CN112072964B - Self-calibration control method of encoder and tricycle driving system thereof - Google Patents

Abstract

The invention discloses a self-calibration control method of an encoder and a tricycle driving system thereof, wherein the self-calibration control operation steps comprise: a10 Power-on the motor with the encoder, and the motor is in a stable constant-speed rotation state through external force; a20 Adjusting the original sine and cosine signals of an induction coil positioned in the encoder, and adjusting the output amplitude of the encoder based on the original sine and cosine signals to enable the original sine and cosine signals of the encoder in each period to reach a uniform output amplitude; a30 Processing and calculating the output amplitude signal to serve as a zero calibration signal of the rotor position and sending the zero calibration signal to the driver; the invention can realize the accurate detection of the real-time position of the rotor, and finally ensure the accurate driving effect of the tricycle driving system.

Description

Self-calibration control method of encoder and tricycle driving system thereof

Technical Field

The invention belongs to the electric vehicle drive control technology, and particularly relates to a self-calibration control method of an encoder, and a tricycle drive system applying the self-calibration control method.

Background

The tricycle has a large market application demand due to the fact that the tricycle has good loading capacity and has specific advantages compared with a two-wheeled vehicle. However, the driving technology adopted by the tricycle continues to use the traditional motor driving technology, and the innovative driving technology of the tricycle is hardly disclosed, and particularly: the Hall sensor installed on the winding is adopted to carry out sensing detection of the position of the rotor, square wave control driving is adopted, and after the Hall sensor is used for a long time under the winding heating environment, the structure of the Hall sensor is easy to damage, so that a tricycle has high failure rate, and meanwhile, the existing control mode has poor speed-raising performance, low working efficiency of the motor and high cost.

The applicant has also paid particular attention to that a tricycle generally needs to have better loading capacity, and simultaneously has the using function of a two-wheeled vehicle, and the applied load range is very wide, so when the tricycle is used, the corresponding load range is wide and uncertain, so that the required tricycle motor needs to have excellent speed-up performance when being driven, and the existing tricycle driving control scheme is relatively lagged behind the recent technical development.

Therefore, based on the fact that the technical development team of the applicant concentrates on research and development experience and accumulated application data experience in the field of electric vehicle driving for many years, a systematic technical scheme is expected to be searched for to improve the technical level of tricycle driving and promote the application development of tricycles.

Disclosure of Invention

In view of this, the present invention provides a self-calibration control method for an encoder and a tricycle driving system thereof, which can realize accurate detection of a real-time position of a rotor, and finally ensure an accurate driving effect of the tricycle driving system.

The technical scheme adopted by the invention is as follows:

a self-calibration control method of an encoder is disclosed, wherein the encoder is arranged on a motor, the encoder adopts an inductive position encoder to detect a rotor position signal in real time, the motor adopts a driver to carry out driving operation, and the driver carries out sine wave driving control on the motor based on the rotor position signal; the encoder is subjected to self-calibration control in advance before the motor is used, wherein the self-calibration control comprises the following operation steps:

a10 Electrifying a motor provided with an encoder, and enabling the motor to be in a stable constant-speed rotation state through external force;

a20 Adjusting the original sine and cosine signals of an induction coil positioned in the encoder, and adjusting the output amplitude of the encoder based on the original sine and cosine signals to enable the original sine and cosine signals of the encoder in each period to reach a uniform output amplitude;

a30 And the output amplitude signal is processed and calculated to be used as a zero calibration signal of the rotor position and then sent to the driver.

Preferably, in step a 10), the rotational speed range of the motor is set to 20-80% of its rated rotational speed.

Preferably, step a 40) is also included after step a 30): the output amplitude signal is stored in the encoder.

Preferably, the encoder is provided with a self-calibration key, and the self-calibration key is pressed to send an instruction for storing the output amplitude signal to the encoder.

Preferably, the motor comprises a stator assembly and a rotor assembly which are connected through electromagnetic induction, and the rotor assembly and the motor are fixedly installed into a whole; the encoder is an inductive position encoder and comprises an encoder rotating module and an encoder stator module which are connected through electromagnetic induction, wherein the encoder rotating module is fixedly installed on the motor shaft, the encoder stator module is fixedly installed at one end of the stator module and is in communication connection with the driver, and a rotor position signal obtained through calculation is sent to the driver.

Preferably, the encoder rotation module is provided with a rotation module printed circuit board, the rotation module printed circuit board is provided with a conductive material scale area, the encoder stator module is provided with a stator module printed circuit board, the stator module printed circuit board is provided with an excitation coil for generating an electromagnetic field, a receiving coil for receiving induced electromotive force and a processing chip, the conductive material scale area is used for influencing the coupling relationship between the excitation coil and the receiving coil, the excitation coil generates alternating electromagnetic field strength and then changes the induced electromotive force on the receiving coil, the receiving coil serves as the induction coil, and the induced electromotive force signal serves as the original sine and cosine signal; after the encoder rotating module rotates for one circle relative to the encoder stator module, the receiving coil obtains original sine and cosine signals of multiple periods, and the original sine and cosine signals are calculated, processed and adjusted through the processing chip, so that the original sine and cosine signals of the encoder in each period reach a uniform output amplitude value.

