TWI763921B - System and method for detecting abnormal control of a motor - Google Patents

Abstract

A system and method is disclosed to detect abnormal control of a motor, using a controller to catch actual control signal, drive control signal, and current signal from an analog/digital changer, detecting the abnormality of the control signals with a reference abnormality detection method, switching off the first power switch when the actual control signal is abnormal, and switching off the second power switch when the drive control signal is abnormal to raise the operation safety of the motor.

Description

Motor control abnormality detection system and method

The present invention relates to a motor, in particular to a system and method for detecting whether the control signals at all levels are abnormal when the motor is controlled to rotate, so as to provide a safe rotation of the motor.

The robot arm has the characteristics of flexible movement, precise positioning and continuous operation, and has become the best tool for manufacturing and assembly on the product production line. The robot arm needs a motor to provide power. How to reduce the danger to personnel or damage to the robot arm when the motor of the robot arm is abnormally controlled, so as to improve the safety of the robot arm, is a major research topic in the industry.

As shown in FIG. 8 , the motor control abnormality detection system 10 of the prior art robot arm uses the controller 11 to calculate an ideal pulse width modulation signal (Pulse Width Modulation, PWM signal for short), and then outputs the control signal of the PWM signal. To the gate driver 12, the gate driver 12 is controlled to output the driving control signal, and the power transistor (Mosfet) and other components in the power converter 13 are controlled to output current to the motor 14, so as to control the motor 14 to be stable operation or stop. The motor control abnormality detection system 10 is additionally provided with a current sensor 15 to detect the running current of the motor 14 and feed back a current signal to the motor control abnormality detection system 10 to monitor whether the running current of the motor 14 is overloaded, insufficient or abnormal to ensure that Safety of the motor 14 .

However, the control detection system of the motor is only equipped with a current sensor to detect the safety of the motor operation, and does not detect the safety of the control signals at all levels. Poor quality, poor assembly, poor welding or short circuit of the components, etc., will reduce the reliability of the components, so that the output control signal will be disturbed, resulting in abnormal motor control, and the abnormal control signal may even cause the motor to run out of control and burn, causing personnel hazard or damage to the robot arm, which will seriously affect the safety of motor operation. Therefore, there are still problems to be solved in the detection of abnormal control signals of the motor.

The object of the present invention is to provide a motor control abnormality detection system. By setting power switches at all levels of control signals, when a motor control abnormality is detected, the controller will immediately disconnect the control signal power switch and stop controlling the motor to lift the motor. Operational safety.

Another object of the present invention is to provide a motor control abnormality detection method, which utilizes the reference abnormality detection method to detect control signals at all levels, analyzes the abnormality and noise level of the control signals at all levels, determines the abnormal state of motor control, and ensures that the motor Operational reliability.

Another object of the present invention is to provide a motor control abnormality detection method. When the motor is initially turned on, the abnormality of the control signals at all levels is checked periodically, the motor is repaired immediately, and then the motor is operated to maintain the correctness of the motor control.

In order to achieve the purpose of the foregoing invention, in the motor control abnormality detection system of the present invention, the controller uses the preset reference control signal of the PWM signal to form the actual control signal of the PWM signal, sets the analog digital converter to capture the control signal, and sets the The power control part controls the disconnection or turn-on of the first power switch and the second power switch, the gate driver receives the actual control signal control, and generates the drive control signal of the PWM signal, and the gate driver is turned off or turned on by the first power switch. The operating power of the driver, the power converter receives the driving control signal to control the output current to the motor, controls the motor to run or stop, and the operating power of the power converter is disconnected or turned on by the second power switch, and the current sensor detects the motor running current signal to monitor the running motor current. The controller uses the analog digital converter to capture the actual control signal, the driving control signal and the current signal, and when the actual control signal is abnormally controlled, the first power switch is disconnected, and the driving control signal is detected abnormally or the current signal is abnormally detected. , turn off the second power switch.

