CN116156860A - Electromagnetic compatibility optimization method for synchronous servo controller of electrically-driven special vehicle - Google Patents
Electromagnetic compatibility optimization method for synchronous servo controller of electrically-driven special vehicle Download PDFInfo
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Abstract
The invention provides an electromagnetic compatibility optimization method of an electric drive special vehicle synchronous servo controller, which solves the technical problem that the existing synchronous servo controller is easy to be subjected to electromagnetic interference. The method comprises the following steps: internal and external electromagnetic signals are isolated through the split-cavity shielding, internal electromagnetic interference is avoided through hole shape and aperture optimization on the side wall, electromagnetic leakage is overcome through aperture and radiation frequency matching optimization through hole heat dissipation, system running states are adjusted through monitoring system progress and interruption, data reliability is optimized through data multiple access redundancy access, and signal acquisition accuracy is improved through sampling filtering. The shielding protection is formed to the maximum extent through a hardware means, the electromagnetic signal interference inside and outside the controller is eliminated, the electromagnetic compatibility is improved, and meanwhile, the reliability of programs, data and signals during the operation of the controller is improved through a software means.
Description
Technical Field
The invention relates to the technical field of electromagnetic radiation, in particular to an electromagnetic compatibility optimization method of an electric drive special vehicle synchronous servo controller.
Background
With the application of electrically driven special vehicles, various actuating devices are undergoing large-scale electrification transformation, so that the large-power electronic conversion equipment is greatly applied, the communication and control structures are complicated, the space layout is compact, the electromagnetic compatibility problem of the whole vehicle is extremely remarkable, and the electromagnetic interference problem of a synchronous servo controller which is greatly applied is particularly serious. The synchronous servo controller has complex functions, and the types of input and output ports comprise high-voltage and high-current alternating current and direct current power ports and high-frequency and low-frequency digital or analog signal ports. Meanwhile, the synchronous servo controller has more internal functional boards, including but not limited to capacitor boards, signal control boards, power conversion boards and various interface circuit boards for energy exchange, signal processing and power conversion, and also includes electric connection cables between the boards. The cable connection between the inside of the synchronous servo controller and the port is easy to cause electromagnetic leakage, electromagnetic interference emission is formed, the emission level of the electromagnetic interference emission exceeds a standard seriously, and even the processing procedures and the processing results of storage and calculation can be directly affected. If the design consideration of the electromagnetic compatibility of the controller is insufficient in the initial design, the subsequent rectifying means is complicated, so that the test verification and time cost, the equipment volume and the manufacturing cost are obviously increased, and the overall improvement of the electromagnetic compatibility effect is limited. A systematic approach to electromagnetic compatibility optimization is needed.
Disclosure of Invention
In view of the above problems, the embodiment of the invention provides an electromagnetic compatibility optimization method for a synchronous servo controller of an electrically driven special vehicle, which performs electromagnetic compatibility optimization from the whole angle of the synchronous servo controller and solves the technical problem that the existing synchronous servo controller is easy to be subjected to electromagnetic interference.
The electromagnetic compatibility optimization method of the synchronous servo controller of the electric drive special vehicle comprises the following steps:
the method comprises the steps that primary cavity-splitting shielding is conducted in a containing cavity of a synchronous servo controller through the arrangement of an isolation side wall, so that a functional cavity for containing a functional board card and a port cavity for containing a port circuit are formed;
performing secondary cavity-dividing shielding by arranging an isolation side wall in the port cavity to form an independent cavity, and accommodating a corresponding port circuit according to a port layout planning rule;
setting corresponding filter circuits according to port circuit attributes in the independent cavities;
an integrated port panel is arranged on the independent cavity, and a circular aviation plug connector matched with the port circuit is arranged on the integrated port panel to serve as a physical connection port.
In an embodiment of the present invention, the method further includes:
a cable through hole matched with the cable passing path is arranged on the isolation side wall;
in the functional cavity, the high-voltage power signal is conducted by a copper bar.
