WO2016015590A1 - 交流接触器的控制器及控制方法 - Google Patents
交流接触器的控制器及控制方法 Download PDFInfo
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- WO2016015590A1 WO2016015590A1 PCT/CN2015/084895 CN2015084895W WO2016015590A1 WO 2016015590 A1 WO2016015590 A1 WO 2016015590A1 CN 2015084895 W CN2015084895 W CN 2015084895W WO 2016015590 A1 WO2016015590 A1 WO 2016015590A1
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
- H02M7/02—Conversion of ac power input into dc power output without possibility of reversal
- H02M7/04—Conversion of ac power input into dc power output without possibility of reversal by static converters
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H47/00—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
- H01H47/02—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for modifying the operation of the relay
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H47/00—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
- H01H47/22—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for supplying energising current for relay coil
- H01H47/223—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for supplying energising current for relay coil adapted to be supplied by AC
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H47/00—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
- H01H47/22—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for supplying energising current for relay coil
- H01H47/32—Energising current supplied by semiconductor device
- H01H47/325—Energising current supplied by semiconductor device by switching regulator
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/12—Arrangements for reducing harmonics from ac input or output
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
- H02H3/08—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current
Definitions
- This invention relates to the field of low voltage electrical appliances and, more particularly, to control techniques for AC contactors.
- the electronic control technology of the AC contactor is mostly based on the control circuit built by the single-chip or discrete components.
- the PWM control method drives the electromagnet of the AC contactor to reliably attract, hold or release.
- the overall technical parameters need to comply with GB14048.4. The requirements specified in the standard and achieve energy saving purposes.
- the Chinese patent application entitled "Energy Saver for AC Contactor” discloses an energy saver for an AC contactor, including a peripheral circuit connected to the AC contactor, and the application number is CN201210196762.4, the publication number is CN102709118A.
- the energy saver disclosed in CN102709118A can only adjust the PWM pulse width of the small current in the electromagnet holding phase under different control voltages, and in the pick-up phase, the PWM pulse width is not adjustable, only through a number of fixed power frequency pulses.
- the driving electromagnet pull-in action can not control the amplitude and dynamic characteristics of the pull-in current, which has a great influence on the pick-up characteristics of the contactor, and is particularly unsuitable for frequent operation, which affects the life of the contactor and is not conducive to energy saving;
- the PWM frequency of the small current in the hold phase is fixed to the power frequency signal.
- the holding current of the 20ms time level is relatively constant current, the dynamic range of the small current within 20ms is large, and the operating frequency band belongs to the human ear. In the range, the noise of the contactor can not be further reduced, and the life of the contactor is also affected.
- the application number is CN201210530495.X
- the publication number is CN103021735A
- the Chinese patent application entitled "AC contactor intelligent control module with high-speed pulse width modulation function” discloses an AC contactor intelligent control module with high-speed pulse width modulation function.
- the utility model comprises an AC/DC power supply, wherein the AC/DC power supply is sequentially supplied with a rectifying and filtering circuit and a power electronic switch for supplying an AC contactor coil; and further comprising a voltage sampling circuit, a single chip control system, a dual DA conversion circuit, and a sawtooth wave generation.
- CN103021735A discloses two completely different control strategies for the electromagnet suction and hold phase.
- the suction phase passes the current feedback loop, adopts the PWM control mode, detects the coil current through the Hall current sensor, and the single chip microcomputer controls the adjustment coil through the current feedback signal. Excitation current; after the end of the suction process, it switches to the low voltage holding circuit through a trigger switching point detecting circuit, and directly supplies DC power to the electromagnet coil in the holding phase to drive the electromagnet to work.
- the entire control module not only adopts the suction and holding two sets of control loops, but also adds the Hall current sensor circuit and the trigger switching point detection circuit.
- Such considerable hardware circuit and software overhead not only increase the cost but also occupy more space, which is particularly disadvantageous for the application of the contactor with smaller current specifications, and the use is limited.
- the coil is kept. The required energy is large, and the above-mentioned low-voltage holding circuit provides sufficient energy to keep the contactor in a holding state, and requires a sufficient capacity to output a certain power, further increasing the cost.
- a freewheeling circuit is disposed in the electromagnet coil circuit.
- the coil current is large in the coil, and the presence of the freewheeling circuit causes the coil current of the contactor during the release process. The change is too slow, making the release process longer and seriously affecting the release performance of the contactor.
- the invention aims to propose a controller and a control method for an AC contactor.