The reference abnormality detection method of the present invention is used for analyzing and judging the control abnormality of each level of control signal of the motor PWM signal, firstly loading multiple pieces of data of unit calculation data, zeroing data index, error signal count, high-level signal count and low-level signal count, check that the absolute value of the input first control signal value of a piece of data minus the corresponding output second control signal value is not less than the default first signal value error, then the second control signal value is listed For an abnormal control signal, after adding the error signal count and accumulating, jump to the data index adding and accumulating step. If the absolute value of the first control signal value minus the second control signal value is less than the default first signal value error, Then the second control signal value is listed as a normal control signal. For the normal control signal, check that the absolute value of the first control signal value minus the second control signal value is less than the default second signal value error, and the second control signal The value must be greater than the preset signal value threshold. If the above two conditions are not met, the second control signal value is a low-level signal, and the count of the low-level signal is accumulated twice. If the above two conditions are met, the second control signal value is It belongs to the high-level signal, accumulate the count of the high-level signal, add the data index, and check whether the comparison unit calculation data is completed. If the comparison unit calculation data is not completed, continue to compare the next data. If Comparing the unit calculation data is completed, calculate the percentage of the second control signal of high level and the percentage of second control signal of low level, and report the control signal when the count of error signals is greater than the preset abnormal times threshold. Abnormal, and then end the method of benchmark abnormality detection, if the error signal count B is not greater than the threshold of abnormal times, continue to the next step to check, check the percentage of the high-level first control signal minus the absolute value of the high-level second control signal The value is less than the signal percentage error, and the absolute value of the low-level first control signal percentage minus the low-level second control signal is less than the signal percentage error. If the above two conditions are not met, the unit calculation data is judged as an abnormal control signal. Report the abnormality of the control signal. If the above two conditions are met, it is judged that the unit calculation data is a normal control signal, and the method of benchmark abnormality detection is ended.

The unit calculation data of the present invention is the time for converting a voltage signal by an analog-digital converter to obtain the number of PWM signals. Check the error signal count and preset the threshold of abnormal times in proportion to the number of units of calculation data. The first signal value error, the second signal value error and the signal value threshold can be set according to the ratio of the high-level first control signal value.

In the present invention, the controller program is initially detected when the motor is turned on. First, the controller controls the disconnection of the first power switch and the second power switch, inputs a preset reference control signal to the controller to generate an actual control signal, and the controller activates the analog-to-digital converter to capture Take the actual control signal, store the actual control signal, check if the input reference control signal is not completed, then continue to input the preset reference control signal, if the input reference control signal is completed, use the reference abnormal detection method to compare and analyze the reference control signal and the actual control signal If the control signal is abnormal, it will report the actual control signal abnormal, and then end the initial detection controller program when the motor is turned on. If the control signal is normal, the controller is normal.

The present invention initially detects the gate driver program when the motor is turned on. First, the controller controls to turn on the first power switch, inputs a preset reference control signal to the controller to generate an actual control signal, and outputs the actual control signal to the gate driver to generate a drive control signal. The controller starts the analog-to-digital converter to capture the actual control signal and the driving control signal, stores the actual control signal and the driving control signal, checks that the input reference control signal is not completed, and continues to input the default reference control signal, if the input reference control signal is completed, Then use the benchmark abnormality detection method to compare and analyze the actual control signal and the drive control signal, check the abnormality of the control signal, report the actual control signal abnormality, and then end the motor startup initial detection controller program to check that the control signal is normal, then the gate driver is normal .

In the present invention, the power converter program is initially detected when the motor is turned on. First, the controller controls to turn on the second power switch, inputs the preset reference control signal to the controller to generate the actual control signal, and outputs the actual control signal to the gate driver to generate the drive control signal. Then output the drive control signal to the power converter, supply current to rotate the motor, use the current sensor to detect the motor current, the controller activates the analog digital converter to capture the motor current, stores the motor current, and checks if the input reference control signal is not completed, then Continue to input the preset reference control signal. If the input of the reference control signal is completed, check whether the motor current is lower than the current setting value. If the motor current is not lower than the current setting value, report the motor current abnormality, and the controller will control the power control section. Disconnect the first power switch and the second power switch, and then end the motor startup initial detection power converter procedure. If the motor current is lower than the current setting value, the power converter is normal.

In the present invention, in the motor running process, the controller controls the conduction of the first power switch and the second power switch, inputs the preset reference control signal to the controller to generate the actual control signal, outputs the actual control signal to the gate driver to generate the drive control signal, and then outputs the actual control signal to the gate driver to generate the drive control signal. Output the drive control signal to the power converter, supply current to rotate the motor, use the current sensor to detect the motor current, the controller activates the analog digital converter to capture the actual control signal, drive control signal and motor current, store the actual control signal, drive Control signal and motor current, check the reference control signal of unfinished unit calculation data, continue to input the default reference control signal, check the reference control signal of the completed unit calculation data, then use the reference abnormal detection method to compare and analyze the reference control signal and the actual Control signal, actual control signal and drive control signal, check, analyze and compare the abnormal control signal, report the actual control signal and drive control signal abnormal, and disconnect the first power switch and the second power switch, stop controlling the motor, check the control If the signal is normal, then check that the motor current is lower than the current setting value, then continue to control the motor to run the operation procedure, check that the motor current is not lower than the current setting value, then report that the motor current is abnormal, and disconnect the second power switch to stop controlling the motor.

