CN214315107U

CN214315107U - Low-cost brushless DC motor controller for electric bicycle

Info

Publication number: CN214315107U
Application number: CN202120264681.8U
Authority: CN
Inventors: 许振伟
Original assignee: Zhejiang Institute of Mechanical and Electrical Engineering Co Ltd
Current assignee: Hangzhou Yongwang Technology Co.,Ltd.
Priority date: 2021-01-30
Filing date: 2021-01-30
Publication date: 2021-09-28
Anticipated expiration: 2031-01-30

Abstract

The utility model belongs to the technical field of the machine controller technique and specifically relates to a low-cost electric bicycle brushless DC motor controller, including host system, power module, drive module, sampling circuit, motor position detection circuit and power protection circuit, power module includes battery and step-down converting circuit, drive module is brushless DC motor drive circuit, and sampling circuit's sense terminal is connected with brushless DC motor drive circuit's output, and sampling circuit's signal output part is connected with host system's input, and motor position detection circuit's sense terminal is connected with brushless DC motor's hall signal end, and motor position detection circuit's output is connected with host system's input, the utility model discloses have simple structure, with low costs, circuit stability is high, the function of easy productization.

Description

Low-cost brushless DC motor controller for electric bicycle

Technical Field

The utility model relates to a machine controller technical field, concrete field is a low-cost electric bicycle brushless DC motor controller.

Background

The electric bicycle has been rapidly developed due to the advantages of the electric bicycle in production and use, and the demand of the brushless dc motor controller of the electric bicycle is gradually increased. On the premise of ensuring reliable performance, the brushless direct current motor controller with low cost obviously has greater competitive advantage. Some products in the current market have better performance, but have high price, no comparative price advantage and are not beneficial to commercialization; some pursue low cost, but the reliability is lower, increase maintenance and operation cost.

SUMMERY OF THE UTILITY MODEL

To the deficiencies of the prior art, an object of the present invention is to provide a low-cost brushless dc motor controller for electric bicycle.

In order to achieve the above object, the utility model provides a following technical scheme: a low-cost brushless DC motor controller for electric bicycle is composed of main control module, power supply module, drive module, sampling circuit, motor position detecting circuit and power supply protecting circuit, the said power supply module consisting of accumulator and step-down converter circuit, the power output of accumulator connected to the input of step-down converter circuit, the said drive module being the drive circuit of brushless DC motor, the output of step-down converter circuit connected to power terminals of main control module and drive circuit of brushless DC motor, the power output of accumulator connected to the power input of drive circuit of brushless DC motor, the signal input of drive circuit of brushless DC motor connected to the output of main control chip, the output of drive circuit connected to three power terminals of brushless DC motor, the detecting end of sampling circuit connected to the output of drive circuit of brushless DC motor, the signal output end of the sampling circuit is connected with the input end of the main control chip, the detection end of the motor position detection circuit is connected with the Hall signal end of the brushless direct current motor, the output end of the motor position detection circuit is connected with the input end of the main control module, the detection end of the power supply protection circuit is connected with the output end of the brushless direct current motor driving circuit, and the output end of the power supply protection circuit is connected with the input end of the main control module.

Preferably, the master control module is an STM32F030K6T6 type microcontroller.

Preferably, the step-down conversion circuit comprises a starting resistor group, a 5V power management chip, a 3.3V power management chip, a charging capacitor, a divider resistor, a voltage regulator tube, a first triode, a second triode and a third triode, wherein the starting resistor group comprises a plurality of resistors which are sequentially connected in series, one end of the starting resistor group is connected with the storage battery, the other end of the starting resistor group is connected with the input end of the 5V power management chip, the output end of the 5V power management chip outputs a 5V power, the output end of the 5V power management chip is connected with the input end of the 3.3V power management chip, and the output end of the 3.3V power management chip outputs a 3.3V power; one end of the charging capacitor is connected with the input end of the 5V power management chip, and the other end of the charging capacitor is grounded; the input end of the 5V power management chip is connected with the negative end of the voltage-stabilizing tube, the positive end of the voltage-stabilizing tube is connected with the base electrode of the triode III, the collector electrode of the triode III is connected with the power output end of the 5V power management chip, and the emitter electrode of the triode III is grounded; the base electrode of the second triode is connected with the collector electrode of the third triode, the emitting electrode of the second triode is grounded, the collector electrode of the second triode is connected with the base electrode of the first triode, the emitting electrode of the first triode is connected with the power supply end of the storage battery after being connected with the divider resistor in series, the collector electrode of the first triode is connected with the input end of the 5V power management chip, and the first triode is a PNP type triode.

Preferably, the driving circuit includes three non-optical coupling bootstrap floating gate driving circuits with the same circuit structure, and the three non-optical coupling bootstrap floating gate driving circuits are respectively connected in a manner of being matched with three power terminals corresponding to the brushless dc motor.

Preferably, the non-optical coupling bootstrap floating gate drive circuit comprises an upper bridge arm drive circuit and a lower bridge arm drive circuit, wherein the upper bridge arm drive circuit comprises a triode four, a triode five, a triode six, a diode one, a diode two, an MOS tube one and a capacitor one; the lower bridge arm driving circuit comprises a triode seventh, a triode eighth, a triode ninth, a diode third, an MOS (metal oxide semiconductor) tube II, a capacitor II and a capacitor III;