- a controller for an AC contactor comprising:
- a filter rectifier circuit connected to an external alternating current to filter and rectify the external alternating current
- the electromagnet assembly is driven by the output of the filter rectifier circuit to perform an action of sucking, holding or releasing;
- a microcontroller connected to the power tube circuit, the microcontroller outputs a control signal to the power tube circuit, and the power tube circuit is turned on or off according to the control signal to control the action of the electromagnet assembly to perform the pull-in, hold or release;
- the controller also includes:
- control signals are PWM control signals having different duty ratios, and the PWM control signals having different duty ratios cause the current to not exceed a predetermined current threshold during the electromagnet assembly during pick-and-hold;
- the current control loop the current control loop provides a current feedback signal to the microcontroller, and the microcontroller turns off the power transistor circuit when the current control loop detects an overcurrent that exceeds the current threshold.
- the controller further includes a switching circuit that adjusts the current threshold according to different phases:
- the switching circuit sets a first current threshold
- the switching circuit sets a second current threshold
- the first current threshold is greater than the second current threshold.
- the controller further includes a PLC control module.
- the PLC control signal is output to the microcontroller, and the microcontroller controls the power tube circuit according to the PLC control signal to control the electromagnet assembly to perform the pull-in. , hold or release action.
- the electromagnet assembly includes an electromagnet coil, a freewheeling circuit, and a demagnetization circuit;
- the freewheeling circuit is connected to the electromagnet coil, and the freewheeling circuit operates to maintain the current in the electromagnet coil during the pickup phase and the holding phase of the electromagnet coil;
- the demagnetization circuit is connected to the electromagnet coil, and during the release phase of the electromagnet coil, the demagnetization circuit breaker
- the demagnetization circuit utilizes the characteristic that the current across the coil of the electromagnet cannot be abruptly changed, and raises the voltage across the coil of the electromagnet so that the energy of the coil of the electromagnet is quickly dissipated.
- the controller of the AC contactor comprises:
- the external alternating current is connected to the input end of the filtering module
- a rectifier module wherein an input end of the rectifier module is connected to an output end of the filter module;
- the source of the power MOS transistor is connected to the second end of the electromagnet coil, and the output end of the MOS transistor driving device is connected to the gate of the power MOS transistor;
- the input end of the switching circuit is connected to the drain of the power MOS tube, and the output end of the switching circuit is connected to the rectifier module;
- a voltage detecting device wherein an input end of the voltage detecting device is connected to an output end of the rectifier module, and an output end of the voltage detecting device outputs a voltage feedback signal;
- a current detecting device the input end of the current detecting device is connected to the drain of the power MOS tube, and the output end of the current detecting device outputs a current feedback signal;
- the input end of the PLC control module receives the logic control signal, and the output end of the PLC control module outputs the PLC control signal;
- a microcontroller that receives a voltage feedback signal from a voltage detecting device, a current feedback signal from the current detecting device, and a PLC control signal from a PLC control module, the microcontroller to the demagnetizing circuit, the MOS tube driving circuit, and the switching circuit Output control signal;
- the power module the input end of the power module is connected to the output end of the rectifier module, and the power module provides DC power for the demagnetization circuit, the MOS tube driving device, the current detecting device, the voltage detecting device, the microcontroller, and the PLC control module.
- the input of the filter module has two input terminals through which external alternating current is input to the filter module.
- the power module outputs a DC power source having a different voltage, wherein
- the power supply module provides a DC power supply for the demagnetization circuit of 15V;
- the DC power supply provided by the power module for the MOS tube driving device is 12V;
- the power supply module provides 5V for the current detection device, voltage detection device, microcontroller and PLC control module.
- the PLC control module includes an AND gate, one input of the AND gate is an enable terminal, and the other input terminal of the AND gate is a control terminal, and the control terminal receives an external control signal through the isolation circuit;
- the control signal received by the control terminal is input to the AND gate through the isolation circuit.
- the signal of the enable terminal and the signal of the control terminal are output by the AND gate after the AND gate operation, and the output of the AND gate is used as The output of the PLC control module outputs a PLC control signal.
- the first input pin of the microcontroller is coupled to the output of the voltage sensing device, the first input pin receives a voltage feedback signal; and the second input pin of the microcontroller is coupled to the output of the current sensing device
- the second input pin receives the current feedback signal;
- the third input pin of the microcontroller is connected to the output end of the PLC control module, and the third input pin receives the PLC control signal;
- the first output pin of the microcontroller is connected Going to the control end of the demagnetization circuit, the first output pin outputs a demagnetization control signal;
- the second output pin of the microcontroller is connected to the control end of the MOS tube driving device, and the second output pin outputs the MOS tube driving signal;
- the third output pin of the controller is connected to the control end of the switching circuit, and the third output pin outputs a switching control signal.
