CN115528864A - Magnetic encoder compensation system and compensation method thereof - Google Patents

Abstract

A magnetic encoder compensation system comprises a permanent magnet motor module, a load motor module, a torsion meter, a power meter and a control module. The control module controls the permanent magnet motor of the permanent magnet motor module to operate in a high rotating speed interval, and controls the load motor of the load motor module to carry out maximum torque dynamic loading on the permanent magnet motor so as to detect torque information and voltage information through the torsion meter and the electric power meter; the control module determines whether to perform zero compensation on the magnetic encoder according to the torque information and the voltage information, calculates a compensation angle according to the zero angle, and performs burning on the magnetic encoder of the permanent magnet motor module according to the compensation angle. The invention also relates to a compensation method of the magnetic encoder.

Description

Magnetic encoder compensation system and compensation method thereof

Technical Field

The invention relates to a magnetic encoder compensation system and a compensation method thereof, in particular to a magnetic encoder compensation system and a compensation method thereof for carrying out zero angle fine adjustment and burning correction through dynamic loading.

Background

As shown in fig. 1, the conventional magnetic encoder compensation system 100a includes a permanent magnet motor module 200, a load motor module 1, and a control module 4. The permanent magnet motor module 200 includes a permanent magnet motor 202 and a magnetic encoder 204 therein, and the load motor module 1 includes a load motor 12 and a high-precision encoder 18. Since the permanent magnet motor module 200 must meet predetermined specifications before shipment from the factory, the angle of the magnetic encoder 204 must be corrected before shipment from the factory. However, in the prior art, the load motor 12 of the load motor module 1 drives the permanent magnet motor 202 of the permanent magnet motor module 200 to rotate through the coupler 12A, and after the signal comparison is performed between the high-precision encoder 18 in the load motor module 1 and the magnetic encoder 204 of the permanent magnet motor 202 to be tested, the angle correction and compensation of the magnetic encoder 204 are performed. However, this method can only correct the angle of the magnetic encoder 204, and after the method is actually assembled in a motor driving system, the overall output performance is still insufficient due to various errors. Moreover, the use of a high precision encoder 18 also increases the cost of construction of the magnetic encoder compensation system 100 a.

Specifically, the magnetic encoder 204 itself has a different concentricity with respect to the rotation axis after assembly, and even a controller of the same model has a signal delay condition and an error. Therefore, even under the same process condition and the same motor controller is used for driving the same batch of permanent magnet motors, the performance of each permanent magnet motor still has a slight difference.

Due to the above disadvantages, even if the same material and the same process are used, the output performance of each permanent magnet motor module 200 cannot be completely consistent, or even a part of the output performance is lower than the specification performance and cannot reach the standard, so that the permanent magnet motor module 200 needs to be reworked or even scrapped. However, most likely, this is due only to the offset of the position signal of the magnetic encoder 204.

Therefore, how to perform the angle fine adjustment and burning correction of the magnetic encoder through data collection under dynamic loading to ensure the consistency of the performance of the permanent magnet motor module, thereby achieving the purposes of reducing the cost of heavy work and working hours and unnecessary scrap loss is a subject to be studied by the inventor of the present disclosure.

Disclosure of Invention

To solve the above problems, the present invention provides a magnetic encoder compensation system to overcome the problems of the prior art. Therefore, the magnetic encoder compensation system comprises a permanent magnet motor module, a load motor module, a torsion meter, a power meter and a control module. The permanent magnet motor module comprises a permanent magnet motor, a permanent magnet motor driver and a magnetic encoder, and the load motor module comprises a load motor and a load motor driver. The power meter is coupled with the permanent magnet motor driver, the torsion meter is coupled with the permanent magnet motor, the load motor and the power meter, and the control module is coupled with the permanent magnet motor module, the load motor module and the power meter. The control module controls the permanent magnet motor to operate in a high rotating speed range between a rated rotating speed and a maximum rotating speed through the permanent magnet motor driver, controls the load motor to operate through the load motor driver so as to dynamically load the maximum torque on the permanent magnet motor, detects torque information corresponding to the permanent magnet motor in the high rotating speed range through the torsion meter, and detects voltage information corresponding to the permanent magnet motor driver in the high rotating speed range through the power meter. The control module compares the torque information with the torque standard and compares the voltage information with the voltage standard to judge whether the performance of the permanent magnet motor reaches the standard, if one of the torque information and the voltage information does not reach the standard, the control module reads the zero angle of the magnetic encoder, calculates the compensation angle corresponding to the zero angle based on the zero compensation control, and burns the magnetic encoder according to the compensation angle.

To solve the above problems, the present invention provides a compensation method for a magnetic encoder to overcome the problems of the prior art. Therefore, the magnetic encoder compensation method of the present invention comprises: (a) And controlling the permanent magnet motor to operate in a high rotating speed range from the rated rotating speed to the maximum rotating speed. (b) The load motor is controlled to run so as to carry out maximum torque dynamic loading on the permanent magnet motor, and meanwhile, torque information corresponding to a high rotating speed interval of the permanent magnet motor is obtained, and voltage information corresponding to a high rotating speed interval of a permanent magnet motor driver for driving the permanent magnet motor is obtained. (c) disabling the permanent magnet motor drive. (d) Comparing the torque information with the torque standard, and comparing the torque information with the voltage standard. (e) Judging whether the performance of the permanent magnet motor reaches the standard according to the comparison result of the step (d), wherein the step (d) comprises the following steps of: (e1) And if the torque information reaches the torque standard and the voltage information reaches the voltage standard, judging that the performance of the permanent magnet motor reaches the standard and judging that the permanent magnet motor is qualified and accepted. (e2) And if the torque information does not reach the torque standard and the voltage information does not reach the voltage standard, judging that the performance of the permanent magnet motor does not reach the standard and judging that the defective product is returned. And (e 3) if one of the torque information and the voltage information does not reach the standard, judging that the magnetic encoder assembled with the permanent magnet motor needs to carry out zero point compensation, reading the zero point angle of the magnetic encoder, calculating the compensation angle corresponding to the zero point angle based on zero point compensation control, and carrying out burning on the magnetic encoder according to the compensation angle. And (f) repeating the steps (a) to (e 3) to determine whether the performance of the permanent magnet motor reaches the standard.

