CN111324049A - AGV has comprehensive diagnosis function servo controller - Google Patents
AGV has comprehensive diagnosis function servo controller Download PDFInfo
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- CN111324049A CN111324049A CN201811523330.3A CN201811523330A CN111324049A CN 111324049 A CN111324049 A CN 111324049A CN 201811523330 A CN201811523330 A CN 201811523330A CN 111324049 A CN111324049 A CN 111324049A
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- 238000003745 diagnosis Methods 0.000 title claims abstract description 8
- 238000001514 detection method Methods 0.000 claims abstract description 46
- 238000007493 shaping process Methods 0.000 claims description 10
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- 238000005070 sampling Methods 0.000 claims description 9
- 230000003321 amplification Effects 0.000 claims description 7
- 238000002955 isolation Methods 0.000 claims description 7
- 238000003199 nucleic acid amplification method Methods 0.000 claims description 7
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- 238000006243 chemical reaction Methods 0.000 claims description 2
- 239000003990 capacitor Substances 0.000 description 10
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- 238000000034 method Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
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- 230000000295 complement effect Effects 0.000 description 1
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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 a servo controller with a comprehensive diagnosis function for an AGV, which comprises a core processor, a CPLD circuit, a motor disconnection detection circuit, an encoder disconnection detection circuit, a driver short-circuit protection detection circuit, a motor current acquisition circuit and an output voltage acquisition circuit. The controller can judge whether the motor is disconnected, whether the encoder is disconnected, whether the driver is short-circuited, and whether the current and the output voltage of the motor exceed the preset threshold value, and protects the motor.
Description
Technical Field
The invention relates to a digital servo controller, in particular to a servo controller with a comprehensive diagnosis function for an AGV.
Background
In an AGV control system, a servo plays an increasingly important role, interfaces are increasingly rich, great flexibility is provided for application, the probability of faults is correspondingly increased, and certain difficulty is caused for troubleshooting. Meanwhile, some faults do not take measures in time to cause abnormal actions of the AGV, such as galloping.
At present, many servos do not have a comprehensive diagnosis function or have few diagnosis functions, and problems are mainly judged by experience of maintenance personnel and further analyzed through instrument measurement. The method has high requirements on the technical level of maintenance personnel, and sometimes needs to take a long time to affect production.
Disclosure of Invention
In order to overcome the defects, the invention aims to analyze and judge by collecting the data of key point positions and give an alarm.
The technical scheme adopted by the invention for realizing the purpose is as follows: a servo controller with integrated diagnostic function for an AGV, comprising: the device comprises a core processor, a CPLD circuit, a motor disconnection detection circuit, an encoder shaping circuit, an encoder disconnection detection circuit, a driver short-circuit protection detection circuit, a motor current acquisition circuit and an output voltage acquisition circuit;
the motor disconnection detection circuit acquires a motor current signal, outputs a PWM (pulse width modulation) signal after filtering, enters the CPLD (complex programmable logic device) circuit after passing through the window comparator to judge the motor disconnection, and then outputs the motor disconnection to the core processor;
the encoder signal is split into 2 paths: one path of the signal is subjected to differential to single-ended conversion through an encoder shaping circuit, enters a CPLD for phase loss judgment and is provided for a QEP interface of a DSP; one path of A \ B \ Z differential signals of the encoder are processed by an encoder disconnection detection circuit, output to a CPLD circuit for further filtering, then subjected to encoder disconnection judgment, and then output to a core processor;
the driver short-circuit protection detection circuit collects voltage drop signals of a power bus, and the voltage drop signals are sequentially processed by the internal sampling amplification circuit, the comparator circuit and the isolation circuit and then output to the core processor;
the motor current acquisition circuit acquires a motor current signal and outputs the motor current signal to the core processor;
the output voltage acquisition circuit acquires voltage signals and outputs the voltage signals to the core processor;
and the core processor is used for receiving the signals output by the modules, and alarming and disconnecting corresponding circuits when the motor is disconnected, the encoder is disconnected, the driver is short-circuited, and the current and the output voltage of the motor exceed preset thresholds.
The motor disconnection detection circuit comprises a proportional-integral circuit output end connected with a window comparison circuit; an amplifier U14A inside the proportional-integral circuit filters the signal to output a PWM signal, and the window comparator circuit consists of 2 comparators to shape and output the filtered PWM signal.
The encoder shaping circuit adopts a line amplifier for converting a differential signal into a single end.
The encoder disconnection detection circuit comprises three branches, wherein each phase signal of an encoder in each branch enters an exclusive-OR gate through a current-limiting resistor, and an output signal of the exclusive-OR gate enters a CPLD (complex programmable logic device) for filtering and then outputs a disconnection signal.
