JP2010028892A - Brushless motor controller, thread winder equipped with it, method of controlling deceleration of brushless motor, and deceleration control program for brushless motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide such structure that can perform deceleration control precisely, in a controller, which controls a brushless motor of such structure that a position sensor for detecting the position of a rotor is arranged at a leading angle. <P>SOLUTION: A motor control unit 20 is equipped with a PWM control unit 23, which changes the wave pattern of a current to be let flow to the coil of the motor by PWM control, based on a signal from a magnetic sensor 14. When the motor control unit 20 controls the brushless motor 10 to be decelerated, the PWM control unit 23 delays the timing of the change of the waveform pattern in cycle units of PWM control. Moreover, the motor control unit 20 is equipped with a delay value setter 22, which sets its delay value, according to the speed range of the rotational speed of the rotor from a set value that is stored in table form in a memory omitted from the figure, and it determines the time to delay the timing of the change of the waveform pattern, according to this delay value. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to control of a brushless motor, and more particularly to control during deceleration of a brushless motor in which a position sensor for detecting the position of a rotor is arranged with an advance angle.

  Conventionally, a brushless motor having a position sensor for detecting the position of the rotor and changing the waveform pattern of energization to the coil at the timing when the position sensor detects the rotor is known. In the brushless motor having this configuration, the analysis of the signal from the position sensor may take a long time, or the excitation of the coil may be delayed, which may cause a delay in the magnetic flux control. Therefore, a configuration in which the position sensor is arranged with an advance angle with respect to the rotation direction of the normal range of the rotor to advance the waveform pattern change timing, thereby compensating for the magnetic flux control delay has been known. Yes. For example, Patent Document 1 discloses a brushless motor of this type.

The brushless motor of Patent Document 1 has a magnetic pole detection element (position sensor) for detecting the pole of the rotor magnet, and the direction switching or on / off operation of the current flowing through the motor coil by detecting the pole of the rotor magnet is a semiconductor. It is the structure performed by an element. This brushless motor has a plurality of sets of the magnetic pole detection elements so as to obtain different advance angles. The brushless motor drive circuit is configured to switch the plurality of sets of magnetic pole detection elements using switch means. Patent Document 1 assumes that the advance angle of the motor can be changed by this configuration, and the maximum torque and the maximum efficiency of the motor can be extracted.
JP-A-6-31780

  When the position sensor is advanced and arranged in a brushless motor, the waveform pattern can be changed at an appropriate timing during acceleration or constant speed, but the waveform pattern change timing may be too early during deceleration. . If the waveform pattern is not changed at an accurate timing, the accuracy of rotation control may be reduced, and power efficiency may be reduced.

  In this regard, the brushless motor of Patent Document 1 is considered to be able to suppress a slight decrease in the accuracy of rotation control by switching to a magnetic pole detection element with a smaller advance angle during deceleration. However, the configuration of Patent Document 1 must include a plurality of sets of magnetic pole detection means, and there is room for improvement from the viewpoint of simplifying the configuration of the brushless motor and reducing manufacturing costs.

  As another method, a timer for the position sensor is provided, and during deceleration control, the waveform pattern is controlled by assuming that the rotor has been detected a predetermined time after the timing at which the position sensor actually detected the rotor. A way to do this is also possible. In this case, the magnetic flux control timing can be electronically delayed as appropriate, but a timer for delaying the timing is required, which complicates the configuration and increases the cost.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to perform precise deceleration control in a brushless motor control device in which a position sensor for detecting the position of a rotor is arranged with an advance angle. It is to provide a simple configuration that enables this.

Means and effects for solving the problems

  The problems to be solved by the present invention are as described above. Next, means for solving the problems and the effects thereof will be described.

  According to a first aspect of the present invention, a brushless comprising a rotor and a position sensor for detecting the position of the rotor, wherein the position sensor controls a brushless motor arranged with a predetermined advance angle. In the motor control device, the following configuration is provided. That is, the brushless motor control device includes a waveform pattern changing unit that changes a waveform pattern of a current flowing through the coil based on a signal from the position sensor. The waveform pattern changing unit changes the waveform pattern of the current flowing through the coil by pulse modulation control, and delays the timing of changing the waveform pattern according to the period of pulse modulation control during deceleration control.

  As a result, during normal rotation, the waveform pattern can be changed so that the detection timing of the rotor is advanced by the advance angle arrangement of the position sensor and the magnetic flux control delay is compensated. On the other hand, at the time of deceleration, it is possible to prevent the waveform pattern from changing too quickly by delaying the waveform pattern change timing. Accordingly, the rotation of the rotor can be precisely controlled even during deceleration, and the rotation of the rotor can be reliably stopped at the intended timing. Moreover, since deceleration control can be performed efficiently, power consumption can be suppressed. Furthermore, since the timing of waveform pattern change is delayed using the period of pulse modulation control, complicated calculations can be omitted, and the burden on the brushless motor control device can be reduced. Furthermore, since it is not necessary to provide a special means such as a timer for delay control of the waveform pattern change timing, the apparatus can be configured simply and a reduction in power consumption can be achieved at low cost.

  The brushless motor control device is preferably configured as follows. That is, the brushless motor control device includes a delay value setting unit that can set different delay values according to the rotational speed of the rotor. The waveform pattern changing unit delays the timing of changing the waveform pattern according to the delay value during deceleration control.

  Thereby, with a simple configuration, the waveform pattern can be changed at an appropriate timing according to the rotation speed, and the rotation of the brushless motor can be controlled more precisely.

  In the brushless motor control device, it is preferable that the waveform pattern changing unit delays the timing of changing the waveform pattern in units of a period of pulse modulation control during deceleration control.

  As a result, the calculation of the waveform pattern change timing can be performed in units of pulse modulation control periods, which can be simplified, and the burden on the brushless motor control device can be further reduced.