Preferably, the rotor assembly comprises permanent magnet steel, and when the permanent magnet steel rotates, the magnetic poles of the permanent magnet steel enable the conductive material scale area to generate an eddy current field for weakening the alternating electromagnetic field strength of the exciting coil.

Preferably, the processing chip cooperates with the exciting coil to generate high-frequency periodic alternating voltage and current, and the alternating current flowing through the exciting coil forms an alternating electromagnetic field in the peripheral region thereof; when the alternating electromagnetic field generated on the exciting coil passes through the receiving coil, the magnetic flux of the receiving coil is alternated, so that the alternating induced electromotive force with the same frequency is generated on each receiving coil.

Preferably, the receiving coils are distributed on the rotating module printed circuit board at intervals in a ring shape; and all the conductive materials on the conductive material scale area are distributed on the rotating module printed circuit board at intervals in an annular shape.

Preferably, a tricycle drive system comprises a motor on a tricycle frame and a drive for controlling the drive operation of the motor, the motor comprising an encoder mounted on a motor shaft, the encoder being in communication with the drive, wherein the encoder employs a self-calibration control method as described above prior to use of the motor.

In order to realize accurate and rapid starting of a tricycle motor adopting an encoder, the encoder is subjected to self-calibration control in advance before the motor is used, the method is characterized in that when a rotating module of the encoder rotates at a specified rotating speed, an induced electromotive force signal serving as an original sine and cosine signal is generated by an internal induction coil (namely a receiving coil) of a stator module of the encoder, based on the original sine and cosine signal, the output amplitude of the encoder is adjusted by a processing chip, so that the original sine and cosine signal of the encoder in each period reaches a uniform output amplitude, the output amplitude signal is sent to a driver as a zero calibration signal of a rotor position after being processed and calculated, further, the self-calibration of the zero position of the rotor is completed, when a subsequent motor is started each time, the driver compares the sine and cosine signal output by the internal induction coil of the encoder with the pre-stored zero calibration signal, the accurate detection of the real-time position of the rotor can be realized, and the accurate driving effect of a tricycle driving system is finally ensured.

Drawings

FIG. 1 is a flow chart of the control steps of the tricycle driving system in the embodiment 1 of the present application;

fig. 2 is a schematic structural view of a motor in embodiment 1 of the present application;

FIG. 3 is a schematic view of the structure of FIG. 2 in another orientation;

fig. 4 is an exploded structural view of a mounting structure of the encoder 2 of fig. 2;

FIG. 5 is an exploded view of the FIG. 2;

fig. 6 is a flow chart of the self-calibration control procedure of the encoder 2 in embodiment 2 of the present application;

fig. 7 is a schematic structural view of a rotor assembly 13 in embodiment 2 of the present application;

FIG. 8 is an exploded view of FIG. 7;

fig. 9 is a schematic structural view of a rotor core in embodiment 2 of the present application;

FIG. 10 is an end view of the structure of FIG. 9;

fig. 11 is a flow chart of the assembly process steps of the combined magnetic steel in embodiment 2 of the present application;

FIG. 12 is an enlarged view of the structure of FIG. 10 at A;

fig. 13 is an exploded view of the circuit board in embodiment 4 of the present application;

fig. 14 is a schematic structural diagram of a circuit board (not shown with a bottom heat dissipation substrate) in embodiment 4 of the present application;

FIG. 15 is a schematic view of the structure of FIG. 14 in another orientation;

fig. 16 is an enlarged schematic view of a mounting structure of a MOS transistor on an over-current heat dissipation aluminum block;

fig. 17 is an exploded view of the mounting structure between the MOS transistor and the contact pad and the elastic pad;

FIG. 18 is a flowchart of a smoothing control step in embodiment 5 of the present application;

FIG. 19 is a schematic view showing communication connection between an encoder and each driver unit in embodiment 6 of the present application;

FIG. 20 is a block diagram showing a flow of a data determination control process in an encoder according to embodiment 6 of the present application;

fig. 21 is a schematic diagram of communication connection of an encoder in security management in embodiment 6 of the present application.

Detailed Description

In order to make those skilled in the art better understand the technical solution of the present invention, the technical solution in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example 1: the embodiment provides a tricycle driving system with low failure rate, which comprises a motor 1 on a tricycle frame (applying a known tricycle structure) and a driver for controlling the driving operation of the motor 1, wherein the motor 1 comprises an encoder 2 arranged on a motor shaft 11, so that the failure rate can be obviously reduced; the encoder 2 is in communication connection with the driver, the encoder 2 sends the detected rotor position signal to the driver, and the driver performs sine wave drive control on the motor based on the rotor position signal, so that the drive precision of the tricycle drive system can be remarkably improved, and fine control is realized; referring to fig. 1, the control steps of the present embodiment include:

s10), after the driver receives the rotor position real-time signal output by the encoder 2, filtering the rotor position real-time signal, and setting a current angle value ThetViL1;

s20), performing deviation value comparison on the current angle value ThetViL1 and the angle value ThetViLast of the previous period, and assigning a current sine wave control actual angle value ThetResult according to a deviation value comparison result; preferably, in this step 20), when the deviation value does not exceed a preset maximum deviation value (it may be enough that the actual control accuracy needs to be specifically set), assigning the current angle value ThetViL1 to the current sine wave control actual angle value ThetResult; when the deviation value exceeds a preset maximum deviation value, assigning a preset maximum angle value to the current sine wave control actual angle value ThetResult to avoid motor current fluctuation;

s30), the driver controls the actual angle value ThetResult to start and control the motor 1 according to the sine wave.