the base of the triode IV is connected with the power output end of the 3.3V power management chip, the emitter of the triode IV is connected with the output end of the main control module, the collector of the triode IV is connected with the base and the emitter of the triode V, the collector of the triode V is connected with the positive terminal of the diode I, the negative terminal of the diode I is connected with the grid of the MOS tube I, the source of the MOS tube I is connected with the storage battery, the drain of the MOS tube I is connected with a power supply end of the brushless direct current motor, the emitter of the triode VI is used for refining the grid of the MOS tube I, the collector of the triode V is respectively connected with the base and the collector of the triode VI, the collector of the triode VI is connected with the drain of the MOS tube I, the input end of the 5V power management chip is connected with the positive terminal of the diode II, the negative terminal of the diode II is connected with the emitter of the triode V and the positive terminal of the capacitor I, and the negative terminal of the capacitor I is connected with the drain of the MOS tube I;

the base of the seventh triode is connected with the power output end of the 3.3V power management chip, the emitter of the seventh triode is connected with the output end of the main control module, the collector of the seventh triode is connected with the base and the emitter of the eighth triode, the input end of the 5V power management chip is connected with the emitter of the eighth triode, the collector of the eighth triode is connected with the positive terminal of the third diode, the negative terminal of the third diode is connected with the grid of the second MOS tube, the source of the second MOS tube is connected with the drain of the first MOS tube, the drain of the second MOS tube is grounded, the emitter of the ninth triode is connected with the grid of the second MOS tube, the collector of the eighth triode is respectively connected with the base and the collector of the ninth triode, the collector of the ninth triode is connected with the drain of the second MOS tube, one end of the second capacitor is connected with the storage battery, the other end of the second capacitor is connected with the drain of the second MOS tube, the positive terminal of the third capacitor is connected with the storage battery, and the negative terminal of the third capacitor is connected with the drain of the second MOS tube.

Preferably, the triode four and the triode seven are NPN type triodes, the triode five, the triode six, the triode eight and the triode nine are PNP type triodes, and the capacitor one and the capacitor three are electrolytic capacitors.

Preferably, the sampling circuit comprises a first voltage stabilizing diode, a second voltage stabilizing diode, a first comparator, a second comparator and a third MOS transistor, the same poles of the first voltage stabilizing diode and the second voltage stabilizing diode are connected with each other, the positive pole of the first voltage stabilizing diode is grounded, the negative pole of the first voltage stabilizing diode is connected with the positive pole input end of the first comparator, the positive pole input end of the first comparator is connected with the output end of the brushless dc motor driving circuit, after the negative pole input end of the first comparator is grounded, the output end of the first comparator is connected with the source electrode of the third MOS transistor, the grid electrode of the third MOS transistor is connected with the output end of the main control module, the drain electrode of the third MOS transistor is connected with the positive pole input end of the second comparator, the output end of the second comparator is connected with the input end of the main control module, and the negative pole input end of the second comparator is connected with the output end of the second comparator.

Preferably, the motor position detection circuit comprises a plug, a first resistor, a second resistor, a third resistor, a fourth resistor, a fifth resistor, a sixth resistor, a fourth capacitor, a fifth capacitor and a sixth capacitor, wherein the plug is connected with three hall signal terminals on the brushless dc motor, one ends of the fourth resistor, the fifth resistor and the sixth resistor are respectively and correspondingly connected with the three hall signal terminals on the plug, the other ends of the fourth resistor, the fifth resistor and the sixth resistor are respectively and correspondingly connected with three input terminals of the main control module, one ends of the first resistor, the second resistor and the third resistor are respectively connected with a power output terminal of a 3.3V power management chip, the other end of the first resistor is connected with one end of the fourth resistor, the other end of the second resistor is connected with one end of the fifth resistor, the other end of the third resistor is connected with one end of the sixth resistor, one end of the fourth resistor, which is connected with the main control module, is grounded after being connected with the fourth capacitor in series, the resistor five is connected with one end of the main control module and is connected with the capacitor in series without back grounding, and the resistor six is connected with one end of the main control module and is connected with the capacitor six in series and then grounded.

Preferably, the power protection circuit comprises a triode ten, a diode four, a capacitor seven, a resistor seven and a resistor eight, wherein a base of the triode ten is connected with an output end of the brushless direct current motor driving circuit after being connected with the resistor eight in series, a collector of the triode ten is connected with a power output end of the 3.3V power management chip, an emitter of the triode ten is connected with a positive electrode end of the diode four, a negative electrode end of the diode four is connected with an input end of the main control module, the capacitor seven is connected with the resistor seven in parallel, one end of the capacitor seven is connected with a negative electrode end of the diode four, and the other end of the capacitor seven is grounded.

Compared with the prior art, the beneficial effects of the utility model are that:

(1) the novel resistance voltage-reducing type switching power supply is adopted to convert the 48V voltage of the storage battery into three system voltages of 12V, 5V and 3.3V, the circuit is composed of a pure resistor and a triode, the cost is relatively low, and the circuit is particularly suitable for the application occasions with moderate power, such as the electric bicycle.

(2) A holding circuit is added in the sampling circuit, so that the defects that a main control chip is long in sampling time and is easily interfered are avoided, and the sampling precision is improved; meanwhile, a voltage regulator tube and a diode are connected beside the current sampling resistor Rs in parallel to limit the amplitude of a sampling signal and prevent negative voltage from being input to a current signal detection end.

(3) In the traditional floating power supply driving method, an optical coupler is required to transmit a driving signal, but the bandwidth and noise sensitivity of the optical coupler are limited, and PWM (pulse width modulation) is difficult to be superimposed in an upper arm driving signal; and the cost is relatively high due to the quick optical coupling. The design adopts a non-optical coupling bootstrap floating gate driving method, and eliminates an optical coupler and reduces the cost on the premise of ensuring the driving reliability.