  According to the second aspect of the present invention, the following configuration is provided in a yarn winding machine for winding a yarn around a package. That is, the yarn winding machine includes a brushless motor and a brushless motor control device. The brushless motor rotates the package. The brushless motor control device controls the brushless motor. The brushless motor includes a rotor and a position sensor for detecting the position of the rotor. The position sensor is arranged with a predetermined advance angle. The brushless motor control device includes a waveform pattern changing unit that changes a waveform pattern of a current flowing through the coil based on a signal from the position sensor. The waveform pattern changing unit changes the waveform pattern of the current flowing through the coil by pulse modulation control, and delays the timing of changing the waveform pattern according to the period of pulse modulation control during deceleration control.

  Thereby, the rotation of the package at the time of deceleration control can be precisely controlled. Accordingly, when yarn breakage, yarn cut, or the like occurs, the rotation of the package can be quickly stopped at the intended timing, and the return operation can be started, and the overall production efficiency can be improved. In addition, it is possible to suppress the consumption of extra power generated in the package stop control.

  In the yarn winding machine, the brushless motor control device includes a delay value setting unit capable of setting a different delay value according to the rotation speed of the rotor, and the waveform pattern changing unit is configured to use a waveform pattern during deceleration control. It is preferable to delay the change timing according to the delay value.

  Thereby, with a simple configuration, the waveform pattern can be changed at an appropriate timing according to the rotation speed, the rotation of the brushless motor can be controlled more precisely, and the quality of the package can be further improved.

  In the yarn winding machine, it is preferable that the waveform pattern changing unit delays the timing of changing the waveform pattern in units of a period of pulse modulation control during deceleration control.

  As a result, the calculation of the waveform pattern change timing can be simplified by performing the pulse modulation control cycle, so that the burden on the brushless motor control device can be further reduced.

  The yarn winding machine may include a winding drum driven by the brushless motor, and the package may be configured to be driven to rotate when the winding drum is driven to rotate.

  Accordingly, the package can be rotated by the brushless motor that is precisely controlled by the brushless motor control device, so that the winding operation of the package can be stably performed.

  In the yarn winding machine, it is preferable that a traverse groove for traversing the yarn wound around the package is formed on the winding drum.

  Thereby, the deceleration control of the package can be precisely performed while traversing the winding drum. Moreover, even if the weight of the surface portion is increased due to the formation of the traverse groove in the cylindrical winding drum and it is difficult to reduce the weight, the deceleration control can be performed efficiently. The rotation can be controlled appropriately.

  In the yarn winding machine, the brushless motor can be configured to directly rotate the package.

  Thereby, since the package is directly driven by the brushless motor that can be precisely controlled even during deceleration control, the winding operation can be performed stably.

  According to the third aspect of the present invention, the following brushless motor deceleration control method is provided. That is, in the brushless motor controlled by this deceleration control method, the position sensor for detecting the position of the rotor is arranged with a predetermined advance angle, and the pulse pattern of the waveform pattern for energizing the coil is controlled by pulse modulation. It is configured to control rotation. The deceleration control method includes a first step of detecting a rotational speed of the brushless motor, and a timing of changing the waveform pattern according to the rotational speed detected in the first step according to a cycle of pulse modulation control. A second step of delaying.

  As a result, during deceleration control, the waveform pattern change timing can be delayed so as not to become too early. Therefore, the rotor can be decelerated quickly and accurately, and the power consumption required for the deceleration control can be suppressed.

  According to the fourth aspect of the present invention, the following brushless motor deceleration control program is provided. That is, in the brushless motor controlled by this deceleration control program, a position sensor for detecting the position of the rotor is arranged with a predetermined advance angle, and the pulse pattern of the waveform pattern for energizing the coil is controlled by pulse modulation. It is configured to control rotation. The deceleration control program includes a first step for detecting a rotation speed of the brushless motor, and a timing for changing the waveform pattern according to the rotation speed detected in the first step according to a cycle of pulse modulation control. A second step of delaying.

  As a result, during deceleration control, the waveform pattern change timing can be delayed so as not to become too early. Therefore, the rotor can be decelerated quickly and accurately, and the power consumption required for the deceleration control can be suppressed. Further, since it is not necessary to add special hardware such as a timer to the configuration, it can be easily applied to an existing brushless motor.

  In the present invention, “delay in units of pulse modulation control period” means that the delay time is an integral multiple of the period of pulse modulation control.

  Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic diagram showing a state of a brushless motor and a brushless motor control device according to the first embodiment of the present invention. FIG. 2 is a schematic diagram schematically showing the internal configuration of the brushless motor.

  The brushless motor 10 shown in FIG. 1 is connected to a motor control unit (brushless motor control device) 20, and the motor control unit 20 controls the rotation speed, rotation direction, and the like of the brushless motor 10. Although not shown, the motor control unit 20 is configured as a microcomputer, and includes a calculation unit such as a CPU and a storage unit such as a ROM. The storage unit stores a control program for controlling the brushless motor 10.

  As shown in FIG. 2, the brushless motor 10 includes a housing 11, a rotor 12, a coil 13, a magnetic sensor (position sensor) 14, and a speed sensor 15 (not shown in FIG. 2).

  As shown in FIGS. 1 and 2, the housing 11 is configured to accommodate each component of the motor, and a rotor 12 is rotatably supported at the center thereof. An output shaft of the motor is fixed to the rotor 12, and a magnet 16 having an 8-pole configuration in which S poles and N poles are alternately arranged every 45 degrees in mechanical angle is attached.

  The housing 11 includes a plurality of holding portions 17 that protrude in the radial direction toward the rotor 12. In the present embodiment, twelve holding portions 17 are arranged side by side at equal intervals in the circumferential direction so as to surround the outer periphery of the rotor 12. And the coil 13 is hold | maintained at the housing 11 by attaching the coil 13 to each of the holding | maintenance part 17. FIG.

  The coil 13 is composed of a three-phase coil of a U-phase wire, a V-phase wire, and a W-phase wire, and is connected by star connection. The coil 13 is arranged in the clockwise direction in FIG. 2 in the order of the U-phase wire, the V-phase wire, and the W-phase wire, and each is wound around the holding portion 17. The coil 13 is connected to the output unit 26 of the motor control unit 20. When the output unit 26 energizes the coil 13, the coil 13 is excited, a magnetic field is generated, and the rotor 12 rotates. In the motor control unit 20 of the present embodiment, a 120-degree energization method in which current flows in any two of the three-phase coils is employed.

