CN200983567Y - High current brushless electromotor controller - Google Patents
High current brushless electromotor controller Download PDFInfo
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- CN200983567Y CN200983567Y CNU2006200173834U CN200620017383U CN200983567Y CN 200983567 Y CN200983567 Y CN 200983567Y CN U2006200173834 U CNU2006200173834 U CN U2006200173834U CN 200620017383 U CN200620017383 U CN 200620017383U CN 200983567 Y CN200983567 Y CN 200983567Y
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Abstract
The utility model relates to a brushless motor controller with great current, wherein at least six power tubes are arranged in a power circuit of the brushless motor controller, at least two power tubes are connected in parallel with upper and lower tubes of each phase of a three-phase winding, voltage is limited in current by a resistance of a current limiting modulation circuit in a motor winding and is transmitted to an optical coupler, an external brake power supply can be isolated by the optical coupler, three sets of speed control circuits are arranged in the controller, at least two sets of the speed control circuits can be regulated and restricted, at least one set of full-open speed limiting modulator or integrated circuit chip for speed limiting and two sets of speed limiting circuits of adjustable current limiting modulator are arranged, and a copper sheet conductor connected with power tubes of the major loop and a major line conductor is welded on the PCB wiring board. The utility model solves problems that in the 500W-3000W high power electric motorcycle, the brushless motor controller works unsteadily under a great current, the voltage fluctuation is great, components of the controller can be damaged by changes of a wave amplitude of voltage easily, and the maximum speed can not be restricted, the current can not be changed, the torque can not be enhanced at will. The brushless motor controller with great current can restrict maximum speed at will in the rated range of rotation speeds of motors.
Description
Technical field
The utility model relates to a kind of brushless motor controller, especially for the controller that cooperates than the big electric current brushless electric machine of high-power electric motorcycle.
Background technology
Brushless motor controller is usually by singlechip microcontroller and resistance, transducer, bridge switching circuit, and the function element that assistant SCM or application-specific integrated circuit (ASIC) are finished control procedure is formed.Be memory, the decoder that the figure signal language is arranged, saw-toothed wave generator and pulse-width modulation functional circuit and can make the conducting of switching circuit power tube or integrate with the drive circuit of control motor speed, input/output port etc. and constitute on one integrated by, ON time by square wave power controlling pipe.At present, the controller circuitry principle that electric bicycle adopted is basic identical or approaching.There are brush and brshless DC motor mostly to adopt the PWM control method speed governing of pulse-width modulation, just select the difference on drive circuit, integrated circuit, switching circuit power transistor and some correlation function for use.Difference on components and parts and the circuit has constituted not quite identical on the controller performance.
No matter brushless direct current motor controller is the brushless electric machine that the disc armature of high speed rotating has gear reduction, or the low-speed brushless motor of outer steel rotor, and its controller is more complicated all, and price is higher.What electric bicycle was commonly used is three-phase brushless motor, and different windings, groove number, magnetic links number are arranged again in three phase electric machine, and the number of windings of conducting is arranged again simultaneously, and in what phase angle conducting, sense of current etc. during conducting.Power circuit of the prior art is six MOSFET power tubes normally, and the drive signal of accepting power driving circuit is implemented conducting or ended, to the three phase windings power supply of motor.Early stage CD4051, DAC1210, the Z80,8098 and universal dsp chip of using, though be single board computer, because they are not application-specific integrated circuit (ASIC)s, can reach the control requirement so need multichip integrated circuit and peripheral devices to cooperate, form more complete control system.Reach same function, circuit is also remarkable.
Brushless motor controller of the prior art also is provided with a control switch as main circuit and uses for further protective circuit in main circuit, protection silicon controlled 32A air switch.The weak point of this protective circuit is when serious short circuit problem takes place for load and circuit, and is slightly inadequate to the silicon controlled protective effect.Because the situation that controllable silicon is burnt short circuit once occurred, this mainly is because after the protective circuit action, controllable silicon can only could turn-off after the power supply zero passage naturally, and the breaking speed of air switch also is limited.Wait other measures to carry out last short-circuit protection so also need to adopt " fast molten " where necessary.