(4) In order to improve the reliability of overcurrent protection, an overcurrent protection signal directly connected to the middle fracture is added outside the normal speed ring and the current ring. The normal motor current regulation is executed by a current loop, and under the condition of few abnormal conditions, AD sampling is not carried out, and an MOS tube is directly closed and turned off through interruption, so that the current is limited to rise. Meanwhile, a holding delay circuit is added at the output action end of the protection circuit to keep the protection state for a certain time, thereby avoiding the overlapping of the occurrence and the cancellation of the protection action.

(5) The electric bicycle controller on the current market generally only has a speed control loop, and the response speed of the controller is low. The design adopts double closed-loop control, comprises a rotating speed outer ring regulator and a current inner ring regulator, and is the core of software design of a control system. The speed regulator makes the motor speed change with the input of the rotating handle and adopts fuzzy self-adaptive PID control strategy. The current regulator enables the motor to be quickly started under the maximum allowable current, reduces the transition process time and adopts Pl control.

Drawings

FIG. 1 is a schematic block diagram of the system of the present invention;

fig. 2 is a schematic circuit diagram of the main control module of the present invention;

FIG. 3 is a schematic circuit diagram of a power module of the present invention;

fig. 4 is a schematic diagram of a non-optical coupling bootstrap floating gate driving circuit of the present invention;

FIG. 5 is a schematic diagram of a sampling circuit according to the present invention;

FIG. 6 is a schematic diagram of a motor position detection circuit according to the present invention;

fig. 7 is a schematic diagram of a power protection circuit of the present invention;

FIG. 8 is a flow chart of the software of the brushless DC motor controller for the low-cost electric bicycle of the present invention;

fig. 9 is a flowchart of the AD interrupt service routine of the present invention;

FIG. 10 is a flow chart of a speed loop adjustment subroutine of the present invention;

fig. 11 is a flowchart of the current loop adjustment subroutine of the present invention.

In the figure: 1. a main control module; 2. starting a resistor group; 3. a 5V power management chip; 4. 3.3V power management chip; 5. a charging capacitor; 6. a voltage dividing resistor; 7. a voltage stabilizing tube; 8. a triode I; 9. a triode II; 10. a triode III; 11. a triode IV; 12. a triode V; 13. a triode six; 14. a first diode; 15. a second diode; 16. a MOS tube I; 17. a first capacitor; 18. a triode seventh; 19. a triode eight; 20. a triode nine; 21. a diode III; 22. a MOS tube II; 23. a second capacitor; 24. a third capacitor; 25. a first voltage stabilizing diode; 26. a second voltage stabilizing diode; 27. a first comparator; 28. a second comparator; 29. a MOS tube III; 30. a plug; 31. a first resistor; 32. a second resistor; 33. a third resistor; 34. a fourth resistor; 35. resistance five; 36. a sixth resistor; 37. a fourth capacitor; 38. a fifth capacitor; 39. a capacitor six; 40. a triode ten; 41. a fourth diode; 42. a capacitor seven; 43. a resistor seven; 44. and eight resistors.

Detailed Description

The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.

Referring to fig. 1 to 7, the present invention provides a technical solution: a low-cost brushless DC motor controller for electric bicycle comprises a main control module 1, a power module, a driving module, a sampling circuit, a motor position detection circuit and a power protection circuit, wherein the power module comprises a storage battery and a voltage reduction conversion circuit, the power output end of the storage battery is connected with the input end of the voltage reduction conversion circuit, the driving module is a brushless DC motor driving circuit, the output end of the voltage reduction conversion circuit is respectively connected with the power ends of the main control module 1 and the brushless DC motor driving circuit, the power output end of the storage battery is connected with the power input end of the brushless DC motor driving circuit, the signal input end of the brushless DC motor driving circuit is connected with the output end of a main control chip, the output end of the driving circuit is connected with three power ends of the brushless DC motor, the detection end of the sampling circuit is connected with the output end of the brushless DC motor driving circuit, the signal output end of the sampling circuit is connected with the input end of the main control chip, the detection end of the motor position detection circuit is connected with the Hall signal end of the brushless direct current motor, the output end of the motor position detection circuit is connected with the input end of the main control module 1, the detection end of the power supply protection circuit is connected with the output end of the brushless direct current motor driving circuit, and the output end of the power supply protection circuit is connected with the input end of the main control module 1.

The handle rotating module signal, the brake module signal and the three-gear switching module signal of the electric bicycle are respectively connected with the input end of the main control module 1, so that the motor can be controlled to be switched on and off by the above modules of the cylinder cover.

The main control module 1 is an STM32F030K6T6 type microcontroller.

The structural block diagram of the low-cost brushless direct current motor controller system of the electric bicycle is shown in fig. 1, an STM32F030K6T6 microcontroller is taken as a core, and a power supply module converts a 48V power supply of a storage battery into three voltages of 12V, 5V and 3.3V to be taken as a system power supply; STM32F030K6T 6's output PWM signal drive inverter, control brushless DC motor operation, the required positional information of commutation is provided by the detection of hall module, and current-voltage is accomplished by AD module detection conversion, and speed input is provided by changeing the handle, and brake equipment provides brake signal, at the operation in-process, needs real-time detection battery voltage, if be in low-voltage state then the warning shut down.

As shown in fig. 2, the STM32F030K6T6 microcontroller is a 32-bit M0 series ARM single-chip microcomputer, which has high cost performance and low price, and is generally packaged by LQFP-32, and is widely applied in the electric bicycle and household appliance industries, in the figure, the resistor R10 and the capacitor C8 form a power-on reset circuit, the capacitors C1 and C11 are power supply filtering decoupling capacitors, and the J6 is a program burning interface, so that the plug can be produced in batch without welding, thereby saving devices and space. AH. BH, CH, AL, BL and CL are six motor drive signals; HA. HB and HC are three-phase hall detection signals; TX and RX are serial communication signals; VSen is the current sense signal, VSen1 is the current sense standby signal; INT is an overcurrent interrupt signal; ZL is a turn signal; SPEED is the handle SPEED signal; LOW _ POW is a battery LOW voltage detection signal.