The invention mainly aims to correct dynamic errors through a maximum torque dynamic loading performance test in a high rotating speed interval, slightly corrects the compensation quantity of the zero angle of the magnetic encoder and records the compensation quantity in the magnetic encoder, and further realizes the technical effect of ensuring the performance of the permanent magnet motor to be completely consistent with the mass production performance.

For a further understanding of the technology, means, and technical effects of the invention to achieve the intended purpose, reference should be made to the following detailed description of the invention and accompanying drawings which are believed to be a further and specific understanding of the objects, features, and characteristics of the invention, and to the accompanying drawings which are provided for reference and illustration purposes only and are not intended to be limiting of the invention.

Drawings

FIG. 1 is a circuit block diagram of a prior art magnetic encoder compensation system;

FIG. 2 is a circuit block diagram of a magnetic encoder compensation system for calibrating a magnetic encoder in accordance with the present invention;

FIG. 3A is a vector diagram illustrating a first embodiment of the basic principle of magnetic compensation according to the present invention;

FIG. 3B is a vector diagram illustrating a second embodiment of the basic principle of magnetic encoding compensation of the present invention;

FIG. 3C is a vector diagram illustrating a third embodiment of the basic principle of magnetic encoding compensation of the present invention;

FIG. 4 is a graphical illustration of the torque specific gravity of the present invention;

FIG. 5 is a flow chart of a magnetic encoder compensation method of the present invention;

FIG. 6 is a detailed implementation of the compensation method of the magnetic encoder of the present invention;

FIG. 7A is a graph of a torque analysis under test validation of the magnetic encoder compensation method of the present invention; and

FIG. 7B is a voltage analysis graph under test verification of the compensation method of the magnetic encoder of the present invention.

Description of reference numerals:

100a, 100b 8230and magnetic encoder compensating system

1\8230andload motor module

12 \ 8230and load motor

14 method 8230and load motor driver

16 \ 8230and load motor coder

18' 8230a high-precision encoder

12A, 12B 8230and coupling

2-8230and torsion meter

3 8230a power meter

4 \ 8230and control module

42 \ 8230and controller

44 \ 8230and writing device

46 \8230andswitch

200 \ 8230and permanent magnet motor module

202 \ 8230and permanent magnet motor

204 8230a magnetic encoder

206 \ 8230and permanent magnet motor driver

Pd \8230anddriving power supply

Ss (s 823000)

Sc \8230andcontrol signal

T _info 8230and torsion information

V _info 8230and voltage information

Spd _cmd 823080 rotation speed command

Spd _MAX 823080 maximum rotation speed

Spd _rated 823080 rated rotation speed

T _cmd 8230am Torque command

T _real 8230and practical torsion

T _target 8230a torque threshold value

T _coefficient 8230and torsion coefficient

V _real 823080 and practical voltage

V _Limit 8230and voltage threshold

Aw(ZeroOffset _write ) 8230a magnetic encoding angle after compensation

Az(ZeroOffset _read ) 823080 and zero angle

Ac(ZeroOffset _compensate ) 823080 and compensating angle

Pa \8230andangle parameter

E8230and back electromotive force

I8230and electric current

Theta 8230and included angle

Z \8230impedance

Step 8230, (S100) - (S600)

Curves 823060, test 1-Test 3

Detailed Description

The technical content and the detailed description of the invention are described as follows with the accompanying drawings:

FIG. 2 is a block diagram of a circuit for calibrating a magnetic encoder compensation system of a magnetic encoder according to the present invention, as shown in FIG. 1. The magnetic encoder compensation system 100b includes a permanent magnet motor module 200, a load motor module 1, a torsion meter 2, an electrometer 3, and a control module 4, and the magnetic encoder compensation system 100b is used to perform pre-calibration and test operations before the permanent magnet motor module 200 leaves the factory, so as to ensure that the permanent magnet motor module 200 can meet the standard of performance specification when leaving the factory, and if not, the magnetic encoder 204 needs to be burned to finely tune the angle of the magnetic encoder 204 so as to make the performance of the permanent magnet motor 202 reach the standard, and if the performance of the permanent magnet motor 202 does not reach the standard after continuous adjustment for several times, the permanent magnet motor 202 needs to be ejected. The permanent magnet motor module 200 includes a permanent magnet motor 202, a magnetic encoder 204, and a permanent magnet motor driver 206, and the permanent magnet motor driver 206 is coupled to the permanent magnet motor 202 and the magnetic encoder 204. Wherein the magnetic encoder 204 is assembled with the permanent magnet motor 202. The permanent magnet motor driver 206 drives the permanent magnet motor 202 to rotate through the driving power source Pd, and the magnetic encoder 204 detects the position of the rotor of the permanent magnet motor 202 to provide the detection signal Ss. The permanent magnet motor module 200 mainly uses a field weakening technique to control the permanent magnet motor 202, so as to achieve better performance of the permanent magnet motor 202 at a high rotation speed.