Present 500W ~ 3000W high-power electric motorcycle, the electric current maximum reaches 70A.The prior art electric machine controller is all unstable usually under big current work, and voltage fluctuation is big, the fragile smd controller of the amplitude change of voltage.And can not limit maximal rate arbitrarily and change electric current and add large torque.In the design of prior art brushless motor controller, be that production engineering specifications such as radiator or main circuit conductor are all very high.On the brushless motor for automobile controller PCB plate of so big electric current, the conductor of circuit is that the weldering of manual back adds tin on circuit board.And on the circuit that big electric current passes through, need to add the very thick cost of one deck than the expensive a lot of metallic tin of copper.Can't accomplish and strengthen the thick automatic producing device of tin, can only adopt the manual technology that weldering adds tin that adds, and the product of manual back weldering is difficult to reach consistency, not only production efficiency is low, the cost height, and can cause certain power tube loose contact or the too small heating phenomenon of conductive cross-sectional area.General electric motor car has only a fixing current-limiting protection function, and the electric current step-up error of each controller is all bigger.
The utility model is further improvement and the development to the prior art brushless motor controller.
Summary of the invention
The purpose of this utility model is the weak point that exists at above-mentioned prior art, provide a kind of and can guarantee that big current work is stable, change in voltage can not damaged smd controller, can limit maximal rate arbitrarily, can change the brushless motor controller that electric current adds large torque.
The technical scheme that its technical problem that solves the utility model adopts is: a kind of big electric current brushless motor controller, comprise power circuit to the power supply of motor three phase windings, speed limit is modulation circuit relatively, current limliting modulation circuit and PCB wiring board, it is characterized in that: described power circuit is arranged with at least six above power tubes, and mutually pipe is at least and be connected to two up and down in each of three phase windings; Wherein the photoelectrical coupler with light-coupled isolation motor hall signal directly is connected with the transducer input, voltage passes to optical coupler to voltage through the resistance current limliting of current limliting modulation circuit in the motor windings, external power brake source light-coupled isolation, be provided with three groups of speed control circuits of any adjustable restriction of at least two groups in the controller, wherein have speed limit modulator or speed limit integrated circuit (IC) chip and two groups of adjustable current limliting modulator speed limit circuit of one group of standard-sized sheet at least; On the PCB wiring board, paste to be welded with and strengthen the load current copper sheet conductor that is connected with main traverse line with power tube major loop conducting.
The utility model has following beneficial effect than prior art.
The utility model is strengthened the sectional area of conductor with the copper sheet of moulding on circuit board, the direct skewer of power tube pin is soldered on the fabrication hole of copper sheet, and pin connects consistent, the consistency height.With the copper sheet conductor power tube and major loop are connected on the PCB wiring board, the stability when having guaranteed big current work can not cause certain power tube loose contact or the too small heating phenomenon of conductive cross-sectional area when making big current work.Having overcome craft, to add tin be consistent poor, is easy to occur above said bad phenomenon.Brake signal is isolated, and with optocoupler external power brake source is isolated, and change in voltage can not have influence on the operate as normal of controller chip when making brake.Can not damage smd controller
Photoelectrical coupler with light-coupled isolation motor hall signal directly is connected with the transducer input, voltage passes to optical coupler to voltage through the resistance current limliting of current limliting modulation circuit in the motor windings, optical coupler is isolated external power brake source, the light-coupled isolation brake signal makes the brake outage, can prevent the transducer voltage variation or burn out chip.Change in voltage can not have influence on the operate as normal of controller chip during brake, can not damage smd controller.When motor broke down, the electric moter voltage recoil can not cause controller chip or other components and parts to damage with light-coupled isolation motor hall signal.The motor hall signal is to controller, and controller installs optocoupler additional, in the machine operation winding voltage be control running also idle running all be tens volts alternating current.(because of motor is a permanent magnetic brushless, can send electricity during idle running comes) motor Hall voltage ability 5～6V, when if motor damages electric leakage or short circuit, possibly with the short circuit of hall signal line, high voltage will return controller from the hall signal line, but through the resistance current limliting voltage is passed to the optical coupler light-coupled isolation, high voltage does not directly pass to control integrated circuit IC chip, can not cause the IC chip to burn or bad phenomenon.