20‧‧‧Motor Control Abnormal Detection System

21‧‧‧Controller

22‧‧‧Gate Driver

23‧‧‧Power Converter

24‧‧‧Motor

25‧‧‧Current Sensor

26‧‧‧Analog-to-Digital Converter

27‧‧‧Power Control Department

S1‧‧‧First Power Switch

S2‧‧‧Second Power Switch

FIG. 1 is a functional diagram of the motor control abnormality detection system of the present invention.

FIG. 2 is a schematic diagram of the motor control signal of the present invention.

FIG. 3 is a flowchart of the benchmark anomaly detection method of the present invention.

FIG. 4 is a flow chart of the motor startup initial detection controller of the present invention.

FIG. 5 is a flow chart of the present invention for the initial detection of the gate driver when the motor is turned on.

FIG. 6 is a flow chart of the current sensor for initial detection of the motor startup according to the present invention.

FIG. 7 is a flow chart of the motor operation procedure of the present invention.

FIG. 8 is a functional diagram of a prior art motor control detection system.

Regarding the technical means adopted by the present invention to achieve the above-mentioned objects and their effects, preferred embodiments are given and described below with the accompanying drawings.

Please refer to FIG. 1 and FIG. 2 at the same time, FIG. 1 is a motor control abnormality detection system 20 of the present invention, and FIG. 2 is a schematic diagram of a motor control signal of the present invention. In Fig. 1, the motor control abnormality detection system 20 of the present invention includes a controller 21, a gate driver 22, a power converter 23, a motor 24, a current sensor 25, and the like. The controller 21 uses the preset reference control signal Pr (see FIG. 2 ) of the PWM signal to interfere with the internal circuit elements of the controller 21 to form the actual control signal Pc (see FIG. 2 ) of the PWM signal, which is output to the gate driver 22 , used to control the gate driver 22 . The controller 21 also uses an analog digital converter (ADC) 26 to capture the actual control signal Pc to detect whether the actual control signal Pc is abnormally controlled. In addition, the controller 21 uses the power control unit 27 to control the first power switch S1 to be turned off or turned on, and is used to supply or cut off the operating power of the gate driver 22 according to the detection of whether the actual control signal Pc is abnormally controlled, so that the gate driver 22 operate or stop.

The controller 21 uses the actual control signal Pc to control the gate driver 22. After the actual control signal Pc is interfered by its internal circuit elements, a drive control signal Pg of the PWM signal is generated, which is output to the power converter 23 to control the output current to the motor 24, so as to The motor 24 is controlled to run or stop. The controller 21 also uses the analog-to-digital converter 26 to capture the driving control signal Pg to detect whether the driving control signal Pg is abnormally controlled. The controller 21 also uses the power control unit 27 to control the second power switch S2 to be turned off or turned on, and is used to supply or cut off the operating power of the power converter 23 according to the detection of whether the driving control signal Pg is abnormally controlled, so that the power converter 23 to operate or stop. The motor control abnormality detection system 20 is additionally provided with a current sensor 25 to detect the current signal of the motor running. The controller 21 uses the analog-to-digital converter 26 to capture the current signal of the current sensor 25 to monitor the running motor current. I. According to the detected abnormality of the motor current I, the controller 21 uses the power control unit 27 to turn off the second power switch S2.

Therefore, in the motor control abnormality detection system 20 of the present invention, a power switch is provided at each level of the control signal. When the abnormal control of the motor 24 is detected, the controller 21 immediately disconnects the power switch of the control signal to stop controlling the motor. 24 rotates to achieve the purpose of the invention to improve the safety of the motor 24 running.

The motor control abnormality detection system 20 of the present invention is aimed at the control signal generators at all levels, such as the controller 21 and the gate driver 22. Due to the interference of the control signals at all levels through the internal components of the control signal generators at all levels, the control signals at all levels are disturbed. The control signals before and after the generator deviate from the ideal control state and produce variation. Therefore, the present invention uses the following reference abnormality detection method to analyze the variation and noise level of the control signals at all levels, and determine whether the motor is abnormally controlled to take immediate action. protection strategy. In FIG. 2, the reference abnormality detection method of the present invention takes the control of the controller 21 as an example. Assuming that the conversion speed of the analog-to-digital converter 26 of the controller 21 to convert the voltage signal is A (signal/microsecond), each signal conversion It takes 1/A (microseconds/signal), the frequency of the output PWM signal from the controller 21 is B (pulse/microsecond), and the period of each PWM signal is 1/B (microseconds/pulse), so the analog-to-digital converter 26 The time required to convert one voltage signal signal is approximately to obtain B/A=N PWM signals, and the N PWM signals are set as the unit calculation data U of the reference abnormality detection method of the present invention.