  The magnetic sensor 14 is composed of a hall sensor or the like, and detects a change in the magnetic field of the magnet 16 that rotates with the rotor 12. As shown in FIG. 2, three magnetic sensors 14 are arranged around the rotor 12, one for each of the U phase, the V phase, and the W phase. The motor control unit 20 determines the position of the magnet 16 based on a combination of states of signals input from the three magnetic sensors 14.

  As shown in FIG. 2, the magnetic sensor 14 is arranged with an advance angle of an appropriate angle from the theoretical position indicated by the chain line. The theoretical position means a position where the magnetic sensor 14 is to be arranged when it is assumed that the generated magnetic flux control delay is zero. The magnitude of the advance angle is determined so that the waveform pattern is appropriately changed at the rotational speed in the normal range where the brushless motor 10 is frequently used. In this embodiment, the advance angle is an electrical angle of 25 degrees. It is set to become. Thus, in this embodiment, since the magnetic sensor 14 is arranged to be advanced (mechanical advance angle), the timing for detecting the position of the rotor 12 is advanced, especially during acceleration and high-speed rotation, the waveform pattern Changes can be made at the appropriate time.

  The speed sensor 15 is configured by a Hall IC or the like, and is configured to detect a change in the magnetic field accompanying the rotation of the rotor 12. The motor control unit 20 calculates the current speed of the rotor 12 based on the change in the signal input from the speed sensor 15.

  Next, the motor control unit 20 will be described. As shown in FIG. 1, the motor control unit 20 includes a speed calculation unit 21, a pulse width modulation control unit (PWM control unit) 23 as a waveform pattern change unit, a delay value setting unit 22, an input unit 25, And an output unit 26. The magnetic sensor 14 and the speed sensor 15 are connected to the input unit 25, and the output unit 26 is connected to the coil 13 of the brushless motor 10.

  The speed calculation unit 21 calculates the rotation speed of the rotor 12 based on a signal received from the speed sensor 15 via the input unit 25.

  The PWM control unit 23 generates a waveform pattern for exciting the coil 13 and transmits it to the output unit 26, and the output unit 26 applies a voltage to the coil 13 according to this waveform pattern to excite it. This waveform pattern is changed at a timing at which the magnetic sensor 14 detects that the rotating rotor 12 has reached a predetermined position (rotation phase), or at a timing later by a predetermined time. As a result, the energization of the coil 13 is successively switched to control the magnetic flux, and the rotor 12 receives the magnetic force and rotates.

  The PWM control unit 23 includes a carrier generation circuit (not shown) for generating a constant carrier frequency. The PWM control unit 23 controls the pulse width (waveform pattern) by changing the ON / OFF timing of the pulse signal within the carrier period. When the magnetic sensor 14 detects a change in the magnetic pole, the PWM control unit 23 performs an interrupt process to change the waveform pattern and change the energization state of the coil 13.

  The delay value setting unit 22 is for determining an integer parameter (delay value) of zero or more related to the delay time when the brushless motor 10 is subjected to deceleration control. The delay value is determined for each of a plurality of speed ranges obtained by dividing the rotation speed region of the rotor 12, and a table (delay value determination table) in which the speed range and the delay value are associated is stored in the storage unit in advance. Yes. In this delay value determination table, the delay value is determined so as to increase as the rotational speed of the rotor 12 decreases. The delay value setting unit 22 selects a delay value in the corresponding speed range from the delay value determination table based on the current speed of the rotor 12 obtained by the speed calculation unit 21 during the deceleration control of the motor. To set.

  Next, the delay control of the waveform pattern change timing by setting the delay value will be described with reference to FIG. FIG. 3 is an explanatory diagram showing the delay control for changing the waveform pattern in relation to the rising timing at which the magnetic sensor is turned on and the carrier signal.

  As shown in FIG. 3, the carrier generation circuit included in the PWM control unit 23 of the present embodiment generates a sawtooth carrier signal, and the PWM control unit 23 controls the waveform pattern based on this carrier signal. . In FIG. 3, the start point of the waveform pattern change is indicated by an arrow for each of a normal case where no delay is performed, a case where the delay value = 1, and a case where the delay value = 2. At normal time, the PWM control unit 23 changes the waveform pattern at the rising timing when the magnetic sensor 14 is turned on.

  When the delay value is set to 1, the PWM control unit 23 delays the rising timing at which the magnetic sensor 14 is turned on by one carrier frequency cycle as compared with the normal time, as shown in FIG. Control to change the waveform pattern. Further, when the delay value is set to 2, the PWM control unit 23 changes the waveform pattern by delaying the magnetic sensor 14 by two periods of the carrier frequency with respect to the rising timing when the magnetic sensor 14 is turned on. To control. As described above, when the waveform pattern change timing is delayed, the delay time is set with respect to the rising timing at which the magnetic sensor 14 is turned on, and the waveform pattern change timing is determined. The delay time is controlled to be an integral multiple of a period corresponding to the carrier frequency.

  The output unit 26 includes a power circuit, and the power circuit is composed of switching elements such as transistors and FETs. The power circuit energizes the coil 13 in accordance with the waveform pattern signal generated by the PWM controller 23.

  With this configuration, when the brushless motor 10 is at a constant speed or accelerating, the motor control unit 20 does not particularly delay the waveform pattern change timing, and the timing at which the magnetic sensor 14 detects a change in the magnetic pole (FIG. 3). The waveform pattern is changed at the normal timing shown in FIG. On the other hand, when the motor decelerates, the motor control unit 20 delays the timing at which the waveform pattern is changed with respect to the rising timing at which the magnetic sensor 14 is turned on, based on the delay value set by the delay value setting unit 22. . Thus, the deceleration control can be performed accurately and efficiently by electronically delaying at the time of deceleration to cancel at least a part of the advance angle due to the arrangement of the magnetic sensor.

  Next, deceleration control of the brushless motor 10 by the motor control unit 20 will be described with reference to FIG. FIG. 4 is a flowchart showing control during deceleration of the brushless motor.

