CN110045665B - Control circuit for direct current contactor and working method thereof - Google Patents
Control circuit for direct current contactor and working method thereof Download PDFInfo
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- CN110045665B CN110045665B CN201910447337.XA CN201910447337A CN110045665B CN 110045665 B CN110045665 B CN 110045665B CN 201910447337 A CN201910447337 A CN 201910447337A CN 110045665 B CN110045665 B CN 110045665B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0423—Input/output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24215—Scada supervisory control and data acquisition
Abstract
The invention relates to the technical field of contactors and discloses a control circuit for a direct-current contactor and a working method thereof. The invention provides a novel control circuit which can realize high efficiency and energy saving during suction of a direct current contactor and can expand the working temperature range, namely, on one hand, by configuring a control level sampling circuit unit, whether the current direct current contactor coil branch of a load needs to be electrified/electrified or not can be identified according to the input condition of a control level, and PWM signals used for driving the electrified operation are output when needed, so that no electric energy consumption is caused during a duty cycle, the purpose of energy saving suction is realized, on the other hand, by configuring a temperature sampling circuit unit, the environment temperature condition can be acquired in real time, and the PWM signals are configured and output in a self-adaptive parameter mode based on the conventional temperature compensation technology, so that the effective working range of the direct current contactor is wider, and the application requirements of more severe environments can be met.
Description
Technical Field
The invention belongs to the technical field of contactors, and particularly relates to a control circuit for a direct current contactor and a working method thereof.
Background
The working principle of the existing direct current contactor is that after a coil branch of the contactor is electrified, coil current generates a magnetic field, then the static iron core generates electromagnetic attraction through the generated magnetic field, the movable iron core is attracted, and the relevant contact switch of the direct current contactor is driven to conduct attraction action (namely, a normally closed contact switch is opened, a normally open contact switch is closed, and the normally closed contact switch and the normally open contact switch are linked). In the normal use process, the electromagnet coil needs to be electrified all the time to work, and electromagnetic attraction force is continuously generated, so that the iron core and the armature are ensured to be attracted, and then the contact and the static contact are driven to be closed, and a circuit is connected. However, the current energy-saving mode of the dc contactor adopts some analog devices, although the structure is simple, the analog signals are very easy to be interfered by external environment due to the variability of the analog signals, and it is difficult to ensure high precision, for example, the normal operating temperature range of the dc contactor is between-20 ℃ to +85 ℃, but delay action, advance action or no action occurs at extreme temperature, so that the controlled electrical products have safety risk problems.
Disclosure of Invention
In order to solve the problems of large power consumption and limited working temperature range during suction of the existing direct current contactor, the invention aims to provide a control circuit for the direct current contactor and a working method thereof.
The technical scheme adopted by the invention is as follows:
the control circuit for the direct current contactor comprises a control level sampling circuit unit, an MCU control circuit unit, a contactor actuation driving circuit unit and a temperature sampling circuit unit, wherein the output end of the control level sampling circuit unit is electrically connected with the first input end of the MCU control circuit unit, the PWM signal output end of the MCU control circuit unit is electrically connected with the control signal input end of the contactor actuation driving circuit unit, and the contactor actuation driving circuit unit is provided with an anode driving end and a cathode driving end which are used for connecting a coil branch of the direct current contactor in parallel;
the temperature sampling circuit unit comprises a tenth resistor, a thermistor and an eleventh capacitor, wherein one end of the tenth resistor is electrically connected with the reference voltage connecting end of the MCU control circuit unit, the other end of the tenth resistor is respectively and electrically connected with the second input end of the MCU control circuit unit, one end of the thermistor and one end of the eleventh capacitor, and the other end of the thermistor and the other end of the eleventh capacitor are respectively grounded.
The circuit is characterized by further comprising a rectifying circuit unit and a filtering circuit unit, wherein the input end of the rectifying circuit unit is used as the control level input end of the whole control circuit, the output end of the rectifying circuit unit is electrically connected with the input end of the filtering circuit unit, and the output end of the filtering circuit unit is electrically connected with the input end of the control level sampling circuit unit and the power supply input end of the contactor attraction driving circuit unit respectively.
Further preferably, the power supply circuit further comprises a voltage stabilizing circuit unit and a fifth diode, wherein the input end of the voltage stabilizing circuit unit is electrically connected with the cathode of the fifth diode, the anode of the fifth diode is electrically connected with the output end of the filter circuit unit, and the output end of the voltage stabilizing circuit unit is electrically connected with the power supply input end of the MCU control circuit unit.
Specifically, the circuit also comprises an external reference voltage sampling circuit unit, wherein the external reference voltage sampling circuit unit comprises an eighth resistor, a controllable precise voltage stabilizing source with the model TL431 and a tenth capacitor;
one end of the eighth resistor is electrically connected with the output end of the voltage stabilizing circuit unit, the other end of the eighth resistor is electrically connected with the reference electrode and the cathode of the controllable precise voltage stabilizing source respectively, the other end of the eighth resistor is also electrically connected with one end of the tenth capacitor and the reference voltage connecting end of the MCU control circuit unit respectively, and the anode of the controllable precise voltage stabilizing source and the other end of the tenth capacitor are grounded respectively.