- a method for controlling an AC contactor including
- the microcontroller Sampling the voltage feedback signal, the microcontroller generates a control signal according to the voltage feedback signal to control the power tube circuit, so that the electromagnet assembly performs the action of sucking, holding or releasing, wherein during the process of attracting and holding the electromagnet assembly,
- the control signals are PWM control signals having different duty cycles, the PWM control signals having different duty cycles such that the current does not exceed a predetermined current threshold during the pick-up and hold of the electromagnet assembly;
- the microcontroller turns off the power tube circuit, and the switching current circuit adjusts the current threshold according to different stages: in the suction phase of the electromagnet assembly, The switching circuit sets a first current threshold, in a holding phase of the electromagnet assembly, the switching circuit sets a second current threshold, and the first current threshold is greater than the second current threshold;
- a PLC module is enabled, and the PLC module outputs a PLC control signal to the microcontroller when enabled, and the microcontroller directly controls the power tube circuit according to the PLC control signal to cause the electromagnet assembly to perform the action of sucking, holding or releasing.
- the controller and control method of the AC contactor of the invention adopts adaptive voltage and current double loop control, and provides a switchable PLC control mode, so that the contactor can reliably attract and maintain in the suction phase in a wide voltage range.
- the stage operates at a substantially constant current and is quickly disconnected during the release phase. It has the characteristics of small size, low cost, simple switching and low power consumption.
- the controller and control method can be applied to contactors of all current levels.
- FIG. 1 discloses a circuit schematic of a controller of an AC contactor in accordance with an embodiment of the present invention.
- FIG. 2 is a block diagram showing a PLC control module in a controller of an AC contactor in accordance with an embodiment of the present invention.
- FIG. 3 discloses a circuit diagram of a switching circuit in a controller of an AC contactor in accordance with an embodiment of the present invention.
- FIG. 4 is a circuit diagram of a demagnetization circuit in a controller of an AC contactor in accordance with an embodiment of the present invention.
- FIG. 5 discloses logic of a control method of an AC contactor according to an embodiment of the present invention.
- the invention provides a controller for an AC contactor, comprising a filter rectifier circuit, an electromagnet assembly, a power tube circuit and a microcontroller.
- the filter rectifier circuit is connected to external AC power to filter and rectify the external AC power.
- the electromagnet assembly is driven by the output of the filter rectifier circuit to perform a pull-in, hold or release action.
- the power tube circuit is connected to the electromagnet assembly.
- the microcontroller is connected to the power tube circuit, and the microcontroller outputs a control signal to the power tube circuit, and the power tube circuit is turned on or off according to the control signal to control the action of the electromagnet assembly to perform the pull-in, hold or release.
- the control mode of the controller is as follows: a voltage feedback signal is obtained through a voltage control loop, and a current feedback signal is obtained through a current control loop.
- the voltage control loop provides a voltage feedback signal to the microcontroller, and the microcontroller generates a control signal according to the voltage feedback signal and outputs the control signal to the power tube circuit, wherein the control signal is during the pick-up and hold of the electromagnet assembly PWM control signals having different duty cycles are output to the power tube circuit such that the current does not exceed a predetermined current threshold during pick-up and hold of the electromagnet assembly.
- the current control loop provides a current feedback signal to the microcontroller, and the microcontroller turns off the power transistor circuit when the current control loop detects an overcurrent that exceeds the current threshold.
- a PLC control module is also provided, and the PLC control module is connected to the microcontroller.
- the PLC control signal is output to the microcontroller, and the microcontroller controls the power tube circuit according to the PLC control signal to control the electromagnet assembly to perform suction.
- the PLC module provides an extended control method for controlling the pull-in, hold or release of the electromagnet directly through the microcontroller using weak current signals.
- weak power control mode strong power control
- a switching circuit is also provided, and the switching circuit adjusts the current threshold according to different phases: in the pickup phase of the electromagnet assembly, the switching circuit sets the first current threshold. The switching circuit sets a second current threshold during the holding phase of the electromagnet assembly. The first current threshold is greater than the second current threshold.
- the controller of the present invention includes an electromagnet coil, a freewheeling circuit, and a demagnetization circuit in the electromagnet assembly.
- the freewheeling circuit is connected to the electromagnet coil, and during the pull-in phase and the holding phase of the electromagnet coil, the freewheeling circuit operates to maintain the current in the electromagnet coil.
- the demagnetization circuit is connected to the electromagnet coil. During the release phase of the electromagnet coil, the demagnetization circuit works.
- the demagnetization circuit utilizes the characteristic that the current at both ends of the electromagnet coil cannot be abruptly, and raises the voltage across the coil of the electromagnet so that the electromagnet coil The energy is quickly dissipated.
- FIG. 1-4 a circuit schematic of a controller of an AC contactor in accordance with an embodiment of the present invention, and a circuit diagram of some of the components and circuits therein are disclosed.
- Figure 1 discloses a circuit schematic of a controller of an AC contactor in accordance with an embodiment of the present invention.
- the thicker lines represent the power loop (higher power loop) and the thinner lines represent the control loop (weak circuit).
- the controller includes:
- the filtering module 101 has an external alternating current connected to the input end of the filtering module 101.