In the rated speed scope of motor, with speed limit modulation, speed limit functional integrated circuit maximum speed limit, speed limit in the volume range of speeds of motor, can limit maximal rate arbitrarily according to customer requirement, this speed limit is that power taking machine hall signal is done sampling rate, and accuracy is very high.Three groups of speed, two groups of any adjustable restrictions, another group standard-sized sheet (in the controller) is applicable to the battery-operated motor cycle that exports to American-European countries, the battery-operated motor cycle that American-European countries can register the license, the maximal rate speed limit of various countries is all different, so design two groups of speed limits especially.Such as: the maximum speed of motor (speed per hour) design is driven to 60Km/h, but the customer requirement F-Zero can not surpass 45Km/h, by this requirement, the rotating speed of motor design can not arbitrarily change surely, can satisfy the controller that has only of this requirement finishes, in controller, the speed limit set-point is connected, and regulate the speed limit potentiometer, be transferred to 45 ± 0.5Km/h on request.Adjustable accuracy is 0.5km/h.
Current limliting is adjustable, the maximum current output protection.If electric motor car excess load current discharge; the danger that can cause the operation of electrical equipment overburden to burn out, the long-time super-large current discharge of battery, meeting reduction of service life or damage; protective current is set is located in the safe maximum current scope, guarantee the safe handling and the life-span of electrical equipment.The utility model can be accurately adjustable by the configuration of vehicle, the current-limiting protection function, and general electric motor car has only a fixing current-limiting protection function, and the electric current step-up error of each controller is all bigger.Two groups of adjustable currents of the present utility model are provided with, and can be provided with on request accurately, and first group is the settings of travelling of the general road conditions of electric motor car, low current (the current protection value is lower) conserve energy; Second group is to quicken the reinforcing electric current setting of travelling in electric motor car when climbing; increase the current protection value; the voltage invariable current increases power and also just increases; motor torque just can reach the effect that reinforcing is quickened in the electric motor car climbing along with increasing; and be provided with time-delay and be provided with; whenever the one fen half of can delaying time by the big electric current of afterburning knob once; cross the delay time electric current and can automatically restore to first group of low current; can change electric current in the time of can or quickening when climbing and add large torque; guarantee the useful life of electrical equipment, like this can be to the safe handling protection of battery maintenance in useful life and electrical equipment.
Description of drawings
In order to further specify rather than limit above-mentioned implementation of the present utility model, below in conjunction with drawings and Examples the utility model is further specified, but therefore the utility model is not limited among the described practical range.All these designs should be considered as disclosed content of present technique and protection range of the present utility model
Fig. 1 is a front view of the present utility model.
Fig. 2 is that the A-A section of Fig. 1 is a left view.
Fig. 3 is Fig. 1 vertical view.
Fig. 4 is a profile organigram of the present utility model.
Fig. 5 is the decomposing schematic representation that the utility model power tube connects the copper sheet conductor.
Fig. 6 is the vertical view that Fig. 4 is contained in the PCB wiring board.
Fig. 7 the utility model control circuit schematic diagram.