The voltage reduction conversion circuit comprises a starting resistor group 2, a 5V power management chip 3, a 3.3V power management chip 4, a charging capacitor 5, a divider resistor 6, a voltage-stabilizing tube 7, a triode I8, a triode II 9 and a triode III 10, wherein the starting resistor group 2 comprises a plurality of resistors which are sequentially connected in series, one end of the starting resistor group 2 is connected with a storage battery, the other end of the starting resistor group is connected with the input end of the 5V power management chip 3, the output end of the 5V power management chip 3 outputs a 5V power, the output end of the 5V power management chip 3 is connected with the input end of the 3.3V power management chip 4, and the output end of the 3.3V power management chip 4 outputs a 3.3V power; one end of the charging capacitor 5 is connected with the input end of the 5V power management chip 3, and the other end is grounded; the input end of the 5V power management chip 3 is connected with the negative end of a voltage regulator tube 7, the positive end of the voltage regulator tube 7 is connected with the base electrode of a triode III 10, the collector electrode of the triode III 10 is connected with the power output end of the 5V power management chip 3, and the emitter electrode of the triode III 10 is grounded; the base of the second triode 9 is connected with the collector of the third triode 10, the emitter of the second triode 9 is grounded, the collector of the second triode 9 is connected with the base of the first triode 8, the emitter of the first triode 8 is connected with the power supply end of the storage battery after being connected with the divider resistor 6 in series, the collector of the first triode 8 is connected with the input end of the 5V power management chip 3, and the first triode 8 is a PNP type triode.

As shown in fig. 3, the brushless dc motor controller is normally operated by the battery, 48V is input from the socket P1, and is converted into three power supplies, including 12V, 5V and 3.3V, required by the system through the novel resistance step-down switching power supply. The circuit realizes the voltage reduction function by resistance voltage division and combining with the output characteristic of the integrated operational amplifier, and obtains stable 5V and 12V voltage output by negative feedback of an output end;

upon power up, transistors Q21 and Q24 are in an off state, and a 48V voltage supplies power to the resistors through resistors R86, R87, and R88. When the Vdr rises to about 7V due to the charging of a capacitor, the output end can output +5V voltage, once the 5V voltage is established, Q24 and Q21 are conducted, 48V voltage is output to the Vdr through resistors R90, R91, R95 and R96 through Q21, because four resistors of the branch are small in resistance value and Q21 is saturated and conducted, the Vdr is rapidly increased to about 12V at the moment, a voltage-dividing resistor on a resistor R115 breaks down a voltage-stabilizing tube D19, Q26 is conducted, the collector output of the resistor is low level, Q24 and Q21 are turned off, a power supply loop returns to the loop of the resistors R86, R87 and R88, because the resistors are large in resistance value, the Vdr is slowly reduced, D19 is slowly turned off and Q26 is turned off, the Q24 and Q21 are turned on again, the power supply is converted to the branch of the resistors R90, R91, R95 and R96, and the branch is rapidly turned on. This is repeated to obtain stable Vdr (12V) and 5V output voltages. Wherein resistance R86, R87 and R88 are called starting resistor again, still have an auxiliary function and play the reposition of redundant personnel effect for main power supply circuit, and the 5V power passes through U5 output 3.3V voltage as main control chip STM32F030K6T6 power.

The driving circuit comprises three non-optical coupling bootstrap floating gate driving circuits with the same circuit structure, and the three non-optical coupling bootstrap floating gate driving circuits are respectively connected in a matching mode corresponding to three power supply ends of the brushless direct current motor.

The non-optical coupling bootstrap floating gate drive circuit comprises an upper bridge arm drive circuit and a lower bridge arm drive circuit, wherein the upper bridge arm drive circuit comprises a triode four 11, a triode five 12, a triode six 13, a diode one 14, a diode two 15, an MOS tube one 16 and a capacitor one 17; the lower bridge arm driving circuit comprises a triode seven 18, a triode eight 19, a triode nine 20, a diode three 21, an MOS tube two 22, a capacitor two 23 and a capacitor three 24;

the base of the triode four 11 is connected with the power output end of the 3.3V power management chip 4, the emitter of the triode four 11 is connected with an output end of the main control module 1, the collector of the triode four 11 is connected with the base and the emitter of the triode five 12, the collector of the triode five 12 is connected with the positive terminal of the diode one 14, the negative terminal of the diode one 14 is connected with the grid of the MOS tube one 16, the source of the MOS tube one 16 is connected with the storage battery, the drain of the MOS tube one 16 is connected with a power supply end of the brushless DC motor, the emitter of the triode six 13 is connected with the grid of the MOS tube one 16, the collector of the triode five 12 is respectively connected with the base and the collector of the triode six 13, the collector of the triode six 13 is connected with the drain of the MOS tube one 16, the input end of the 5V power management chip 3 is connected with the positive terminal of the diode two 15, the negative terminal of the diode two 15 is respectively connected with the emitter of the triode five 12 and the positive terminal of the capacitor one 17, the negative electrode end of the capacitor I17 is connected with the drain electrode of the MOS transistor I16;

the base of the triode seven 18 is connected with the power output end of the 3.3V power management chip 4, the emitter of the triode seven 18 is connected with the output end of the main control module 1, the collector of the triode seven 18 is connected with the base and the emitter of the triode eight 19, the input end of the 5V power management chip 3 is connected with the emitter of the triode eight 19, the collector of the triode eight 19 is connected with the positive electrode end of the diode three 21, the negative electrode end of the diode three 21 is connected with the grid of the MOS tube two 22, the source of the MOS tube two 22 is connected with the drain of the MOS tube one 16, the drain of the MOS tube two 22 is grounded, the emitter of the triode nine 20 is connected with the grid of the MOS tube two 22, the collector of the triode eight 19 is respectively connected with the base and the collector of the triode nine 20, the collector of the triode nine 20 is connected with the drain of the MOS tube two 22, one end of the capacitor two 23 is connected with the storage battery, the other end of the capacitor two 23 is connected with the drain of the MOS tube two 22, the positive end of the capacitor III 24 is connected with the storage battery, and the negative end of the capacitor III 24 is connected with the drain electrode of the MOS tube II 22.