The load motor module 1 includes a load motor 12, a load motor driver 14 and a load motor encoder 16, and the load motor driver 14 couples the load motor 12 and the load motor encoder 16. The load motor driver 14 controls and adjusts the driving power Pd (i.e., voltage and current) of the load motor 12 according to the detection signal Ss. The load motor 12 is coupled to the permanent magnet motor 202 to dynamically load the permanent magnet motor 202 with maximum torque. In an easy implementation manner, the load motor 12 is mechanically connected to the permanent magnet motor 202 through the coupling 12B, so as to perform the pre-calibration and test operation of maximum torque dynamic loading by connecting the permanent magnet motor 202 through the coupling 12B.

The torsion meter 2 is coupled to the permanent magnet motor 202, the load motor 12 and the power meter 3, and is used for detecting the torsion of the permanent magnet motor 202 to provide an actual torsion T _real . The power meter 3 is coupled to the permanent magnet motor driver 206 and is used for detecting the voltage on the permanent magnet motor driver 206 for driving the permanent magnet motor 202 to provide an actual voltage V _real And obtaining voltage information V by calculation _info And applying the actual torque T _real Calculated as torque information T _info . The control module 4 is coupled to the permanent magnet motor module 200, the load motor module 1 and the power meter 3, and performs pre-calibration and testing operations of the permanent magnet motor module 200 by controlling the permanent magnet motor module 200 and the load motor module 1. Specifically, the control module 4 controls the operation of the permanent magnet motor 202 by controlling the permanent magnet motor driver 206 and the load motor 12 by controlling the load motor driver 14. When the permanent magnet motor 202 and the load motor 12 are running, the control module 4 receives the torque information T _info And voltage information V _info The operating conditions of the permanent magnet motor 202 and the permanent magnet motor driver 206 are known to determine whether the permanent magnet motor module 200 is good.

Further, when the permanent magnet motor module 200 is assembled, the zero point compensation of the magnetic encoder 204 is performed first by using a dc positive method to correct the static error of the permanent magnet motor module 200. However, the permanent magnet motor module 200 after static error correction still causes the reference position signal to shift due to component dimensional tolerance, material performance variation, and assembly variation. The reference position signal offset is usually caused by the delay of signal transmission, which is the dynamic error of the permanent magnet motor module 200. In the permanent magnet motor module 200 controlled by the flux weakening technique, due to the effect of the current control, the dynamic error generates a significant amount of error for the performance of the permanent magnet motor 202, and especially at high rotation speed, the accuracy requirement for the position feedback is extremely high. At higher rotational speeds or deeper low magnetic conditions, the dynamic error will be greatly amplified, causing the feedback position of the magnetic encoder 204 to be misaligned. Therefore, the main object and technical effect of the present invention is to achieve the technical effect of ensuring that the performance of the permanent magnet motor 202 is fully consistent with the mass production performance by correcting the dynamic error through a maximum torque dynamic loading performance test (for example, but not limited to, 3000rpm or more) at a high rotation speed to slightly correct the zero point angle Az of the magnetic encoder 204.

Referring to fig. 1 again, the control module 4 controls the permanent magnet motor driver 206 through the control signal Sc to control the permanent magnet motor 202 to operate at the maximum rotation speed. In practice, the signal error can be effectively obtained even when the permanent magnet motor is running fast enough to perform dynamic error compensation, so that the control module 4 controls the permanent magnet motor 202 to operate in a high rotation speed range from the rated rotation speed to the maximum rotation speed. The control module 4 also controls the load motor 12 by controlling the load motor driver 14 via the control signal Sc such that the load motor 12 dynamically loads the permanent magnet motor 202 with maximum torque via the coupling 12B. Then, the torque meter 2 detects the actual torque T of the permanent magnet motor 202 operating in the high speed range _real The wattmeter 3 detects the actual voltage V output by the permanent magnet motor driver 206 when the permanent magnet motor 202 is operating in the high speed region _real And is calculated to provide voltage information V _info And will the actual torque force T _real Calculated as torque information T _info . Specifically, the torsion meter 2 is disposed between the coupling 12B and the permanent magnet motor 202, and the torsion meter 2 is electrically connected to electric powerAnd (3) counting. The torsion meter 2 detects the actual torque T of the permanent magnet motor 202 _real And is supplied to the power meter 3, the power meter 3 will real torque force T _real Calculated as torque information T _info And the wattmeter 3 will transmit the torque force information T _info And voltage information V _info And is provided to the control module 4.

The control module 4 receives the torque force information T _info And voltage information V _info And according to the torque information T _info Determining the corresponding actual torque T _real Whether the torque standard is met or not and according to the voltage information V _info Determine the corresponding actual voltage V _real Whether the voltage standard is met. That is, the control module 4 is based on the torque information T _info And voltage information V _info Whether the performance of the permanent magnet motor 202 meets the torque standard and the voltage standard, respectively, is determined to adjust (fine tune) the zero angle Az of the magnetic encoder 204. Specifically, the torque standard is that the permanent magnet motor 202 is designed according to a predetermined torque standard, the torque information T _info Greater than or equal to a predetermined torque criterion representing an actual torque T _real Greater than or equal to a predetermined torque threshold. The voltage standard is a predetermined voltage standard designed by the permanent magnet motor driver 206, and the voltage information V _info Less than or equal to a predetermined voltage criterion represents the actual voltage V _real Less than or equal to a predetermined voltage threshold. The magnetic encoder compensation system 100b of the present invention primarily adjusts and validates the torque information T _info Reach the torque standard and confirm the voltage information V _info The voltage criteria are met to obtain an angle parameter Pa meeting the torsion and voltage criteria, where the angle parameter Pa includes a compensated magnetic encoding angle Aw required for writing to the magnetic encoder 204.