Since the reference control signal Pr of the controller 21 is the default, the N PWM signals of the unit calculation data U in the reference control signal Pr, each reference signal value Prn, the high-level reference signal value Pr_H, and the low-level reference signal The value Pr_L, the percentage Pr_H% of the high-level reference signal, and the percentage Pr_L% of the low-level reference signal are all known. When the controller 21 uses the reference control signal Pr to generate the actual control signal Pc, the controller 21 uses the analog-to-digital converter 26 to capture the actual control signal Pc, and compares each captured reference control signal value Prn with the corresponding generated value of each reference control signal Pc. An actual control signal value Pcn is compared and analyzed. First, the first signal value error X1 is preset, and the absolute value of the reference control signal value Prn minus the actual control signal value Pcn is less than the first signal value error X1, that is, |Prn-Pcn| Within the acceptable error range, the actual control signal value Pcn is listed as a normal control signal, otherwise it is listed as an abnormal control signal, and the error signal count B is set to accumulate in sequence.

Next, for the normal control signal, the second signal value error X2 is preset, and the absolute value of the reference signal control signal value Prn minus the actual control signal value Pcn is smaller than the second signal value error X2, that is, |Prn-Pcn|< X2, and another preset signal value threshold X3, the actual control signal value Pcn must be greater than the signal value threshold X3, that is, Pcn>X3, to filter the actual control signal value Pcn of high and low levels. For the actual control signal value Pcn that meets the above-mentioned two conditions, the row belongs to the high-level signal, and the high-level signal count H is set to accumulate sequentially. For the actual control signal value Pcn that does not meet the above-mentioned two conditions, the column belongs to the low-level signal, and the low-level signal count L is set to accumulate in sequence. The first signal value error X1, the second signal value error X2, and the signal value threshold X3, for example, can be set according to the ratio of the high-level reference control signal value Pr_H.

After the controller 21 completes the analysis and comparison of the unit calculation data U, it divides the high-level signal count H by the sum of the high-level signal count H and the low-level signal count L, that is, Pc_H%=H/(H+L )*100%, calculate the percentage of the high-level actual control signal Pc_H, the percentage of the low-level actual control signal Pc_L can be obtained from the calculated high-level actual control signal Pc_H%, that is, Pc_L%=1-Pc_H %.

Next, the controller 21 checks the error signal count B, and pre-sets a threshold value C1 of abnormal times according to an appropriate ratio according to the N PWM signals of the known unit calculation data U. If the error signal count B is greater than the preset abnormal times threshold C1, Indicates that the actual control signal Pc is abnormally large, and the controller 21 has a problem in processing the signal, and must report the abnormality of the control signal. If the error signal count B is not greater than the preset abnormal count threshold C1, it means that the actual abnormal count of the control signal Pc is within an acceptable range, and the controller 21 can still maintain normal control. Then, according to the known percentage Pr_H% of the high-level reference signal and the percentage Pr_L% of the low-level reference signal, the signal percentage error C2 is preset according to an appropriate ratio. If the percentage of the high-level reference signal Pr_H% and the high-level actual control signal The absolute value of the subtraction of Pc_H% is less than the signal percentage error C2, namely |Pr_H%-Pc_H%|<C2, and the absolute value of the subtraction of the low-level reference signal percentage Pr_L% and the low-level actual control signal Pc_L% is less than the signal percentage The error C2, namely |Pr_L%-Pc_L%|<C2, indicates that the variation of the high-low level ratio of the signal is within the acceptable error range, which is a normal control signal. If the variation is too large, it belongs to an abnormal control signal, and the controller 21 has a problem in processing the signal, and must report the abnormality of the control signal, so as to complete the reference abnormality detection method of the present invention.