Specifically, the voltage stabilizing circuit unit comprises a tenth voltage stabilizing tube, a ninth capacitor, a voltage stabilizer, a third capacitor and a fourth capacitor, wherein a cathode of the tenth voltage stabilizing tube, one end of the ninth capacitor and an input end of the voltage stabilizer are respectively and electrically connected with the input end of the voltage stabilizing circuit unit, an output end of the voltage stabilizer is respectively and electrically connected with one end of the third capacitor, one end of the fourth capacitor and the output end of the voltage stabilizing circuit unit, and an anode of the tenth voltage stabilizing tube, the other end of the ninth capacitor, a grounding end of the voltage stabilizer, the other end of the third capacitor and the other end of the fourth capacitor are respectively grounded.
Specifically, the rectifying circuit unit adopts a single-phase bridge rectifying circuit, and/or the filtering circuit unit adopts a pi-type filtering circuit.
Preferably, the control level sampling circuit unit includes a first resistor, a second resistor, a third resistor and a fifth capacitor, wherein one end of the first resistor is electrically connected with the input end of the control level sampling circuit unit, the other end of the first resistor is electrically connected with one end of the second resistor, one end of the third resistor and one end of the fifth capacitor respectively, the other end of the second resistor and the other end of the fifth capacitor are grounded respectively, and the other end of the third resistor is electrically connected with the output end of the control level sampling circuit unit.
Preferably, a protection branch is connected in parallel between the positive electrode driving end and the negative electrode driving end of the contactor suction driving circuit unit, wherein the protection branch comprises a seventh diode and a ninth resistor, an anode of the seventh diode is electrically connected with the negative electrode driving end, a cathode of the seventh diode is electrically connected with one end of the ninth resistor, and the other end of the ninth resistor is electrically connected with the positive electrode driving end.
Specifically, the contactor actuation driving circuit unit includes a sixth resistor, a seventh resistor, a first MOS transistor, a sixth diode, a fourth resistor, a fifth resistor, a ninth voltage regulator, a sixth capacitor, a second MOS transistor, an eighth diode, and an eleventh diode;
One end of the sixth resistor is electrically connected with the control signal input end of the contactor actuation driving circuit unit, the other end of the sixth resistor is respectively electrically connected with one end of the seventh resistor and the grid electrode of the first MOS tube, and the other end of the seventh resistor and the source electrode of the first MOS tube are respectively grounded;
the anode of the sixth diode is electrically connected with the power supply input end of the contactor suction driving circuit unit, the cathode of the sixth diode is electrically connected with one end of the fourth resistor, the other end of the fourth resistor is respectively and electrically connected with one end of the fifth resistor, the cathode of the ninth voltage stabilizing tube, one end of the sixth capacitor and the grid electrode of the second MOS tube, and the other end of the fifth resistor, the anode of the ninth voltage stabilizing tube, the other end of the sixth capacitor and the source electrode of the second MOS tube are respectively and electrically connected with the drain electrode of the first MOS tube;
the positive electrode of the eighth diode is electrically connected with the power supply input end of the contactor actuation driving circuit unit, the negative electrode of the eighth diode is electrically connected with the negative electrode of the eleventh diode and the positive electrode driving end of the contactor actuation driving circuit unit respectively, the positive electrode of the eleventh diode is electrically connected with the drain electrode of the first MOS tube, and the drain electrode of the second MOS tube is electrically connected with the negative electrode driving end of the contactor actuation driving circuit unit.
Specifically, the MCU control circuit unit adopts a microprocessor chip with the model of mega8A and a peripheral circuit thereof.
The other technical scheme adopted by the invention is as follows:
a method of operating a control circuit for a dc contactor as hereinbefore described, comprising the steps of:
s101, after receiving a first level analog quantity from a control level sampling circuit unit, an MCU control circuit unit carries out analog-to-digital conversion on the first level analog quantity into a first level numerical value;
s102, after the MCU control circuit unit acquires N first level numerical values which are continuously sampled, calculating a current control level numerical value by adopting a median average method, wherein N is a natural number between 4 and 12;
s103, judging whether the current control level value is within the contactor actuation voltage threshold value range or not by the MCU control circuit unit, if yes, executing step S104, otherwise, controlling the PWM signal output end not to output or stop outputting the PWM signal, and returning to execute step S101;
s104, if no PWM signal is output currently, executing a step S105, otherwise, periodically executing a step S106;
s105, performing analog-to-digital conversion on a second level analog quantity from a temperature sampling circuit unit into a second level numerical quantity by an MCU control circuit unit, then obtaining a first PWM signal parameter suitable for starting contactor actuation by looking up a table according to the second level numerical quantity, then controlling a PWM signal output end to output a corresponding large current PWM signal according to the first PWM signal parameter, enabling a direct current contactor coil branch connected in parallel between a positive electrode driving end and a negative electrode driving end to electrically start an actuation contact switch, and periodically executing step S106 after a first delay time is elapsed, wherein the first PWM signal parameter comprises amplitude, frequency and/or duty ratio;
S106, the MCU control circuit unit converts the third level analog quantity from the temperature sampling circuit unit into a third level numerical quantity in an analog-to-digital mode, then a second PWM signal parameter suitable for maintaining the contactor to be attracted is obtained through table lookup according to the third level numerical quantity, and then a corresponding small current PWM signal is output by the PWM signal output end according to the second PWM signal parameter, so that an attracting contact switch is electrically maintained on a coil branch of the direct current contactor connected between the positive electrode driving end and the negative electrode driving end in parallel, wherein the second PWM signal parameter comprises amplitude, frequency and/or duty ratio.
