WO2024169147A1 - 一种三相电源缺相检测电路及bldc电机控制器 - Google Patents

一种三相电源缺相检测电路及bldc电机控制器 Download PDF

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Publication number
WO2024169147A1
WO2024169147A1 PCT/CN2023/113414 CN2023113414W WO2024169147A1 WO 2024169147 A1 WO2024169147 A1 WO 2024169147A1 CN 2023113414 W CN2023113414 W CN 2023113414W WO 2024169147 A1 WO2024169147 A1 WO 2024169147A1
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Prior art keywords
circuit
power supply
phase
input
resistor
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Ceased
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PCT/CN2023/113414
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English (en)
French (fr)
Inventor
陈云生
张�杰
张泽隆
徐小三
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Zhongshan Broad Ocean Motor Co Ltd
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Zhongshan Broad Ocean Motor Co Ltd
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Publication of WO2024169147A1 publication Critical patent/WO2024169147A1/zh
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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R1/00—Details of instruments or arrangements of the types included in groups G01R5/00 - G01R13/00 and G01R31/00
    • G01R1/30—Structural combination of electric measuring instruments with basic electronic circuits, e.g. with amplifier
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R29/00—Arrangements for measuring or indicating electric quantities not covered by groups G01R19/00 - G01R27/00
    • G01R29/16—Measuring asymmetry of polyphase networks
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/40—Testing power supplies
    • G01R31/42—AC power supplies
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H9/00—Emergency protective circuit arrangements for limiting excess current or voltage without disconnection
    • H02H9/02—Emergency protective circuit arrangements for limiting excess current or voltage without disconnection responsive to excess current
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J9/00—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting
    • H02J9/04—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source
    • H02J9/06—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over, e.g. UPS systems
    • 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
    • H02M3/00—Conversion of DC power input into DC power output
    • H02M3/02—Conversion of DC power input into DC power output without intermediate conversion into AC
    • H02M3/04—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters
    • H02M3/06—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using resistors or capacitors, e.g. potential divider
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
    • H02P29/02—Providing protection against overload without automatic interruption of supply
    • H02P29/024—Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor

Definitions

  • the invention relates to a three-phase power supply phase loss detection circuit and a BLDC motor controller.
  • BLDC motors are widely used in various electrical equipment due to their advantages such as environmental protection, power saving and easy control, such as fans, air conditioners, electric drills, vacuum cleaners, etc.
  • the electrical wiring diagram is shown in Figure 1.
  • the three-phase AC input power of the mains is connected to the motor controller of the BLDC motor through an air switch.
  • a surge protection circuit is set behind the three-phase rectifier circuit in the motor controller, as shown in Figure 2.
  • the surge protection circuit includes a relay and a PTC resistor.
  • the electromagnetic switch JK in the relay is connected in parallel with the PTC resistor, and the coil RY in the relay is input by the microprocessor MCU in the motor controller.
  • the output signal (generally through the relay drive circuit) is controlled.
  • the electromagnetic switch JK in the relay Before the motor controller is powered on, the electromagnetic switch JK in the relay is disconnected. When the power is turned on, the current flows through the PTC resistor into the charging capacitor and the inverter circuit.
  • the PTC resistor has a good resistance to surge current and effectively protects the charging capacitor and the IGBT switch in the inverter circuit.
  • the microprocessor MCU outputs a signal to control the coil RY in the relay to close the electromagnetic switch JK, thereby short-circuiting the PTC resistor.
  • the current coming out of the three-phase rectifier circuit passes through the electromagnetic switch JK into the charging capacitor and the inverter circuit, avoiding the loss of electric energy by the PTC resistor during motor operation.
  • UPS Uninterruptable Power Supply
  • UPS Uninterruptable Power Supply
  • the main advantage of UPS lies in its uninterruptible power supply capability.
  • the UPS energy storage battery supplies power to the load.
  • Most of the above load electrical equipment or systems using UPS power supply contain BLDC motors.
  • the BLDC motor should be protected.