- the input of the filter module 101 has two input terminals A1, A2 through which external alternating current is input to the filter module 101.
- the rectifier module 102 has an input end connected to the output of the filter module 101.
- the filtering module 101 and the rectifying module 102 filter and rectify the external alternating current to generate a pulsed direct current, and the rectifying module 102 outputs the pulsed direct current to the electromagnet coil 103, the power module 108 and the voltage detecting device 111.
- the rectifier module 102 is also coupled to the switching circuit 105 for receiving feedback signals from the switching circuit 105.
- the electromagnet coil 103, the freewheeling circuit 106, and the demagnetization circuit 107 together constitute an electromagnet assembly of the controller.
- the first end M1 of the electromagnet coil is connected to the output end of the rectifying module 102, and the second end M2 of the electromagnet coil is connected to the input terminals of the freewheeling circuit 106 and the demagnetizing circuit 107, the freewheeling circuit 106 and the demagnetizing circuit 107
- the output is connected to the first end M1 of the electromagnet coil.
- the freewheeling circuit 106 and the demagnetizing circuit 107 are substantially parallel, and the freewheeling circuit 106 and the demagnetizing current 107 alternately operate at different stages, as will be described in more detail below.
- Power MOS transistor 104 and MOS transistor driver 109 source of power MOS transistor 104 S is connected to the second terminal M2 of the electromagnet coil 103, and the output of the MOS transistor driving device 109 is connected to the gate G of the power MOS transistor 104.
- the drain D of the power MOS transistor 104 is connected to the switching circuit 105, and the control terminal of the MOS transistor driving device 109 is controlled by the microcontroller 112, and the microcontroller 112 controls the turning-on or turn-off of the power MOS transistor 104 through the MOS transistor driving circuit 109. .
- the switching circuit 105 has an input terminal connected to the drain D of the power MOS transistor 104, an output terminal of the switching circuit 105 connected to the rectifier module 102, and a control terminal of the switching circuit 105 controlled by the microcontroller 112.
- the voltage detecting means 111 the input end of the voltage detecting means 111 is connected to the output end of the rectifying module 102, and the output end of the voltage detecting means 111 outputs a voltage feedback signal to the microcontroller 112.
- the current detecting device 110 has an input terminal connected to the drain D of the power MOS transistor 104, and an output terminal of the current detecting device 110 outputs a current feedback signal to the microcontroller 112.
- FIG. 2 discloses a block diagram of a PLC control module in a controller of an AC contactor in accordance with an embodiment of the present invention.
- the PLC control module 113 includes an AND gate. One input of the AND gate is the enable terminal PLCEN, and the other input of the AND gate is the control terminal PLCD.
- the control terminal PLCD receives an external control signal through the isolation circuit.
- the enable terminal PLCEN can be connected to a unit of the DIP switch, and the input of the enable signal is implemented by the unit's DIP switch.
- the isolation circuit can be implemented by an optocoupler isolation circuit.
- PLCEN When PLCEN is enabled, the control signal of the PLCD of the control terminal can be input to the AND gate through the optocoupler isolation circuit.
- the signal input by the enable terminal PLCEN and the signal input by the control terminal PLCD are processed in the AND gate to generate a PLC control signal, and outputted to the microcontroller 112 by the output terminal PLCON.
- the microcontroller 112 receives the voltage feedback signal from the voltage detecting device 111, the current feedback signal from the current detecting device 110, and the PLC control signal from the PLC control module 113, and the microcontroller 112 goes to the demagnetizing circuit 107, MOS tube drive circuit 109 And the switching circuit 105 outputs a control signal.
- the first input pin PI1 of the microcontroller 112 is coupled to the output of the voltage detecting device 111, and the first input pin PI1 receives the voltage feedback signal.
- the second input pin PI2 of the microcontroller 112 is coupled to the output of the current sensing device 110, and the second input pin PI2 receives the current feedback signal.
- the third input pin PI3 of the microcontroller 112 is connected to the output terminal PLCON of the PLC control module 113, and the third input pin PI3 receives the PLC control signal.
- the first output pin PO1 of the microcontroller 112 is connected to the control terminal of the demagnetization circuit 107, and the first output pin PO1 outputs a demagnetization control signal.
- the second output pin PO2 of the microcontroller 112 is connected to the control terminal of the MOS transistor driving device 109, and the second output pin PO2 outputs a MOS transistor driving signal.
- the third output pin PO3 of the microcontroller 112 is connected to the control terminal of the switching circuit 105, and the third output pin PO3 outputs a switching control signal.
- the power module 108 the input end of the power module 108 is connected to the output end of the rectifier module 102, and the power module 108 is a demagnetization circuit 107, a MOS tube driving device 109, a current detecting device 110, a voltage detecting device 111, a microcontroller 112, and a PLC.