The beneficial effects of the invention are as follows:
(1) The invention provides a novel control circuit which can realize high efficiency and energy saving and can expand the working temperature range when a direct current contactor is in suction, namely, on one hand, by configuring a control level sampling circuit unit, whether the current direct current contactor coil branch of a load needs to be electrified/electrified or not can be identified according to the input condition of a control level, and a PWM signal for driving the electrified operation is output when the current contactor coil branch is needed, so that no electric energy consumption is caused in a duty cycle period, the purpose of energy saving suction is realized, on the other hand, by configuring a temperature sampling circuit unit, the environment temperature condition can be acquired in real time, and the PWM signal is subjected to self-adaptive parameter configuration and output based on a conventional temperature compensation technology, so that the effective working range of the direct current contactor is wider, and the application requirement of a harsher environment can be met.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a block diagram of control circuitry for a dc contactor provided by the present invention.
Fig. 2 is a circuit diagram of a control level sampling circuit unit in the control circuit provided by the invention.
Fig. 3 is a circuit diagram of an MCU control circuit unit in the control circuit provided by the present invention.
Fig. 4 is a circuit diagram of a contactor actuation driving circuit unit in the control circuit provided by the present invention.
Fig. 5 is a circuit diagram of a temperature sampling circuit unit in the control circuit provided by the invention.
Fig. 6 is a circuit diagram of a rectifying circuit unit, a filtering circuit unit and a voltage stabilizing circuit unit in the control circuit provided by the invention.
Fig. 7 is a specific circuit diagram of an external reference voltage sampling circuit unit in the control circuit provided by the invention.
Detailed Description
The invention will be further elucidated with reference to the drawings and to specific embodiments. The present invention is not limited to these examples, although they are described in order to assist understanding of the present invention. Specific structural and functional details disclosed herein are merely representative of example embodiments of the invention. This invention may, however, be embodied in many alternate forms and should not be construed as limited to the embodiments set forth herein.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments of the present invention.
It should be understood that for the term "and/or" that may appear herein, it is merely one association relationship that describes an associated object, meaning that there may be three relationships, e.g., a and/or B, may represent: a alone, B alone, and both a and B; for the term "/and" that may appear herein, which is descriptive of another associative object relationship, it means that there may be two relationships, e.g., a/and B, it may be expressed that: a alone, a alone and B alone; in addition, for the character "/" that may appear herein, it is generally indicated that the context associated object is an "or" relationship.
It will be understood that when an element is referred to herein as being "connected," "connected," or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to herein as being "directly connected" or "directly coupled" to another element, it means that there are no intervening elements present. In addition, other words used to describe relationships between elements (e.g., "between … …" pair "directly between … …", "adjacent" pair "directly adjacent", etc.) should be interpreted in a similar manner.
It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises," "comprising," "includes," "including" and/or "including," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, and do not preclude the presence or addition of one or more other features, quantities, steps, operations, elements, components, and/or groups thereof.
It should be appreciated that in some alternative embodiments, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or the figures may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
It should be understood that specific details are provided in the following description to provide a thorough understanding of the example embodiments. However, it will be understood by those of ordinary skill in the art that the example embodiments may be practiced without these specific details. For example, a system may be shown in block diagrams in order to avoid obscuring the examples with unnecessary detail. In other instances, well-known processes, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the example embodiments.
Example 1
As shown in fig. 1 to 7, the control circuit for a dc contactor provided in this embodiment includes a control level sampling circuit unit, an MCU control circuit unit, a contactor actuation driving circuit unit, and a temperature sampling circuit unit, where an output end of the control level sampling circuit unit is electrically connected to a first input end ADC of the MCU control circuit unit, a PWM signal output end PWM of the MCU control circuit unit is electrically connected to a control signal input end of the contactor actuation driving circuit unit, and the contactor actuation driving circuit unit is configured with an anode driving end po+ and a cathode driving end PO "for connecting in parallel a dc contactor coil branch KM; the temperature sampling circuit unit comprises a tenth resistor R10, a thermistor R11 and an eleventh capacitor C11, wherein one end of the tenth resistor R10 is electrically connected with a reference voltage connecting end VERF of the MCU control circuit unit, the other end of the tenth resistor R10 is respectively and electrically connected with a second input end ADC1 of the MCU control circuit unit, one end of the thermistor R11 and one end of the eleventh capacitor C11, and the other end of the thermistor R11 and the other end of the eleventh capacitor C11 are respectively grounded.
As shown in fig. 1 to 5, in the specific structure of the control circuit, the control level sampling circuit unit is configured to obtain the control level inputted from the outside, and transmit the obtained result to the MCU control circuit unit; specifically, as shown in fig. 2, the control level sampling circuit unit may include, but is not limited to, a first resistor R1, a second resistor R2, a third resistor R3, and a fifth capacitor C5, where one end of the first resistor R1 is electrically connected to an input end of the control level sampling circuit unit, the other end of the first resistor R1 is electrically connected to one end of the second resistor R2, one end of the third resistor R3, and one end of the fifth capacitor C5, the other end of the second resistor R2 and the other end of the fifth capacitor C5 are respectively grounded, and the other end of the third resistor R3 is electrically connected to an output end of the control level sampling circuit unit; therefore, the first level analog quantity reflecting the control level can be obtained by dividing the input control level through the first resistor R1 and the second resistor R2 (in addition, the third resistor R3 mainly plays a role in input current limiting, and the fifth capacitor C5 mainly plays a role in filtering out higher harmonics). The temperature sampling circuit unit is used for acquiring an external environment temperature condition and transmitting an acquired result to the MCU control circuit unit, wherein a real-time level analog quantity reflecting the environment temperature condition is obtained by dividing a reference voltage (which can be used as a standard pole reflecting the environment temperature because the reference voltage is maintained unchanged) in a mode that the tenth resistor R10 and the thermistor R11 (the resistance value of the thermistor generally varies in a nonlinear way along with the change of the environment temperature) are also used for dividing the reference voltage; in addition, the tenth capacitor C10 still plays a role in filtering out higher harmonics.