  When the deceleration control of the brushless motor 10 is started, the motor control unit 20 stands by until the detection value of the magnetic sensor 14 changes (S101). When the detection value of the magnetic sensor 14 changes, the current rotation speed is calculated by the speed calculation unit 21, a delay value corresponding to the speed range including the obtained speed is acquired from the delay value determination table, and the delay value The setting unit 22 sets an integer variable representing the remaining waiting time for realizing the delay (S102).

  Next, the PWM control unit 23 monitors the carrier signal and repeats the process of decrementing the value of the integer variable every time one cycle elapses until the value of the integer variable becomes 0 or less (S103, S104). When the value of the integer variable becomes 0, the PWM control unit 23 changes the waveform pattern (S105). Then, the process returns to S101, and the processes from S101 to S105 are repeated until the deceleration control is completed.

  As described above, in the deceleration control of the present embodiment, first, the delay value is set to an integer variable, and then the integer variable is subtracted by 1 every time the carrier period elapses, and the waveform is continued until the integer variable becomes zero. It waits without changing the pattern. With this control, the waveform pattern change timing is delayed by the time obtained by multiplying the carrier period by the delay value. For example, when the delay value is set to 2, the processing from S103 to S104 is repeated twice, and the waveform pattern change timing is delayed by two carrier frequency periods. Thus, in this embodiment, since the carrier period is used as a reference for the delay time, it is not necessary to provide a timer for setting the delay timing, and precise deceleration control can be performed at low cost. .

  As described above, the delay value is set in advance for each speed range, and is set so as to increase in order to reduce the error as the rotational speed of the rotor 12 decreases. Thereby, at the time of deceleration control, the waveform pattern can be changed at an appropriate timing regardless of the rotation speed of the motor, and the control of the brushless motor 10 can be made efficient.

  Next, with reference to FIG. 5, the effect at the time of applying the motor control part 20 of this embodiment to the brushless motor 10 is demonstrated. FIG. 5A is a graph showing the relationship between the rotational speed and current of a conventional brushless motor, and FIG. 5B shows the rotational speed (r / min) when the motor control unit 20 of the present invention is applied. It is a graph which shows the relationship with an electric current (A).

  5 (a) and 5 (b) both show the relationship between the change in the rotation speed of the rotor 12 when the deceleration control is performed from the rotation speed in the normal range, and the current that changes with the change in the rotation speed. Is shown. As shown in FIG. 5A and FIG. 5B, when deceleration control is performed and the rotational speed of the rotor 12 starts to decrease, the current amplitude becomes intense in both the conventional technique and the present embodiment. However, when the current amplitude at this time is compared, in the control of the prior art (FIG. 5A), the current amplitude falls within the range of 5A to -5A from the time when the rotational speed falls below 4800 (r / min). The peak is reached when the rotational speed reaches 600 (r / min), and then converges. On the other hand, in the control by the motor control unit 20 of the present invention (FIG. 5 (b)), as in the prior art, a peak is reached when the rotational speed reaches 600 (r / min), and then converges. Even when the rotational speed falls below 4800 (r / min), the amplitude changes in the range of approximately 5A to -5A. After that, although the rotation speed decreases and the amplitude gradually increases, as shown in FIG. 5, the amplitude changes in a smaller range than in the case of the prior art. Thereby, it turns out that the power consumption at the time of deceleration control can be suppressed by applying the motor control part 20 of this invention.

  As described above, the brushless motor 10 of the present embodiment includes the rotor 12 and the magnetic sensor 14 for detecting the position of the rotor 12, and the magnetic sensor 14 has a predetermined advance angle. Be placed. The motor control unit 20 that controls the brushless motor 10 includes a PWM control unit 23 that changes a waveform pattern of a current flowing through the coil 13 based on a signal from the magnetic sensor 14. The PWM controller 23 changes the waveform pattern of the current flowing through the coil 13 by pulse width modulation control. At the time of deceleration control of the brushless motor 10, the PWM control unit 23 delays the timing of changing the waveform pattern according to the carrier period of the PWM control.

  As a result, during normal rotation, the waveform pattern can be changed so as to advance the detection timing of the rotor by the advance angle arrangement of the magnetic sensor 14 and compensate for the magnetic flux control delay. On the other hand, at the time of deceleration, it is possible to prevent the waveform pattern from changing too quickly by delaying the waveform pattern change timing. Accordingly, the rotation of the rotor 12 can be precisely controlled even during deceleration, and the rotation of the rotor 12 can be reliably stopped at the intended timing. Moreover, since deceleration control can be performed efficiently, power consumption can be suppressed. Furthermore, since the timing of changing the waveform pattern is delayed using a period corresponding to the carrier frequency, there is no need for complicated calculation and the burden on the CPU of the motor control unit 20 can be reduced. In addition, since it is not necessary to provide a special configuration such as a timer for delay control of the waveform pattern change timing, the apparatus can be configured simply and power consumption can be reduced at low cost.

  Further, the motor control unit 20 of the present embodiment includes a delay value setting unit 22, which includes the rotation speed of the rotor 12 based on a delay value determination table stored in a storage unit (not shown). Different delay values can be set according to the speed range. The PWM control unit 23 delays the timing of changing the waveform pattern according to the delay value.

  Thereby, with a simple configuration, the waveform pattern can be changed at an appropriate timing according to the speed range, and the brushless motor 10 can be controlled more precisely.

  In addition, the PWM control unit 23 included in the motor control unit 20 of the present embodiment delays the timing of changing the waveform pattern during the deceleration control of the brushless motor 10 by a time that is an integral multiple of the PWM control carrier cycle (in units of cycles). Let

  Thereby, the calculation of the waveform pattern change timing can be simplified by using an integer, and the load on the motor control unit 20 can be further reduced.

  Further, the motor control unit 20 of the present embodiment performs the deceleration control of the brushless motor 10 by the following method. That is, in the first step, the rotational speed of the brushless motor 10 is detected (S102 in FIG. 4). In the second step, the waveform pattern change timing is delayed according to the carrier period (by an integral multiple of the carrier period) in accordance with the rotational speed detected in the first step (S103 to S104).