Preferably, referring to fig. 2, 3 and 4, in the present embodiment, the motor 1 includes a stator assembly 12 and a rotor assembly 13 connected by electromagnetic induction, and the rotor assembly 13 is fixedly integrated with the motor shaft 11; the encoder 2 adopts an inductive position encoder and comprises an encoder rotating module 21 and an encoder stator module 22 which are connected through electromagnetic induction, wherein the encoder rotating module 21 is fixedly installed on the motor shaft 11, the encoder stator module 22 is fixedly installed at one end of the stator assembly 20 and is in communication connection with the driver, a rotor position signal obtained through calculation is sent to the driver, the rotor position signal has high precision and high resolution, the purposes of starting and stopping the motor 1, controlling the speed, monitoring the power density and the like can be accurately realized, and the encoder is suitable for working under various severe environmental conditions including a humid, muddy and dusty working environment;

preferably, in the present embodiment, the stator assembly 12 is located at the outer periphery of the rotor assembly 13 (i.e. an inner rotor motor), and in other embodiments, an outer rotor motor may also be used; more preferably, in this embodiment, the encoder rotation module 21 is provided with a rotation module printed circuit board (not specifically shown), the rotation module printed circuit board is provided with a conductive material scale area (a specific scale value is selected according to actual needs), the encoder stator module 22 is provided with a stator module printed circuit board (not specifically shown), the stator module printed circuit board is provided with an excitation coil for generating an electromagnetic field, a receiving coil for receiving induced electromotive force, and a processing chip, wherein the conductive material scale area is used for influencing a coupling relationship between the excitation coil and the receiving coil, and the induced electromotive force on the receiving coil is changed after the excitation coil generates an alternating electromagnetic field strength; when the encoder rotation module 21 rotates one circle relative to the encoder stator module 22, the receiving coil obtains a plurality of periodic receiving signals, and the receiving signals are calculated and processed by the processing chip and then output rotor position signals to the driver;

in this embodiment, the rotor assembly 13 includes a permanent magnet steel 13a, when the permanent magnet steel 13a rotates, the N and S magnetic poles of the permanent magnet steel 13a enable the conductive material scale region to generate an eddy current field for weakening the intensity of the alternating electromagnetic field of the excitation coil, which can be beneficial to the formation of the alternating electromagnetic field; the processing chip is matched with the exciting coil to generate high-frequency periodic alternating voltage and current, and alternating current flowing through the exciting coil forms an alternating electromagnetic field in the peripheral region of the alternating current; when the alternating electromagnetic field generated on the exciting coil passes through the receiving coil, the magnetic flux of the receiving coil is alternated, so that the alternating induced electromotive force with the same frequency is generated on each receiving coil;

particularly preferably, in the present embodiment, the receiving coils are annularly spaced on the rotating module printed circuit board; all the conductive materials on the conductive material scale area are distributed on the rotating module printed circuit board at intervals in a ring shape;

on the basis of referring to fig. 2, fig. 3 and fig. 4, and further referring to fig. 5, the present embodiment further preferably provides a convenient mounting structure of the encoder 2, wherein the encoder rotating module 21 is sleeved on the encoder mounting sleeve 23, and the encoder mounting sleeve 23 is fixedly mounted on the motor shaft 11; the encoder stator module 22 is fixedly installed on the motor end cover through an encoding installation disc 24; preferably, in this embodiment, the stator assembly 12 is provided with a heat dissipation mounting cylinder 15 at the periphery thereof, the heat dissipation mounting cylinder 15 is cast or machined by an aluminum profile, and is provided with a plurality of heat dissipation fins 15a; the two ends of the heat dissipation installation cylinder 15a are fixedly provided with a first motor end cover 14a and a second motor end cover 14b respectively; the coding installation disc 24 is fixedly installed on the second motor end cover 14b, and a fan 16 for motor heat dissipation is fixedly installed on the motor shaft 11 positioned on the outer side of the coding installation disc 24;

preferably, in the present embodiment, the encoder mounting sleeve 23 is mounted and connected with the motor shaft 11 through a flat key or an interference fit or a shrink fit or a spline; meanwhile, the encoder stator module 22 is provided with a guide mounting hole 22a, and the outer periphery of the encoder mounting sleeve 23 is inserted in the guide mounting hole 22a in a clearance manner;

preferably, in the present embodiment, the encoder mounting plate 24 is relatively selectively sleeved on the motor shaft 11 through a bearing 25, and the encoder stator module 22 is installed between the second motor end cover 14b and the encoder mounting plate 24; the encoder stator module 22 is fixedly mounted on the encoding mounting disc 24 through a screw fastener, and the encoding mounting disc 24 is fixedly mounted on the second motor end cover 14b through a screw fastener;

preferably, in this embodiment, the heat dissipation mounting cylinder 15 is provided at the periphery thereof with mounting grooves 15b spaced apart from each other, and each mounting groove 15b is used for fixing and mounting the heat dissipation mounting cylinder 15, the first motor end cap 14a and the second motor end cap 14b into a whole by inserting a screw fastener 17, so that the heat dissipation mounting cylinder 15 of this embodiment is not only beneficial to the external protection effect of the motor 1 in high-speed operation, but also can be matched with the fan 16 to work, thereby achieving the rapid heat dissipation effect of the motor 1.