The MCU (Microcontroller Unit, micro control unit) is used for judging whether the coil branch of the direct current contactor (which is connected between the positive electrode driving end PO+ and the negative electrode driving end PO-of the contactor suction driving circuit unit) is required to be electrified or electrified according to the sampling result from the control level sampling circuit unit, so that the contact switch is sucked in through an electrified mode or released through an electrified mode; on the other hand, when it is determined that the power-on operation is required, according to the sampling result from the temperature sampling circuit unit, performing temperature compensation configuration on signal parameters (including, but not limited to, amplitude, frequency, duty cycle, and the like) of a PWM (Pulse Width Modulation) signal to be output, and then controlling to output a corresponding PWM signal according to the signal parameters, so that after the PWM signal is output to the contactor suction driving circuit unit, the power-on operation can be performed efficiently and energy-effectively (i.e., energy saving is achieved by using the characteristic that no power is consumed in the duty cycle), and still perform power-on or power-off operation on a coil branch of the dc contactor at an extreme temperature, for example, performing temperature compensation configuration through a PID algorithm, that is, performing adaptive signal parameter configuration according to a deviation ratio (P), an integral (I), and a derivative (D) in process control; the method has the advantages of simple principle, easy realization, wide application range, mutually independent control parameters, simple parameter selection and the like. Specifically, as shown in fig. 3, the MCU control circuit unit may, but not limited to, use a microprocessor chip of model mega8A and its peripheral circuits. In addition, the related control program can be adaptively modified based on the existing conventional program.
The contactor actuation driving circuit unit is used for powering on (comprising powering on for starting the actuation contact switch and powering on for maintaining the actuation contact switch) or powering off a coil branch of the direct current contactor connected in parallel between the positive electrode driving end PO+ and the negative electrode driving end PO-according to the existence of an input PWM signal, the current magnitude and the like. Specifically, as shown in fig. 4, the contactor pull-in driving circuit unit may include, but is not limited to, a sixth resistor R6, a seventh resistor R7, a first MOS transistor ic2_1, a sixth diode D6, a fourth resistor R4, a fifth resistor R5, a ninth voltage regulator D9, a sixth capacitor C6, a second MOS transistor ic2_2, an eighth diode D8, and an eleventh diode D11; one end of the sixth resistor R6 is electrically connected to the control signal input end of the contactor actuation driving circuit unit, the other end of the sixth resistor R6 is electrically connected to one end of the seventh resistor R7 and the gate of the first MOS transistor ic2_1, and the other end of the seventh resistor R7 and the source of the first MOS transistor ic2_1 are grounded; the anode of the sixth diode D6 is electrically connected to the power supply input end VCC of the contactor pull-in driving circuit unit, the cathode of the sixth diode D6 is electrically connected to one end of the fourth resistor R4, the other end of the fourth resistor R4 is electrically connected to one end of the fifth resistor R5, the cathode of the ninth voltage regulator D9, one end of the sixth capacitor C6 and the gate of the second MOS tube ic2_2, and the other end of the fifth resistor R5, the anode of the ninth voltage regulator D9, the other end of the sixth capacitor C6 and the source of the second MOS tube ic2_2 are electrically connected to the drain of the first MOS tube ic2_1, respectively; the anode of the eighth diode D8 is electrically connected to the power supply input end VCC of the contactor actuation driving circuit unit, the cathode of the eighth diode D8 is electrically connected to the cathode of the eleventh diode D11 and the positive electrode driving end po+ of the contactor actuation driving circuit unit, the anode of the eleventh diode D11 is electrically connected to the drain electrode of the first MOS tube ic2_1, and the drain electrode of the second MOS tube ic2_2 is electrically connected to the negative electrode driving end po+ of the contactor actuation driving circuit unit. The characteristic that the two MOS tubes can control the on/off of the drain and the source through the grid voltage is utilized, the coil branch of the direct current contactor can be subjected to intermittent power-on operation at high frequency (the working frequency of PWM signals is generally about 20 KHz) according to PWM signals, and the contact switch is effectively attracted; in addition, because the electromagnetic attraction generated by the coil branch circuit has the characteristic of delaying disappearance, the contact switch is not released immediately although no electric energy is consumed in a gap duty period (generally only about 50 us), so that the energy-saving purpose is realized.