The driver short-circuit protection detection circuit comprises a sampling amplification circuit consisting of a resistor R802 and an amplifier U8, a comparator circuit consisting of a comparator U9A and an isolation circuit consisting of an optical coupler OC 1.
The core processor adopts a DSP processor.
The motor current acquisition circuit includes: the Hall current sensor collects a motor current signal, and the motor current signal is output to the DSP for A/D collection after passing through a proportional-integral amplifying circuit consisting of an amplifier U14B.
The output voltage acquisition circuit includes: the voltage signal output by the motor is collected, and the voltage signal is connected to the DSP for A/D collection through a filter circuit to a proportional-integral amplifier circuit consisting of an amplifier U16B.
The invention has the following beneficial effects and advantages:
1. the detection is comprehensive: the method comprises the steps that the output of a driver is short-circuited and broken, the voltage of a power supply is too high or too low, the servo temperature is too high, any broken line (comprising a power supply and a ground wire) of an encoder is broken, and the encoder is in phase failure; simulating given zero point abnormity, tachometer zero point abnormity, current sensor zero point abnormity, servo driver output overcurrent, servo position out-of-tolerance, servo speed stall, servo heartbeat abnormity and the like.
2. The alarm indication is comprehensive: when an alarm appears, the indicator light flashes to indicate the alarm at the current highest level, and the low-level alarms are displayed only when the high-level alarms disappear. But all current alarms can be displayed by viewing the alarm code.
3. The safety is high: when an alarm occurs, the protection mode is immediately entered, and the given and PID energy is cleared. The alarm state is maintained even if the alarm disappears later until the alarm reset signal is received, and the uncontrollable phenomenon is prevented.
4. The setting is flexible: each alarm is provided with a shielding code, so that different application environment requirements are met.
5. The cost is low: the invention adopts a mode of combining hardware and software, the inherent sensor of the system is often used for signal acquisition, and only a small amount of operational amplifiers and comparators or gate circuits are needed to be added. And the signals enter the CPLD and are uniformly processed. For example: the motor disconnection detection is that the signal output by the inherent current sensor is utilized for processing, and the signal is amplified after being filtered, and a PWM signal is extracted and enters a CPLD for judgment.
Drawings
FIG. 1 is a schematic diagram of a controller according to the present invention.
Fig. 2 is a schematic diagram of the motor disconnection detection of the present invention.
FIG. 3 is a schematic diagram of the output short-circuit protection detection of the driver according to the present invention.
FIG. 4 is a circuit diagram of the encoder disconnection detection circuit of the present invention.
Fig. 5 is a circuit diagram of the motor current collection of the present invention.
FIG. 6 is a circuit diagram of the output voltage detection circuit of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
FIG. 1 is a schematic diagram of a servo controller according to the present invention. The method comprises the following steps: the core processor is composed of a DSP2407, a CPLD, a motor disconnection detection circuit, an encoder disconnection detection circuit, a driver short-circuit protection circuit, a motor current acquisition circuit, an output voltage acquisition circuit and the like. Wherein: the secondary end voltage of the motor disconnection detection current sensor is filtered, and then a PWM signal is extracted and enters the CPLD for judgment after passing through the shaping circuit. After the encoder signal enters the servo, the encoder signal is divided into 2 paths: one path of the signal passes through a differential-to-single end of an encoder shaping circuit and then enters a CPLD for phase loss judgment, and is provided for a QEP interface of a DSP; one path inputs A \ B \ Z differential signals into an exclusive-OR gate circuit for processing, and output signals enter a CPLD for filtering and then are subjected to disconnection judgment. The driver output short-circuit protection circuit utilizes the voltage drop on the power bus sampling resistor to be amplified through an amplifier, outputs trigger pulse after being compared with a threshold value, and is connected to a PDPINTA pin of the DSP2407 after being isolated by an optical coupler; when a short circuit occurs, the PDPINTA pin is pulled low, which causes the PWM driving signal to disappear, thereby cutting off the power output and controlling the output of PWM to achieve the purpose of protection. The power supply voltage detection circuit sends the detection result to the DSP2407, compares the detection result with a set high-low threshold, and exceeds the threshold for protection. The servo temperature detection circuit detects the temperature of the bottom plate and exceeds a threshold value for protection.