  • the UPS power switching process that is, the AC input failure of the mains is switched to the UPS power supply
  • the BLDC motor will trigger a huge impact current to enter the motor controller, which is easy to damage the controller hardware.
  • the electrical wiring diagram is shown in Figure 3.
  • the main reason for the damage to the motor controller hardware is that in the case of AC input failure and power failure, the coil RY in the relay in the surge protection circuit is It takes at least a few seconds to release all the electrical energy and disconnect the electromagnetic switch JK in the relay.
  • the switching time from the AC input power failure to the UPS power supply is less than 2 seconds. Therefore, the huge impact current generated during the UPS power switching process directly passes through the electromagnetic switch JK in the relay, causing a great impact on the electronic devices behind it and damaging the motor controller hardware.
  • the air switch used in the middle connection may also trip, and there is a high probability that the power supply will trip.
  • An object of the present invention is to provide a three-phase power supply phase loss detection circuit, which can not only output a phase loss signal, but also quickly output a relay control signal, so that before the UPS power is switched, the coil RY in the relay in the surge protection circuit in the BLDC motor controller can quickly release the electric energy, so that the electromagnetic switch JK in the relay is disconnected, so as to avoid the huge impact current generated during the UPS power switching process from damaging the motor controller hardware.
  • Another object of the present invention is to provide a BLDC motor controller to solve the technical problem in the prior art that during the UPS power switching process, the surge protection circuit of the motor controller fails to protect against surge current due to untimely response, causing damage to the motor controller hardware.
  • a three-phase power supply phase loss detection circuit characterized in that it includes a 3-way rectifier circuit, a step-down circuit and a comparison circuit 1, the input ends of the 3-way rectifier circuits are respectively connected to the three-phase input power supplies U, V, and W, the output ends of the 3-way rectifier circuits are connected together as the input end of the step-down circuit, the output end of the step-down circuit is connected to the input end of the comparison circuit 1, and the output end of the comparison circuit 1 is used as the output end of the three-phase power supply phase loss signal Vdp, characterized in that the three-phase power supply phase loss signal Vdp is separated by a diode D561 and processed by a filter circuit as a signal input of a comparison circuit 2 and a comparison circuit 3, the output end of the comparison circuit 2 is used as a relay control signal Vdp-1 output, and the output end of the comparison circuit 3 is used as a fast-response three-phase power supply phase loss signal Vdp-2 output.
  • the above-mentioned three-phase power supply phase loss signal Vdp is connected to the positive electrode of the diode D561, the negative electrode of the diode D561 is connected to one end of the resistor R563, the other end of the resistor R563 is grounded, and the filter circuit is connected in parallel to the resistor R563. both ends of .
  • the above-mentioned filtering circuit includes a capacitor C561 and a capacitor C562, and the capacitor C561 and the capacitor C562 are respectively connected in parallel to both ends of the resistor R563.
  • the above-mentioned comparison circuit 2 adopts comparator chip U56A
  • the comparison circuit 3 adopts comparator chip U56B.
  • the reference voltage Vref2 input of the comparison circuit 2 and the comparison circuit 3 is provided by the reference voltage power supply circuit, so that the input signals of the comparison circuit 2 and the comparison circuit 3 are the same, and the output signals are also the same.
  • the above-mentioned reference voltage power supply circuit includes resistor R561, resistor R562 and capacitor C568. After resistor R561 and resistor R562 are connected in series, their two ends are connected to power supply VCC1 and ground respectively. Capacitor C568 is connected in parallel at both ends of resistor R561, and the reference voltage Vref2 is drawn between resistor R561 and resistor R562.
  • a BLDC motor controller includes a three-phase power supply phase loss detection circuit, a three-phase rectifier circuit, a surge protection circuit, a bus charging capacitor C5, an inverter circuit, an IGBT drive circuit and a microprocessor MCU.
  • the three-phase input power supplies U, V and W are connected to the input end of the three-phase rectifier circuit.
  • the output end of the three-phase rectifier circuit is connected to the surge protection circuit to charge the bus charging capacitor C5.
  • the bus charging capacitor C5 provides a DC bus voltage Vbus for the inverter circuit.