Therefore, through the detailed description of the control circuit for the direct current contactor, the novel control circuit which can realize high efficiency and energy saving during the suction of the direct current contactor and can expand the working temperature range can be provided, namely, on one hand, through the configuration of the control level sampling circuit unit, whether the current direct current contactor coil branch of a load needs to be electrified/electrified or not can be identified according to the input condition of the control level, and PWM signals for driving the electrified operation are output when needed, so that no electric energy is consumed in a duty period, the energy saving suction purpose is realized, and on the other hand, the environment temperature condition can be acquired in real time through the configuration of the temperature sampling circuit unit, and the adaptive parameter configuration and the output are carried out on the PWM signals based on the conventional temperature compensation technology, so that the effective working range of the direct current contactor is wider, and the application requirements of a harsher environment can be met. Through product test, the control circuit of the design can enable the direct current contactor to normally work at the temperature of minus 40 ℃ to minus +125 ℃ (the working temperature range of the existing direct current contactor is generally between minus 20 ℃ to minus +85 ℃), so that the safety risk caused by the limiting temperature is greatly reduced, and the control circuit is particularly suitable for outdoor automobile charging piles under special geographic environments.
Optimally, considering that the output of the duty ratio and the PWM signal is not in a linear relation, the PWM signal suitable for the current temperature environment can be configured and output through a complex temperature compensation algorithm, the complex algorithm is operated to occupy more CPU resources, the calculated duty ratio error is larger, and meanwhile, the coil branch current required by maintaining suction is far smaller than the coil branch current required by starting suction, so that the following specific steps S101-S106 can be preferably adopted for the control circuit to realize further rapid, low-error and energy-saving power-on operation.
And S101, the MCU control circuit unit receives the first level analog quantity from the control level sampling circuit unit and then converts the first level analog quantity into a first level numerical value. In this step S101, the analog-to-digital conversion purpose may be achieved by an analog-to-digital converter inside the MCU.
S102, after the MCU control circuit unit acquires N first level numerical values which are continuously sampled, calculating the current control level numerical value by adopting a median average method, wherein N is a natural number between 4 and 12. In this step S101, the median averaging method is an existing conventional mean processing method, that is, for N data sampled consecutively, one maximum value and one minimum value are removed, and then an arithmetic average of N-2 data is calculated.
S103, judging whether the current control level value is within the contactor actuation voltage threshold value range or not by the MCU control circuit unit, executing step S104 if the current control level value is within the contactor actuation voltage threshold value range, otherwise, controlling the PWM signal output end not to output or stopping outputting the PWM signal, and returning to execute step S101. In step S103, the contactor actuation voltage threshold range is a preset value, for example, 8 to 36V.
S104, if no PWM signal is found to be output currently, executing step S105, otherwise, periodically executing step S106. In the step S104, no PWM signal is currently output to indicate that the contact switch is currently released, the step S105 is required to output a high current PWM signal to start the actuation operation, the step S106 is required to output a low current PWM signal to perform the actuation maintaining operation, and the step S106 is required to output a low current PWM signal to perform the actuation maintaining operation. The current sizes of the large-current PWM signal and the small-current PWM signal are relatively speaking, and the MOS tube also has the function of amplifying the current with stable gain when being conducted, so that the current passing through the coil branch is necessarily smaller than that when the suction is started when the suction is maintained, and the purpose of low holding power, such as about 2W, can be realized.
S105, the MCU control circuit unit converts the second level analog quantity from the temperature sampling circuit unit into a second level numerical quantity, then the second level numerical quantity is used for looking up a table to obtain a first PWM signal parameter suitable for starting the contactor to attract, then a corresponding large current PWM signal is output by the PWM signal output end according to the first PWM signal parameter, so that a attraction contact switch is electrically started on a coil branch of the direct current contactor connected in parallel between the positive electrode driving end PO+ and the negative electrode driving end PO-, and the step S106 is periodically executed after a first delay time is elapsed, wherein the first PWM signal parameter can be used for not limited to comprise amplitude, frequency, duty ratio and the like. In the step S105, the purpose of analog-to-digital conversion can be achieved through an analog-to-digital converter in the MCU, the related look-up table can be obtained by sorting according to limited ground product test data in advance, then the first PWM signal parameters are rapidly configured based on the look-up table mode, finally the high-current PWM signal suitable for the power-on driving without error under the current temperature condition is controlled and output according to the first PWM signal parameters, thereby avoiding the real-time operation of the temperature compensation algorithm and reducing the CPU resource requirement for the MCU control circuit unit when the suction is started.
S106, the MCU control circuit unit converts the third level analog quantity from the temperature sampling circuit unit into a third level numerical quantity, then the third level numerical quantity is used for looking up a table to obtain second PWM signal parameters suitable for maintaining the attraction of the contactor, and then the PWM signal output end is controlled to output a corresponding low-current PWM signal according to the second PWM signal parameters, so that the attraction contact switch is electrically maintained on a coil branch of the direct-current contactor connected between the positive electrode driving end PO+ and the negative electrode driving end PO-, wherein the second PWM signal parameters can include amplitude, frequency, duty ratio and the like. In the step S106, the purpose of analog-to-digital conversion can be achieved through an analog-to-digital converter inside the MCU, the related look-up table can also be obtained by sorting according to limited ground product test data in advance, then the second PWM signal parameters are rapidly configured based on the look-up table mode, finally the low-current PWM signal suitable for carrying out error-free maintenance power-on driving under the current temperature condition is controlled and output according to the second PWM signal parameters, thereby avoiding the real-time operation of the temperature compensation algorithm and reducing the CPU resource requirement for the MCU control circuit unit during maintenance of suction.
Therefore, by the working method described in the steps S101 to S106, PWM signals which are most suitable for the current temperature condition to perform the error-free actuation can be rapidly and accurately output at low cost, the working power requirement during the actuation maintenance can be greatly reduced, and the energy consumption is further reduced.