In an embodiment of the present invention, the method further includes:
and a circular through hole with the diameter smaller than the wavelength corresponding to the working frequency of the internal circuit is arranged on the port cavity, and a through hole matrix is formed through the circular through hole for heat dissipation and ventilation.
In one embodiment of the present invention, a hardware running environment of system software for a synchronous servo controller includes:
and setting a monitoring process of a main process of system software, and triggering the reset of the main process according to hardware timing.
In an embodiment of the present invention, the method further includes:
and setting a monitoring process of system software interrupt, and triggering a system alarm according to the interrupt state.
In an embodiment of the present invention, the method further includes:
and setting a monitoring process of communication, and triggering communication bus reset on line according to the state of the bus register.
In one embodiment of the present invention, a hardware running environment of system software for a synchronous servo controller includes:
forming a redundant process for data access.
In an embodiment of the present invention, the redundancy processing for forming data access includes:
the ferroelectric memory write three-taking-two processing mode is carried out on the important parameters: the data are stored in three non-adjacent areas of the ferroelectric memory respectively, when software is initialized, the data in the three areas are compared, if any two areas are identical, the data are considered to be correct, and if the data are not identical, the data are considered to be interfered, and default parameters are adopted or error processing is carried out.
In one embodiment of the present invention, a hardware running environment of system software for a synchronous servo controller includes:
a filtering process that forms the signal samples.
In an embodiment of the present invention, the filtering process for forming the signal samples includes:
the same analog signal is acquired by adopting a plurality of channels, and a maximum and minimum removing and averaging algorithm is carried out in software; the input signal of the switching value is acquired for a plurality of times, the acquisition period is not more than 10ms, and the input signal is considered to be high level when the input signal of the switching value is continuously acquired for 5 times and is high level, otherwise, the input signal of the switching value is low level.
The electromagnetic compatibility optimization method of the synchronous servo controller of the electrically driven special vehicle forms a cavity-dividing shielding configuration design based on container hardware aiming at electromagnetic spectrum characteristics of input and output signals, such as power, frequency and voltage coupling coherence and the like of a synchronous servo controller circuit, and provides a product shielding cavity optimization scheme. The isolation sidewalls are utilized to limit the electromagnetic interference range in the receiving cavity depending on the type of board card circuit. And corresponding filter circuits and cable connection structures are provided for external cable extension paths, shielding protection is formed to the maximum extent, external electromagnetic signal interference is eliminated, and electromagnetic compatibility is improved.
Drawings
Fig. 1 is a schematic flow chart of an electromagnetic compatibility optimization method (hardware) of an electrically driven special vehicle synchronous servo controller according to an embodiment of the invention.
Fig. 2 is a schematic view showing a cavity-dividing shielding configuration of a synchronous servo controller of an electrically-driven special vehicle according to an embodiment of the invention.
Fig. 3 is a schematic distribution diagram of a filter circuit of a synchronous servo controller of an electrically driven special vehicle according to an embodiment of the invention.
Fig. 4 is a schematic diagram of internal wiring of a synchronous servo controller of an electrically driven special vehicle according to an embodiment of the invention.
Fig. 5 is a front view of a synchronous servo controller of an electrically driven special vehicle according to an embodiment of the present invention.
Fig. 6 is a schematic diagram of a shielding layer overlapping structure of a circular aviation plug connector of an electric drive special vehicle synchronous servo controller according to an embodiment of the invention.
Fig. 7 is a schematic flow chart of an electromagnetic compatibility optimization method (software) of an electrically driven special vehicle synchronous servo controller according to an embodiment of the invention.