- the control module 113 provides a DC power source.
- the power module 108 outputs DC power supplies having different voltages, wherein the DC power supply provided by the power module 108 to the demagnetization circuit 107 is 15V.
- the DC power supply provided by the power module 108 to the MOS tube driving device 109 is 12V.
- the DC power supply provided by the power module 108 for the current detecting device 110, the voltage detecting device 111, the microcontroller 112, and the PLC control module 113 is 5V.
- the frequency of the AC control voltage input by the external AC power source is 50 Hz, and is rectified by the rectifier module 102 to become 100 Hz.
- the voltage detecting circuit 111 processes the rectified voltage signal to obtain a voltage feedback signal, and the voltage feedback signal is sent to the microcontroller 112.
- the voltage sampling port is the first input pin PI1.
- the microcontroller 112 sets the sampling period to 10 ms, and obtains the effective value of the control voltage by performing a true RMS operation on the sampling point, and uses this as a basis for controlling the operation of the electromagnet assembly.
- the working voltage of the contactor is 110-230V.
- the contactor must be reliably sucked under the control power supply voltage of 85% ⁇ 110%, and released and completely disconnected at 20% ⁇ 75%. From this, it is determined that the pull-in voltage is 90 to 255 V, the holding voltage is 80 to 255 V, and the release voltage is 80 V.
- the release voltage and the minimum value of the pull-in voltage have a hysteresis voltage of 10V.
- the setting of the threshold voltage ensures reliable attraction and release of the electromagnet and prevents the chattering from being caused by the chattering.
- the microcontroller 112 outputs a control signal to the power tube circuit according to the voltage range of the feedback voltage, and controls the electromagnet to perform a corresponding action through the power tube circuit.
- the control electromagnet performs the pull-in action, and if the feedback voltage is the hold voltage, the control electromagnet performs the hold action, and if the feedback voltage is the release voltage, the control electromagnet performs the release action.
- the contactor has a pull-in voltage of 90 to 255 V and a holding voltage of 80 to 255 V, both of which are in a range.
- the feedback voltage may be different.
- PWM technology is applied to reliably control the solenoid coil.
- the microcontroller 112 controls the current in the pull-in and hold phases by outputting PWM waveforms having different duty cycles to the MOS transistor driving device and the power MOS transistor.
- the pull-in, hold PWM duty cycle at different control voltages is stored in the FLASH or EEPROM of the microcontroller 112, and the associated PWM duty cycle is read from the FLASH or EEPROM when the microcontroller 112 is powered up.
- the microcontroller 112 After sampling the control voltage of 2 cycles (20 ms), the microcontroller 112 issues a set PWM waveform according to the control voltage (the control voltage is a voltage feedback signal output by the voltage detecting device 111) for the pull-in phase control.
- the control voltage is continuously detected by the voltage feedback means 111 to modify the PWM duty cycle in real time.
- the pull-in action should be completed, at which point the microcontroller 112 then The acquired control voltage adjusts the PWM duty cycle to the hold interval and continuously adjusts.
- This control method in which the duty ratio of the duty cycle with the control voltage (voltage feedback signal) is adjusted in real time during the pull-in and hold phases is advantageous to achieve the best suction-force cooperation and reduce the core bounce, which is beneficial to realize dynamic control and prolong contactor life. .
- the microcontroller 112 When the control voltage (ie, the voltage feedback signal) is in the normal pull-in and hold interval, ie, 80 to 255V, the microcontroller 112 continues to control based on the control voltage and outputs a PWM having a corresponding duty cycle. If the feedback voltage is lower than 80V, the contactor performs a release action. If the feedback voltage is higher than the upper limit of the pull-in voltage, such as 255V, then the fault may cause the voltage to be too high, and the circuit needs to be turned off in time to protect. Device.
- the controller of the present invention provides a current detecting device 110 that collects a current feedback signal and provides it to the microcontroller 112.
- the microcontroller 112 compares the current feedback signal collected by the current detecting device 110 with a current threshold. When the current feedback signal is greater than the threshold, it indicates that an overcurrent occurs, and at this time, the microcontroller 112 stops the output of the PWM signal to turn off the power transistor circuit.
- the microcontroller 112 should set different current thresholds for control corresponding to different phases.
- Switching circuit 105 is used to achieve adjustment of the current threshold at different stages.
- 3 discloses a circuit diagram of a switching circuit in a controller of an AC contactor in accordance with an embodiment of the present invention.
- the switching circuit 105 includes resistors R4, R5, R6, R7, R8, R9, and R10, a capacitor C1, and a MOS transistor Q2.
- the resistors R4, R5 and R6 are connected in parallel, and the R7 is connected in series with the MOS transistor Q2 and then connected in parallel with the resistors R4, R5 and R6.