On one hand, the encoder rotating module 21 is sleeved on the encoder mounting sleeve 23, and is quickly and fixedly arranged on the motor shaft 11 through the encoder mounting sleeve 23; on the other hand, encoder stator module 22 passes through the fixed installation of code mounting disc 24 on second motor end cover 14b, and encoder stator module 22 is located between code mounting disc 24 and second motor end cover 14b, and the installation is firm reliable, is difficult for receiving external force and damages, avoids breaking down.

Example 2: on the basis of the tricycle driving system provided in embodiment 1, this embodiment 2 further provides a self-calibration control method of the encoder 2, where the encoder 2 uses an inductive position encoder to detect a rotor position signal in real time; before the motor 1 is used, the encoder 2 performs a self-calibration control in advance, wherein, referring to fig. 6, the operation steps of the self-calibration control include:

a10 Power on the motor 1 provided with the encoder 2, and the motor 1 is in a stable constant-speed rotation state through external force, preferably, in the step A10), the rotation speed range of the motor 1 is set to be 20-80% of the rated rotation speed when the motor is normally driven;

a20 Adjusting the original sine and cosine signals of an induction coil inside the encoder 2, and adjusting the output amplitude of the encoder based on the original sine and cosine signals, so that the original sine and cosine signals of the encoder 2 in each period (the calculation period can be usually set to microsecond level, for example, set to 50-100 microseconds) reach a uniform output amplitude; preferably, in the present embodiment, the receiving coil serves as an induction coil, and the induced electromotive force signal serves as an original sine-cosine signal; after the encoder rotating module rotates for one circle relative to the encoder stator module, the receiving coil obtains original sine and cosine signals of a plurality of periods, and the original sine and cosine signals are calculated, processed and adjusted through the processing chip, so that the original sine and cosine signals of the encoder in each period reach a unified output amplitude;

a30 Processing and calculating the output amplitude signal, and sending the output amplitude signal to a driver as a zero calibration signal of the rotor position.

A40 Stores the output amplitude signal in the encoder 2; particularly preferably, in the present step a 40), the encoder 2 is provided with a self-calibration key, and by pressing the self-calibration key, the self-calibration key is used for sending an instruction for storing the output amplitude signal to the encoder 2.

Through the encoder self-calibration control scheme provided by the embodiment, the rotor real-time position can be accurately detected, and the accurate driving effect of the tricycle driving system can be finally ensured.

Example 3: on the basis of the embodiments 1 and 2, the embodiment further provides a high-efficiency tricycle driving system, the motor 1 adopts a salient pole permanent magnet synchronous motor beneficial to flux weakening control, the stator assembly 12 includes a stator core (not shown) and a winding (not shown), the rotor assembly 13 includes a rotor core 13b and permanent magnet steel 13a; the speed regulation range of the salient pole permanent magnet synchronous motor is improved by carrying out field weakening control on the salient pole permanent magnet synchronous motor, and the torque of the salient pole permanent magnet synchronous motor is improved by improving the number of turns of a coil of a single winding, wherein the speed regulation range of the salient pole permanent magnet synchronous motor is 0-2000 rpm;

preferably, in the present embodiment, referring to fig. 7, 8, 9 and 10, the rotor core 13b is provided with a plurality of first core chutes 31 uniformly spaced in the first inner circumferential direction thereof and a plurality of second core chutes 32 uniformly spaced in the first inner circumferential direction thereof, wherein the first core chutes 32 and the second core chutes 32 have an included angle therebetween (in the present embodiment, the first core chutes 31 respectively have a first included angle a1=37 ° and a second included angle a2=73 ° with the adjacent second core chutes 32); the first inner circumference is distributed alternately, and the permanent magnet steel 13b is embedded in the first iron core chute 31 and the second iron core chute 32 respectively, so that high-power weak magnetic control is facilitated, and demagnetization is not easy to occur;

preferably, the embodiment provides a combined magnetic steel of a tricycle driving motor, the permanent magnetic steel 13b in each iron core chute 31, 32 adopts a plurality of permanent magnetic steel units 33 which are stacked and combined in parallel and in a segmented manner, the stacking number of the permanent magnetic steel units 33 is selected according to the lengths of the iron core chutes 31, 32 in which the permanent magnetic steel units are located, and the same magnetic poles between the adjacent permanent magnetic steel units 33 in the single iron core chute 31, 32 are stacked in a contact manner; the thickness and the width of each permanent magnetic steel unit 33 in the single iron core chute 31, 32 are equal, and the length of each permanent magnetic steel unit 33 is equal or unequal;

preferably, in the present embodiment, the length-diameter ratio of permanent magnetic steel unit 33 ranges from 0.18 to 0.2, the thickness of permanent magnetic steel unit 33 ranges from 1.1 to 2mm, and permanent magnetic steel unit 33 is made of neodymium iron boron; in this embodiment, the preferable scheme of the permanent magnetic steel unit 33 can be directly referred to the patent document of the previous application CN208539674U of the present applicant, and this embodiment is not specifically described; further preferably, in the present embodiment, the lengths of the permanent magnet steel units 33 are equal, the length range is 10-30mm, 3-6 permanent magnet steel units 33 are embedded in the single iron core chutes 31, 32, specifically, the length L of the iron core chutes 31, 32 is about 87-90mm, and 5 permanent magnet steel units 33 with equal lengths are respectively embedded;