  As a result, during deceleration control, the waveform pattern change timing can be delayed so as not to become too early. Therefore, the rotor can be decelerated quickly and accurately, and the power consumption required for the deceleration control can be suppressed.

  Moreover, the deceleration control program memorize | stored in the motor control part 20 of this embodiment contains the following steps. That is, in the first step, the rotational speed of the brushless motor 10 is detected (S102). In the second step, the waveform pattern change timing is delayed according to the carrier period (by an integral multiple of the carrier period) in accordance with the rotational speed detected in the first step (S103 to S104).

  As a result, during deceleration control, the waveform pattern change timing can be delayed so as not to become too early. Therefore, the rotor can be decelerated quickly and accurately, and the power consumption required for the deceleration control can be suppressed. Further, the above-described effects can be obtained only by changing the program of the motor control unit 20 without adding a special configuration such as a timer to existing hardware. Therefore, the efficiency of the deceleration control can be realized at a low cost.

  In addition, the brushless motor 10 of 1st Embodiment demonstrated above is applicable to the winder unit with which an automatic winder (yarn winding machine) is provided, for example. Next, a second embodiment in which the brushless motor 10 and the motor control unit 20 of the first embodiment are used in an automatic winder will be described with reference to FIG. FIG. 6 is a front view schematically showing a winder unit included in the automatic winder of the second embodiment.

  The automatic winder shown in FIG. 6 includes a plurality of winder units 50 arranged side by side and a machine control device (not shown) arranged at one end in the arranged direction. The winder unit 50 winds the spun yarn 70 unwound from the yarn supplying bobbin 51 around the winding bobbin 52 while traversing to form a package 60 having a predetermined length and a predetermined shape. As shown in FIG. 6, the winder unit 50 includes a winding unit main body 53 and a unit control unit 80.

  The winding unit main body 53 includes, in the yarn traveling path between the yarn supplying bobbin 51 and the winding drum 54, in order from the yarn supplying bobbin 51 side, an unwinding auxiliary device 55, a tension applying device 56, and a splicer device. 57 and a clearer 58 are arranged.

  The unwinding assisting device 55 assists the unwinding of the yarn from the yarn supplying bobbin 51 by lowering the regulating member 61 covering the core tube in conjunction with the unwinding of the yarn from the yarn supplying bobbin 51. . The regulating member 61 comes into contact with the balloon formed on the yarn feeding bobbin 51 by the rotation and centrifugal force of the yarn unwound from the yarn feeding bobbin 51, and applies an appropriate tension to the balloon to release the yarn. Assist the cocoon. An unillustrated sensor for detecting the chase portion of the yarn feeding bobbin 51 is provided in the vicinity of the restricting member 61. When the sensor detects the descent of the chase portion, the restricting member 61 is followed accordingly. For example, it can be lowered by an air cylinder (not shown).

  The tension applying device 56 applies a predetermined tension to the traveling spun yarn 70. As the tension applying device 56, for example, a gate type device in which movable comb teeth are arranged with respect to fixed comb teeth can be used. The movable comb teeth can be rotated by, for example, a rotary solenoid so that the comb teeth are engaged or released. The tension applying device 56 can apply a certain tension to the wound yarn to improve the quality of the package 60. For the tension applying device 56, for example, a disk type can be adopted in addition to the gate type.

  The splicer device 57 detects the lower thread on the yarn feeding bobbin 51 and the yarn on the package 60 side when the clearer 58 detects a yarn defect, or when the yarn breaks during unwinding from the yarn feeding bobbin 51. The upper thread is spliced.

  The clearer 58 is provided with an unillustrated sensor for detecting the thickness of the spun yarn 70. The clearer 58 is configured to detect a yarn defect by monitoring a yarn thickness signal from the sensor. Further, in the vicinity of the clearer 58, a cutter (not shown) for cutting the spun yarn 70 immediately when a yarn defect is detected is attached.

  On the lower side and upper side of the splicer device 57, the lower yarn guide pipe 65 that catches the lower yarn on the yarn feeding bobbin 51 side and guides it to the splicer device 57, and the upper yarn on the package 60 side is caught on the splicer device 57. An upper thread guide pipe 63 for guiding is provided. Further, the lower thread guide pipe 65 and the upper thread guide pipe 63 are configured to be rotatable about shafts 71 and 72, respectively. A suction port 66 is formed at the tip of the lower thread guide pipe 65, and a suction mouth 64 is provided at the tip of the upper thread guide pipe 63. Appropriate negative pressure sources are connected to the lower thread guide pipe 65 and the upper thread guide pipe 63, respectively, and a suction flow is generated in the suction port 66 and the suction mouth 64 so that the thread ends of the upper thread and the lower thread are moved. It is configured so that it can be sucked and captured.

  Further above the splicer device 57, the take-up bobbin (paper tube, core tube) 52 is traversed by a cradle 67 configured to be able to rotatably hold the take-up bobbin (paper tube, core tube) 52, and the take-up bobbin 52 is driven. And a winding drum (traverse drum) 54 for the purpose. The cradle 67 is configured to be swingable in a direction in which the cradle 67 approaches or separates from the winding drum 54, whereby the package 60 is brought into contact with or separated from the winding drum 54. A spiral traverse groove 68 is formed on the outer peripheral surface of the winding drum 54, and the spun yarn 70 is traversed by the traverse groove 68.

  Further, the winding drum 54 of the present embodiment is configured in a cylindrical shape having a cavity inside, and the traverse groove 68 is formed by forming the surface portion in a concave shape. A plurality of traverse grooves 68 are formed in the winding drum 54, so that a single winding drum 54 can be wound with a different number of winds. Further, the winding unit main body 53 of the present embodiment includes a switching means for the traverse groove 68 including a pin cylinder (not shown). This switching means can change the number of winds during winding by switching the traverse groove 68 with which the spun yarn 70 is engaged.

  By this switching means, ribbon winding can be effectively avoided by switching to a traverse groove having a different number of winds when the ribbon winding generation diameter is reached. Further, even when changing the lot such that the yarn type, count or winding shape is different, the number of winds can be changed only by switching the traverse groove by the switching means, and the replacement work of the winding drum 54 is omitted. can do. Therefore, it is possible to flexibly cope with a lot change and to improve the productivity of the automatic winder.