The triode four 11 and the triode seven 18 are NPN type triodes, the triode five 12, the triode six 13, the triode eight 19 and the triode nine 20 are PNP type triodes, and the capacitor one 17 and the capacitor three 24 are electrolytic capacitors.

At present, in the power driving application of a direct current brushless motor of an electric vehicle, a floating power supply method is widely adopted, and an optical coupler is adopted to transmit a driving signal and realize electrical isolation. The method has the advantages of simple structure, fast switching and low power consumption, but has the obvious defects that: firstly, the bandwidth and the noise sensitivity are limited, and PWM modulation is difficult to be superposed in an upper arm driving signal; on the other hand, the broadband quick optical coupler has relatively high cost. For this reason, the design adopts a non-optical coupling floating gate driving method, and one phase A of a three-phase driving circuit is shown in FIG. 4;

in the circuit shown in fig. 4, the upper part is the upper arm driving circuit, and the lower part is the lower arm driving circuit, and the main design innovation is embodied in the upper arm driving circuit.

When the AH driving signal is at a high level, Q2 and Q1 are turned off, and the 12V driving power supply Vdr charges the capacitor E2 to about 12V through the diode D1; when the AH driving signal is at a low level, Q2 and Q1 are conducted, the voltage (about 12V) on E2 passes through a diode D2 and a resistor R6 to the gate of an upper arm MOS tube V1, the potential of the gate is kept 12V higher than the potential A of the source of the MOS tube, and the reliable conduction of the MOS tube V1 is ensured.

When the AL driving signal is at a high level, Q5 and Q6 are cut off, and the grid electrode of the MOS tube of the lower bridge arm is in a cut-off state without driving voltage; when AL is low, Q5 and Q6 are turned on, the 12V driving power Vdr passes through diode D5 and resistor R21 to the gate of lower arm MOS transistor V2, and V2 is in a conducting state. Capacitors C6 and C14 are MOS transistor gate charge leakage resistors and also are driving buffer capacitors, resistor R22 is an E2 charging current-limiting resistor, and capacitors C13 and E4 are filter capacitors.

The sampling circuit comprises a first voltage stabilizing diode 2514, a second voltage stabilizing diode 2615, a first comparator 27, a second comparator 28 and a third MOS tube 29, the same pole ends of the first voltage stabilizing diode 2514 and the second voltage stabilizing diode 2615 are connected with each other, the positive pole end of the first voltage stabilizing diode 2514 is grounded, the negative pole end of the first voltage stabilizing diode 2514 is connected with the positive pole input end of the first comparator 27, the positive pole input end of the first comparator is connected with the output end of the brushless direct current motor driving circuit, after the negative pole input end of the first comparator 27 is grounded, the output end of the first comparator 27 is connected with the source electrode of the third MOS tube 29, the grid electrode of the third MOS tube 29 is connected with the output end of the main control module 1, the drain electrode of the third MOS tube 29 is connected with the positive pole input end of the second comparator 28, the output end of the second comparator 28 is connected with the input end of the main control module 1, and the negative pole input end of the second comparator 28 is connected with the output end of the second comparator 28.

The AD of STM32F030K6T6 itself does not meet the requirement of fast sampling, and a fast external sampling circuit is designed as shown in fig. 5. The circuit belongs to a series-connection type sample-and-hold circuit, and as the frequency width of the TSV912 is far larger than the frequency range of a current signal, an amplifier formed by an operational amplifier and a resistor is considered to be linear. The current signal of the motor winding is converted into a voltage signal Isen through a constantan wire Rs, a voltage regulator tube D28 limits the sampling signal to be below 3.3V, and a diode D29 limits the sampling signal to be positive voltage. After Isen is filtered, amplification and conditioning are carried out through an operational amplifier U3A, wherein a pull-up resistor R2 shifts the input signal to the positive direction. During sampling, setting a grid driving signal of a sampling switch MOS tube Q58 high, and outputting a Vsen signal as a corresponding voltage signal;

the circuit has two new characteristics: firstly, a holding circuit is added, a traditional sampling circuit is not provided with a Q58 part and a U3B part, a current signal is directly sampled, and due to the fact that the sampling time of the STM32F030 is long, interference is easily caused in the period, and the sampling precision is not high; secondly, a sampling resistor Rs is connected with a voltage regulator tube D28 and a diode D29 in parallel to limit the amplitude of a sampling signal, particularly D29, and during the PWM reversing sequence, negative voltage is prevented from being input to a current signal detection end and the circuit is not favorable for normal work.