- Resistors R9 and R10 serve as auxiliary resistors for the control terminal, and resistor R9 is the control terminal START of switching circuit 105, which is coupled to microcontroller 112.
- Resistor R8 and capacitor C1 act as auxiliary resistors and capacitors for the input and output.
- the Icoil terminal shown in FIG. 3 is the output terminal of the switching circuit 105.
- the In terminal shown in FIG. 3 is an input terminal of the switching circuit 105 and is connected to the drain D of the power MOS transistor 104.
- the microcontroller 112 When the contactor is in the pickup phase, the microcontroller 112 outputs a control signal to the control terminal START, and the pull-in phase control signal is at a high level.
- the MOS transistor Q2 is turned on, and the resistors R4 and R5 are turned on.
- R6 and R7 form a parallel relationship.
- the voltage signal on the resistor network is output from Icoil to the microcontroller 112 as a feedback signal.
- the microcontroller 112 sets a corresponding larger current threshold according to the feedback signal. After the end of the pull-in phase, the signal output from the microcontroller 112 to START is low, the MOS transistor Q2 is turned off, and the voltage signal on the resistor R7 is output from the Icoil to the microcontroller 112 as feedback. Based on the feedback signal, the microcontroller 112 sets a corresponding smaller current threshold for the hold phase. Since the voltage signal on the resistor network and the voltage signal on R7 are different, the microcontroller 112 can achieve the goal of segmentation control according to the difference of the signal.
- the controller of the present invention also includes a demagnetization circuit 107 in the electromagnet assembly.
- 4 is a circuit diagram of a demagnetization circuit in a controller of an AC contactor in accordance with an embodiment of the present invention. As shown in FIG. 4, the demagnetization circuit 107 is connected to both ends of the electromagnet coil 103. In Fig. 4, the electromagnet coil 103 is represented by L1, and both ends of L1 are the M1 end and the M2 end, respectively.
- the demagnetization circuit 107 includes voltage regulators VR1, VR2, and VR3, a diode D1, a MOS transistor Q1, resistors R1, R2, and R3, and capacitors C2 and C3.
- the +D15V terminal is the power input and is connected to the power module.
- the DeMagnet terminal is a control terminal and is connected to the microcontroller 112. When the contactor is in the pull-in or hold phase, the signal output from the microcontroller 112 to the DeMagnet terminal is at a high level.
- the MOS transistor Q1 is not turned on, and the holding current flows in the L1;
- the MOS transistor Q1 is turned on, and L1 flows through the MOS transistor Q1 and the diode D1 through the freewheeling current; when the contactor is in the release phase, the signal output from the microcontroller 112 to the DeMagnet terminal is low, the MOS transistor Q1 is turned off, at this time, the power MOS transistor 104 is also in the off state, and L1 quickly releases energy through the voltage regulator tubes VR2 and VR3 to achieve the purpose of rapid release of the electromagnet.
- the invention also discloses a control method of an AC contactor, comprising:
- the microcontroller Sampling the voltage feedback signal, the microcontroller generates a control signal according to the voltage feedback signal to control the power tube circuit, so that the electromagnet assembly performs the action of sucking, holding or releasing, wherein during the process of picking and holding the electromagnet assembly, the control The signals are PWM control signals having different duty ratios, and the PWM control signals having different duty ratios are output to the power tube circuit such that the current does not exceed a predetermined current threshold during the pick-up and hold of the electromagnet assembly;
- the microcontroller turns off the power tube circuit, and the switching current circuit adjusts the current threshold according to different stages: in the pickup phase of the electromagnet assembly, the switching circuit sets a first current threshold, in the holding phase of the electromagnet assembly, The switching circuit sets a second current threshold, and the first current threshold is greater than the second current threshold;
- a PLC module is enabled, and the PLC module outputs a PLC control signal to the microcontroller when enabled, and the microcontroller directly controls the power tube circuit according to the PLC control signal to cause the electromagnet assembly to perform the action of sucking, holding or releasing.
- FIG. 5 discloses a logic diagram of a method of controlling an AC contactor in accordance with an embodiment of the present invention. As shown in FIG. 5, the control method of the AC contactor of the present invention includes the following process:
- the system initializes and performs an initialization task.
- control voltage > pull-in voltage it is judged whether the contactor is in the pull-in position. If the contactor is not in the pull-in position, adjust the duty cycle of the PWM in the pull-in phase, set the peak of the pull-in current, turn on the power MOS tube, perform the pull-in action, start the pull-in delay, and adjust the current after the delay arrives.
- the peak value is the holding current peak. If the contactor is in the pull-in position, set the hold current peak directly. After the setting of the hold current peak is completed, the duty ratio of the PWM in the hold phase is adjusted. After completing this operation, return to the step of detecting the interrupt flag and wait for the next interrupt flag to appear.