  The take-up bobbin 52 is driven when the take-up drum 54 disposed to face the take-up bobbin 52 rotates. The winding drum 54 is connected to the output shaft of the brushless motor 10, and the operation of the brushless motor 10 is controlled by the motor control unit 20. With this configuration, the spun yarn 70 unwound from the yarn supplying bobbin 51 can be wound around the winding bobbin 52 at an appropriate speed.

  In the brushless motor 10, a magnetic sensor for detecting the position of the rotor is arranged with an advance angle. The motor control unit 20 includes a speed calculation unit 21, a PWM control unit 23, and a delay value setting unit 22. At the time of winding at a steady speed and at the time of acceleration, the change timing of the waveform pattern is advanced by utilizing the fact that the detection timing of the rotor is advanced by the advancement of the magnetic sensor. On the other hand, when the rotational speed of the package 60 is subjected to deceleration control, a delay value is set and the change timing is electronically delayed so that the waveform pattern change timing does not become too early.

  In the winding unit main body 53 configured as described above, when yarn breakage or yarn cutting occurs during winding, the motor control unit 20 decelerates and stops the rotation of the brushless motor 10 in order to stop the rotation of the package 60. At this time, the PWM control unit 23 performs the deceleration control shown in the flowchart of FIG. That is, a delay value is set according to the rotation speed of the brushless motor 10, and the timing of changing the waveform pattern is delayed based on this delay value. The rotation of the package 60 is finally stopped by a package brake mechanism (not shown).

  After the package 60 stops, the upper thread is captured. The upper thread catching starts the reverse rotation of the package 60 and simultaneously rotates the upper thread guide pipe 63 to the catching position in the vicinity of the package 60 so that the thread end of the upper thread to be unwound is the tip of the suction mouse 64. This is done by sucking in. The thread end of the captured upper thread is guided to the splicer device 57 by the upper thread guide pipe 63 rotating downward.

  Further, the lower thread is captured almost simultaneously with the upper thread. The lower yarn is captured by sucking the yarn end on the yarn feeding bobbin 51 side through the suction port 66 of the lower yarn guide pipe 65. The thread end of the captured lower thread is guided to the splicer device 57 by the lower thread guide pipe 65 turning upward. Thereafter, the yarn ends of the upper yarn and the lower yarn are spliced by the splicer device 57, and the winding operation is resumed.

  On the other hand, the yarn joining operation when all the yarns of the yarn supplying bobbin 51 are wound around the package 60 and a new yarn supplying bobbin is supplied is performed as follows. That is, when the clearer 58 detects that there is no running yarn, the unit control unit 80 transmits a signal for decelerating and stopping the package 60 to the motor control unit 20. Upon receiving this signal, the motor control unit 20 performs the deceleration control shown in the flowchart of FIG.

  Next, the motor control unit 20 reverses the package 60 that has stopped rotating, and unwinds the upper thread from the package 60. The yarn end of the upper yarn is captured by suction with the suction mouth 64 of the upper yarn guide pipe 63 and guided to the splicer device 57 by the rotation of the upper yarn guide pipe 63. At almost the same time, the yarn end of the new yarn bobbin side yarn (lower yarn) is blown up by the air flow, and is sucked and captured by the suction port 66 of the lower yarn guide pipe 65. The lower end of the lower thread is unwound from the yarn supplying bobbin 51 by the rotation of the lower thread guide pipe 65, and the yarn end is guided to the splicer device 57. In addition, the splicer device 57 joins the yarn ends of the upper yarn and the lower yarn. After completion of the yarn joining operation, the brushless motor 10 is driven to resume the winding operation.

  In addition to the yarn splicing operation as described above, the deceleration control of the package 60 is also performed in the doffing operation of collecting the full package 60. That is, when the length of the spun yarn 70 wound around the package 60 reaches a predetermined length, the motor control unit 20 immediately performs the deceleration control shown in the flowchart of FIG. 4 to decelerate the rotation of the package 60. And finally stop. Thereafter, the doffing operation is performed by an unillustrated automatic doffing device that travels between the winding units of the automatic winder. Specifically, the automatic doffing device travels to the position of the winding unit where the package 60 is fully wound, collects the fully wound package that has stopped rotating, and then winds the empty winding bobbin 52 to the winding unit. Supply to the take-up unit.

  As described above, the automatic winder of the present embodiment includes the brushless motor 10 and the motor control unit 20. The brushless motor 10 rotates the package 60. The motor control unit 20 controls the brushless motor 10. The brushless motor 10 includes a rotor 12 and a magnetic sensor 14 for detecting the position of the rotor 12. The magnetic sensor 14 is arranged with a predetermined advance angle. In addition, the motor control unit 20 includes a PWM control unit 23 that changes a waveform pattern of a current flowing through the coil based on a signal from the magnetic sensor 14. The PWM control unit 23 changes the waveform pattern of the current flowing through the coil by pulse width modulation control, and delays the timing of changing the waveform pattern according to the carrier period of PWM control during deceleration control.

  Thereby, rotation of the package 60 at the time of deceleration control can be controlled precisely. Therefore, when yarn breakage, yarn cut, or the like occurs, the rotation of the package 60 can be quickly stopped at the intended timing to start the return operation (yarn splicing operation or the like), and the overall production efficiency can be improved. Moreover, the electric power required for the stop control of the package 60 can be suppressed.

  In the automatic winder of the present embodiment, the motor control unit 20 includes a delay value setting unit 22, and the delay value setting unit 22 is based on a delay value determination table stored in a storage unit (not shown). Different delay values can be set according to the speed range including the rotation speed. The PWM control unit 23 delays the timing of changing the waveform pattern according to the delay value.

  Thereby, with a simple configuration, the waveform pattern can be changed at an appropriate timing according to the speed range, the brushless motor 10 can be controlled more precisely, and the quality of the package can be further improved.