The power supply circuit comprises a contactor suction driving circuit unit, a rectifying circuit unit, a filter circuit unit, a contactor suction driving circuit unit, a control level sampling circuit unit and a contactor suction driving circuit unit, wherein the input end of the rectifying circuit unit is used as a control level input end IN of the whole control circuit, the output end of the rectifying circuit unit is electrically connected with the input end of the filter circuit unit, and the output end of the filter circuit unit is electrically connected with the input end of the control level sampling circuit unit and the power supply input end VCC of the contactor suction driving circuit unit respectively. As shown in fig. 1 and 6, the rectifying circuit unit is used for rectifying the input control level, so that the control level signal can be imported whether the control level signal is connected in a positive way or a reverse way, and the purposes of inputting in a non-polarity way and preventing the internal chip from being burnt out during the reverse way are achieved; specifically, as shown in fig. 6, the rectifying circuit unit may, but is not limited to, employ a single-phase bridge rectifying circuit. The filter circuit unit is used for filtering out higher harmonics in the control level so as to avoid signal interference to the subsequent control level sampling link; specifically, as shown in fig. 6, the filter circuit unit may, but is not limited to, use a pi-type filter circuit, for example, a pi-type filter circuit composed of a plurality of capacitors and inductors.
Preferably, the power supply circuit further comprises a voltage stabilizing circuit unit and a fifth diode D5, wherein an input end AVCC of the voltage stabilizing circuit unit is electrically connected with a cathode of the fifth diode D5, an anode of the fifth diode D5 is electrically connected with an output end of the filter circuit unit, and an output end of the voltage stabilizing circuit unit is electrically connected with a power supply input end +5V of the MCU control circuit unit. As shown in fig. 1 and 6, the power supply circuit design can be simplified by acquiring the stable operating voltage for supplying power to the MCU control circuit unit from the input control level (the control level may always have a voltage, i.e., for example, 5V level is input when the contact switch needs to be released and 12V level is input when the contact switch needs to be actuated). Specifically, as shown in fig. 6, the voltage stabilizing circuit unit may include, but is not limited to, a tenth voltage stabilizing tube D10, a ninth capacitor C9, a voltage stabilizer IC1, a third capacitor C3, and a fourth capacitor C4, where a cathode of the tenth voltage stabilizing tube D10, one end of the ninth capacitor C9, and an input end of the voltage stabilizer IC1 are electrically connected to an input end AVCC of the voltage stabilizing circuit unit, and an output end of the voltage stabilizer IC1 is electrically connected to one end of the third capacitor C3, one end of the fourth capacitor C4, and an output end of the voltage stabilizing circuit unit, respectively, and an anode of the tenth voltage stabilizing tube D10, the other end of the ninth capacitor C9, a ground end of the voltage stabilizer IC1, the other end of the third capacitor C3, and the other end of the fourth capacitor C4 are grounded, respectively. The tenth voltage regulator tube D10 is configured to protect the voltage regulator IC1 from being burned out, so as to ensure that the MCU control unit always has a working voltage supply to protect the dc contactor. In addition, the model of the voltage regulator IC1 may be, but not limited to, NCV4264, and the tenth voltage regulator D10 may be, but not limited to, a 43V voltage regulator.
The circuit comprises an external reference voltage sampling circuit unit, wherein the external reference voltage sampling circuit unit comprises an eighth resistor R8, a controllable precise voltage stabilizing source U4 with the model TL431 and a tenth capacitor C10; one end of the eighth resistor R8 is electrically connected with the output end of the voltage stabilizing circuit unit, the other end of the eighth resistor R8 is electrically connected with the reference electrode and the cathode of the controllable precise voltage stabilizing source U4 respectively, the other end of the eighth resistor R8 is also electrically connected with one end of the tenth capacitor C10 and the reference voltage connecting end VERF of the MCU control circuit unit respectively, and the anode of the controllable precise voltage stabilizing source U4 and the other end of the tenth capacitor C10 are grounded respectively. As shown in fig. 7, considering that the error exists in the internal reference voltage of the MCU control circuit unit, and thus the problem of poor consistency of the dc contactor (which is mainly reflected in that the error of the pull-in voltage or the pull-out voltage is relatively large) is caused, by designing the external reference voltage sampling circuit unit including the TL431, the analog sampling comparison of the internal reference voltage and the external reference voltage can be performed by the externally introduced reference voltage, the error of the internal reference voltage is reduced, and finally, the consistency of the pull-in operation is greatly improved. Furthermore, the analog sample comparison procedure referred to above may be adapted based on existing conventional procedures.
Preferably, a protection branch is connected in parallel between the positive electrode driving end po+ and the negative electrode driving end PO-of the contactor suction driving circuit unit, wherein the protection branch comprises a seventh diode D7 and a ninth resistor R9, an anode of the seventh diode D7 is electrically connected with the negative electrode driving end PO-, a cathode of the seventh diode D7 is electrically connected with one end of the ninth resistor R9, and the other end of the ninth resistor R9 is electrically connected with the positive electrode driving end po+. As shown in fig. 4, considering that two MOS transistors are easy to burn out after long-time operation, by designing the protection branch, it can be ensured that the reverse electromotive force will not burn out the MOS transistors, and the service life of the dc contactor can be prolonged by 50% as found by product test.