As shown in FIG. 3 , it is a flow chart of the method for detecting an anomaly in the benchmark of the present invention. The detailed steps for detecting the abnormality of the control signal using the reference abnormality detection method in the present invention are described as follows: Step P1, start the reference abnormality detection method; Step P2, load N pieces of data of the unit calculation data, and reset the data index n, Return to zero error signal count B, high-level signal count H, and low-level signal count L; Step P3, compare and analyze the reference control signal value Prn of the nth data with the corresponding actual control signal value Pcn; Step P4 , if the absolute value of the reference control signal value Prn minus the actual control signal value Pcn is smaller than the default first signal value error X1, that is |Prn-Pcn|<X1, then the actual control signal value Pcn is listed as a normal control signal, and Go to step P6, otherwise the absolute value of the reference control signal value Prn minus the actual control signal value Pcn is not less than the default first signal value error X1, then the actual control signal value Pcn is listed as an abnormal control signal, and go to step P5, set the After the error signal count B is accumulated one time, go to step P9.

In step P6, the absolute value of the comparison reference control signal value Prn minus the actual control signal value Pcn is smaller than the preset second signal value error X2, ie |Prn-Pcn|<X2, and the actual control signal value Pcn must be greater than the preset signal value The value threshold X3, that is, Pcn>X3, if the above two conditions are not met, then the actual control signal value Pcn belongs to the low-level signal, and go to step P7 to accumulate the low-level signal count L and add 1 time, and then go to step P9, if If the above two conditions are met, the actual control signal value Pcn belongs to a high-level signal, and the process proceeds to step P8, the accumulated high-level signal count L is incremented by 1, and then to step P9, the data index n is accumulated and incremented by 1, ready for comparison Next data; step P10, check whether the data index n is equal to N data? The comparison of unit calculation data has been completed. If the comparison of unit calculation data has not been completed, go back to step P3 and continue to compare the next data. If the comparison of unit calculation data has been completed, go to step P11 to calculate the actual high-level level. The percentage of the control signal Pc_H and the percentage of the actual control signal Pc_L at the low level.

Then in step P12, check whether the error signal count B is greater than the preset abnormal count threshold C1? If the error signal count B is greater than the abnormal times threshold C1, go to step P13, report the control signal as abnormal, then go to step P16, if the error signal count B is not greater than the abnormal times threshold C1, go to step P14, and then check the high level The absolute value of the subtraction of the reference control signal percentage Pr_H% and the high-level actual control signal Pc_H% is less than the signal percentage error C2, that is, |Pr_H%-Pc_H%|<C2, and the low-level reference control signal percentage Pr_L% and the low-level reference control signal The absolute value of the subtraction of the actual control signal Pc_L% is less than the signal percentage error C2, that is, |Pr_L%-Pc_L%|<C2. If the above two conditions are not met, go to step P13 to report that the control signal is abnormal, and then go to step P16, If the above two conditions are met, go to step P15 to determine that the signal is a normal control signal; finally, in step P16, end the reference abnormality detection method of the present invention.

Although the reference control signal Pr and the actual control signal Pc input and output before and after the controller are used as the object of analysis and comparison, as long as the input reference control signal Pr is set as the reference control signal Pr of the reference abnormality detection method. The first control signal, the output actual control signal Pc is set as the second control signal of the reference abnormality detection method, the reference abnormality detection method can also be applied to the gate driver, correspondingly substitute the actual control signal Pc of the input gate driver into The first control signal of the reference abnormality detection method is to substitute the drive control signal Pg output by the gate driver into the second control signal of the reference abnormality detection method, which can also be used to analyze and compare the actual control of the input and output before and after the gate driver. The signal Pc and the driving control signal Pg determine whether the control signal of the gate driver is abnormal.

Therefore, in the motor control detection method of the present invention, the reference abnormality detection method can be used to detect the control signal generators at all levels, analyze the abnormality and noise level of the control signals of the control signal generators at all levels, and determine whether the motor control is controlled or not. In case of abnormality, the motor is immediately reported to stop, so as to achieve the purpose of the invention to ensure the reliability of the motor operation.