  Further, in the automatic winder of the present embodiment, the PWM control unit 23 included in the motor control unit 20 sets the timing of waveform pattern change during the deceleration control of the brushless motor 10 for a time that is an integral multiple of the PWM control carrier cycle (cycle). Delay in units).

  Thereby, the calculation of the waveform pattern change timing can be simplified by using an integer, and the load on the motor control unit 20 can be further reduced.

  The automatic winder of this embodiment includes a winding drum 54 driven by the brushless motor 10, and the package 60 is driven to rotate as the winding drum 54 rotates.

  Thereby, since the package 60 can be rotated by the brushless motor 10 precisely controlled by the motor control unit 20, the winding work of the package 60 can be stably performed.

  In the automatic winder of this embodiment, the winding drum 54 is formed with a traverse groove 68 for traversing the yarn wound around the package 60.

  Thereby, the deceleration control of the package 60 can be performed precisely while traversing the winding drum 54. Further, the winding drum 54 is often formed in a cylindrical shape (hollow shape) for weight reduction, but the winding drum 54 having a hollow portion inside has a traverse groove 68 as in the present embodiment. In this case, the shape of the peripheral surface portion of the winding drum 54 becomes complicated, and the weight of the winding drum 54 increases. However, since the deceleration control can be efficiently performed in the present embodiment, the rotation of the package 60 can be appropriately controlled even when the winding drum 54 that is difficult to reduce in weight as described above is used.

  Hereinafter, driving of the winding drum 54 with the traverse groove 68 will be described in detail. That is, when the traverse groove is formed in the winding drum 54 configured in a hollow shape, it is necessary to form the bottom and wall of the traverse groove, so that the winding drum is more than the case without the traverse groove. Will increase in weight. Therefore, even if one kind of traverse groove is formed on the winding drum, the presence of the traverse groove limits the weight reduction of the winding drum. Moreover, in recent years, from the viewpoint of effectively avoiding the ribbon winding and the replacement of the winding drum, the type of winding drum 54 having a plurality of types of traverse grooves 68 as in the present embodiment is used. In this case, it is more difficult to reduce the weight.

  In order to drive the winding drum 54 having such a large weight, it is necessary to increase the capacity of the brushless motor 10 in order to accurately perform the deceleration control. However, if the capacity is increased, problems such as an increase in cost occur. In this respect, the brushless motor 10 of the present embodiment is configured to enable the motor controller 20 to perform high-speed rotation of the winding drum 54 and accurate deceleration stop control, and therefore uses the winding drum 54 with increased weight. Even in this case, accurate deceleration control can be performed without increasing the capacity of the brushless motor 10. As a result, the time until deceleration stop can be shortened, and the productivity of the automatic winder package can be improved.

  Next, a third embodiment of the present invention will be described. FIG. 7 shows a schematic diagram of a configuration of a winder unit 50 provided in the automatic winder according to this embodiment. In the following description, the same or similar configurations as those in the second embodiment described above may be denoted by the same reference numerals in the drawings, and description thereof may be omitted.

  In the third embodiment, the winding unit main body 53 provided in the winder unit 50 includes a cradle 67 configured to be able to grip the winding bobbin 52 in a rotatable manner. The winding unit main body 53 includes an arm-type traverse device 91 for traversing the spun yarn 70, and a contact roller 92 that can be driven and rotated in contact with the peripheral surface of the winding bobbin 52 or the peripheral surface of the package 60. It is equipped with. The cradle 67 is configured to be rotatable about a rotation shaft 73, and an increase in the yarn layer diameter due to winding of the spun yarn 70 around the winding bobbin 52 can be absorbed by the rotation of the cradle 67. It is configured as follows.

  In addition, an analog unillustrated angle sensor for detecting the angle (rotation angle) of the cradle 67 is attached to the rotation shaft 73. Since the angle of the cradle 67 changes as the package 60 gets thicker, the diameter of the yarn layer of the package 60 can be detected by detecting the rotation angle of the cradle 67 by the angle sensor. Thereby, the traverse device 91 is controlled according to the package yarn diameter, whereby the yarn can be traversed appropriately. The angle sensor may be a digital sensor, or any other means that can detect the package yarn diameter.

  The traverse device 91 is provided in the vicinity of the contact roller 92. The traverse device 91 includes an elongated arm member 93 configured to be rotatable around a support shaft, a hook-shaped traverse guide 90 formed at the tip of the arm member 93, and a traverse guide for driving the arm member 93. A drive motor 94. The arm member 93 is reciprocally swung as indicated by the arrow in FIG. 7 by the traverse guide drive motor 94, whereby the spun yarn 70 is traversed. The operation of the traverse guide drive motor 94 is controlled by the unit controller 80.

  The brushless motor 10 is attached to a portion of the cradle 67 that sandwiches the take-up bobbin 52, so that the take-up bobbin 52 is driven to rotate and the spun yarn 70 is taken up. The brushless motor 10 has the same configuration as the brushless motor shown in FIGS. 1 and 2, and is controlled by the motor control unit 20. The motor control unit 20 has the same configuration as the motor control unit 20 shown in FIG. 1 and includes a speed calculation unit 21, a delay value setting unit 22, and a PWM control unit 23.

  Also in the automatic winder of the third embodiment, when the yarn breakage or the yarn cut occurs, the brushless motor 10 is controlled to decelerate while delaying the timing of changing the waveform pattern, thereby accurately rotating the package 60 in a short time. Can be stopped. The subsequent yarn joining operation and doffing operation are the same as those in the second embodiment described above, and thus the description thereof is omitted.

  As described above, in the automatic winder of this embodiment, the brushless motor 10 directly drives the package 60 to rotate.

  Thus, the package 60 is directly driven by the brushless motor 10 that can be precisely controlled even during deceleration control. Therefore, the winding operation can be performed stably.

  Although the preferred embodiment of the present invention has been described above, the above configuration can be further modified as follows.

  In the above embodiment, when the delay value is set to 1, the timing for changing the waveform pattern is configured to be delayed by one cycle of the carrier signal, but the present invention is not limited to this configuration. For example, when the delay value is set to 1, the relationship between the delay value and the actual delay time can be changed as appropriate, such as setting the delay time to be two periods or three periods or more of the carrier signal. Further, the waveform pattern change timing is not limited to the case where the waveform pattern is delayed by an integral multiple of the carrier period.