  • the surge protection circuit includes a relay, a relay drive circuit and a PTC resistor.
  • the electromagnetic switch JK in the relay is connected in parallel with the PTC resistor.
  • the microprocessor MCU outputs a signal to the relay drive circuit to control the coil RY in the relay, thereby controlling the electromagnetic switch JK to be attracted. Or disconnected; the signal input ends of the three-phase power supply phase loss detection circuit are respectively connected to the three-phase input power supplies U, V, and W, and are characterized in that: the three-phase power supply phase loss detection circuit adopts the above-mentioned three-phase power supply phase loss detection circuit, and the three-phase power supply phase loss signal Vdp and the fast-response three-phase power supply phase loss signal Vdp-2 output by the three-phase power supply phase loss detection circuit are input to the microprocessor MCU, and the output signal of the microprocessor MCU controls the operation of the inverter circuit through the IGBT drive circuit, and the relay control signal Vdp-1 output by the three-phase power supply phase loss detection circuit is connected to an input signal end of the relay drive circuit, so that before the UPS power is switched, the coil RY in the relay is discharged in advance to disconnect the electromagnetic
  • the DC bus voltage Vbus is also connected to the input end of the DC-DC buck circuit, and the output end of the DC-DC buck circuit provides different power supply voltages to power the inverter circuit and the microprocessor MCU.
  • the present invention has the following effects:
  • the output end of the comparison circuit 1 is used as the output end of the three-phase power supply phase loss signal Vdp, and the three-phase power supply phase loss signal Vdp is used as the signal input of the comparison circuit 2 and the comparison circuit 3 after being separated by the diode D561 and processed by the filter circuit, the output end of the comparison circuit 2 is used as the relay control signal Vdp-1 output, and the output end of the comparison circuit 3 is used as the fast-response three-phase power supply phase loss signal Vdp-2 output.
  • the coil RY in the relay in the surge protection circuit in the BLDC motor controller can quickly release the electric energy, so that the electromagnetic switch JK in the relay is disconnected, so as to avoid the huge impact current generated during the UPS power switching process from damaging the motor controller hardware.
  • the three-phase power supply phase loss detection circuit can protect the motor controller from being damaged by the impact current during the UPS power switching process by adding several components.
  • the modification cost is low and the modification is simple and easy.
  • the shutdown relay control is pure hardware control, which can prevent damage to the microprocessor MCU.
  • FIG1 is a schematic diagram of electrical wiring of various electrical equipment with BLDC motors in the prior art
  • FIG. 2 is a circuit block diagram of a controller of a BLDC motor in the prior art
  • FIG3 is a schematic diagram of electrical wiring of various electrical equipment with BLDC motors in the prior art after using a UPS power supply;
  • FIG. 4 is a circuit block diagram of a three-phase power supply phase loss detection circuit provided in Embodiment 1 of the present invention.
  • FIG5 is a circuit diagram of a portion corresponding to FIG4;
  • FIG6 is a circuit diagram of another part corresponding to FIG4;
  • FIG7 is a perspective view of a BLDC motor according to a second embodiment of the present invention.
  • FIG8 is a perspective view of a BLDC motor controller according to a second embodiment of the present invention.
  • FIG. 9 is a cross-sectional view of a BLDC motor according to a second embodiment of the present invention.
  • FIG. 10 is a circuit block diagram of a BLDC motor controller according to a second embodiment of the present invention.
  • FIG11A is a circuit diagram corresponding to a portion of a three-phase rectifier circuit in FIG10 ;
  • FIG11B is a circuit diagram corresponding to the inverter circuit portion in FIG10 ;
  • FIG11C is a circuit diagram corresponding to the relay drive circuit portion in FIG10 ;
  • FIG13 is a waveform diagram of the impact current generated by a conventional BLDC motor controller when the UPS power supply is switched;
  • FIG. 14 is a waveform diagram of the impact current generated by the BLDC motor controller of the present invention when the UPS power supply is switched.