The important point of the servo driver is safety, and the servo driver can be protected quickly when unsafe factors occur; when the servo driver is powered on, initializing all variables, and then initializing CAN, SPI, A/D, QEP, PWM, a timer and the like; and after the zero point acquisition, the output voltage zero point acquisition, the simulation given zero point acquisition and the speed measuring machine feedback zero point acquisition of the current sensor are finished. Detecting the state of each working point, giving an alarm when deviating from the normal range, and when the given value or the feedback value is in a non-zero state in an analog mode, carrying out safety protection on the servo to prevent sudden start, and removing the protection only when the given value is reduced to zero.
The motor disconnection detection circuit is composed of a proportional-integral amplifier, a window comparison circuit and a CPLD determination module as shown in FIG. 2. The CUR signal comes from the secondary end of the current sensor, and the resistors R509, R510 and R511, the capacitor C517 and the amplifier U14A form a proportional-integral amplifier to amplify the weak current signal; the resistors R512-R515, the capacitors C515-C516 and U12(A, B) jointly form a window comparator.
The connection relation of the specific circuit of the proportional-integral amplifier is as follows: the non-inverting input end of the amplifier U14A is connected to the CUR signal through a resistor R509, the inverting input end is grounded through a resistor R510, a resistor R511 and a capacitor C517 are connected between the inverting input end and the output end in parallel, and the output end is connected with a window comparison circuit.
The connection relation of the specific circuit of the window comparison circuit is as follows: the comparison circuit comprises two LM393 comparators, a pin 2 of a U12A and a pin 5 of a U12B are connected and then connected with the output of a U14A, a pin 6 of a U12B is connected with a positive threshold VA point, the VA point is connected to a positive terminal of a power supply VCC through a resistor R513, and is connected with a negative terminal of the power supply VCC after being connected in parallel through a resistor R512 and a capacitor C515, a pin 3 of the U12A is connected with a negative threshold VB point, the VB point is connected to a positive terminal of the power supply VCC through a resistor R514, and is connected with the negative terminal of the power supply VCC after being connected in parallel through a resistor R515 and a capacitor C516, and a pin 1 of the U12A and a pin 7 of the U12 59.
Where R512-R513 set the forward compare point VA and R514-R515 set the reverse compare point VB, the U12 output is high when the amplified current signal is between VA and VB. When the signal voltage exceeds VA or falls below VB, U12 outputs a low level, which is connected to pin 16 of U2CPLD for decision. When the motor is normally connected, the output PWM current of the driver is in a loop, so that the secondary end of the current sensor has the same PWM pulse, and the pulse with the same frequency generated after passing through the detection circuit enters the CPLD for judgment. After the motor is disconnected, PWM (pulse-width modulation) pulsation can not occur at the secondary end of the current sensor, so that the output of the disconnection detection circuit is always kept at a high level.
The output short detection circuit is shown in fig. 3: the method comprises three parts of sampling amplification, comparison and isolation.
The sampling amplification is composed of a resistor R802 and an amplifier U8(AD623), and R802 is a power bus sampling resistor. R805-R806 and the comparator U9A (LM393AD) form a comparison circuit, and R805-R806 set a comparison threshold. And the R808-R809 and OC1(6N137) optical couplers form an isolation circuit.
The specific connection relations of the sampling amplification, the comparison and the isolation comprise: the resistor R802 is connected between the input ends of the amplifier U8 in parallel, the output end of the amplifier U8 is connected with the inverting input end of the comparator U9A, the non-inverting input end of the comparator U9A is connected with a power supply VDD through the resistor R806 and is connected with a driver through the resistor R805; the output end of U9A is connected with opto-coupler OC1, and opto-coupler OC1 output end is connected with the DSP. When the driver output current increases, the voltage drop across R802 increases and the output voltage of U8 increases. Under normal conditions, the voltage of a pin 2 of the comparator U9A is lower than the threshold voltage of a pin 3, a pin 1 of the U9A outputs a high level, an input diode of an OC1 optocoupler is not conducted, a pin 6 of the OC1 is a high level, a pin 7 of the DSP PDPINTA is a high level, and the PWM outputs normally. When the current of a power bus is increased to a certain value, the voltage of a pin 2 of U9A exceeds a threshold value of a pin 3, a pin 1 of U9A outputs low level, a light emitting diode of OC1 is conducted, and a pin 6 of OC1 outputs low level, so that a pin PDPINTA of a DSP is caused to be low level, the PWM output pin of the DSP is caused to be in a high impedance state, the output of a MOSFET is cut off, and the damage of a power tube is avoided. Since the MOSFET transistor is momentarily damaged due to the extremely large current flowing in the short-circuit state, the MOSFET must be turned off within 10us, which is difficult to satisfy at a software level. The detection circuit is completely in a hardware mode, and the total time does not exceed 7us by adding logic processing in the DSP. For this function to operate reliably, the threshold value needs to be set taking into account the maximum output current of the driver, typically 3-4 times the maximum value. Note that this function requires the DSP to turn on the PDPINTA interrupt.