  The position of the rotor 12 can be changed to be detected by various position sensors such as an encoder instead of using the magnetic sensor 14 as in the above embodiment.

  The mounting position of the magnetic sensor 14 is not limited to the position of the above-described embodiment (see FIG. 2), and is arranged with an appropriate advance angle (mechanical advance angle) at the time of assembly of the brushless motor, for example. be able to. The advance amount of the magnetic sensor 14 may be appropriately determined in consideration of the rotational speed region where the brushless motor 10 is normally used.

  The carrier generation circuit of the PWM control unit 23 can be changed to a configuration that generates, for example, a triangular wave as a carrier signal instead of a sawtooth wave.

  Instead of the configuration in which the waveform pattern is changed by pulse width modulation control, the configuration can be changed to a configuration in which the waveform pattern is changed by pulse amplitude modulation control.

  In the brushless motor 10 of the above embodiment, the configurations of the rotor 12 and the coil 13 can be changed as appropriate. For example, the configuration of the magnet attached to the rotor can be a 2-pole or 4-pole configuration, or the number of holding portions 17 to which the coils 13 are attached can be changed.

  The rotational speed of the rotor 12 can be changed to be calculated from the detection value of the magnetic sensor 14, for example, instead of the configuration detected by the speed sensor 15.

  The winder unit 50 (FIG. 7) of the third embodiment has a configuration in which the package 60 is directly driven by the brushless motor 10, but the configuration can be changed to a configuration in which the contact roller 92 is driven by the brushless motor 10 (contact roller drive type). it can. Moreover, it can change to the structure provided with a belt drive type traverse device instead of the arm type traverse device 91.

The schematic diagram which shows the mode of the brushless motor and brushless motor control apparatus which concern on 1st Embodiment of this invention. The schematic diagram which shows roughly the internal structure of a brushless motor. Explanatory drawing which shows the delay control of a waveform pattern change by the relationship between the rise timing which a magnetic sensor turns ON, and a carrier signal. The flowchart which shows the control at the time of the deceleration of a brushless motor. The graph which shows each change of the electric current at the time of carrying out deceleration control of the brushless motor by the method of a prior art and this invention. The front view of the winder unit with which the automatic winder which concerns on 2nd Embodiment is provided. The front view of the winder unit with which the automatic winder which concerns on 3rd Embodiment is provided.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Brushless motor 11 Housing 12 Rotor 13 Coil 14 Magnetic sensor (position sensor)
15 Speed sensor 20 Motor controller (brushless motor controller)
22 Delay value setting unit 23 PWM control unit (waveform pattern changing unit)

Claims (11)

In a brushless motor control device, comprising: a rotor; and a position sensor for detecting the position of the rotor, wherein the position sensor controls a brushless motor arranged with a predetermined advance angle.
A waveform pattern changing unit for changing a waveform pattern of a current flowing through the coil based on a signal from the position sensor;
The waveform pattern changing unit changes a waveform pattern of a current flowing through the coil by pulse modulation control, and delays the timing of changing the waveform pattern according to the period of the pulse modulation control during deceleration control. Motor control device. The brushless motor control device according to claim 1,
A delay value setting unit capable of setting a different delay value according to the rotation speed of the rotor,
The waveform pattern changing unit delays the timing of changing a waveform pattern according to the delay value during deceleration control. The brushless motor control device according to claim 1 or 2,
The said waveform pattern change part delays the timing of a waveform pattern change at the period of pulse modulation control at the time of deceleration control, The brushless motor control apparatus characterized by the above-mentioned. In a yarn winding machine for winding a yarn around a package,
A brushless motor for rotating the package;
A brushless motor control device for controlling the brushless motor;
With
The brushless motor includes a rotor and a position sensor for detecting the position of the rotor,
The position sensor is arranged with a predetermined advance angle,
The brushless motor control device includes a waveform pattern changing unit that changes a waveform pattern of a current flowing through the coil based on a signal from the position sensor,
The waveform pattern changing unit changes a waveform pattern of a current flowing through the coil by pulse modulation control, and delays the timing of changing the waveform pattern according to the period of the pulse modulation control during deceleration control. Take machine. The yarn winding machine according to claim 4,
The brushless motor control device includes a delay value setting unit capable of setting different delay values according to the rotation speed of the rotor, and the waveform pattern changing unit sets the timing of changing the waveform pattern during the deceleration control. A yarn winding machine characterized by delaying in accordance with the speed. The yarn winding machine according to claim 4 or 5,
The said waveform pattern change part delays the timing of a waveform pattern change in the period of pulse modulation control at the time of deceleration control, The yarn winding machine characterized by the above-mentioned. A yarn winding machine according to any one of claims 4 to 6,
A winding drum driven by the brushless motor;
The yarn winding machine, wherein the package is driven to rotate as the winding drum is driven to rotate. The yarn winding machine according to claim 7,
The yarn winding machine is characterized in that a traverse groove for traversing the yarn wound around the package is formed in the winding drum. A yarn winding machine according to any one of claims 4 to 6,
The yarn winding machine, wherein the brushless motor directly rotates the package. In a brushless motor deceleration control method in which a position sensor for detecting the position of the rotor is arranged with a predetermined advance angle, and the rotation of the rotor is controlled by pulse modulation control of a waveform pattern energized to the coil.
A first step of detecting a rotational speed of the brushless motor;
A second step of delaying the timing of changing the waveform pattern in accordance with the period of pulse modulation control in accordance with the rotational speed detected in the first step;
A reduction control method for a brushless motor, comprising: In a brushless motor deceleration control program in which a position sensor for detecting the position of the rotor is arranged with a predetermined advance angle, and the rotation of the rotor is controlled by pulse modulation control of a waveform pattern energized to the coil.
A first step of detecting a rotational speed of the brushless motor;
A second step of delaying the timing of changing the waveform pattern in accordance with the period of pulse modulation control in accordance with the rotational speed detected in the first step;
A reduction control program for a brushless motor, comprising:

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