  • the present embodiment provides a three-phase power supply phase loss detection circuit, characterized in that it includes a 3-way rectifier circuit, a step-down circuit and a comparison circuit 1, the input ends of the 3-way rectifier circuits are respectively connected to the three-phase input power supplies U, V and W, the output ends of the 3-way rectifier circuits are connected together as the input ends of the step-down circuit, the output ends of the step-down circuits are connected to the input ends of the comparison circuit 1, and the output end of the comparison circuit 1 is used as the output end of the three-phase power supply phase loss signal Vdp, characterized in that the three-phase power supply phase loss signal Vdp is separated by a diode D561 and processed by a filter circuit as a signal input of a comparison circuit 2 and a comparison circuit 3, the output end of the comparison circuit 2 is used as a relay control signal Vdp-1 output, and the output end of the comparison circuit 3 is used as a fast-response three-phase power supply phase loss
  • the relay control signal Vdp-1 at the output end of the comparison circuit 2 can be used as the relay control signal in the surge protection circuit in the BLDC motor controller, so that before the UPS power is switched, the coil RY in the relay in the surge protection circuit in the BLDC motor controller can quickly release the electric energy and disconnect the electromagnetic switch JK in the relay, thereby avoiding the huge impact current generated during the UPS power switching process from damaging the motor controller hardware.
  • the above-mentioned three-phase power supply phase loss signal Vdp is connected to the positive electrode of the diode D561, the negative electrode of the diode D561 is connected to one end of the resistor R563, the other end of the resistor R563 is grounded, and the filter circuit is connected in parallel at both ends of the resistor R563.
  • the above-mentioned filter circuit includes a capacitor C561 and a capacitor C562, and the capacitor C561 and the capacitor C562 are respectively connected in parallel at both ends of the resistor R563.
  • the above-mentioned comparison circuit 2 adopts comparator chip U56A
  • the comparison circuit 3 adopts comparator chip U56B.
  • the reference voltage Vref2 input of the comparison circuit 2 and the comparison circuit 3 is provided by the reference voltage power supply circuit, so that the input signals of the comparison circuit 2 and the comparison circuit 3 are the same, and the output signals are also the same.
  • the above-mentioned reference voltage power supply circuit includes resistor R561, resistor R562 and capacitor C568. After resistor R561 and resistor R562 are connected in series, their two ends are connected to power supply VCC1 and ground respectively. Capacitor C568 is connected in parallel to the two ends of resistor R561, and the reference voltage Vref2 is drawn between resistor R561 and resistor R562.
  • the waveform of the input port of comparator 1 is distributed on the limit line, as shown in Figure 12, and the output terminal Vdp of comparator 1 outputs a high level; when the three-phase input power supply U, V, W is missing a phase, the waveform of the input port of comparator 1 is partially below the limit line, as shown in Figure 12, and the output terminal Vdp of comparator 1 outputs alternating high and low levels; the main function of the filtering circuit is to process the alternating high and low levels output by the output terminal Vdp of comparator 1 and remove the low-level signal, as shown in Figure 12, so that the input terminal signals of comparison circuit 2 and comparison circuit 3 are stable and straightened into a straight line.
  • the present invention can protect the motor controller from being damaged by the impact current during the UPS power switching process by adding several components (a diode D561, three capacitors, three resistors, and two comparators used as triggering protection circuits when switching UPS power) on the basis of the original three-phase power supply phase loss detection circuit.
  • the modification cost is low and the modification is simple and easy.
  • the client can be prevented from the undesirable phenomenon of circuit breaker tripping and power tripping during the UPS power switching process.
  • the shutdown relay control is a pure hardware control, which can prevent the microprocessor MCU in the motor controller from being damaged.
  • Embodiment 2 is a diagrammatic representation of Embodiment 1:
  • the BLDC motor provided in this embodiment is composed of a motor 1 and a BLDC motor controller 2.
  • the motor 1 includes a stator assembly 12, a rotor assembly 13 and a housing assembly 11.
  • the stator assembly 13 is mounted on the housing assembly 11, and the rotor assembly 13 is sleeved on the inner side of the stator assembly 12.
  • the motor controller 2 includes a control box 22 and a control circuit board 21 installed in the control box 22.