Please refer to FIG. 4 , FIG. 5 and FIG. 6 at the same time, FIG. 4 is a flow chart of the motor startup initial detection controller of the present invention, FIG. 5 is a flow chart of the motor startup initial detection gate driver of the present invention, and FIG. 6 is the present invention The flow chart of the initial detection of the current sensor when the motor is turned on. The reference abnormality detection method of the present invention can be applied to the motor startup initial detection process. In FIG. 4, in step R1, the controller process of the motor startup initial detection starts; in step R2, the controller controls the power control part to disconnect the first motor. A power switch S1 and a second power switch S2; Step R3, input the preset reference control signal Pr to the controller to generate the actual control signal Pc; Step R4, the controller activates the analog-to-digital converter to capture the actual control signal Pc; Step R5, Store the actual control signal Pc; in step R6, check whether the input of the reference control signal Pr is completed? If the input of the reference control signal Pr is not completed, go back to step R3 and continue to input the preset reference control signal Pr. If the input of the reference control signal Pr is completed, then go to step R7, and use the reference abnormal detection method to compare and analyze the reference control signal Pr and Actual control signal Pc; Step R8, check whether the control signal analyzed and compared by the reference abnormality detection method is normal? If the control signal is abnormal, go to step R9 to report that the actual control signal Pc is abnormal, then go to step R10 to end the motor startup initial detection controller program, and repair the controller. If the control signal is normal, the controller is normal, and then go to Step R11, prepare to enter the next detection procedure.

In FIG. 5 , the initial detection of the motor startup of the present invention enters the next detection process, that is, the gate driver is detected. In step T1, the initial detection of the gate driver of the motor is started; in step T2, the controller controls the power control Part turns on the first power switch S1; Step T3, input the preset reference control signal Pr to the controller to generate the actual control signal Pc, and output the actual control signal Pc to the gate driver to generate the drive control signal Pg; Step T4, the controller activates the analog digital The converter captures the actual control signal Pc and the driving control signal Pg; in step T5, the actual control signal Pc and the driving control signal Pg are stored; in step T6, it is checked whether the reference control signal Pr is completed? If the reference control signal Pr is not completed, go back to step T3 and continue to input the preset reference control signal Pr. If the reference control signal Pr is completed, then go to step T7, use the detection benchmark abnormal detection method to compare and analyze the actual control signal Pc and the drive Control signal Pg; Step T8, check whether the control signal analyzed and compared by the reference abnormality detection method is normal? If the control signal is abnormal, go to step T9, report that the drive control signal Pg is abnormal, and then go to step T10, end the motor startup initial detection gate driver program, and repair the controller. If the control signal is normal, the gate driver is normal. Then go to step T11, ready to enter the next detection procedure.

In FIG. 6 , the initial detection of the motor startup of the present invention enters the next detection process, that is, the detection of the power converter. In step V1, the initial detection of the power converter when the motor is turned on begins; in step V2, the controller controls the power control Part turns on the second power switch S2; Step V3, input the preset reference control signal Pr to the controller to generate the actual control signal Pc, output the actual control signal Pc to the gate driver to generate the drive control signal Pg, and then output the drive control signal Pg to the power The converter supplies current to rotate the motor, and uses the current sensor to detect the motor current I; Step V4, the controller starts the analog-to-digital converter to capture the motor current I; Step V5, stores the motor current I; In Step V6, check whether the completion Refer to the control signal Pr? If the reference control signal Pr is not completed, go back to step V3 and continue to input the preset reference control signal Pr. If the reference control signal Pr is completed, go to step V7 to check whether the motor current I is lower than the current setting value? If the motor current I is not lower than the current set value, go to step V8, report that the motor current I is abnormal, and then go to step V9, the controller controls the power control part to turn off the first power switch S1 and the second power switch S2, and then enter Step V10 , end the motor startup initial detection power converter procedure, and repair the power converter. If the motor current I is lower than the current setting value, go to step V11 to prepare to enter the motor running procedure.

As shown in FIG. 7 , it is a flow chart of the motor operation procedure of the present invention. When the motor is turned on, through the initial detection procedure of the motor startup of the present invention, it is confirmed that no abnormality occurs in the control signals at all levels, and the motor can be operated safely. The motor control abnormality detection method of the present invention can also be used to monitor the abnormal operation of the motor control. The detailed steps are described as follows: In step X1, the motor operation procedure is started, and the controller controls the power control part to conduct The first power switch S1 and the second power switch S2; Step X2, input the preset reference control signal Pr to the controller to generate the actual control signal Pc, output the actual control signal Pc to the gate driver to generate the drive control signal Pg, and then output the drive control signal The signal Pg is sent to the power converter to supply current to rotate the motor, and the current sensor is used to detect the motor current I; Step X3, the controller activates the analog-to-digital converter to capture the actual control signal Pc, the driving control signal Pg and the motor current I; Step X4, store the actual control signal Pc, the drive control signal Pg and the motor current I; in step X5, check whether the reference control signal Pr of the unit calculation data is completed? If the reference control signal Pr of the unit calculation data is not completed, go back to step X2, and continue to input the default reference control signal Pr. If the reference control signal Pr of the unit calculation data is completed, go to step X6, and use the benchmark abnormality detection method to compare Analyze the reference control signal Pr and the actual control signal Pc, and the actual control signal Pc and the drive control signal Pg; step X7, check whether the control signals analyzed and compared by the reference abnormality detection method are normal? If the control signal is abnormal, go to step X8, report that the actual control signal Pc and the driving control signal Pg are abnormal, and turn off the first power switch S1 and the second power switch S2, then go to step X11, stop controlling the motor, if the control signal is normal , then go to step X9 to check whether the motor current I is lower than the current set value? If the motor current I is lower than the current set value, go back to step X2, and continue to control the motor to run the operation procedure. If the motor current I is not lower than the current set value, go to step X10, report that the motor current I is abnormal, and disconnect the second motor. The power switch S2 then proceeds to step X11 to stop controlling the motor.