When the control module 4 is based on the torque information T _info Determining the actual torque T _real Reaches the torque standard and is based on the voltage information V _info Determine the actual voltage V _real When the voltage standard is reached, the control module 4 determines that the performance of the permanent magnet motor 202 of the permanent magnet motor module 200 reaches the standard, so that the permanent magnet motor module 200 is determined as good (i.e. the calibration and test of the magnetic encoder 204 is completed and the test before the factory is finished)Trial).

When the control module 4 is based on the torque information T _info Determining the actual torque T _real Not meeting the torque standard or according to the voltage information V _info Determine the actual voltage V _real If the voltage standard is not met, the angle parameter Pa to be compensated and adjusted needs to be calculated if any of the above conditions occurs, wherein the angle parameter Pa includes a compensated magnetic encoding angle Aw required for writing into the magnetic encoder 204. Then, the calculated angle parameter Pa is written into the magnetic encoder 204, for example, in a burning manner, so as to adjust the angle of the magnetic encoder 204 and compensate the performance of the permanent magnet motor 202. Further, the control module 4 includes a controller 42 and a writing device 44. The controller 42 is coupled to the permanent magnet motor module 200, the load motor module 1, the torsion meter 2 and the power meter 3, and is configured to read the zero angle Az from the magnetic encoder 204 and the torsion information T provided by the power meter 3 _info And calculating an angle parameter Pa with the torque standard. The write device 44 (for example, but not limited to, a writer or other device with a write function) is coupled to the controller 42 and the magnetic encoder 204, and is used for writing the angle parameter Pa into the magnetic encoder 204 to adjust (i.e., fine-tune) the zero-point angle Az of the magnetic encoder 204 for zero-point compensation. The calculation method of the angle parameter Pa is mainly to read the zero angle Az of the magnetic encoder 204 by detecting the permanent magnet motor module 200, and the control module 4 reads the zero angle Az according to the actual torque T _real The torque error with the torque threshold (i.e., the torque criterion) generates the compensation angle Ac, the sum of the zero-point angle Az and the compensation angle Ac is calculated as the angle parameter Pa, and the angle parameter Pa is written into the magnetic encoder 204. In one embodiment, the power meter 3 is coupled to the controller 42 of the control module 4.

However, in some cases, the permanent magnet motor module 200 may be defective during assembly, so that the permanent magnet motor 202 of the permanent magnet motor module 200 may not be able to reach the standard regardless of the adjustment. Thus, the control module 4 can preset a predetermined number of times to repeatedly calibrate the magnetic encoder 204. After the control module 4 repeatedly writes different angle parameters Pa into the magnetic encoder 204 for a predetermined number of times, if the performance of the permanent magnet motor 202 of the permanent magnet motor module 200 cannot reach the standard all the time, it is determined that the permanent magnet motor module 200 is a defective product (NG) returning piece.

The control module 4 may optionally further include a switch 46. The switch 46 is coupled between the writing device 44 and the magnetic encoder 204, and when the writing device 44 intends to write the angle parameter Pa into the magnetic encoder 204, the controller 42 controls the switch 46 to be turned on, so that the angle parameter Pa can be written into the magnetic encoder 204. When it is not necessary to write the angle parameter Pa to the magnetic encoder 204, the controller 42 controls the switch 46 to be turned off to open the path between the writing device 44 and the magnetic encoder 204. It is worth mentioning that, since the testing platform of the compensation system 100b of the present invention can perform the calibration of the magnetic encoder 204 and the actual torque T of the permanent magnet motor 202 at the same time _real Actual voltage V of permanent magnet motor driver 206 _real Thus, only a single platform is required to complete the testing and calibration of the permanent magnet motor module 200. In contrast to the prior art magnetic encoder compensation system 100a of FIG. 1, which can only be calibrated for the magnetic encoder 204, the voltage and torque testing of the permanent magnet motor module 200 requires another platform for testing again. Therefore, compared to the prior art of FIG. 1, the magnetic encoder compensation system 100b of the present invention can achieve the technical effect of saving the testing and calibration time.

Please refer to fig. 3A to 3C, which are vector diagrams of the basic principles of magnetic encoding compensation (the first to third embodiments) of the present invention, and refer to fig. 2. In fig. 3A to 3C, the vertical axis is q-axis, the horizontal axis is d-axis, and the vectors of the back electromotive force E and the current I of the permanent magnet motor module 200 are shown in fig. 3A to 3C, respectively. FIG. 3A assumes that the magnetic encoder provides the best reference of the origin at 70 degrees, and FIGS. 3B-3C are magnetic encoders that have been angularly offset, respectively. In fig. 3A, an angle θ between the back electromotive force E and the current I (i.e. the compensated magnetic programming angle Aw for programming the magnetic encoder 204) is 70 degrees. Since the voltage V = E + Z × I (where Z is impedance), the magnitude of the voltage V vector varies with the magnitude of the angle θ without changing the magnitude of the impedance Z vector. In fig. 3B and 3C, the included angle θ is assumed to be shifted from 70 degrees to 80 degrees and 60 degrees, respectively. As shown in fig. 3B, when the origin reference provided by the magnetic encoder is shifted from 70 degrees to 80 degrees, the included angle θ between the current I and the back-emf E varies. Resulting in a reduction in the required voltage V and an increase in the maximum rotational speed of the permanent magnet motor 202. Conversely, as shown in fig. 3C, when the origin reference provided by the magnetic encoder is shifted from 70 degrees to 60 degrees, the required voltage V increases, and the maximum rotation speed of the permanent magnet motor 202 decreases.