As shown in fig. 4, the encoder shaping circuit uses a 4-way differential-to-single-ended line amplifier AM26LV32, outputs AO, BO, ZO shaping signals to the CPLD for phase loss detection, and then outputs the signals to the DSP. Encoder broken string detection circuit: the CPLD is composed of an exclusive OR gate circuit and a CPLD. The resistors R700-R714 and the exclusive-OR gates U6A, U6B and U6C (the models are SN74HC86D) form disconnection detection, each phase signal of the encoder enters the exclusive-OR gate through the current limiting resistor, in order to filter out burrs, an output signal enters the CPLD for filtering, and finally, which phase has the disconnection is given. The encoder disconnection detection circuit is as follows: R700-R714 resistor network, XOR gate U6(A, B, C) and CPLD (EPM570T 100). A first branch: the A end is connected with a pin 1 of an exclusive-OR gate U6A through a resistor R702, the/A end is connected with a pin 2 of a U6A through a resistor R701, the A end and the/A end are connected with an R700 in series, the pin 1 of the exclusive-OR gate U6A is grounded through a resistor R704, the pin 2 is grounded through a resistor R703, and the output end 3 of the exclusive-OR gate U6A is connected with a DSP. A second branch circuit: the B end is connected with a 4 pin of an exclusive-OR gate U6B through a resistor R706, the/B end is connected with a 5 pin of a U6B through a resistor R707, an R705 is connected between the B end and the/B end in series, the 4 pin of the exclusive-OR gate U6B is grounded through a resistor R709, the 5 pin is grounded through a resistor R708, and the output 6 end of the exclusive-OR gate U6B is connected with a DSP. A third branch circuit: the terminal C is connected with a pin 9 of an exclusive-OR gate U6C through a resistor R711, the terminal/C is connected with a pin 10 of a U6C through a resistor R712, the terminal C and the terminal/C are connected with an R710 in series, the pin 9 of the exclusive-OR gate U6C is grounded through a resistor R714, the pin 10 is grounded through a resistor R713, and the output end 8 of the exclusive-OR gate U6C is connected with the DSP. Because the level of each phase of differential pair of the encoder is complementary under normal conditions, the high level is output after passing through the XOR gate, and after one line is disconnected, the level of the disconnected end tends to the level of the un-disconnected end, and the low level is output after passing through the XOR gate; when both are disconnected, the input voltage of the exclusive or gate is grounded through R703 and R704, and the output voltage of the exclusive or gate is also low. And the three-phase detection level is sent to the CPLD for line breakage judgment. Because the encoder signals can be interfered in different degrees, the signals output by the exclusive-or gate often have burrs, and therefore filtering processing is added inside the CPLD. Actual tests show that the detection is successful when any line is broken.
As shown in fig. 5, the motor current collecting circuit includes: the motor loop current is input by the Hall current sensor CSK7-25, the output end CUR is grounded after being connected in parallel with the capacitor C518 through the resistor R501, the output end CUR is also connected with the inverting input end of the amplifier U14B through the resistor R502, the resistor R505 and the capacitor C519 are connected in parallel between the inverting input end and the output end of the amplifier U14B (the model is LM2262), the non-inverting input end of the amplifier U14B is connected with 2.5V through the resistor R503 and grounded through the resistor R503, and the output end of the amplifier U14B is connected with the DSP. The motor loop current is input by the Hall current sensor CSK7-25, the output end CUR is converted into a voltage signal through the R501, and the voltage signal enters an ADCIN06 pin of the DSP for A/D acquisition after passing through a proportional-integral amplifier consisting of R502-R505, C519 and U14B.
As shown in fig. 6, the output voltage acquisition circuit includes a filter circuit and a proportional-integral amplifier circuit. The filter circuit includes: the negative end of the motor output is output through resistors R560 and R562, the positive end of the motor output is output through resistors R561 and R563, a lead wire led out between the resistors R560 and R562 is sequentially connected between the resistors R561 and R563 through capacitors C560 and C561, capacitors C562 and C563, resistors R564 and R565 are connected between the output ends of the filter circuit in series, and the resistors R564 and R565 are grounded. The proportional-integral amplifier circuit includes: the resistor R566 is connected to the inverting input end of the amplifier U16B, a resistor R569 and a capacitor C568 are connected between the inverting input end and the output end of the amplifier U16B in parallel, the resistor R567 is connected to the non-inverting input end of the amplifier U16B, the non-inverting input end is connected to 2.5V through the resistor R568, and the output end of the amplifier U16B (model number LM2262) is connected to the DSP. The voltage at the two ends of the motor is filtered through R560-R565 and C560-C563, and then enters an ADCIN05 pin of the DSP for A/D acquisition after passing through a proportional-integral amplifier composed of R566-R569, C568 and U16B.