Detailed Description
The present invention will be further described with reference to the drawings and the detailed description below, in order to make the objects, technical solutions and advantages of the present invention more apparent. It will be apparent that the described embodiments are only some, but not all, embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
An electromagnetic compatibility optimization method of the synchronous servo controller of the electrically driven special vehicle is shown in fig. 1. In fig. 1, an embodiment of the present invention includes:
-performing a one-time cavity-splitting shielding by providing an isolation sidewall within the receiving cavity of the synchronous servo controller, forming a functional cavity receiving the functional board card and a port cavity receiving the port circuit;
-secondary cavity-dividing shielding is performed in the port cavity by arranging an isolation side wall to form an independent cavity, and corresponding port circuits are accommodated according to port layout planning rules;
-setting corresponding filter circuits in the independent cavities according to port circuit properties;
-providing an integrated port panel on the separate cavity, providing a circular aviation plug connector adapted to the port circuitry on the integrated port panel as a physical connection port.
The isolation sidewall is made of electromagnetic shielding material, for example, the same material as the accommodating cavity.
The functional board card is respectively provided with main functional circuits of the synchronous servo controller, such as circuit integration or functional chips for signal control, power conversion, energy exchange, data processing and the like. One end of the port circuit is connected with a corresponding pin of the functional board card or the adapting circuit, and the other end of the port circuit is connected with the physical port in an adapting way to perform basic signal connection functions such as protocol conversion of specific input and output signals and amplitude conversion of physical quantity.
The port circuitry of existing synchronous servo controllers typically includes:
a high voltage power supply input port circuit for alternative access of 380VAC and 540VDC power supply;
the low-voltage power supply input port circuit is used for connecting a 24VDC power supply;
the UVW output port circuit is used for outputting three-phase high-voltage wires;
the band-type brake signal output port circuit is used for outputting band-type brake signals;
the motor position encoder access port circuit is used for accessing position encoding signals;
the temperature sensor access port circuit is used for temperature signal access;
the CAN communication I/O port circuit is used for inputting and outputting CAN communication signals;
the in-place sensor access port circuit is used for in-place feedback signal access;
and the external brake resistor port circuit is used for connecting the brake resistor.
The above partial function ports can form a composite function connection port under the same physical port connection requirement.
The configuration of the synchronous servo controller of an embodiment of the present invention for cavity-division shielding is shown in fig. 2. In fig. 2, the primary split-cavity shield forms a rear functional cavity and a front port cavity, and the secondary split-cavity shield forms three adjacent independent cavities in the left, middle and right.
The port layout of the synchronous servo controller according to an embodiment of the present invention is shown in fig. 5. As shown in connection with fig. 2 and 5, a high voltage input port circuit is disposed in the left independent cavity to form ports including, but not limited to, a high voltage power input port; a low-voltage input port circuit is arranged in the independent right cavity, and the formed ports comprise but are not limited to a low-voltage power input port; the middle independent cavity is provided with a high-voltage input port circuit, a bidirectional communication port circuit and a collected signal access port circuit, and the formed ports comprise, but are not limited to, an external brake resistor port, a UVW and first band-type brake signal composite output port, a motor position encoder and temperature sensor access port, a standby second band-type brake signal output port, an in-place sensor access port and a first-path and second-path CAN communication I/O port.
In one embodiment of the present invention, the port layout planning rule includes:
for an input signal:
the high-voltage power signal and the low-voltage power signal are far away as far as possible;
the sensor acquisition signal can adopt a composite function port;
for the output signal:
the output power signal is as far away from the input power signal as possible;
for communication signals:
the communication signal is as far away from the high voltage power signal as possible.
The filter circuit is carried in a filter plate shape, and the filter plate is connected with the corresponding port circuit for adapting and the circuit for adapting to form signal filtering of the corresponding port circuit. Common filter circuits include, but are not limited to, three-phase Y-capacitors, common mode inductors, primary RC low pass filters, secondary RC low pass filters, primary LC low pass filters, secondary LC low pass filters, and the like.