further preferably, in the present embodiment, the rotor core 13b is provided with a plurality of insertion slots 34 uniformly distributed at intervals in the second inner circumferential direction, both ends of the rotor core 13b are respectively provided with a first baffle 35a and a second baffle 35b, and each insertion slot 34 locks and installs the rotor core 13b with the first baffle 35a and the second baffle 35b into a whole through an insertion locking member 36; wherein, the first baffle 35a and the second baffle 35b contact at least part of the surface area of the iron core chutes 31 and 32, so as to prevent the permanent magnetic steel units 33 in the iron core chutes 31 and 32 from being ejected due to the repulsion of like poles; specifically, in the present embodiment, the outer circumferences of the first baffle 35a and the second baffle 35b are both circular and are concentrically installed and distributed with the rotor core 13b, respectively, while the second inner circumference is concentrically distributed with the first inner circumference, wherein the outer diameters of the first baffle 35a and the second baffle 35b are both larger than the diameter of the first inner circumference, specifically, in the present embodiment, the outer diameters of the first baffle 35a and the second baffle 35b are equal and are both about 70mm, and the diameter of the first inner circumference is about 58mm.

Preferably, in the present embodiment, the rotor core 13b includes a plurality of rotor core stamped sheets, wherein each rotor core stamped sheet is provided with laminated slots 37 uniformly distributed at intervals in a third inner circumferential direction, and the rotor core stamped sheets are locked and laminated into a whole through the insertion and matching of the fasteners 37a and the laminated slots 37; the laminated grooves 37 and the insertion grooves 34 are alternately distributed in the inner circumferential direction, and specifically, the outer diameter of the third inner circumference is about 56mm;

as further shown in fig. 11, the present embodiment further provides an assembly process of the combined magnetic steel, including the following steps:

b10 The required number of permanent magnet steel units are sequentially inserted into the iron core slots according to the lengths of the iron core chutes 31 and 32, each permanent magnet steel unit is in a parallel segmented stacking combined structure in the iron core chutes 31 and 32, and the same magnetic poles between the adjacent permanent magnet steel units 33 in the single iron core slots 31 and 32 are in a contact stacking shape;

b20 A first baffle 35a and a second baffle 35b are respectively coaxially arranged at two ends of the rotor core 13b, and the insertion grooves 34 among the first baffle 35a, the rotor core 13b and the second baffle 35b are respectively correspondingly matched;

b30 Through the insertion and matching of the locking piece 36 and each insertion slot 34, the first baffle 35a, the rotor core 13b and the second baffle 35b are locked into a whole, and the permanent magnet steel units 33 in the single core chutes 31 and 32 can be prevented from being ejected due to the repulsion of like poles.

Preferably, in the present embodiment, please further refer to fig. 12, the rotor core 13b includes a plurality of main arc-shaped rotor core segments 38 and a plurality of inner curved rotor core segments 39, and the main arc-shaped rotor core segments 38 and the inner curved rotor core segments 39 are alternately integrated or separately connected to form a closed arc shape, which is beneficial to the field weakening effect of the motor 1; particularly preferably, in the present embodiment, the inner bending type rotor core section 39 serves as a connecting section between the first core chute 31 and the second core chute 32, and the center line of the inner bending type rotor core section 39 coincides with the center line between the first core chute 31 and the second core chute 32.

Example 4: the drivers of the tricycle driving systems in the embodiments 1, 2 and 3 respectively comprise a circuit board 4 provided with a plurality of MOS tubes 41; the specific number and distribution of the MOS transistors 41 on the circuit board, and the arrangement of the plurality of capacitor devices 42 on the circuit board 4 according to actual needs in this embodiment are all common knowledge and conventional technical means in the field of drive control, and therefore, for the specific hardware structure design of the circuit board 4, the detailed description of this embodiment is not further provided;

referring to fig. 13, 14, 15, 16, and 17, in this embodiment 4, a circuit board 4 with a high heat dissipation effect is provided, one side of each of the pins of the MOS tubes 41 is welded on the circuit board 4, and meanwhile, the output end of the other side of the MOS tube 41 is fixedly mounted on an over-current heat dissipation aluminum block 45 (which may be in a strip shape, a block shape, or other special shapes, but is not particularly limited in this embodiment) through a fastener 43 sleeved with an elastic gasket and electrically connected to the over-current heat dissipation aluminum block 45, and the over-current heat dissipation aluminum block 45 is fixedly mounted on the circuit board 4 and in insulation contact with the outside; preferably, in the present embodiment, the fastening piece 43 is respectively sleeved with a contact pad 44a and an elastic pad 44b, the output end of the other side of the MOS transistor 41 is provided with an insertion hole 41a, the fastening piece 43 penetrates through the insertion hole 41a and then is fastened, installed and connected with the over-current heat dissipation aluminum block 45, wherein the elastic pad 44b and the contact pad 44a are sequentially arranged between the end of the fastening piece 43 and the over-current heat dissipation aluminum block 45, and the contact pad 44a is in contact connection with the over-current heat dissipation aluminum block 45; particularly preferably, in the present embodiment, the gate pin 41b and the source pin 41c of the MOS transistor 41 are respectively soldered on the circuit board 4, and the output terminal on the other side of the MOS transistor 41 is a MOS transistor drain, and the MOS transistor drain 41d is provided with an insertion hole 41a;