The motor position detection circuit comprises a plug 30, a resistor I31, a resistor II 32, a resistor III 33, a resistor IV 34, a resistor V35, a resistor VI 36, a capacitor IV 37, a capacitor V38 and a capacitor VI 39, wherein the plug 30 is connected with three Hall signal ends on the brushless DC motor, one ends of the resistor IV 34, the resistor V35 and the resistor VI 36 are respectively and correspondingly connected with three Hall signal ends on the plug 30, the other ends of the resistor IV 34, the resistor V35 and the resistor VI 36 are respectively and correspondingly connected with three input ends of the main control module 1, one ends of the resistor I31, the resistor II 32 and the resistor III 33 are respectively connected with a power output end of the 3.3V power management chip 4, the other end of the resistor I31 is connected with one end of the plug 30 connected with the resistor IV 34, the other end of the resistor II 32 is connected with one end of the plug 30 connected with the resistor V35, the other end of the resistor III 33 is connected with one end of the plug 30 connected with the resistor VI 36, the fourth resistor 34 is connected with the fourth capacitor 37 in series at one end of the main control module 1 and then grounded, the fifth resistor 35 is connected with the fifth capacitor 1 in series at one end of the main control module 1 and then grounded, and the sixth resistor 36 is connected with the sixth capacitor 39 in series at one end of the main control module 1 and then grounded.

As shown in fig. 6, the plug J7 is externally connected to hall signals on the brushless dc motor, and the three hall signals are pulled up to high level by pull-up resistors R78, R79, and R80, i.e., active low level. R82, R84, R89, C31, C32 and C33 are filter circuits, and three signals HA, HB and HC after filtering are connected into STM32F030K6T6 for processing.

The power supply protection circuit comprises a triode ten 40, a diode four 41, a capacitor seven 42, a resistor seven 43 and a resistor eight 44, wherein the base of the triode ten 40 is connected with the output end of the brushless direct current motor driving circuit after being connected with the resistor eight 44 in series, the collector of the triode ten 40 is connected with the power supply output end of the 3.3V power supply management chip 4, the emitter of the triode ten 40 is connected with the positive electrode end of the diode four 41, the negative electrode end of the diode four 41 is connected with the input end of the main control module 1, the capacitor seven 42 is connected with the resistor seven 43 in parallel, one end of the capacitor seven 42 is connected with the negative electrode end of the diode four 41, and the other end of the capacitor seven 42 is grounded.

The electric bicycle often has the condition of motor stalling, in addition, the manual misoperation also can cause the overcurrent condition, and the overcurrent all requires to be handled in the shortest time. The microcontroller can regulate and control the current through current sampling under normal working conditions, but under some abnormal conditions, the protection action time of the microcontroller is possibly longer, and the protection action time mainly comprises the following factors:

the A/D conversion time is long and needs about 20 us;

secondly, current detection is carried out according to periods, and each period is 100 us;

and thirdly, the current sampling circuit is generally provided with a filtering link, the signal sampling is delayed, and the time can reach 10-20us according to different parameters.

Considering the above together, in the worst case, the response time of the microcontroller to the step overcurrent may exceed 150us, which may cause device damage to a few abnormal situations.

The design adds the overcurrent protection signal directly connected to the middle fracture outside the normal speed ring and the current ring, and the specific method is as follows: and (4) normal motor speed regulation, namely when the current does not exceed the warning current value, the current regulation is executed by a current loop. Under a few abnormal conditions including locked rotor and short circuit, the current rises rapidly, and at the moment, AD sampling is not carried out, and the MOS tube is directly closed through interruption to limit the current rise. However, the interference may cause fluctuations in the flip level of the logic comparator circuit, which may cause overlap of protection effects and affect the turn-off function. Therefore, a holding delay circuit is required to be added at the output action end of the protection circuit, so that the protection action can be rapidly executed, and the protection state can be kept for a certain time, thereby avoiding the overlapping of the occurrence and the cancellation of the protection action, as shown in fig. 7;

when overcurrent occurs and ISen rises to a current detection value, the triode Q9 is conducted, the diode is conducted in a forward bias mode, the capacitor C39 is charged through the resistor R84 (with a small resistance value), the voltage of an INT point rises rapidly, the microcontroller is connected to an interrupt pin (interrupt rising edge detection), and the MOS tube is closed rapidly after an interrupt program is started. When the overcurrent signal ISen is cancelled, the level of the capacitor C39 can only be slowly discharged to a low level through the resistor R90 (with a larger resistance), and after the interrupt pin detects the falling edge jump, the protection mechanism is exited, and the circuit enters a normal operation state.

According to the technical scheme, a software flow chart of the brushless direct current motor controller of the low-cost electric bicycle is shown in fig. 8 and mainly comprises a main program, a functional subprogram and an interruption subprogram, wherein the functional subprogram comprises a system initialization module, a position sensor Hall signal capture module, a phase change module, an A/D conversion module and a double closed-loop speed control module. Initialization essentially completes the setting of internal registers, I/O ports, a/D conversion initial values, interrupt registers, and initial values for some state variables. The main software body adopts a sequential structure to realize system initialization and starting of the brushless direct current motor, and then circularly calls an interrupt service subprogram to realize the function and normal operation of the electric bicycle.

1. Hall signal capturing and phase-changing module

STM32F030K6T6 controls the orderly break-make of power switch tube in the contravariant main circuit through detecting hall position sensor output, realizes brushless DC motor's electronic commutation, consequently needs to detect correct hall position signal. When the device runs normally, three paths of Hall signals are output as mutually-differenced 60-degree electrical angle square waves, and six effective input states can be detected by a capture port of the main control chip. If the operation is failed, an illegal state is detected, the operation program is stopped at the moment, if the motor is not started, an invalid state is detected, and a soft start subprogram is operated at the moment to realize the starting of the motor. The commutation module inquires a corresponding relation table (table 1) of input of the position sensor and conduction of a switching tube according to three paths of Hall position signals obtained by the Hall signal capture module, and turns on a power MOSFET corresponding to the inverter main circuit, so that sequential energization of three-phase stator windings of the brushless direct current motor is realized, and the driving motor is driven to run continuously.