In summary, the control circuit for the direct current contactor and the working method thereof provided by the embodiment have the following technical effects:
(1) The embodiment provides a novel control circuit which can realize high efficiency and energy saving and can expand the working temperature range when the direct current contactor is sucked, namely, on one hand, by configuring the control level sampling circuit unit, whether the current direct current contactor coil branch of a load needs to be electrified/electrified or not can be identified according to the input condition of the control level, and a PWM signal used for driving the electrified operation is output when needed, so that no electric energy consumption is caused in a duty cycle period, the purpose of energy saving suction is realized, on the other hand, the environment temperature condition can be acquired in real time by configuring the temperature sampling circuit unit, and the PWM signal is configured and output in a self-adaptive parameter mode based on the conventional temperature compensation technology, so that the effective working range of the direct current contactor is wider, and the application requirement of a harsher environment can be met.
The various embodiments described above are merely illustrative and may or may not be physically separate if reference is made to the unit being described as separate components; if a component is referred to as being a unit, it may or may not be a physical unit, may be located in one place, or may be distributed over multiple network elements. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment. Those of ordinary skill in the art will understand and implement the present invention without undue burden.
The above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some of the technical features thereof can be replaced by equivalents. Such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Finally, it should be noted that the invention is not limited to the alternative embodiments described above, but can be used by anyone in various other forms of products in the light of the present invention. The above detailed description should not be construed as limiting the scope of the invention, which is defined in the claims and the description may be used to interpret the claims.
Claims (8)
1. A control circuit for a dc contactor, characterized by: the control level sampling circuit unit is electrically connected with a first input end (ADC) of the MCU control circuit unit, a PWM signal output end (PWM) of the MCU control circuit unit is electrically connected with a control signal input end of the contactor actuation drive circuit unit, and the contactor actuation drive circuit unit is provided with an anode drive end (PO+) and a cathode drive end (PO-) which are used for connecting a DC contactor coil branch (KM) in parallel;
the temperature sampling circuit unit comprises a tenth resistor (R10), a thermistor (R11) and an eleventh capacitor (C11), wherein one end of the tenth resistor (R10) is electrically connected with a reference voltage connection end (VERF) of the MCU control circuit unit, the other end of the tenth resistor (R10) is respectively electrically connected with a second input end (ADC 1) of the MCU control circuit unit, one end of the thermistor (R11) and one end of the eleventh capacitor (C11), and the other end of the thermistor (R11) and the other end of the eleventh capacitor (C11) are respectively grounded;
The control level sampling circuit unit comprises a first resistor (R1), a second resistor (R2), a third resistor (R3) and a fifth capacitor (C5), wherein one end of the first resistor (R1) is electrically connected with the input end of the control level sampling circuit unit, the other end of the first resistor (R1) is respectively and electrically connected with one end of the second resistor (R2), one end of the third resistor (R3) and one end of the fifth capacitor (C5), the other end of the second resistor (R2) and the other end of the fifth capacitor (C5) are respectively grounded, and the other end of the third resistor (R3) is electrically connected with the output end of the control level sampling circuit unit;
the contactor actuation driving circuit unit comprises a sixth resistor (R6), a seventh resistor (R7), a first MOS tube (IC2_1), a sixth diode (D6), a fourth resistor (R4), a fifth resistor (R5), a ninth voltage stabilizing tube (D9), a sixth capacitor (C6), a second MOS tube (IC2_2), an eighth diode (D8) and an eleventh diode (D11);
one end of the sixth resistor (R6) is electrically connected with the control signal input end of the contactor suction driving circuit unit, the other end of the sixth resistor (R6) is electrically connected with one end of the seventh resistor (R7) and the grid electrode of the first MOS tube (IC2_1) respectively, and the other end of the seventh resistor (R7) and the source electrode of the first MOS tube (IC2_1) are grounded respectively;
The anode of the sixth diode (D6) is electrically connected to the power supply input end (VCC) of the contactor pull-in driving circuit unit, the cathode of the sixth diode (D6) is electrically connected to one end of the fourth resistor (R4), the other end of the fourth resistor (R4) is electrically connected to one end of the fifth resistor (R5), the cathode of the ninth voltage regulator tube (D9), one end of the sixth capacitor (C6) and the gate of the second MOS tube (ic2_2), and the other end of the fifth resistor (R5), the anode of the ninth voltage regulator tube (D9), the other end of the sixth capacitor (C6) and the source of the second MOS tube (ic2_2) are electrically connected to the drain of the first MOS tube (ic2_1), respectively;
the positive electrode of the eighth diode (D8) is electrically connected with the power supply input end (VCC) of the contactor actuation drive circuit unit, the negative electrode of the eighth diode (D8) is electrically connected with the negative electrode of the eleventh diode (D11) and the positive electrode driving end (PO+) of the contactor actuation drive circuit unit respectively, the positive electrode of the eleventh diode (D11) is electrically connected with the drain electrode of the first MOS tube (IC2_1), and the drain electrode of the second MOS tube (IC2_2) is electrically connected with the negative electrode driving end (PO-) of the contactor actuation drive circuit unit.
2. A control circuit for a dc contactor as claimed in claim 1, wherein: the power supply circuit comprises a contactor suction driving circuit unit, and is characterized by further comprising a rectifying circuit unit and a filter circuit unit, wherein the input end of the rectifying circuit unit is used as a control level input end (IN) of the whole control circuit, the output end of the rectifying circuit unit is electrically connected with the input end of the filter circuit unit, and the output end of the filter circuit unit is electrically connected with the input end of the control level sampling circuit unit and a power supply input end (VCC) of the contactor suction driving circuit unit respectively.