The filter circuit distribution of the synchronous servo controller of the electrically driven special vehicle in an embodiment of the invention is shown in fig. 3. As shown in fig. 2 and 3, in the left independent cavity, a filter plate 1 and a filter plate 2 are provided, a port Y capacitor and a piezoresistor are provided on the filter plate 1, a two-stage low-pass filter circuit is provided on the filter plate 2, the filter plate 1 is provided under the high-voltage power supply input port circuit, and the filter plate 2 is provided thereon. The high-voltage power supply input port circuit is input by 380VAC and 540VDC, and the two-stage filter circuit of the common filter board 2 is combined after rectification to reduce power supply noise and inhibit ripple. The filter board 1 is used for capacitive filtering to ground of each terminal of the high-voltage power supply input port and voltage clamping when overvoltage occurs in the circuit.
As shown in fig. 2 and 3, in the independent cavity on the right side, a filter board 4 is provided, and a two-stage low-pass filter circuit is provided on the filter board 4, for the two-stage filtering between the positive and negative of the low-voltage power supply port 24V.
As shown in fig. 2 and 3, in the middle independent cavity, a filter plate 3 and a filter plate 5 are arranged, a three-phase Y capacitor or a common-mode inductor is arranged on the filter plate 3, and a capacitance to ground is arranged on the filter plate 5. The filter plate 3 is used for filtering the UVW output port circuit. The filter board 5 is used for filtering capacitance to ground of the communication I/O port circuit and the sensor signal access circuit, and suppressing electromagnetic interference of each low-voltage access circuit.
The shielding layer lap joint structure of the circular aviation plug connector of the synchronous servo controller of the electric drive special vehicle in an embodiment of the invention is shown in fig. 6. As shown in connection with fig. 5 and 6, the functional pins of the circular aviation plug connector are adapted to connect with the port connection circuits on the corresponding port circuits. The plug and socket connection mode in the circular aviation plug connector adopts threaded connection. The circular aerial plug connector connects the outer cable portion (plug or socket) to the shielding braid of the outer cable surface to form a 360 degree circumferential electrical connection.
The electromagnetic compatibility optimization method of the embodiment of the invention forms a cavity-division shielding configuration design based on container hardware and provides a product shielding cavity optimization scheme aiming at electromagnetic spectrum characteristics of synchronous servo controller circuits such as power, frequency, voltage, signal coupling coherence and the like of input and output signals. The isolation sidewalls are utilized to limit the electromagnetic interference range in the receiving cavity depending on the type of board card circuit. And corresponding filter circuits and cable connection structures are provided for external cable extension routes, shielding protection is formed to the maximum extent, external electromagnetic signal interference is eliminated, and electromagnetic compatibility is improved.
As shown in fig. 1, in an embodiment of the present invention, the method further includes:
-providing a cable via on the isolation sidewall matching the pass-through cable path;
in the functional cavity, the high voltage power signal is conducted with copper bars.
The internal wiring of the synchronous servo controller of the electrically driven special vehicle according to an embodiment of the invention is shown in fig. 4. In fig. 4, the cable via hole has a semicircular cross-sectional shape corresponding to the wire diameter of the passing cable. In the functional cavity, copper bars are electrically connected between the high-voltage positive terminals and the high-voltage negative terminals of the functional boards. The copper bars are designed to ensure enough electrical spacing between the positive and negative copper bars and the manufacturing process, the length is as short as possible, the width is as wide as possible, and meanwhile, the structures at corners and the like are as smooth as possible, so that stray inductance is reduced, and electromagnetic interference is inhibited.
The electromagnetic compatibility optimization method of the embodiment of the invention aims at the internal electromagnetic signal interference to form the optimal design of cable layout. The layout optimization aiming at the cable diameter and the cable type can effectively inhibit electromagnetic interference among internal circuits, improve electromagnetic compatibility and simultaneously eliminate electromagnetic leakage.
As shown in fig. 1, in an embodiment of the present invention, the method further includes:
-providing circular through holes with a diameter smaller than the wavelength corresponding to the operating frequency of the internal circuit on the port cavity, forming a matrix of through holes for heat dissipation and ventilation.