FIG. 4 is a schematic diagram of a torque specific gravity curve of the present invention, as shown in FIGS. 2-3C. The output torque performance of the permanent magnet motor 202 is significantly related to the included angle θ between the back electromotive force E and the current I, and the following mathematical calculation formula can be referred to:

T _e ＝λ _E ×I _q →T _e ＝λ _E ×I×cosθ…(1)

wherein T is _e Is an electromagnetic torque, and T _r Is reluctance torque, its resultant total torque T _t As shown in dashed lines in fig. 4. It is obvious that when the reference position of the magnetic encoder 204 is shifted, the included angle θ will be changed, which causes the output torque performance of the permanent magnet motor 202 to be varied. Therefore, the actual torque T can be known _real Magnitude of (i.e. total torque T) _t Magnitude) and actual voltage V _real Is proportional to the magnitude of (i.e. voltage V in fig. 3 a-3 c). However, in practical applications, since the permanent magnet motor 202 is operated in the high speed range, the actual voltage V of the permanent magnet motor driver 206 is _real The voltage specification of the permanent magnet motor module 200 (e.g., without limitation, the voltage specification of the internal components) cannot be exceeded, which would risk runaway. Therefore, the control module 4 is in the actual torque T _real Reaches the torque standard and has the actual voltage V _real In the case of a voltage criterion also being reached, the actual voltage V is optionally reduced by adjusting (trimming) the angle parameter Pa _real (actual torque T at this time) _real And subsequently decreased) but still meet the torque and voltage standards. Thus, the technical effect of improving the voltage margin of the permanent magnet motor module 200 specification can be achieved. On the other hand, when the control module 4 is judgingInterstagon torsion T _real Not reaching the torque threshold and simultaneously the actual voltage V _real If the voltage threshold is not reached, it is determined that the permanent magnet motor module 200 is rejected as defective (NG).

Fig. 5 is a flow chart of a motor operation method of the compensation method of the magnetic encoder of the present invention, which is combined with fig. 2-4. The magnetic encoder compensation method is used for correcting the magnetic encoder 204 of the permanent magnet motor module 200, and the magnetic encoder compensation method includes performing zero point correction with a relatively large angle on the magnetic encoder 204 after the permanent magnet motor 202 and the magnetic encoder 204 are assembled (S100). When the permanent magnet motor module 200 is assembled, the zero position of the magnetic encoder 204 is corrected first by using a dc positive method, so as to correct the static error of the permanent magnet motor module 200. This step is not a necessary step, and the requirements of the actual permanent magnet motor module 200 during assembly are all considered. The permanent magnet motor 202 is then docked with the load motor 12. Preferably, the load motor 12 mechanically docks the permanent magnet motor 202 via the coupling 12B to enable pre-calibration and testing operations for maximum torque dynamic loading of the permanent magnet motor 202 via the coupling 12B, as will be described in detail later.

Then, the permanent magnet motor 202 is controlled to operate at the rated rotation speed Spd _rated To a maximum speed of rotation Spd _MAX A high rotation speed interval (S120) defined therebetween. Preferably, the control module 4 controls the permanent magnet motor 202 to operate at the rated rotation speed Spd by controlling the permanent magnet motor driver 206 _rated To the maximum speed Spd _MAX The high speed interval in between, makes permanent magnet motor 202 enough fast operation and can effectively obtain the signal error and carry out dynamic error compensation. Then, the control module 4 controls the load motor 14 to operate by controlling the load motor driver 14 to perform the maximum torque dynamic loading on the permanent magnet motor 202, and obtains the torque information T corresponding to the permanent magnet motor 202 in the high rotation speed interval when the permanent magnet motor 202 stably operates at a specific speed in the high rotation speed interval _info And when the permanent magnet motor 202 is operated in the high rotation speed interval, the voltage information V corresponding to the permanent magnet motor driver 206 _info (S140). Preferably, the implementation mode isThe control module 4 controls the load motor 12 by controlling the load motor driver 14 to dynamically load the permanent magnet motor 202 with maximum torque through the coupling 12B. Then, the torque meter 2 detects the actual torque T of the permanent magnet motor 202 operating in the high speed range _real And is supplied to the wattmeter 3, the wattmeter 3 will real torsion T _real Calculated as torque information T _info The wattmeter 3 detects the actual voltage V output by the driver 206 when the permanent magnet motor 202 is operating in the high speed region _real Calculated to provide voltage information V _info . Finally, the wattmeter 3 sends the torque information T _info And voltage information V _info And provided to the controller 42.

Then, the permanent magnet motor driver 206 is disabled (S160). Preferably, the permanent magnet motor driver 206 is powered off or stopped to control the permanent magnet motor driver 206 with the control signal Sc, and the permanent magnet motor driver 206 is confirmed to be powered off, and the permanent magnet motor 202 and the magnetic encoder 204 are confirmed to be stopped. Preferably, the load motor 12 should also be controlled to stop for accurate detection. The purpose of disabling the permanent magnet motor driver 206 is to enable the control module 4 to accurately calculate an angle parameter Pa, and write the angle parameter Pa into the encoder 204, for example, by burning, to complete the angle correction of the magnetic encoder 204 and the performance compensation of the permanent magnet motor 202, wherein the angle parameter Pa includes a compensated magnetic encoding angle Aw required for writing into the magnetic encoder 204.

Then, according to the torque information T _info Comparing with torque standard and according to voltage information V _info Comparing with the voltage standard to determine whether the performance of the permanent magnet motor 202 reaches the standard (S200). Preferably, the control module 4 receives the actual torque T provided by the torque meter 2 through the power meter 3 when the permanent magnet motor 202 and the load motor 12 are running _real And the calculated torque force information T _info With the wattmeter 3 at the actual voltage V _eral Calculated provided voltage information V _info According to the torque information T _info Determining the corresponding actual torque T _real Whether the torque reaches the torque standard or not and according to the voltage information V _info Determine what corresponds toActual voltage V of _real Whether the voltage standard is met. Specifically, the torque standard is that the permanent magnet motor 202 is designed according to a predetermined torque standard, the torque information T _info Greater than or equal to the predetermined torque criterion representing the actual torque T _real Greater than or equal to a predetermined torque threshold. The voltage standard is the predetermined voltage specification, voltage information V, of the permanent magnet motor driver 206 according to design _info The voltage criterion less than or equal to the predetermined voltage is representative of the actual voltage V _real Less than or equal to a predetermined voltage threshold.