preferably, in the present embodiment, the circuit board 4 is mounted on a bottom heat dissipation substrate 46 having a plurality of heat dissipation fins 46a in an insulating manner, the electrical over-current heat dissipation aluminum block 45 is integrally mounted and connected with the bottom heat dissipation substrate 46 through an insulating fastening kit 47, and an insulating adhesive layer (not shown) is disposed between the electrical over-current heat dissipation aluminum block 45 and the bottom heat dissipation substrate 46; an aluminum block heat dissipation boss 46b corresponding to the over-current heat dissipation aluminum block 45 is arranged on the bottom heat dissipation substrate 46, an aluminum block through window 48 for penetrating through the aluminum block heat dissipation boss 46b is arranged on the circuit board 4, and the aluminum block heat dissipation boss 46b penetrates through the aluminum block limiting window 48 and then is in insulation contact with the corresponding over-current heat dissipation aluminum block 45.

Preferably, in the present embodiment, the over-current heat dissipation aluminum block 45 is fixedly mounted on the circuit board 4 and the bottom heat dissipation substrate 46 by fasteners distributed in a triangular shape, and particularly preferably, in the present embodiment, the fasteners include insulating fastening kits 47 (screw fasteners sleeved with insulating sleeves), and in order to ensure the fastening mounting effect, some of the fasteners further include insulating mounting gaskets 47a in fastening fit with the corresponding fasteners.

Preferably, in the present embodiment, the height of the over-current heat dissipation aluminum block 45 is 15-25mm, and the maximum thickness of the bottom heat dissipation substrate 46 (including the heat dissipation reinforcing rib 31) is 25-35mm; the circuit board 4 adopts a PCB, and the bottom radiating substrate 46 adopts an aluminum radiating substrate, so that the quick radiating effect is facilitated;

preferably, in the present embodiment, the bottom heat dissipation substrate 46 is provided with a limiting groove 46c for limiting the placement of the circuit board 4, and an insulating silica gel ring 49 is clamped on the periphery of the limiting groove 46 c.

The integral installation structure of the embodiment is simple and convenient for dismounting the MOS tube 41, and meanwhile, the over-current heat dissipation aluminum block 45 is not only used as a power-running installation device of the MOS tube 41, but also used as a rapid heat dissipation contact structure of the MOS tube 41, so that on the basis of realizing large-current connection of the MOS tube 41 (about 75A), consumption of a thick copper plate is avoided, the structure cost is low, and a good heat dissipation effect is achieved; this application further provides and installs circuit board 4 insulation on bottom heat dissipation base plate 46, and bottom heat dissipation base plate 46 and the heat conduction contact of binding a border between the electric heat dissipation aluminium pig 45 further do benefit to circuit board 4's radiating effect.

The embodiment also provides a tricycle which is driven to operate by the tricycle driving system, and the circuit board of the tricycle driving system adopts the circuit board 4.

Example 5: the other technical solutions of this embodiment are the same as those of embodiments 1 to 4, except that this embodiment proposes an automatic speed regulation control method of a tricycle driving system, where the tricycle driving system includes a motor (whose speed regulation range is 0 to 2000 rpm) on a tricycle frame and a driver for controlling the driving operation of the motor 1, the tricycle driving system is provided with an automatic gear shifting device in communication connection with the driver, and an output end of the automatic gear shifting device is in transmission connection with rear wheels of a tricycle; the automatic gear shifting device is provided with a low-speed reduction ratio gear P1 and a high-speed reduction ratio gear P2, whether the automatic gear shifting device needs to shift gears is judged through a driver based on the running condition of the tricycle, and meanwhile, the driver smoothly controls the motor 1 in the gear shifting process of the automatic gear shifting device, so that the tricycle can be prevented from shaking or slumping in the running process;

preferably, in the present embodiment, please refer to fig. 18, the smoothing control includes the following control procedures:

c10 The driver confirms the gear shifting demand signal sent by the automatic gear shifting device;

c20 The driver takes the state that the automatic gear shifting device is in a neutral gear P0 as a gear shifting condition, and controls and adjusts the rotating speed of the motor to a target rotating speed based on the detected rotating speed of the rear wheels and a gear shifting demand signal after the gear shifting condition is judged to be reached;

c30 Automatic shifting devices execute a shift request.