  • the circuit board 21 integrates a three-phase power supply phase loss detection circuit, a three-phase rectification circuit, a surge protection circuit, a bus charging capacitor C5, an inverter circuit, an IGBT drive circuit and a microprocessor MCU.
  • the three-phase input power supplies U, V, and W are connected to the input end of the three-phase rectification circuit.
  • the output end of the three-phase rectification circuit is connected to the surge protection circuit to charge the bus charging capacitor C5.
  • the bus charging capacitor C5 provides a DC bus voltage Vbus for the inverter circuit.
  • the surge protection circuit includes a relay, a relay drive circuit and a PTC resistor.
  • the electromagnetic switch JK in the relay is connected in parallel with the PTC resistor.
  • the microprocessor MCU outputs a signal to the relay drive circuit to control the coil RY in the relay, thereby controlling the electromagnetic switch JK to be attracted or Disconnect; the signal input ends of the three-phase power supply phase loss detection circuit are respectively connected to the three-phase input power supplies U, V, and W.
  • the three-phase power supply phase loss detection circuit adopts a three-phase power supply phase loss detection circuit described in Example 1.
  • the three-phase power supply phase loss signal Vdp and the fast-response three-phase power supply phase loss signal Vdp-2 output by the three-phase power supply phase loss detection circuit are input to the microprocessor MCU.
  • the output signal of the microprocessor MCU controls the operation of the inverter circuit through the IGBT drive circuit.
  • the relay control signal Vdp-1 output by the three-phase power supply phase loss detection circuit is connected to an input signal end of the relay drive circuit, so that before the UPS power is switched, the coil RY in the relay is discharged in advance to disconnect the electromagnetic switch JK in the relay.
  • the DC bus voltage Vbus is also connected to the input end of the DC-DC buck circuit, and the output end of the DC-DC buck circuit provides different power supply voltages to power the inverter circuit and the microprocessor MCU.
  • the relay driving circuit includes a resistor R192, a resistor R123, a resistor R6, a transistor Q8, and a transistor Q9 to form a push-pull driving circuit to drive the coil RY in the relay.
  • the +15V power supply reaches the base of the transistor Q8 through the voltage regulator tube ZD7, the resistor R116, the diode D223, and the resistor R192.
  • One end of the capacitor C99 is connected between the diode D223 and the resistor R192, and the other end of the capacitor C99 is grounded GND.
  • the relay control signal Vdp-1 output by the three-phase power supply phase loss detection circuit is connected between the capacitor C99 and the resistor R192.
  • the transistors Q8 and Q9 When the relay control signal Vdp-1 is a low-level signal, the transistors Q8 and Q9 are both turned off, the coil RY in the relay is de-energized, and the electromagnetic switch JK in the relay is disconnected; when the relay control signal Vdp-1 is a high-level signal, the transistors Q8 and Q9 are both turned on, the coil RY in the relay is energized, and the electromagnetic switch JK in the relay is closed.
  • the collector of a transistor Q18 is connected between the resistor R116 and the diode D223, and the base of the transistor Q18 is connected to the resistor R144 as the input of the microprocessor MCU.
  • the output signal K1 is connected to the input terminal of the output signal K1; the emitter of the transistor Q18 is grounded to GND.
  • the output signal K1 of the microprocessor MCU and the relay control signal Vdp-1 are complementary to each other by the separation of the diode D223, and both can independently control the driving relay.
  • the ground GND and +15V are also connected to the capacitor C98, and one end of the resistor R146 is connected between the resistor R144 and the base of the transistor Q18, and the other end of the resistor R146 is grounded to GND.
  • the working principle of the present invention is: assuming that the motor controller of the present invention is operated under the condition of UPS power supply, as shown in Figure 3, when the three-phase AC input of the mains is normal (no phase loss), the BLDC motor controller 2 controls the motor 1 to operate normally, and when the external power supply is within the rated voltage range, Vdp is a stable high level, the output signal Vdp-2 of the comparison circuit three and the output signal Vdp-1 of the comparison circuit two are both high levels, the relay maintains the energized state, and the motor maintains the original normal operating state.