Then, if the torque information T _info Reach the torque standard and the voltage information V _info When the voltage standard is met, the performance of the permanent magnet motor 202 is determined to be up to standard and the permanent magnet motor 202 and the magnetic encoder 204 assembled therewith are determined to be acceptable (S220). In detail, when the control module 4 is based on the torque information T _info Determining the actual torque T _real Reaches the torque standard and is based on the voltage information V _info Determine the actual voltage V _real When the voltage standard is reached, the control module 4 judges that the motor performance of the permanent magnet motor module 200 reaches the standard, so that the permanent magnet motor module 200 can be determined as a good product (i.e., the calibration and test operations of the magnetic encoder 204 are completed and the test before the factory shipment is passed). In step (S220), the actual torque T can be optionally included _real Reaches the torque standard and has the actual voltage V _real When the voltage standard is reached, the actual torque T is reduced by adjusting the angle parameter Pa _real And the actual voltage V _real . In practice, since the permanent magnet motor 202 operates in the high speed range, the actual voltage V of the permanent magnet motor driver 206 _real Low and therefore less likely to exceed the voltage specifications of the permanent magnet motor module 200 (e.g., without limitation, the voltage specifications of the internal components), and the risk of runaway may be avoided. It should be noted that the control module 4 is in the actual torque T _real Reach the standard of torsion and the actual voltage V _real In the case of also reaching the voltage standard, the actual voltage V is reduced by adjusting (trimming) the angle parameter Pa _real (actual torsion T) _real And then decreased), but it still needs to meet the torque standard and voltage standard, so as to achieve the goal of increasing the permanent magnet motorA technical effect of the voltage margin of the module 200 specification, wherein the angle parameter Pa includes a compensated magnetic encoding angle Aw required for writing to the magnetic encoder 204.

Then, if the torque information T _info Does not reach the torque standard and simultaneously has voltage information V _info If the voltage level is not reached, the performance of the permanent magnet motor 202 is determined to be not reached and the permanent magnet motor 202 and the magnetic encoder 204 are determined to be defective (S240). In detail, when the control module 4 is in the state of being based on the torque information T _info Determining the actual torque T _real Does not reach the torque threshold value and simultaneously is based on the voltage information V _info Determine the actual voltage V _real If the voltage threshold is not reached, it is determined that the permanent magnet motor module 200 is a defective (NG) reject.

Then, if the torque information T _info And voltage information V _info If one of the two signals does not reach the standard, it is determined that the magnetic encoder 204 needs to perform zero point compensation, and the control module 4 reads a zero point angle Az of the magnetic encoder 204 in cooperation with the torque information T _info And calculating a compensation angle Ac of the magnetic encoder 204 based on the zero point compensation control in the torsion standard, and burning the magnetic encoder 204 according to the compensation angle Ac to realize the zero point compensation of the magnetic encoder 204 (S260). In a preferred embodiment, the control module 4 includes a controller 42 and a writing device 44. The controller 42 controls the torque according to the zero angle Az and the torque information T _info The controller 42 calculates an angle Pa to the write device 44 according to the zero angle Az and the compensation angle Ac, and the write device 44 writes the angle Pa into the magnetic encoder 204 by burning or other methods to adjust (i.e. fine-tune) the zero angle Az of the magnetic encoder 204 for zero compensation. The angle parameter Pa is preferably calculated by reading the zero point angle Az of the magnetic encoder 204 by detecting the permanent magnet motor module 200, and the control module 4 reads the zero point angle Az according to the actual torque T _real The torsion error calculation with the torsion threshold (i.e., the torsion criteria) generates the compensation angle Ac, such that the sum of the zero-point angle Az and the compensation angle Ac is calculated as the angle parameter Pa, wherein the angle parameter Pa includes a compensated value required for writing to the magnetic encoder 204Magnetic encoding angle Aw. The compensation angle Ac calculated by the zero point compensation in the step (S260) is set to compensate the performance of the permanent magnet motor 202, and the compensation angle Ac calculated by the zero point compensation in the step (S100) is set to be smaller than the adjustment angle by the zero point correction.

Then, the steps (S120) to (S260) are repeated to repeatedly fine-tune the angle of the magnetic encoder 204 and confirm whether the performance of the permanent magnet motor 202 reaches the standard (S280). In the loop from the step (S120) to the step (S260), if the performance of the permanent magnet motor 202 reaches the standard after the adjustment, the process ends at the step (S220). Conversely, if the torque information T _info And voltage information V _info If one of the angles is not reached to the standard after the previous adjustment, the step (S260) is repeated to burn the magnetic encoder 204 again to adjust the zero point angle Az again. Finally, after the adjustment from the step (S120) to the step (S260) is repeatedly performed for a predetermined number of times, and the performance of the permanent magnet motor 202 is not yet met, it is determined as a defective item rejected (S300). It should be noted that, in some cases, the permanent magnet motor module 200 may have defects during manufacturing or assembling, so that the permanent magnet motor module 200 may not meet the performance standard regardless of the alignment. Therefore, the control module 4 can preset a predetermined number of times to repeatedly calibrate the magnetic encoder 204. After the control module 4 performs the burning process on the magnetic encoder 204 to perform the zero point compensation for a predetermined number of times, if the performance of the permanent magnet motor 202 of the permanent magnet motor module 200 cannot reach the standard all the time, it is determined that the permanent magnet motor 202 is a defective (NG) rejected component.