In the present embodiment, the shift demand includes a high-Speed shift demand for shifting the low reduction gear P1 to the high reduction gear P2, and the target rotation Speed of the motor 1 _Target = current Speed of motor _{At present} * (1/P2)/(1/P1), and a low-Speed-shift request to shift the high-Speed reduction gear P2 to the low-Speed reduction gear P1, a target rotational Speed of the motor _Target = current Speed of motor _{At present} * (1/P1)/(1/P2); after receiving the gear shifting demand signal, the driver adjusts the motor speed to the target speed within 0.6-3 seconds, and particularly preferably, the gear shifting time is controlled to be completed within 1 second;

preferably, in the present embodiment, the driver determines whether the driving condition of the tricycle is in a climbing driving state or a flat driving state based on the input real-time changes of the motor speed, the motor phase line current and the vehicle bus current; when the grade climbing driving state is switched into the grade climbing driving state, the automatic gear shifting device is judged to need low-speed gear shifting, and when the grade climbing driving state is switched into the grade climbing driving state, the automatic gear shifting device is judged to need high-speed gear shifting;

specifically, the present embodiment further describes a specific automatic shift process:

in the present embodiment, P1=1:30 P2=1:10; the driver receives a rear wheel rotating speed signal from the automatic speed changing device, the driver outputs a judgment signal needing to be shifted to a relay switch of the automatic gear shifting device, and the automatic gear shifting device is switched into a neutral gear P0 state after receiving the judgment signal needing to be shifted and sends a gear shifting demand signal to the driver:

when the gear shifting requirement is a high-speed gear shifting requirement, and detection shows that the rotating speed of the rear wheels is greater than 10km/h, after the gear shifting condition is met, the current rotating speed of the motor 1 is 600r/min, the reduction ratio of P1=1 is that the rotating speed of the rear wheels is 20r/min, if the speed reduction ratio is directly switched to a high-speed gear P2=1, the rotating speed of the rear wheels is switched to 600 ÷ 10=60r/min, compared with 20r/min before gear shifting, the rotating speed has large change, and the fact that the tricycle has obvious pause and shake during riding is reflected: therefore, the smoothing control process as described above is implemented, wherein in step C20), the PWM duty ratio of the driver is reduced (the period of the open-close pipe can be driven according to different rotation speeds) by looking up a table by the driver software, so that the motor Speed is reduced to the target rotation Speed _Target ＝600r/min*(1/P2)/(1/P1)＝200r/min；

When the gear shifting requirement is a low-speed gear shifting requirement, and detection shows that the rotating speed of the rear wheel is less than 5km/h, after the gear shifting condition is met, the current rotating speed of the motor 1 is 300r/min, the reduction ratio of P2=1 is that the rotating speed of the rear wheel is 30r/min, if the speed reduction ratio is directly switched to a low-speed gear of P1=1, the rotating speed of the rear wheel is switched to 300 ÷ 30=10r/min, compared with 30r/min before gear shifting, the rotating speed has large change, and the phenomenon that riding on the whole tricycle is obviously bumpy and jittered is shown: therefore, a smoothing control process as described above is implemented, wherein in step C20), the motor Speed is increased to the target rotational Speed by looking up a table by the driver software, increasing the PWM duty ratio of the driver according to a time function by looking up a table by the driver software _Target ＝300r/min*(1/P1)/(1/P2)＝900r/min。

Example 6: the other technical solutions of this embodiment are the same as those of embodiments 1-5, except that this embodiment proposes an encoder control method of a multi-module driving system (see CN 10924343A for a specific technical solution); referring to fig. 19, the multi-module driving system includes a three-phase ac motor having a plurality of winding units and a plurality of driver units (including a first driver unit, a second driver unit, a unit of 8230; a unit of n driver, each driver unit being connected to each other in communication), each driver unit being configured to control an operation of a corresponding winding unit, the three-phase ac motor (also, a salient-pole permanent magnet synchronous motor) including an encoder mounted on a motor shaft; the encoder control method includes: the first driver unit is used as a bidirectional communication data connection between a main driver and an encoder, the main driver sends a starting and/or stopping signal to the encoder, and the encoder sends a rotor position signal to the main driver; the other driver units are in one-way communication data connection with the encoder and used for receiving rotor position signals output by the encoder; the failure rate is low, and the data communication management correspondingly applied to the multi-module driving system is realized;

preferably, in this embodiment, the communication data connection mode adopts a wired communication mode (e.g., uart or can) and/or a wireless communication mode (e.g., bluetooth, GPRS, WIF).

In view of compatible use with a multi-module driving system with hall assemblies installed, preferably, in the present embodiment, some or all of the winding units are provided with hall assemblies, and the hall assemblies are in data communication connection with their corresponding driver units; the driver unit is respectively provided with an encoder interface for accessing a first rotor position signal and an HALL interface (for accessing a Hall assembly signal of a corresponding winding unit) for accessing a second rotor position signal; referring to fig. 20, the encoder control method of the present embodiment further includes the following data determination control processes:

d10 When the driver unit receives the first rotor position signal output by the encoder and/or the second rotor position signal output by the Hall assembly;

d20 The driver unit judges whether the first rotor position signal data are matched or not according to the back electromotive force of the winding unit corresponding to the driver unit, if the judgment result is matched, the step D30 is carried out, and if the judgment result is not matched, the step D40 is carried out);

d30 The driver unit controls the operation of the corresponding winding unit based on the first rotor position signal;

d40 Judging whether the driver unit is matched with the second rotor position signal data according to the back electromotive force of the corresponding winding unit, if so, entering the step D50), and if not, judging that the multi-module driving system fails;

d50 And the driver unit performs operation control of the winding unit corresponding thereto based on the second rotor position signal.

According to the embodiment, through the data judgment control process, the universality of the multi-module driving system is good, and the fault occurrence rate of the multi-module driving system can be further reduced.