Embodiment
In Fig. 1～6, a controller housing 1 to protection of the components and parts in the controller and water-tight effect is arranged, can be shaped on the heat radiation film trap 10 that sets off electric motor car car load outward appearance type body on it.On the shell 1 bedplate face heat conduction and heat radiation device 2 that vertically is bent upwards extension is housed.Described radiator can be an aluminium radiator.Be connected the power tube 4 that is connected with 12 MOSFET on the power circuit of PCB wiring board 9 side by side, this power circuit is powered to motor three phase windings.In three phase windings each is managed at least up and down mutually and is connected to two.Be to strengthen the load current conducting, on described PCB wiring board 9, paste the copper sheet conductor 8 that is connected with main traverse line with the main circuit power pipe that is welded with.Described copper sheet conductor 8 can conduct electricity the conduction film-making 8.2 of film-making 8.1, negative pole and three output conduction film-makings 8.3 that are shaped on fabrication hole by positive pole to be formed.By its copper sheet power tube 4 and major loop are connected, the direct skewer of power tube pin is soldered on the fabrication hole of copper sheet.Output main traverse line 7 directly is connected with copper sheet, thereby forms reliable and stable connecting.Be insulating heat-conductive, between power tube 4 and radiator 2, empire cloth 3 be housed.Photoelectrical coupler 5 with light-coupled isolation motor hall signal directly is connected with the transducer input.Two adjustable resistances 6 that are used for transferring the reference voltage of speed limit sampling are arranged in the speed limit modulation circuit.In order to prevent that the circuit part supply power voltage from changing because of load variations, relatively stable direct voltage utilizes the characteristic of capacitor charge and discharge, and main circuit power 48V also is connected to electrochemical capacitor 17.The effect of this big electric capacity is the picture reservoir a bit, makes original surging current export smoothly, and the supply can guarantee a large amount of water in downstream the time.Voltage passes to optical coupler 5 to voltage through the resistance current limliting of current limliting modulation circuit in the motor windings.Signal Spacing optical coupler 11 brake signal optical couplers 12 are with external power brake source light-coupled isolation.Be provided with three groups of speed speed limit circuit in the controller, have two groups of any adjustable restriction speed limit modulators 6 and speed limit integrated circuit 15 chip IC at least, the speed of another group standard-sized sheet; Two groups of adjustable current limliting modulator 13 speed limit circuit are arranged.Optical coupler 16 is connected with the normally closed heat portective switch of controller radiator, and optical coupler the 1st pin is connected with a wherein pin of normally closed heat portective switch, also connects a pull-up resistor and receives+6V voltage, another pin ground connection of normally closed heat portective switch.Optical coupler pin 2,3 and ground connection, the 4th pin are received the 19th pin guard signal pin of control chip 24 through diode.Its effect is when the controller radiator temperature is overheated; normally closed heat portective switch just disconnects; optical coupler the 1st pin just has voltage to be supplied with by pull-up resistor+6V; optical coupler is promptly worked the 19th pin guard signal of control chip 24 is moved to ground by the 4th pin to the 3 pin, and the 19th pin of control chip 24 does not have the signal output that quits work to reach controller radiator overheat protective function.
Often open the heat portective switch that heat portective switch 27 is motor internals among Fig. 7; heat portective switch is just closed moves ground to the 19th pin guard signal of control chip 24 to when motor overheating is opened often, and the 19th pin of control chip 24 does not have signal to quit work to export and reaches the motor internal overheat protective function.Speed limit circuit in the speed limit comparison modulation circuit 18 is provided with two groups of adjustable reference voltages, and these two groups of voltages are to be used for comparing with the 5th pin restricting signal circuit 19 voltages of speed limit integrated circuit 15IC chip.It can be by the requirement of client's speed limit maximum speed, set reference voltage, when speed requires up to set point, speed limit integrated circuit 15 chip IC output voltages and reference voltage equivalence, if output voltage is higher than comparator, comparator will be left behind the unnecessary speed of speed governing and be allowed motor 25 be higher than set point never, can reach the requirement of maximum speed speed limit.