In one embodiment of the invention, a matrix of through holes is provided below the ports on the integrated port panel to form a waveguide louver, as shown in fig. 5. The maximum diameter of the holes of the circular through holes in the through hole matrix is not more than lambda/20 (lambda is the wavelength corresponding to the highest working frequency of the internal circuit). The adoption of a fan cooling mode for heat dissipation can not cause the controller to generate electromagnetic radiation. The circular through hole density can not lead to the heat dispersion to be influenced when guaranteeing the casing rigidity.
The electromagnetic compatibility optimization method of the embodiment of the invention gives consideration to electromagnetic radiation inhibition under the equipment heat radiation condition. The waveguide ventilation window structure is formed aiming at the wavelength rule of the radiation source so as to avoid electromagnetic leakage.
An electromagnetic compatibility optimization method for the synchronous servo controller of the electrically driven special vehicle according to an embodiment of the invention is shown in fig. 7. In fig. 7, an embodiment of the present invention is directed to a hardware running environment of system software of a synchronous servo controller, including:
-setting up a monitoring procedure of a system software main process, triggering a main process reset according to a hardware timing.
The instant monitoring of the CPU executing main program process is formed. Judging whether the main program process runs or enters dead cycle due to strong electromagnetic interference according to the hardware timing data, and triggering the main process to reset and automatically recovering the main program process once the main process fault is found.
In one embodiment of the present invention, the period of the main program is set to be T, and the CPU does not execute the main program in the time of t+Δt, to indicate that the main program "runs off" or goes into dead loop by mistake. The specific design method is as follows: when the CPU works normally, the watchdog counter is cleared at intervals, and if the reset operation is not performed for a certain time, the watchdog circuit gives a reset signal to force the CPU to reset.
-setting a monitoring procedure of the system software interrupt, triggering a system alarm according to the interrupt status.
When the main program process is normal, the system interrupt is in a continuously called state. Judging whether interrupt processing is not responsive to the occurrence of interrupt due to electromagnetic interference according to the interrupt calling state, and immediately alarming and triggering a subsequent fault processing program once a system interrupt fault is found.
In one embodiment of the present invention, in the system software design, when the interrupt works normally, the program times the interrupt counter to accumulate, if the counter value does not change, it indicates that the interrupt is not normally executed, and an interrupt unresponsiveness condition occurs. The design program immediately gives an alarm, stops the subsequent execution, and prevents uncontrollable situations.
-setting a monitoring procedure of the communication, triggering a communication bus reset on-line according to the bus register state.
CAN bus communication relies on underlying bus registers. Judging whether the CAN bus automatically enters a bus off-line state due to electromagnetic interference according to the state of the bus register, and correcting the value of the bus register to reset the communication bus on line once a communication fault is found, so as to restore communication.
In an embodiment of the invention, after the accumulated error count of the monitoring CAN module is more than or equal to 255, the monitoring CAN module automatically enters a bus off-line state, and when the bus is off-line due to strong electromagnetic interference, the communication is automatically recovered after the CAN module is off-line by configuring the corresponding register count of the CAN bus.
-forming a redundant process of data access.
Redundancy processes include, but are not limited to, identical data multiple memory address segment storage, identical data multiple data source read alignment. The data reading and writing errors or data loss can be effectively avoided, and a data backup mechanism and a reading and checking mechanism can be formed.
In one embodiment of the present invention, the ferroelectric memory write-three-two processing mode is performed on important parameters: the data are stored in three non-adjacent areas of the ferroelectric memory respectively, when software is initialized, the data in the three areas are compared, if any two areas are identical, the data are considered to be correct, and if the data are not identical, the data are considered to be interfered, and default parameters are adopted or error processing is carried out.
-a filtering process to form signal samples.
The deviation correction of the sampled data can be formed by parallel sampling, high-rate sampling, sampled data average processing and the like.