Therefore, the detection method of the motor control of the present invention can be applied to the initial startup or operation of the motor. By periodically checking the control signals of the control signal generators at all levels and the abnormality of the motor current, the motor can be stopped immediately for maintenance, and then the motor can be repaired. The purpose of the invention is to maintain the correctness of the motor control by allowing the motor to operate.

The above descriptions are only for the convenience of describing the preferred embodiments of the present invention, and the scope of the present invention is not limited to these preferred embodiments. Any changes made according to the present invention shall not depart from the spirit of the present invention. , all belong to the scope of the patent application of the present invention.

20‧‧‧Motor Control Abnormal Detection System

21‧‧‧Controller

22‧‧‧Gate Driver

23‧‧‧Power Converter

24‧‧‧Motor

25‧‧‧Current Sensor

26‧‧‧Analog-to-Digital Converter

27‧‧‧Power Control Department

S1‧‧‧First Power Switch

S2‧‧‧Second Power Switch

Claims (9)

A motor control anomaly detection system, comprising: a controller, using a preset reference control signal of a PWM signal to form an actual control signal of the PWM signal, setting an analog-to-digital converter to capture the control signal, and setting a power control part to control a first control signal. A power switch and the second power switch are disconnected or turned on; the gate driver is controlled by receiving the actual control signal, and generates a driving control signal of the PWM signal, and the operating power of the gate driver is turned off or turned on by the first power switch. ; Power converter, receives the drive control signal to control the output current to the motor, controls the motor to run or stop, and disconnects or turns on the operating power of the power converter by the second power switch; Current sensor, detects the current of the motor running signal to monitor the running motor current; wherein, the controller uses an analog digital converter to capture the actual control signal, drive control signal and current signal, and when the actual control signal is detected abnormally, the first power switch is disconnected to detect the drive control When the signal control is abnormal, the second power switch is disconnected, and when the abnormal current signal is detected, the second power switch is disconnected. A method for detecting abnormality in motor control. The steps of analyzing and judging the abnormality of control signals of various control signals of a motor PWM signal by using a reference abnormality detection method include: loading a plurality of pieces of data of unit calculation data, zeroing data indicators, error signal counts, High-level signal count and low-level signal count; check that the absolute value of the input first control signal value of a piece of data minus the corresponding output second control signal value is not less than the default first signal value error, then the first The two control signal values are listed as abnormal control signals. After adding the error signal count and accumulating, jump to the data index adding and accumulating step. If the absolute value of the first control signal value minus the second control signal value is less than the preset number If there is an error in the signal value, the second control signal value is classified as a normal control signal; for the normal control signal, check that the absolute value of the first control signal value minus the second control signal value is less than the default second signal value error, And the second control signal value must be greater than the preset signal value threshold. If the above two conditions are not met, the second control signal value is a low-level signal, and the count of the low-level signal is accumulated twice. If the above two conditions are met, then The second control signal value belongs to the high-level signal, and the count of the high-level signal is accumulated again and again; the data index is accumulated again and again, and check whether the comparison of the unit calculation data is completed. If the comparison of the unit calculation data is not completed, continue the comparison For the next data, if the unit calculation data has been compared, calculate the percentage of the high-level second control signal and the low-level second control signal; check that the error signal count is greater than the preset abnormal count threshold. , then report the abnormality of the control signal, and then end the method of benchmark abnormality detection. If the error signal count B is not greater than the threshold of abnormal times, continue to the next step to check; check the percentage of the first control signal at the high level minus the first control signal at the high level The absolute value of the two control signals is less than the signal percentage error, and the absolute value of the low-level first control signal percentage minus the low-level second control signal is less than the signal percentage error. If the above two conditions are not met, the unit calculation data is determined as Abnormal control signal, report abnormal control signal. If the above two conditions are met, the unit calculation data will be judged as normal control signal, and the method of benchmark abnormality detection will be terminated. The method for detecting abnormality in motor control as described in item 2 of the scope of the patent application, wherein the unit calculation data is the time taken to convert a voltage signal by an analog-to-digital converter to obtain the number of PWM signals. The method for detecting abnormality in motor control as described in item 3 of the scope of the patent application, wherein the error signal count is checked, and a threshold value of abnormal times is preset in proportion to the number of units of calculation data. The motor control abnormality detection method as described in claim 2, wherein the first signal value