Speed limit integrated circuit 15 is connected between motor Signal Spacing photoelectric coupled circuit 20 and the control chip 24, and the motor Hall integrated circuit, and is connected with wherein optic coupling element to motor Signal Spacing photoelectric coupled circuit 20 by the resistance current limliting.From the hall signal of motor Hall integrated circuit isolation optic coupling element through motor Signal Spacing photoelectric coupled circuit 20, pull-up resistor+6V voltage and motor hall signal Synchronization Control convert signal to and deliver to control chip 24 and work.The motor hall signal is input to control chip 24, is read from motor hall signal frequency by control chip 24, and converts the 5th pin that voltage outputs to control chip 24 to.This frequency changes synchronously with motor speed, and the voltage of the high more output of frequency is also high, and The voltage is got and done the 6th pin speed limit comparative voltage.
Brake signal is isolated photoelectric coupled circuit 21 and is isolated optic coupling element by brake signal and form and connect sensitive switch on the brake lever.Sensitive switch during brake on the brake lever leads to brake signal with the 12V of DC/DC electricity through the resistance current limliting isolates optic coupling element, and optic coupling element work is left behind the voltage signal of the 19th pin of control chip 24 over the ground, allows the controller output that quits work.
Wherein be electrically connected relatively modulation circuit 18 comparators of speed limit, be electrically connected control chip 24 the 9th pin, the current limliting modulation circuit 23 that is electrically connected speed regulating handle 26 again has two adjustable resistances and two groups of circuit that work is different that are used for transferring the current sampling reference voltage.VR3 in the circuit is a reference voltage of transferring first group of current limitation, and VR4 is a reference voltage of transferring second group forcing current current limliting.First group of VR3 directly is connected with voltage+6V, directly can compare the voltage current limliting after mixing up setting, generally is used as the first retaining electric current (lower a group).And second group of VR4 powers to it by a triode.Current limliting modulation circuit 23 output triodes connect delay circuit 22, are connected with an afterburning knob of often opening knob on the delay circuit.Triode triggers just conductings by delay circuit 22, and+6V voltage is fed to the reference voltage of VR4 modulation setting forcing current, first group of height of voltage ratio.Voltage is done current limliting relatively by output reference voltage to comparator by VR4 when by afterburning knob, and the variation of current limitation value increases to set point.After delay time, electric current automatically restores to first group of reference set value.When pressing knob one time, delay circuit just has the signal output in-90 seconds.
The 12V power supply of battery-operated motor cycle generally is to pass through transducer by 48V, converts 12V voltage to.By transducer power supply, power supply is to supply with controller by brake switch when brake switch in brake, and controller adds photoelectricity and is coupled and controls.
Claims (7)
1. one kind big electric current brushless motor controller, comprise power circuit to the power supply of motor three phase windings, speed limit is modulation circuit relatively, the speed limit integrated circuit, current limliting modulation circuit and PCB wiring board, it is characterized in that: described power circuit is arranged with at least six above power tubes, and mutually pipe is at least and be connected to two up and down in each of three phase windings; Wherein the photoelectrical coupler with light-coupled isolation motor hall signal directly is connected with the transducer input, and voltage passes to optical coupler to voltage through the resistance current limliting of current limliting modulation circuit in the motor windings, external power brake source light-coupled isolation; Be provided with three groups of speed control circuits of any adjustable restriction of at least two groups in the controller, wherein have speed limit modulator or speed limit integrated circuit (IC) chip and two groups of adjustable current limliting modulator speed limit circuit of one group of standard-sized sheet at least; On the PCB wiring board, paste and be welded with the copper sheet conductor that is connected with main traverse line with the power tube of major loop.
2. brushless motor controller according to claim 1 is characterized in that: described copper sheet conductor conducts electricity the conduction film-making of film-making, negative pole and the film-making of output conduction by positive pole to be formed, and described power tube connects with major loop by its copper sheet handle.
3. brushless motor controller according to claim 1 is characterized in that: be connected on the power circuit of PCB wiring board and be connected with 12 MOSFET power tubes side by side.
4. brushless motor controller according to claim 1 is characterized in that: two adjustable resistances that are used for transferring the reference voltage of current sampling are arranged in the described current limliting modulation circuit.