TABLE 1 Hall sensor signal and conducting switch tube corresponding relation

HA、HB、HC	Switch tube corresponding to conduction
		1 0 0	V1 and V4
1 1 0	V3 and V4
		1 1 1	V3 and V0
0 1 1	V5 and V0
		0 0 1	V5 and V2
0 0 0	V1 and V2

A fault flag bit is arranged in the phase change module, after the phase change subprogram is started, whether a fault exists in the motor is judged, and if the fault exists, the main control chip responds to a fault signal to start the protection subprogram; if the operation is normal, the commutation module only needs to commutate normally according to the input, and the commutation mark needs to be cleared after commutation is finished.

When the brushless DC motor is static, the rotor position sensor has no commutation signal output, and the motor can not be started by itself. The additional circuit is adopted to control the starting of the motor, but the system cost is increased, the reliability is not high, the soft starting is realized by controlling the brushless direct current motor by a software program, and the soft starting control process is as follows: any two phases of the three-phase windings are electrified under the control of a program, the magnetic potential synthesized by the stator pulls the magnetic poles of the rotor to the same direction as the axis of the rotor, and thus the initial position of the permanent magnet rotor is obtained. Then according to the rotation direction of the motor and the conduction sequence table of the switch tube, the program controls the corresponding windings to be sequentially electrified so that the motor runs, the position of the rotor is not detected in the period, the phase change time interval of the windings is controlled in a time delay manner by software, the duty ratio of the output PWM is also controlled by the program, the duty ratio is slowly increased for reducing the torque pulsation, and when a phase change period is finished, the motor has a certain running speed, the soft start is skipped at the moment, the position sensor detects the position signal of the rotor, and the relation table of the input of the position sensor and the conduction switch tube is inquired, so that the self-control running of the motor is realized.

AD interrupt service program module

The battery voltage, the conversion handle input and the current detection analog quantity in the control system are converted into digital quantities through an A/D converter. During the operation of the brushless DC motor for the electric bicycle, the sampling and control of the rotating speed and the current are completed in an A/D interruption service subroutine. Transient spike interference may be generated in the stator winding commutation process, and in order to improve the accuracy and reliability of the current sampling value, the current sampling time is generally set at the midpoint of the conduction period of the inverter power switching tube. When the current sampling value is larger than the maximum value set by the program, the winding is judged to be overcurrent, the current protection is interrupted in response to the current protection, the current protection is started, and six paths of driving signals of the controller are blocked to be output. When the current sampling value is within the normal range, the software program is normally executed, the speed outer ring and the current inner ring are adjusted according to the input quantity of the rotating handle, and the flow of the A/D interrupt service subprogram is shown in FIG. 9.

3. Double closed loop control module

The double closed-loop control module is the core of the software design of the control system, and has great influence on the control performance of the brushless direct current motor, and comprises a rotating speed outer loop regulator and a current inner loop regulator. The rotating speed regulator makes the rotating speed of the motor change along with the input of the rotating handle, requires good steady-state performance and strong adaptability, and adopts a fuzzy self-adaptive PID control strategy. The current regulator enables the motor to be quickly started under the maximum allowable current, the transition process time is shortened, and the requirement can be met by adopting the traditional Pl control. The input of the rotating speed outer ring regulator is the deviation of a speed given value and a feedback value, and the given value of the current regulator is obtained through fuzzy self-adaptive PID operation. The input of the current inner ring regulator is the deviation between the output of the rotating speed regulator and the current detection value, and the output PWM duty ratio of the controller is regulated through the current regulation PI operation to change the rotating speed of the brushless direct current motor.

The rotating speed ring is the core for realizing the speed control of the brushless direct current motor, better dynamic and static performances of the system can be obtained by adopting a fuzzy self-adaptive PID control strategy, and the defect of poor rapidity of the rotating speed control of a single closed loop can be overcome by introducing a current ring. The rotation speed loop mainly comprises two links of current speed value calculation and fuzzy self-adaptive PID operation, as shown in FIG. 10.

The current regulator is used as an inner ring of the brushless direct current motor double closed-loop control, the motor winding current is controlled while the motor rotating speed is ensured to track the set value of the rotating handle quickly, and the motor is prevented from being damaged due to overcurrent in the rotating speed regulating process. In order to control the rotation speed of the brushless dc motor, the output of the current PI regulator should be converted into the duty ratio value of the output PWM, the terminal voltage of the stator winding determines the rotation speed of the motor, so the magnitude of the winding current is proportional to the rotation speed, the current error determines the PWM duty ratio, and the flow of the current loop regulation subroutine is shown in fig. 11.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims

1. The utility model provides a low-cost brushless DC motor controller of electric bicycle which characterized in that: the device comprises a main control module, a power supply module, a driving module, a sampling circuit, a motor position detection circuit and a power supply protection circuit, wherein the power supply module comprises a storage battery and a voltage reduction conversion circuit, the power output end of the storage battery is connected with the input end of the voltage reduction conversion circuit, the driving module is a brushless direct current motor driving circuit, the output end of the voltage reduction conversion circuit is respectively connected with the power supply ends of the main control module and the brushless direct current motor driving circuit, the power output end of the storage battery is connected with the power input end of the brushless direct current motor driving circuit, the signal input end of the brushless direct current motor driving circuit is connected with the output end of a main control chip, the output end of the driving circuit is connected with three power supply ends of the brushless direct current motor, the detection end of the sampling circuit is connected with the output end of the brushless direct current motor driving circuit, and the signal output end of the sampling circuit is connected with the input end of the main control chip, the detection end of the motor position detection circuit is connected with a Hall signal end of the brushless direct current motor, the output end of the motor position detection circuit is connected with the input end of the main control module, the detection end of the power supply protection circuit is connected with the output end of the brushless direct current motor driving circuit, and the output end of the power supply protection circuit is connected with the input end of the main control module.