FIG. 6 is a detailed implementation diagram of the compensation method of the magnetic encoder according to the present invention, referring to FIGS. 2-5, and referring back to FIG. 5. In step (S400), the magnetic encoder compensating system 100b performs the maximum torque dynamic loading test and executes steps (S100) to (S160) of fig. 5. The control module 4 controls the permanent magnet motor driver 206 to provide the spin speed command Spd _cmd The permanent magnet motor 202 is driven to the rated speed Spd _rated To the maximum speed Spd _MAX In the high speed interval, and the maximum torque dynamic is performed when the permanent magnet motor 202 stably operates at a specific speed in the high speed intervalLoad and at the same time cause the permanent magnet motor driver 206 to provide a torque command T _cmd The torque output of the permanent magnet motor 202 is controlled to 100%. In step (S420), the step (S200) of fig. 5 is executed to determine the actual torque T respectively _real Whether or not it is greater than or equal to a predetermined torque threshold T _target True voltage V _real Whether or not it is less than or equal to a predetermined voltage threshold V _Limit . In step (S440), the performance of the permanent magnet motor 202 is determined to be acceptable. In step (S460), the actual torque T _real With the actual voltage V _real The standard is not met, so that the permanent magnet motor module 200 is directly judged as a defective goods (NG) rejected piece. In steps (S480-1) and (S480-2), the actual torque T is applied _real With the actual voltage V _real So that the correction steps of the steps (S500) to (S560) are continued.

In step (S500), the controller 42 receives the actual torque T provided by the torsion meter 2 through the electric power meter 3 _real And apply the actual torque T _real Calculated as torque information T _info Torque information T provided from the wattmeter 3 to the controller 42 _info Voltage information V _info And zero angle ZeroOffset provided by magnetic encoder 204 _read (Az) to prepare for subsequent calculation of the angle parameter Pa. In step (S520), the controller 42 calculates the compensation angle of the magnetic encoder 204 to be compensated as: zeroOffset _compensate (Ac)＝(T _real -T _target )T _coefficient . Wherein, T _coefficient Is a torsion coefficient T _coefficient May be obtained by analog analysis of controller 42. In step (S540), the controller 42 calculates the compensated magnetic encoding angle Aw to be written into the magnetic encoder 204 as: zeroOffset _write (Aw)＝ZeroOffset _read (Az)-ZeroOffset _compensate 。

In step (S560), the control module 4 compensates the angle ZeroOffset according to _compensate The corresponding angle parameter Pa is calculated by writing the angle parameter Pa into the magnetic encoder 204 via the writing device 44 to adjust (i.e., fine tune) the angle of the magnetic encoder 204 and compensate for the permanent magnetThe performance of the motor 202. After the step (S560) is completed, the process proceeds to a step (S580) to determine whether the angle parameter Pa has been written to the magnetic encoder 204 a predetermined number of times. If so, it is determined that the permanent magnet motor module 200 is a defective item (NG) rejected item (S600). If not, the process returns to step (S400), where the angle parameter Pa includes a compensated magnetic encoding angle Aw required for writing to the magnetic encoder 204.

Fig. 7A is a torsion analysis diagram of the magnetic encoder compensation method according to the present invention under test and verification, and fig. 7B is a voltage analysis diagram of the magnetic encoder compensation method according to the present invention under test and verification, which are combined with fig. 2 to 6, and refer to fig. 7A and 7B in reverse. In fig. 7A, it is confirmed that the torque output specification of the permanent magnet motor 202 is greater than 6Nm in the high rotation speed range (9000 rpm), and it is ensured that the performance of the permanent magnet motor 202 can be reached when the rotation speed of the permanent magnet motor is lower than 9000 rpm. Similarly, in fig. 7B, the voltage output specification defined to meet the specification is less than 35V to ensure that the permanent magnet motor driver 206 does not lose control of the system due to the over-voltage during each rotation speed operation.

In fig. 7A and 7B, for example, when the permanent magnet motor 202 is operated at 9000rpm, the curve Test1 of the Test result satisfies the performance specification due to the voltage, but the torque does not satisfy the performance specification ((e.g., torque: 5.58Nm, voltage: 31.28V), the zero-point angle Az should be adjusted by the zero-point compensation to correct the performance of the permanent magnet motor module 200. The curve Test2 of the Test result satisfies the performance specification due to the torque, but the voltage is greater than the performance specification (torque: 6.5Nm, voltage: 35.1V), the zero-point angle Az should be adjusted by the zero-point compensation to correct the performance of the permanent magnet motor module 200. The curve Test3 of the Test result is again tested after the zero-point angle Az is adjusted by the zero-point compensation, and both the torque and the voltage meet the performance specification (torque: 6.3Nm, voltage: 34.217V), which proves that the compensation mechanism of the present invention can effectively improve the performance of the permanent magnet motor module 200.

According to the magnetic encoder compensation system and the magnetic encoder compensation method provided by the invention, the dynamic error is corrected through the maximum torque dynamic loading performance test in a high rotating speed interval, the compensation quantity of the zero point angle of the magnetic encoder is slightly corrected and is burnt in the magnetic encoder, and the technical effect of ensuring the performance of the permanent magnet motor to completely exert the consistency with the mass production performance is further realized.

It should be understood, however, that the detailed description and drawings are only for the purpose of illustrating preferred embodiments of the present invention and that the invention is not limited thereto, since the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention.