5. brushless motor controller according to claim 1, it is characterized in that: described speed limit integrated circuit is connected between motor Signal Spacing photoelectric coupled circuit and the control chip, the motor Hall integrated circuit, and is connected with wherein optic coupling element to motor Signal Spacing photoelectric coupled circuit by the resistance current limliting.
6. according to claim 1 or 4 described brushless motor controllers, it is characterized in that: described current limliting modulation circuit output is connected with delay circuit, is connected with an afterburning knob of often opening knob on this delay circuit.
7. according to claim 1 or 4 described brushless motor controllers, it is characterized in that: also comprise main circuit power and the electrochemical capacitor that connects.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNU2006200173834U CN200983567Y (en) | 2006-08-04 | 2006-08-04 | High current brushless electromotor controller |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNU2006200173834U CN200983567Y (en) | 2006-08-04 | 2006-08-04 | High current brushless electromotor controller |
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| Publication Number | Publication Date |
|---|---|
| CN200983567Y true CN200983567Y (en) | 2007-11-28 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
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| CNU2006200173834U Expired - Fee Related CN200983567Y (en) | 2006-08-04 | 2006-08-04 | High current brushless electromotor controller |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103199776A (en) * | 2013-04-18 | 2013-07-10 | 中国扬子集团滁州扬子空调器有限公司 | Circuit for switching fixed rotating speed and adjustable rotating speed of outdoor direct-current motor of air-conditioner |
| CN103441714A (en) * | 2013-08-29 | 2013-12-11 | 福尔斯通电子(昆山)有限公司 | Drive circuit of direct-current brushless three-phase Hall sensor motor |
| CN103647486A (en) * | 2013-12-24 | 2014-03-19 | 天津清源电动车辆有限责任公司 | Separately excited DC machine controller of electric automobile |
| CN104065313A (en) * | 2014-07-15 | 2014-09-24 | 常州乐士雷利电机有限公司 | Drive control device of brushless direct current motor |
| CN106026635A (en) * | 2015-11-30 | 2016-10-12 | 东莞市港奇电子有限公司 | DC/DC converter |
| CN106659038A (en) * | 2016-11-13 | 2017-05-10 | 刘军 | Power controller based on die-casting mould structure |
| CN110011577A (en) * | 2019-05-13 | 2019-07-12 | 上海睿丰自动化系统有限公司 | A kind of two-way double group motor driven cards |
-
2006
- 2006-08-04 CN CNU2006200173834U patent/CN200983567Y/en not_active Expired - Fee Related
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103199776A (en) * | 2013-04-18 | 2013-07-10 | 中国扬子集团滁州扬子空调器有限公司 | Circuit for switching fixed rotating speed and adjustable rotating speed of outdoor direct-current motor of air-conditioner |
| CN103199776B (en) * | 2013-04-18 | 2016-05-25 | 中国扬子集团滁州扬子空调器有限公司 | Direct current generator fixed rotating speed and adjustable rotating speed commutation circuit outside air conditioning chamber |
| CN103441714A (en) * | 2013-08-29 | 2013-12-11 | 福尔斯通电子(昆山)有限公司 | Drive circuit of direct-current brushless three-phase Hall sensor motor |
| CN103647486A (en) * | 2013-12-24 | 2014-03-19 | 天津清源电动车辆有限责任公司 | Separately excited DC machine controller of electric automobile |
| CN104065313A (en) * | 2014-07-15 | 2014-09-24 | 常州乐士雷利电机有限公司 | Drive control device of brushless direct current motor |
| CN106026635A (en) * | 2015-11-30 | 2016-10-12 | 东莞市港奇电子有限公司 | DC/DC converter |
| CN106659038A (en) * | 2016-11-13 | 2017-05-10 | 刘军 | Power controller based on die-casting mould structure |
| CN110011577A (en) * | 2019-05-13 | 2019-07-12 | 上海睿丰自动化系统有限公司 | A kind of two-way double group motor driven cards |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| C19 | Lapse of patent right due to non-payment of the annual fee | ||
| CF01 | Termination of patent right due to non-payment of annual fee |