Considering that the multi-module driving system of the present embodiment has a plurality of driver units, in order to avoid many potential safety hazards caused by manual non-compliance procedures or illegal disassembly and assembly, and to improve the anti-theft performance, preferably, on the basis of using the above-mentioned encoder control method, please refer to fig. 21, the present embodiment further provides an encoder safety management method for a multi-module driving system, where the encoder uses handshake identification safety management, including: before the multi-module driving system is started, one-way handshake signals are sent to a main driver in advance, and after the main driver identifies the one-way handshake signals and sends the handshake signals back to an encoder, it is judged that each driver unit can enter the starting work; when the main driver can not send back the handshake signal, judging that the driver units are not matched with the encoders, and stopping inputting the rotor position signal to each driver unit; through this signal management of shaking hands, can carry out quick verification to the encoder before the motor starts with the matching of each driver unit, can start through verifying the rear, has promoted this embodiment multimode actuating system's safety management level effectively.

It should be noted that the multi-module driving system encoder control method and the safety management method thereof proposed in embodiment 6 can be used as a driving system of an electric two-wheeled vehicle or an electric three-wheeled vehicle, and can also be used in other driving applications requiring large power (the output power range of a three-phase ac motor is 500W-20 KW), and the embodiment is not particularly limited.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Claims (8)

1. A self-calibration control method of an encoder, wherein the encoder is arranged on a motor, and is characterized in that the encoder adopts an inductive position encoder for detecting a rotor position signal in real time, the motor adopts a driver for driving operation, and the driver performs sine wave driving control on the motor based on the rotor position signal; the encoder is subjected to self-calibration control in advance before the motor is used, wherein the self-calibration control comprises the following operation steps:

a10 Electrifying a motor provided with an encoder, and enabling the motor to be in a stable constant-speed rotation state through external force; the rotating speed range of the motor is set to be 20-80% of the rated rotating speed;

a20 Adjusting the original sine and cosine signals of an induction coil positioned in the encoder, and adjusting the output amplitude of the encoder based on the original sine and cosine signals to enable the original sine and cosine signals of the encoder in each period to reach a uniform output amplitude;

a30 Processing and calculating the output amplitude signal to be used as a zero calibration signal of the rotor position and sending the zero calibration signal to the driver;

a40 Storing the output amplitude signal in the encoder;

when the subsequent motor is started every time, the driver compares sine and cosine signals output by the induction coil in the receiving encoder with the pre-stored zero calibration signal, so that the accurate detection of the real-time position of the rotor can be realized.

2. The self-calibration control method according to claim 1, characterized in that the encoder is provided with a self-calibration key for sending an instruction to the encoder to store the output amplitude signal by pressing the self-calibration key.

3. The self-calibration control method of claim 1, wherein the motor comprises a stator assembly and a rotor assembly connected by electromagnetic induction, the rotor assembly being fixedly integrated with the motor; the encoder adopts inductive position encoder, and the encoder that includes the electromagnetic induction connection rotates module and encoder stator module, wherein, encoder rotates module fixed mounting in on the motor shaft, encoder stator module fixed mounting in stator module one end, and with driver communication connection sends the rotor position signal that obtains of calculating the driver.

4. The self-calibration control method according to claim 3, wherein the encoder rotation module is provided with a rotation module printed circuit board, the rotation module printed circuit board is provided with a conductive material scale area, the encoder stator module is provided with a stator module printed circuit board, the stator module printed circuit board is provided with an excitation coil for generating an electromagnetic field, a receiving coil for receiving induced electromotive force and a processing chip, the conductive material scale area is used for influencing the coupling relationship between the excitation coil and the receiving coil, the excitation coil generates alternating electromagnetic field strength to change the induced electromotive force on the receiving coil, the receiving coil serves as the induction coil, and the induced electromotive force signal serves as the original sine and cosine signal; after the encoder rotating module rotates for one circle relative to the encoder stator module, the receiving coil obtains original sine and cosine signals of multiple periods, and the original sine and cosine signals are calculated, processed and adjusted through the processing chip, so that the original sine and cosine signals of the encoder in each period reach a uniform output amplitude value.

5. The self-calibration control method of claim 4, wherein the rotor assembly comprises permanent magnet steel, and when the permanent magnet steel rotates, the magnetic poles of the permanent magnet steel enable the conductive material scale areas to generate eddy current fields for weakening the alternating electromagnetic field strength of the excitation coils.

6. The self-calibration control method according to claim 4, wherein the processing chip cooperates with the excitation coil to generate a high-frequency periodic alternating voltage and current, and the alternating current flowing through the excitation coil forms an alternating electromagnetic field in a peripheral region thereof; when the alternating electromagnetic field generated on the exciting coil passes through the receiving coil, the magnetic flux of the receiving coil is alternated, so that the alternating induced electromotive force with the same frequency is generated on each receiving coil.

7. The self-calibration control method of claim 6, wherein the receiving coils are annularly spaced on the rotating module printed circuit board; and all the conductive materials on the conductive material scale area are distributed on the rotating module printed circuit board at intervals in an annular shape.

8. A tricycle drive system comprising a motor on a tricycle frame and a drive for controlling the drive operation of the motor, characterised in that the motor comprises an encoder mounted on the shaft of the motor, the encoder being in communication with the drive, wherein the encoder employs a self-calibrating control method as claimed in any one of claims 1 to 7 prior to use of the motor.

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