Claims (11)

1. A magnetic encoder compensation system, comprising:

a permanent magnet motor module, including a permanent magnet motor, a permanent magnet motor driver and a magnetic encoder;

a load motor module including a load motor and a load motor driver;

a power meter coupled to the permanent magnet motor driver;

a torque meter coupled to the permanent magnet motor, the load motor and the wattmeter; and

a control module coupled to the permanent magnet motor module, the load motor module and the power meter;

the control module controls the permanent magnet motor to operate in a high rotation speed interval between a rated rotation speed and a maximum rotation speed through the permanent magnet motor driver, controls the load motor to operate through the load motor driver so as to perform maximum torque dynamic loading on the permanent magnet motor, detects torque information corresponding to the high rotation speed interval of the permanent magnet motor through the torsion meter, and detects voltage information corresponding to the high rotation speed interval of the permanent magnet motor driver through the electric power meter;

the control module compares the torque information with a torque standard and compares the voltage information with a voltage standard to judge whether the performance of the permanent magnet motor reaches the standard, if one of the torque information and the voltage information does not reach the standard, the control module reads a zero angle of the magnetic encoder, calculates a compensation angle corresponding to the zero angle based on zero compensation control, and burns the magnetic encoder according to the compensation angle.

2. The magnetic encoder compensation system of claim 1, wherein the torque meter detects an actual torque of the permanent magnet motor during the high speed interval, calculates the torque information, the power meter detects an actual voltage of the permanent magnet motor driver during the high speed interval, calculates the voltage information, and the control module determines whether the torque information meets the torque criteria according to whether the actual torque is greater than or equal to a torque threshold, and determines whether the voltage information meets the voltage criteria according to whether the actual voltage is less than or equal to a voltage threshold.

3. The magnetic encoder compensation system of claim 2, wherein the control module calculates the compensation angle according to a torque error between the actual torque and the torque threshold when the performance of the permanent magnet motor is not reached, and records an angle parameter of the magnetic encoder with a total calculation of the zero angle and the compensation angle.

4. The magnetic encoder compensation system of claim 1, wherein the load motor is coupled to the permanent magnet motor by a coupling, the torque meter is disposed between the coupling and the permanent magnet motor, and the torque meter is electrically connected to the power meter.

5. The magnetic encoder compensation system of claim 1, wherein the control module comprises:

a controller coupled to the permanent magnet motor module, the load motor module and the power meter for calculating the compensation angle according to the zero angle, the torque information and the torque standard; and

and the writing device is coupled with the controller and the magnetic encoder and is used for burning the magnetic encoder according to the compensation angle.

6. A magnetic encoder compensation method, comprising:

(a) Controlling a permanent magnet motor to operate in a high rotating speed interval between a rated rotating speed and a maximum rotating speed;

(b) Controlling a load motor to operate so as to carry out maximum torque dynamic loading on the permanent magnet motor, and simultaneously obtaining torque information corresponding to the high rotating speed interval of the permanent magnet motor and voltage information corresponding to a permanent magnet motor driver for driving the permanent magnet motor in the high rotating speed interval;

(c) Disabling the permanent magnet motor drive;

(d) Comparing the torque information with a torque standard, and comparing the voltage information with a voltage standard;

(e) Judging whether the performance of the permanent magnet motor reaches the standard according to the comparison result of the step (d), wherein the judging step comprises the following steps of:

(e1) If the torque information reaches the torque standard and the voltage information reaches the voltage standard, judging that the performance of the permanent magnet motor reaches the standard and judging that the permanent magnet motor is accepted as a good product;

(e2) If the torque information does not reach the torque standard and the voltage information does not reach the voltage standard, judging that the performance of the permanent magnet motor does not reach the standard and judging that the defective goods are returned; and

(e3) If one of the torque information and the voltage information does not reach the standard, judging that a magnetic encoder assembled with the permanent magnet motor needs to carry out zero point compensation, reading a zero point angle of the magnetic encoder, calculating a compensation angle corresponding to the zero point angle based on zero point compensation control, and burning the magnetic encoder according to the compensation angle; and

(f) Repeating the steps (a) to (e 3) to determine whether the performance of the permanent magnet motor is up to the standard.

7. The magnetic encoder compensation method of claim 6, further comprising, prior to step (a):

zero point correction is performed for the magnetic encoder.

8. The magnetic encoder compensation method of claim 6, wherein step (d) comprises:

(d1) Detecting an actual torque of the permanent magnet motor in the high-rotation-speed interval, calculating to provide the torque information, and judging whether the torque information reaches the torque standard according to whether the actual torque is greater than or equal to a torque threshold value; and

(d2) Detecting an actual voltage output by the permanent magnet motor driver when the permanent magnet motor runs in the high rotating speed interval, calculating to provide the voltage information, and judging whether the voltage information reaches the voltage standard according to whether the actual voltage is less than or equal to a voltage threshold value or not.

9. The magnetic encoder compensation method of claim 8, wherein step (e 1) further comprises:

and adjusting and reducing the actual torque and the actual voltage by adjusting an angle parameter, wherein the angle parameter is obtained by calculating according to the sum of the zero angle and the compensation angle.

10. The magnetic encoder compensation method of claim 8, wherein step (e 3) comprises:

(e31) Reading the zero angle of the magnetic encoder by detecting the permanent magnet motor module;

(e32) Calculating the compensation angle according to a torque error between the actual torque and the torque threshold; and

(e33) And calculating an angle parameter burned in the magnetic encoder according to the sum of the zero angle and the compensation angle.

11. The magnetic encoder compensation method of claim 6, further comprising:

(g) After the step (e 3) is repeatedly executed for a predetermined number of times and the performance of the permanent magnet motor is not yet up to the standard, it is determined that the permanent magnet motor is a defective product and the permanent magnet motor is returned.

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