error, the second signal value error and the signal value threshold are set according to the ratio of the high-level first control signal value. The motor control abnormality detection method as described in claim 2, wherein the step of the reference abnormality detection method applied to the motor startup initial detection controller program includes: the controller controls to turn off the first power switch and the second power switch. Power switch; input the default reference control signal to the controller to generate the actual control signal; the controller activates the analog-to-digital converter to capture the actual control signal; stores the actual control signal; checks if the input reference control signal is not completed, then continues to input the default reference control If the input of the reference control signal is completed, use the reference abnormality detection method to set the reference control signal as the first control signal and the actual control signal as the second control signal, compare and analyze the reference control signal and the actual control signal; check the reference The abnormality detection method analyzes and compares the control signal abnormality, reports the actual control signal abnormality, and then ends the initial detection controller program when the motor is turned on. If the control signal analyzed and compared by the reference abnormality detection method is normal, the controller is normal. The motor control abnormality detection method as described in claim 2, wherein the step of applying the reference abnormality detection method to the initial detection of the gate driver program when the motor is turned on comprises: the controller controls the first power switch to be turned on; Set the reference control signal to the controller to generate the actual control signal, and output the actual control signal to the gate driver to generate the drive control signal; the controller activates the analog-to-digital converter to capture the actual control signal and the drive control signal; Store the actual control signal and the drive control signal ; Check that the input reference control signal is not completed, then continue to input the default reference control signal. If the input reference control signal is completed, use the reference abnormal detection method to set the actual control signal as the first control signal and the drive control signal as the first control signal. Two control signals, compare and analyze the actual control signal and the drive control signal; check the reference abnormality detection method to analyze and compare the control signal abnormality, report the actual control signal abnormality, and then end the motor startup initial detection controller program, if the reference abnormality is detected Method Analysis and comparison If the control signal is normal, the gate driver is normal. The motor control abnormality detection method as described in claim 7, wherein the step of initially detecting the power converter when the motor is turned on comprises: the controller controls the second power switch to be turned on; inputting a preset reference control signal to the controller Generate the actual control signal, output the actual control signal to the gate driver to generate the drive control signal, and then output the drive control signal to the power converter, supply current to rotate the motor, use the current sensor to detect the motor current; the controller activates the analog-to-digital converter Capture motor current; store motor current; check if the input reference control signal is not completed, continue to input the preset reference control signal, if the input reference control signal is completed, check whether the motor current is lower than the current set value; if the motor current is not lower than If the current setting value is set, the motor current is reported abnormal, and the controller controls the power control part to disconnect the first power switch and the second power switch, and then ends the motor startup initial detection power converter procedure, if the motor current is lower than the current setting value , the power converter is normal. The motor control abnormality detection method as described in claim 2, wherein the steps of applying the reference abnormality detection method to the motor operation procedure include: controlling the controller to turn on the first power switch and the second power switch; inputting a preset Set the reference control signal to the controller to generate the actual control signal, output the actual control signal to the gate driver to generate the drive control signal, and then output the drive control signal to the power converter, supply current to rotate the motor, and use the current sensor to detect the motor current; The controller activates the analog-to-digital converter to capture the actual control signal, drive control signal and motor current; stores the actual control signal, drive control signal and motor current; checks the reference control signal of the unfinished unit calculation data, and continues to input the default reference control signal Signal, check the reference control signal of the completed unit calculation data, then use the reference abnormal detection method to compare and analyze the reference control signal and the actual control signal, and the actual control signal and the drive control signal; check the reference abnormal detection method to analyze and compare the control signal abnormality , then report that the actual control signal and drive control signal are abnormal, and disconnect the first power switch and the second power switch, stop controlling the motor, check that the control signal is normal, and then check whether the motor current is lower than the current setting value; if the motor current is low If the motor current is not lower than the current setting value, the motor current is reported as abnormal, and the second power switch is turned off to stop controlling the motor.

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