3. A control circuit for a dc contactor as claimed in claim 2, wherein: the power supply circuit further comprises a voltage stabilizing circuit unit and a fifth diode (D5), wherein an input end (AVCC) of the voltage stabilizing circuit unit is electrically connected with a cathode of the fifth diode (D5), an anode of the fifth diode (D5) is electrically connected with an output end of the filter circuit unit, and an output end of the voltage stabilizing circuit unit is electrically connected with a power supply input end (+ 5V) of the MCU control circuit unit.
4. A control circuit for a dc contactor as claimed in claim 3, wherein: the circuit also comprises an external reference voltage sampling circuit unit, wherein the external reference voltage sampling circuit unit comprises an eighth resistor (R8), a controllable precise voltage stabilizing source (U4) with the model TL431 and a tenth capacitor (C10);
One end of the eighth resistor (R8) is electrically connected with the output end of the voltage stabilizing circuit unit, the other end of the eighth resistor (R8) is electrically connected with the reference electrode and the cathode of the controllable precise voltage stabilizing source (U4) respectively, the other end of the eighth resistor (R8) is also electrically connected with one end of the tenth capacitor (C10) and the reference voltage connecting end (VERF) of the MCU control circuit unit respectively, and the anode of the controllable precise voltage stabilizing source (U4) and the other end of the tenth capacitor (C10) are grounded respectively.
5. A control circuit for a dc contactor as claimed in claim 3, wherein: the voltage stabilizing circuit unit comprises a tenth voltage stabilizing tube (D10), a ninth capacitor (C9), a voltage stabilizer (IC 1), a third capacitor (C3) and a fourth capacitor (C4), wherein the cathode of the tenth voltage stabilizing tube (D10), one end of the ninth capacitor (C9) and the input end of the voltage stabilizer (IC 1) are respectively and electrically connected with the input end (AVCC) of the voltage stabilizing circuit unit, the output end of the voltage stabilizer (IC 1) is respectively and electrically connected with one end of the third capacitor (C3), one end of the fourth capacitor (C4) and the output end of the voltage stabilizing circuit unit, and the anode of the tenth voltage stabilizing tube (D10), the other end of the ninth capacitor (C9), the grounding end of the voltage stabilizer (IC 1), the other end of the third capacitor (C3) and the other end of the fourth capacitor (C4) are respectively grounded.
6. A control circuit for a dc contactor as claimed in claim 1, wherein: a protection branch is connected in parallel between the positive electrode driving end (PO+) and the negative electrode driving end (PO-) of the contactor suction driving circuit unit, wherein the protection branch comprises a seventh diode (D7) and a ninth resistor (R9), the anode of the seventh diode (D7) is electrically connected with the negative electrode driving end (PO'), the cathode of the seventh diode (D7) is electrically connected with one end of the ninth resistor (R9), and the other end of the ninth resistor (R9) is electrically connected with the positive electrode driving end (PO+).
7. A control circuit for a dc contactor as claimed in claim 1, wherein: the MCU control circuit unit adopts a microprocessor chip with the model of mega8A and a peripheral circuit thereof.
8. A method of operating a control circuit for a dc contactor as claimed in any one of claims 1 to 7, comprising the steps of:
s101, after receiving a first level analog quantity from a control level sampling circuit unit, an MCU control circuit unit carries out analog-to-digital conversion on the first level analog quantity into a first level numerical value;
S102, after the MCU control circuit unit acquires N first level numerical values which are continuously sampled, calculating a current control level numerical value by adopting a median average method, wherein N is a natural number between 4 and 12;
s103, judging whether the current control level value is within the contactor actuation voltage threshold value range or not by the MCU control circuit unit, if yes, executing step S104, otherwise, controlling the PWM signal output end not to output or stop outputting the PWM signal, and returning to execute step S101;
s104, if no PWM signal is output currently, executing a step S105, otherwise, periodically executing a step S106;
s105, performing analog-to-digital conversion on a second level analog quantity from a temperature sampling circuit unit into a second level numerical quantity by an MCU control circuit unit, then obtaining a first PWM signal parameter suitable for starting contactor actuation by looking up a table according to the second level numerical quantity, then controlling a PWM signal output end to output a corresponding large current PWM signal according to the first PWM signal parameter, enabling a direct current contactor coil branch connected in parallel between a positive electrode driving end (PO+) and a negative electrode driving end (PO-) to electrically start an actuation contact switch, and periodically executing step S106 after a first delay time elapses, wherein the first PWM signal parameter comprises amplitude, frequency and/or duty ratio;
S106, the MCU control circuit unit converts the third level analog quantity from the temperature sampling circuit unit into a third level numerical quantity in an analog-to-digital mode, then a second PWM signal parameter suitable for maintaining the suction of the contactor is obtained through table lookup according to the third level numerical quantity, and then a corresponding low-current PWM signal is output by the PWM signal output end according to the second PWM signal parameter, so that a suction contact switch is electrically maintained on a coil branch of the direct-current contactor connected between the positive electrode driving end (PO+) and the negative electrode driving end (PO-) in parallel, wherein the second PWM signal parameter comprises amplitude, frequency and/or duty ratio.
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