2.A low cost electric bicycle brushless dc motor controller according to claim 1, wherein: the master control module is an STM32F030K6T6 type microcontroller.

3. A low cost electric bicycle brushless dc motor controller according to claim 1, wherein: the voltage reduction conversion circuit comprises a starting resistor group, a 5V power management chip, a 3.3V power management chip, a charging capacitor, a divider resistor, a voltage stabilizing tube, a first triode, a second triode and a third triode, wherein the starting resistor group comprises a plurality of resistors which are sequentially connected in series, one end of the starting resistor group is connected with a storage battery, the other end of the starting resistor group is connected with the input end of the 5V power management chip, the output end of the 5V power management chip outputs a 5V power, the output end of the 5V power management chip is connected with the input end of the 3.3V power management chip, and the output end of the 3.3V power management chip outputs a 3.3V power; one end of the charging capacitor is connected with the input end of the 5V power management chip, and the other end of the charging capacitor is grounded; the input end of the 5V power management chip is connected with the negative end of the voltage-stabilizing tube, the positive end of the voltage-stabilizing tube is connected with the base electrode of the triode III, the collector electrode of the triode III is connected with the power output end of the 5V power management chip, and the emitter electrode of the triode III is grounded; the base electrode of the second triode is connected with the collector electrode of the third triode, the emitting electrode of the second triode is grounded, the collector electrode of the second triode is connected with the base electrode of the first triode, the emitting electrode of the first triode is connected with the power supply end of the storage battery after being connected with the divider resistor in series, the collector electrode of the first triode is connected with the input end of the 5V power management chip, and the first triode is a PNP type triode.

4. A low cost electric bicycle brushless dc motor controller according to claim 3, wherein: the driving circuit comprises three non-optical coupling bootstrap floating gate driving circuits with the same circuit structure, and the three non-optical coupling bootstrap floating gate driving circuits are respectively connected in a matching mode corresponding to three power supply ends of the brushless direct current motor.

5. A low cost electric bicycle brushless DC motor controller according to claim 4, characterized in that: the non-optical coupling bootstrap floating gate drive circuit comprises an upper bridge arm drive circuit and a lower bridge arm drive circuit, wherein the upper bridge arm drive circuit comprises a triode IV, a triode V, a triode VI, a diode I, a diode II, an MOS tube I and a capacitor I; the lower bridge arm driving circuit comprises a triode seventh, a triode eighth, a triode ninth, a diode third, an MOS (metal oxide semiconductor) tube II, a capacitor II and a capacitor III;

6. A low cost brushless DC motor controller for electric bicycle according to claim 5, wherein: the fourth triode and the seventh triode are NPN type triodes, the fifth triode, the sixth triode, the eighth triode and the ninth triode are PNP type triodes, and the first capacitor and the third capacitor are electrolytic capacitors.

7. A low cost electric bicycle brushless dc motor controller according to claim 1, wherein: the sampling circuit comprises a voltage stabilizing diode I, a voltage stabilizing diode II, a comparator I, a comparator II and a MOS tube III, wherein the same pole ends of the voltage stabilizing diode I and the voltage stabilizing diode II are mutually connected, the positive pole end of the voltage stabilizing diode I is grounded, the negative pole end of the voltage stabilizing diode I is connected with the positive pole input end of the comparator I, the positive pole input end of the comparator I is connected with the output end of the brushless direct current motor driving circuit, after the negative pole input end of the comparator I is grounded, the output end of the comparator I is connected with the source electrode of the MOS tube III, the grid electrode of the MOS tube III is connected with the output end of the main control module, the drain electrode of the MOS tube III is connected with the positive pole input end of the comparator II, the output end of the comparator II is connected with the input end of the main control module, and the negative pole input end of the comparator II is connected with the output end of the comparator II.

8. A low cost electric bicycle brushless dc motor controller according to claim 3, wherein: the motor position detection circuit comprises a plug, a first resistor, a second resistor, a third resistor, a fourth resistor, a fifth resistor, a sixth resistor, a fourth capacitor, a fifth capacitor and a sixth capacitor, wherein the plug is connected with a three-way Hall signal end on the brushless DC motor, one ends of the fourth resistor, the fifth resistor and the sixth resistor are respectively correspondingly connected with the three-way Hall signal end on the plug, the other ends of the fourth resistor, the fifth resistor and the sixth resistor are respectively correspondingly connected with a three-way input end of a main control module, one ends of the first resistor, the second resistor and the third resistor are respectively connected with a power output end of a 3.3V power management chip, the other end of the first resistor is connected with one end of the fourth resistor, the other end of the second resistor is connected with one end of the fifth resistor, the other end of the third resistor is connected with one end of the sixth resistor, one end of the fourth resistor is connected with the main control module, and then is grounded after being connected with the fourth capacitor in series, the resistor five is connected with one end of the main control module and is connected with the capacitor in series without back grounding, and the resistor six is connected with one end of the main control module and is connected with the capacitor six in series and then grounded.

9. A low cost electric bicycle brushless dc motor controller according to claim 3, wherein: the power protection circuit comprises a triode ten, a diode four, a capacitor seven, a resistor seven and a resistor eight, wherein the base of the triode ten is connected with the output end of the brushless direct current motor driving circuit after being connected with the resistor eight in series, the collector of the triode ten is connected with the power output end of the 3.3V power management chip, the emitter of the triode ten is connected with the positive electrode end of the diode four, the negative electrode end of the diode four is connected with the input end of the main control module, the capacitor seven is connected with the resistor seven in parallel, one end of the capacitor seven is connected with the negative electrode end of the diode four, and the other end of the capacitor seven is grounded.