  • the three-phase power phase loss signal Vdp output by the three-phase power phase loss detection circuit is an alternating high and low level square wave signal, which is processed by the separation of diode D561 and the filter circuit to form a stable straight signal as the input signal of the comparison circuit three and the comparison circuit two, and the reference voltage Vref2 is large, so the output signal Vdp-2 of the comparison circuit three and the output signal Vdp-1 of the comparison circuit two are both high level, the relay keeps the absorbing state, the motor enters the phase loss protection operation state, and the microprocessor MCU outputs 6 blocking pulse signals to turn off the 6 IGBT electronic switch tubes in the inverter circuit (that is, turn off the transistor Q1, transistor Q2, transistor Q3, transistor Q4, transistor Q5 and transistor Q6 in Figure 11B).
  • the microprocessor MCU has 2 input ports to receive the three-phase power phase loss signal Vdp and the fast-response three-phase power phase loss signal Vdp-2; and the microprocessor MCU internally sets the signal Vdp-2 to take precedence over the level of the signal Vdp. Because Vdp is an unstable voltage with alternating high and low levels, the microprocessor MCU needs to detect multiple cycles of alternating high and low levels to determine that it is in a phase loss state. However, when the external power supply is phase-lost, the signal Vdp is an unstable voltage with alternating high and low levels.
  • the microprocessor MCU When the microprocessor MCU needs to detect that Vdp is at a low level and the signal Vdp-2 is at a high level, it immediately enters the phase loss protection state. The reaction speed when the power supply is phase-lost is improved and the reaction time is shortened.
  • the signal Vdp When the three-phase AC input of the mains is in a power-off state, the signal Vdp is a stable low level, the reference voltage Vref2 input of the comparison circuit 2 and the comparison circuit 3 is provided by the reference voltage power supply circuit, and the reference voltage Vref2 is much larger than the zero voltage.
  • the output signal Vdp-2 of the comparison circuit 3 and the output signal Vdp-2 of the comparison circuit 2 Vdp-1 is low level and before power failure, the electromagnetic switch JK of the relay is in the disconnected state, and the motor stops.