- control voltage > the pull-in voltage it is further determined whether the hold voltage ⁇ control voltage ⁇ the pull-in voltage is established.
- the holding voltage ⁇ control voltage ⁇ the pull-in voltage it is judged whether or not the contactor is in the pull-in position.
- the hold current peak is set, and then the hold phase is adjusted.
- the duty cycle of the PWM After completing this operation, return to the step of detecting the interrupt flag and wait for the next interrupt flag to appear. If the contactor is not in the pull-in position, complete this operation directly, return to the step of detecting the interrupt flag, and wait for the next interrupt flag to appear.
- the controller and control method of the AC contactor of the invention adopts adaptive voltage and current double loop control, and provides a switchable PLC control mode, so that the contactor can reliably attract and maintain in the suction phase in a wide voltage range.
- the stage operates at a substantially constant current and is quickly disconnected during the release phase. It has the characteristics of small size, low cost, simple switching and low power consumption.
- the controller and control method can be applied to contactors of all current levels.
Abstract
Description
Claims (10)
- 一种交流接触器的控制器,包括:滤波整流电路,连接到外部交流电,对外部交流电进行滤波整流;电磁铁组件,由滤波整流电路的输出驱动,执行吸合、保持或释放的动作;功率管电路,连接到电磁铁组件;微控制器,连接到功率管电路,微控制器向功率管电路输出控制信号,功率管电路根据所述控制信号导通或关断,以控制电磁铁组件执行吸合、保持或释放的动作;其特征在于,该控制器还包括:电压控制环,电压控制环向微控制器提供电压反馈信号,微控制器依据所述电压反馈信号产生所述控制信号并将控制信号输出给功率管电路,其中在电磁铁组件的吸合和保持的过程中,所述控制信号是具有不同占空比的PWM控制信号,该具有不同占空比的PWM控制信号使得在电磁铁组件在吸合和保持的过程中电流不超过预定的电流阈值;电流控制环,电流控制环向微控制器提供电流反馈信号,在电流控制环检测到超过所述电流阈值的过流电流时,微控制器关断功率管电路。
- 如权利要求1所述的交流接触器的控制器,其特征在于,还包括切换电路,切换电路根据不同的阶段调节所述电流阈值:在电磁铁组件的吸合阶段,所述切换电路设置第一电流阈值;在电磁铁组件的保持阶段,所述切换电路设置第二电流阈值;第一电流阈值大于第二电流阈值。
- 如权利要求1所述的交流接触器的控制器,其特征在于,还包括PLC控制模块,PLC模块在使能时向微控制器输出PLC控制信号,微控 制器依据PLC控制信号控制功率管电路,以控制电磁铁组件执行吸合、保持或释放的动作。
- 如权利要求1所述的交流接触器的控制器,其特征在于,所述电磁铁组件包括电磁铁线圈、续流电路和去磁电路;所述续流电路连接到电磁铁线圈,在电磁铁线圈的吸合阶段和保持阶段,所述续流电路工作,维持电磁铁线圈中的电流;所述去磁电路连接到电磁铁线圈,在电磁铁线圈的释放阶段,所述去磁电路工作,去磁电路利用电磁铁线圈两端电流不能突变的特性,抬高电磁铁线圈两端的电压,使得电磁铁线圈能量快速耗散。
- 如权利要求1-4中任一项所述的交流接触器的控制器,其特征在于,包括:滤波模块(101),外部交流电流连接到滤波模块(101)的输入端;整流模块(102),整流模块(102)的输入端连接到滤波模块(101)的输出端;电磁铁线圈(103)、续流电路(106)、去磁电路(107),电磁铁线圈的第一端(M1)连接到整流模块(102)的输出端,电磁铁线圈的第二端(M2)连接到续流电路(106)和去磁电路(107)的输入端,续流电路(106)和去磁电路(107)的输出端连接到电磁铁线圈的第一端(M1);功率MOS管(104)和MOS管驱动装置(109),功率MOS管(104)的源极(S)连接到电磁铁线圈(103)的第二端(M2),MOS管驱动装置(109)的输出端连接到功率MOS管(104)的栅极(G);切换电路(105),切换电路(105)的输入端连接到功率MOS管(104)的漏极(D),切换电路(105)的输出端连接到整流模块(102);电压检测装置(111),电压检测装置(111)的输入端连接到整流模块(102)的输出端,电压检测装置(111)的输出端输出电压反馈信号;电流检测装置(110),电流检测装置(110)的输入端连接到功率MOS管(104)的漏极(D),电流检测装置(110)的输出端输出电流反馈信号;PLC控制模块(113),PLC控制模块(113)的输入端接收逻辑控制信号,PLC控制模块(113)的输出端(PLCON)输出PLC控制信号;微控制器(112),微控制器(112)接收来自电压检测装置(111)的电压反馈信号、来自电流检测装置(110)的电流反馈信号和来自PLC控制模块(113)的PLC控制信号,微控制器(112)向去磁电路(107)、MOS管驱动电路(109)和切换电路(105)输出控制信号;电源模块(108),电源模块(108)的输入端连接到整流模块(102)的输出端,电源模块(108)为去磁电路(107)、MOS管驱动装置(109)、电流检测装置(110)、电压检测装置(111)、微控制器(112)和PLC控制模块(113)提供直流电源。