In one embodiment of the invention, the same analog signal is acquired by adopting a plurality of channels, and the maximum and minimum removing and average taking algorithm is performed in software; the switching value input signal is acquired for a plurality of times, the acquisition period is not more than 10ms, and the switching value input signal is considered to be high level when the switching value signal is high level for 5 times continuously acquired, otherwise, the switching value input signal is low level, and vice versa.
The electromagnetic compatibility optimization method of the embodiment of the invention utilizes a software method to monitor, judge and process the reliability in the processes of signal acquisition, data access and hardware resource calling. The data accidents caused by electromagnetic interference can be found and corrected in real time, and the operation accidents can be timely perceived and timely reset. And the balance of input cost and optimization efficiency in overcoming electromagnetic interference is ensured.
The present invention is not limited to the above-mentioned embodiments, and any changes or substitutions that can be easily understood by those skilled in the art within the technical scope of the present invention are intended to be included in the scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.
Claims (10)
1. An electromagnetic compatibility optimization method of an electric drive special vehicle synchronous servo controller is characterized by comprising the following steps of:
the method comprises the steps that primary cavity-splitting shielding is conducted in a containing cavity of a synchronous servo controller through the arrangement of an isolation side wall, so that a functional cavity for containing a functional board card and a port cavity for containing a port circuit are formed;
performing secondary cavity-dividing shielding by arranging an isolation side wall in the port cavity to form an independent cavity, and accommodating a corresponding port circuit according to a port layout planning rule;
setting corresponding filter circuits according to port circuit attributes in the independent cavities;
an integrated port panel is arranged on the independent cavity, and a circular aviation plug connector matched with the port circuit is arranged on the integrated port panel to serve as a physical connection port.
2. The electromagnetic compatibility optimization method of claim 1, further comprising:
a cable through hole matched with the cable passing path is arranged on the isolation side wall;
in the functional cavity, the high-voltage power signal is conducted by a copper bar.
3. The electromagnetic compatibility optimization method of claim 2, further comprising:
and a circular through hole with the diameter smaller than the wavelength corresponding to the working frequency of the internal circuit is arranged on the port cavity, and a through hole matrix is formed through the circular through hole for heat dissipation and ventilation.
4. A method of optimizing electromagnetic compatibility as claimed in any one of claims 1 to 3, wherein the hardware running environment for the system software of the synchronous servo controller comprises:
and setting a monitoring process of a main process of system software, and triggering the reset of the main process according to hardware timing.
5. The electromagnetic compatibility optimization method of claim 4, further comprising:
and setting a monitoring process of system software interrupt, and triggering a system alarm according to the interrupt state.
6. The electromagnetic compatibility optimization method of claim 4, further comprising:
and setting a monitoring process of communication, and triggering communication bus reset on line according to the state of the bus register.
7. A method of optimizing electromagnetic compatibility as claimed in any one of claims 1 to 3, wherein the hardware running environment for the system software of the synchronous servo controller comprises:
forming a redundant process for data access.
8. The electromagnetic compatibility optimization method of claim 7, wherein the redundant process of creating data access includes:
the ferroelectric memory write three-taking-two processing mode is carried out on the important parameters: the data are stored in three non-adjacent areas of the ferroelectric memory respectively, when software is initialized, the data in the three areas are compared, if any two areas are identical, the data are considered to be correct, and if the data are not identical, the data are considered to be interfered, and default parameters are adopted or error processing is carried out.
9. A method of optimizing electromagnetic compatibility as claimed in any one of claims 1 to 3, wherein the hardware running environment for the system software of the synchronous servo controller comprises:
a filtering process that forms the signal samples.
10. The electromagnetic compatibility optimization method of claim 9, wherein the filtering process to form signal samples includes:
the same analog signal is acquired by adopting a plurality of channels, and a maximum and minimum removing and averaging algorithm is carried out in software; the input signal of the switching value is acquired for a plurality of times, the acquisition period is not more than 10ms, and the input signal is considered to be high level when the input signal of the switching value is continuously acquired for 5 times and is high level, otherwise, the input signal of the switching value is low level.
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