  • the UPS power supply is switched to about 500ms-1 second, the relay is in the disconnected state, and the current flows through the PTC resistor into the bus charging capacitor C5.
  • the function of the PTC resistor is to prevent current mutation. At this time, it can effectively solve the high current caused by switching the power supply and protect the electronic components of the BLDC motor relay from high current shock.
  • the traditional BLDC motor controller withstands a current shock of 148A during the switching of the UPS power supply.
  • the BLDC motor controller of the present invention withstands a current shock of 56A during the switching of the UPS power supply. It can be seen from the experiment that the technical solution of the present invention can greatly reduce the current shock during the switching of the UPS power supply and effectively protect the electronic components of the motor controller.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Control Of Ac Motors In General (AREA)
  • Inverter Devices (AREA)

Abstract

一种三相电源缺相检测电路及BLDC电机控制器，包括3路的整流电路、降压电路和比较电路一，3路的整流电路的输入端分别连接三相输入电源U、V、W，3路的整流电路的输出端连接在一起作为降压电路的输入端，降压电路的输出端连接到比较电路一的输入端，比较电路一的输出端作为三相电源缺相信号Vdp的输出端，三相电源缺相信号Vdp通过二极管D561的分隔和滤波电路处理后作为比较电路二和比较电路三的信号输入，比较电路二的输出端用作为继电器控制信号Vdp-1输出，比较电路三的输出端作为快速响应的三相电源缺相信号Vdp-2输出。三相电源缺相检测电路可保护电机控制器，避免在UPS电源切换过程中被冲击电流损坏，改造成本低、简单容易。

Description

一种三相电源缺相检测电路及BLDC电机控制器 技术领域：
本发明涉及一种三相电源缺相检测电路及BLDC电机控制器。
背景技术：
目前，BLDC电机由于环保节电便于控制等优点广泛用于各种电器设备中，例如风扇、空调、电钻、吸尘器等，其电气接线图见图1所示，市电的三相交流输入电源通过空气开关再与BLDC电机的电机控制器连接，为了防止因从断电到接通电源造成的浪涌电流冲击，在电机控制器里面的三相整流电路的后面设置浪涌保护电路，见图2所示，浪涌保护电路包括继电器和PTC电阻，继电器中的电磁开关JK与PTC电阻并联起来，继电器中的线圈RY由电机控制器中的微处理器MCU输出信号(一般经过继电器驱动电路)控制，电机控制器通电前，继电器中的电磁开关JK是断开的，接通电源的时，电流流经PTC电阻进入充电电容和逆变电路，PTC电阻对浪涌电流具有良好的抵御作用，有效保护后方的充电电容和逆变电路中的IGBT开关，当电流平稳后，微处理器MCU输出信号控制继电器中的线圈RY使电磁开关JK吸合，从而将PTC电阻短路，从三相整流电路出来的电流经过电磁开关JK进入充电电容和逆变电路，避免电机运行中PTC电阻对电能的损耗。
UPS(Uninterruptable Power Supply)，即不间断电源，广泛应用于可靠供电的场合，如控制设备及其紧急保护系统、应急照明、系统网络系统、医疗系统、消防安全报警系统等场合。UPS的主要优点，在于它的不间断供电能力，当市电交流电输入故障时，UPS的储能电池向负载供电。以上使用UPS电源的负载电器设备或系统中，大多含有BLDC电机，BLDC电机作为核心动力部件理应受到重点保护，但BLDC电机在UPS电源切换过程中(即市电交流电输入故障切换为UPS电源供电)会触发出极大的冲击电流进入电机控制器处，容易损坏控制器硬件，其电气接线图见图3所示。造成损坏电机控制器硬件的主要原因是：在市电交流电输入故障掉电情况下，防浪涌保护电路中的继电器中的线圈RY至 少需要几秒时间才能释放完电能，使继电器中的电磁开关JK断开，而UPS电源从市电交流电输入掉电到UPS电源供电的切换时间不到2秒，因此UPS电源切换过程中产生的极大的冲击电流直接经过继电器中的电磁开关JK，对后方的电子器件造成极大冲击，损坏电机控制器硬件，而且中间连接使用的空气开关也可能会跳开，供电电源也有不小的概率会跳闸。