- 如权利要求5所述的交流接触器的控制器,其特征在于,所述滤波模块(101)的输入端具有两个输入端子(A1、A2),外部交流电通过该两个输入端子(A1、A2)输入到滤波模块(101)。
- 如权利要求5所述的交流接触器的控制器,其特征在于,所述电源模块(108)输出具有不同电压的直流电源,其中,电源模块(108)为去磁电路(107)提供的直流电源为15V;电源模块(108)为MOS管驱动装置(109)提供的直流电源为12V;电源模块(108)为电流检测装置(110)、电压检测装置(111)、微控制器(112)和PLC控制模块(113)提供的直流电源为5V。
- 如权利要求5所述的交流接触器的控制器,其特征在于,所述PLC控制模块(113)包括一个与门,所述与门的一个输入端为使能端(PLCEN), 所述与门的另一个输入端为控制端(PLCD),控制端(PLCD)通过隔离电路接收外部的控制信号;在使能端(PLCEN)使能时,控制端(PLCD)接收的控制信号通过隔离电路输入到与门中,使能端(PLCEN)的信号和控制端(PLCD)的信号经过与门运算后由与门的输出端输出,与门的输出端作为PLC控制模块的输出端(PLCON)输出PLC控制信号。
- 如权利要求5所述的交流接触器的控制器,其特征在于,微控制器(112)的第一输入管脚(PI1)连接到电压检测装置(111)的输出端,第一输入管脚(PI1)接收电压反馈信号;微控制器(112)的第二输入管脚(PI2)连接到电流检测装置(110)的输出端,第二输入管脚(PI2)接收电流反馈信号;微控制器(112)的第三输入管脚(PI3)连接到PLC控制模块(113)的输出端(PLCON),第三输入管脚(PI3)接收PLC控制信号;微控制器(112)的第一输出管脚(PO1)连接到去磁电路(107)的控制端,第一输出管脚(PO1)输出去磁控制信号;微控制器(112)的第二输出管脚(PO2)连接到MOS管驱动装置(109)的控制端,第二输出管脚(PO2)输出MOS管驱动信号;微控制器(112)的第三输出管脚(PO3)连接到切换电路(105)的控制端,第三输出管脚(PO3)输出切换控制信号。
- 一种交流接触器的控制方法,其特征在于,包括:对外部交流电进行滤波整流,经滤波整流后的输出驱动电磁铁组件;由微控制器控制功率管电路的导通或关断,通过功率管电路的导通或关断使得电磁铁组件执行吸合、保持或释放的动作;采样电压反馈信号,微控制器依据电压反馈信号产生控制信号来控制功率管电路,使得电磁铁组件执行吸合、保持或释放的动作,其中在电磁 铁组件的吸合和保持的过程中,所述控制信号是具有不同占空比的PWM控制信号,该具有不同占空比的PWM控制信号使得在电磁铁组件的吸合和保持的过程中电流不超过预定的电流阈值;采样电流反馈信号,在电流控制环检测到超过电流阈值的过流电流时,微控制器关断功率管电路,由一切换电路根据不同的阶段调节电流阈值:在电磁铁组件的吸合阶段,所述切换电路设置第一电流阈值,在电磁铁组件的保持阶段,所述切换电路设置第二电流阈值,并且第一电流阈值大于第二电流阈值;使能一PLC模块,该PLC模块在使能时向微控制器输出PLC控制信号,微控制器依据PLC控制信号直接控制功率管电路使得电磁铁组件执行吸合、保持或释放的动作。
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ES15827157T ES2781192T3 (es) | 2014-07-30 | 2015-07-23 | Controlador y método de control para contactor de corriente alterna |
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EP15827157.7A EP3176803B1 (en) | 2014-07-30 | 2015-07-23 | Controller and control method for alternating current contactor |
US15/329,210 US10256063B2 (en) | 2014-07-30 | 2015-07-23 | Controller and control method for alternating current contactor |
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EP3176803A1 (en) | 2017-06-07 |
CN105321770A (zh) | 2016-02-10 |
CA2956170C (en) | 2023-01-24 |
US10256063B2 (en) | 2019-04-09 |
EP3176803B1 (en) | 2019-12-25 |
ES2781192T3 (es) | 2020-08-31 |
US20170213677A1 (en) | 2017-07-27 |
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CN105321770B (zh) | 2017-09-15 |
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