filter is as follows
Wherein
，
、
And
as shown in fig. 7, the voltage passing through the low pass filterAnd the voltage of the simulated neutral pointComparing to obtain zero crossing point of back electromotive force, neglecting fluctuation of neutral point voltage
Is composed of
Is therefore only considered
Of an alternating current component of
In the back electromotive force detection circuit shown in fig. 7, appropriate resistances and capacitances are selected so that
To obtain
Will be provided withCarrying out approximately equivalent step signal processing, and obtaining by the formula (3)
AC amplitude of output voltage after passing through low pass filter
Is provided with
Wherein,
for follow current angle, is the current follow current time
The electrical angle of the conversion is calculated,
is the frequency of the back emf of the motor,
to modify the scale factor, take
=1，
In the same way
AC amplitude of output voltage after passing through low pass filterIs provided with
And satisfy
，
Is non-linear and computationally complex, but because ofThe fluctuation range is small, and the method of engineering approximation is adopted, so that the method can be regarded as constant value approximation calculation
According to the formulas (4) and (5), as shown in FIG. 9,
and
phase angle of
Satisfy the requirement of
When in use
When taking 20 degrees, can obtain
In the formula:
in order to compensate for the angle, the angle is adjusted,
the microprocessor is used for calculating the phase advance angle obtained by the formula, so that after the relation between the current follow current angle and the current magnitude is measured, the controller can determine the phase advance angle in real time only by detecting the phase current of the motor.
3. The integrated position sensorless drive motor of claim 1, wherein the shaft body of the rotor shaft is provided with ceramic coatings, the ceramic coatings comprise a front ceramic coating and a rear ceramic coating, and the front ceramic coating and the rear ceramic coating respectively correspond to the bearing mounting positions.
4. The integrated position sensorless drive motor of claim 1 wherein each phase winding of the stator winding is interleaved with a single winding passing through the holes of the stator core to form a four-coil series connection of windings.
5. The integrated position sensorless drive motor of claim 1 wherein a heat sink plate is mounted between the end cap and the motor stator.
6. The integrated position sensorless drive motor of claim 1 wherein the end cap has bosses contacting the driver modules and fins on the outside to tightly connect the driver modules to the end cap.
7. The integrated position sensorless drive motor of claim 1 wherein the drive circuit and the main circuit ground are isolated from the control circuit ground.
8. The integrated position sensorless driving motor according to claim 1, wherein the driving board is provided with a temperature detection circuit for detecting temperatures of the rectifying and inverting module, the power board and the motor in real time.
9. The integrated position sensorless driving motor according to claim 1, wherein the outer rotor is formed by a housing body and a flange mounting surface at an end of the housing body, and the housing body and the flange mounting surface are formed by one-time stretch forming.
10. The integrated position sensorless drive motor according to claim 3, wherein the rotor shaft body has an annular groove on its outer periphery corresponding to the bearing, and the front ceramic coating and the rear ceramic coating are respectively disposed in the grooves.
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|---|---|---|---|
| CN201110273548.XA CN102307033B (en) | 2011-09-15 | 2011-09-15 | Integrated driving motor without position sensor |
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|---|---|---|---|
| CN201110273548.XA CN102307033B (en) | 2011-09-15 | 2011-09-15 | Integrated driving motor without position sensor |
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