In addition, the servo controller of the present invention can also determine: simulating the functions of abnormal given zero point, abnormal zero point of a tachometer, abnormal zero point of a current sensor, output overcurrent of a servo driver, out-of-tolerance of servo position, stalling of servo speed, abnormal servo heartbeat and the like. When the simulation mode is adopted for setting, the starting-up initialization detection simulates a set zero point and a speed measuring machine feedback zero point, when the zero point is not in the zero position, the alarm protection is carried out, and the setting can be continued only when the alarm disappears after the zero point is adjusted, so that the abnormal starting is prevented. The fault detection mainly comprises the steps of collecting working point states, then carrying out software analysis and judgment, and protecting abnormal parking.
Claims (8)
1. An AGV has a servo controller with a comprehensive diagnosis function, characterized by comprising: the device comprises a core processor, a CPLD circuit, a motor disconnection detection circuit, an encoder shaping circuit, an encoder disconnection detection circuit, a driver short-circuit protection detection circuit, a motor current acquisition circuit and an output voltage acquisition circuit;
the motor disconnection detection circuit acquires a motor current signal, outputs a PWM (pulse width modulation) signal after filtering, enters the CPLD (complex programmable logic device) circuit after passing through the window comparator to judge the motor disconnection, and then outputs the motor disconnection to the core processor;
the encoder signal is split into 2 paths: one path of the signal is subjected to differential to single-ended conversion through an encoder shaping circuit, enters a CPLD for phase loss judgment and is provided for a QEP interface of a DSP; one path of A \ B \ Z differential signals of the encoder are processed by an encoder disconnection detection circuit, output to a CPLD circuit for further filtering, then subjected to encoder disconnection judgment, and then output to a core processor;
the driver short-circuit protection detection circuit collects voltage drop signals of a power bus, and the voltage drop signals are sequentially processed by the internal sampling amplification circuit, the comparator circuit and the isolation circuit and then output to the core processor;
the motor current acquisition circuit acquires a motor current signal and outputs the motor current signal to the core processor;
the output voltage acquisition circuit acquires voltage signals and outputs the voltage signals to the core processor;
and the core processor is used for receiving the signals output by the modules, and alarming and disconnecting corresponding circuits when the motor is disconnected, the encoder is disconnected, the driver is short-circuited, and the current and the output voltage of the motor exceed preset thresholds.
2. The servo controller with the integrated diagnostic function for the AGV according to claim 1, wherein the motor disconnection detecting circuit comprises a proportional-integral circuit output end connected with a window comparing circuit; an amplifier U14A inside the proportional-integral circuit filters the signal to output a PWM signal, and the window comparator circuit consists of 2 comparators to shape and output the filtered PWM signal.
3. The AGV servo controller with integrated diagnostic function of claim 1 wherein said encoder shaping circuit uses a differential to single ended line amplifier.
4. The servo controller with integrated diagnostic function for AGVs according to claim 1, wherein said encoder disconnection detection circuit comprises three branches, in which each phase signal of the encoder enters an xor gate through a current limiting resistor, and the xor gate outputs a signal to a CPLD for filtering and outputting a disconnection signal.
5. The servo controller with the integrated diagnostic function for the AGV of claim 1, wherein the driver short-circuit protection detection circuit comprises a sampling amplification circuit consisting of a resistor R802 and an amplifier U8, a comparator circuit consisting of a comparator U9A, and an isolation circuit consisting of an optical coupler OC 1.
6. The servo controller for AGV having integrated diagnostic function according to claim 1, wherein said core processor is a DSP processor.
7. The servo controller for AGV having integrated diagnostic function according to claim 1, wherein said motor current collecting circuit comprises: the Hall current sensor collects a motor current signal, and the motor current signal is output to the DSP for A/D collection after passing through a proportional-integral amplifying circuit consisting of an amplifier U14B.
8. The servo controller for AGV having integrated diagnosis function according to any one of claims 1 to 7, wherein said output voltage collecting circuit comprises: the voltage signal output by the motor is collected, and the voltage signal is connected to the DSP for A/D collection through a filter circuit to a proportional-integral amplifier circuit consisting of an amplifier U16B.
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Application publication date: 20200623 |