发明内容：
本发明的一个目的是提供一种三相电源缺相检测电路，除了能输出缺相信号，而且还能快速输出一个继电器控制信号，使UPS电源切换前，能快速使BLDC电机控制器中的防浪涌保护电路中的继电器中的线圈RY释放完电能，使继电器中的电磁开关JK断开，避免UPS电源切换过程中产生的极大的冲击电流损坏电机控制器硬件。
本发明的另一个目的是提供一种BLDC电机控制器，解决现有技术中在UPS电源切换过程，电机控制器的防浪涌保护电路因反应不及时未能起到防浪涌电流的作用，造成损坏电机控制器硬件的技术问题。
本发明的目的是通过下述技术方案予以实现的。
一种三相电源缺相检测电路,其特征在于：包括3路的整流电路、降压电路和比较电路一，3路的整流电路的输入端分别连接三相输入电源U、V、W，3路的整流电路的输出端连接在一起作为降压电路的输入端，降压电路的输出端连接到比较电路一的输入端，比较电路一的输出端作为三相电源缺相信号Vdp的输出端，其特征在于：三相电源缺相信号Vdp通过二极管D561的分隔和滤波电路处理后作为比较电路二和比较电路三的信号输入，比较电路二的输出端用作为继电器控制信号Vdp-1输出，比较电路三的输出端作为快速响应的三相电源缺相信号Vdp-2输出。
上述的三相电源缺相信号Vdp连接二极管D561的正极，二极管D561的负极连接电阻R563的一端，电阻R563的另一端接地，滤波电路并联在电阻R563 的两端。
上述的滤波电路包括电容C561和电容C562，电容C561和电容C562分别并联在电阻R563的两端。
上述的比较电路二采用比较器芯片U56A，比较电路三采用比较器芯片U56B，比较电路二和比较电路三的参考电压Vref2输入由参考电压供电电路提供，使到比较电路二和比较电路三的输入信号相同，输出信号也相同。
上述的参考电压供电电路包括电阻R561、电阻R562和电容C568，电阻R561和电阻R562串联后两端分别连接电源VCC1和地，电容C568并联在电阻R561的两端，电阻R561和电阻R562的中间引出参考电压Vref2。
一种BLDC电机控制器，包括三相电源缺相检测电路、三相整流电路、浪涌保护电路、母线充电电容C5、逆变电路、IGBT驱动电路和微处理器MCU，三相输入电源U、V、W连接到三相整流电路的输入端，三相整流电路的输出端连接浪涌保护电路后给母线充电电容C5充电，母线充电电容C5为逆变电路提供直流母线电压Vbus，浪涌保护电路包括继电器、继电器驱动电路和PTC电阻，继电器中的电磁开关JK与PTC电阻并联起来，微处理器MCU输出信号到继电器驱动电路来控制继电器中的线圈RY，以此控制电磁开关JK的吸合或者断开；三相电源缺相检测电路的信号输入端分别连接三相输入电源U、V、W，其特征在于：所述的三相电源缺相检测电路采用上述所述的一种三相电源缺相检测电路，三相电源缺相检测电路输出的三相电源缺相信号Vdp和快速响应的三相电源缺相信号Vdp-2输入到微处理器MCU，微处理器MCU的输出信号通过IGBT驱动电路控制逆变电路工作，三相电源缺相检测电路输出的继电器控制信号Vdp-1连接到继电器驱动电路的一个输入信号端，以便在UPS电源切换前，使继电器中的线圈RY提前放电，断开继电器中的电磁开关JK。
上述的直流母线电压Vbus还连接到DC-DC降压电路输入端，DC-DC降压电路的输出端提供不同的供电电压为逆变电路和微处理器MCU供电。
本发明与现有技术相比，具有如下效果：
1)本发明的三相电源缺相检测电路,比较电路一的输出端作为三相电源缺相信号Vdp的输出端，三相电源缺相信号Vdp通过二极管D561的分隔和滤波电路处理后作为比较电路二和比较电路三的信号输入，比较电路二的输出端用作继电器控制信号Vdp-1输出，比较电路三的输出端作为快速响应的三相电源缺相信号Vdp-2输出，它除了能输出缺相信号，而且还能快速输出一个继电器控制信号，使UPS电源切换前，能快速使BLDC电机控制器中的防浪涌保护电路中的继电器中的线圈RY释放完电能，使继电器中的电磁开关JK断开，避免UPS电源切换过程中产生的极大的冲击电流损坏电机控制器硬件。
2)三相电源缺相检测电路通过新增几个元器件可保护电机控制器在UPS电源切换过程中被冲击电流损坏，改造成本低，改造简单容易。
3)可防止客户端在切换UPS电源过程发生空开跳开和电源跳闸的不良现象。
4)关断继电器控制为纯硬件控制，可防止冲坏微处理器MCU。
5)本发明的其它优点在实施例部分展开详细描述。
附图说明：
图1是现有技术中的带BLDC电机的各种电器设备的电气接线示意图；
图2是现有技术中BLDC电机的控制器的电路方框图；
图3是现有技术中的带BLDC电机的各种电器设备使用UPS电源后的电气接线示意图；
图4是本发明实施例一提供的三相电源缺相检测电路的电路方框图；
图5是图4对应的一部分的电路图；
图6是图4对应的另一部分的电路图；
图7是本发明实施例二的BLDC电机的立体图；
图8是本发明实施例二的BLDC电机控制器的立体图；
图9是本发明实施例二的BLDC电机的剖视图；
图10是本发明实施例二的BLDC电机控制器的电路方框图；
图11A是图10中的三相整流电路部分对应的电路图；
图11B是图10中的逆变电路部分对应的电路图；
图11C是图10中的继电器驱动电路部分对应的电路图；
图12是本发明的三相电源缺相检测电路的各个比较器入口端和出口端的波形图；
图13是传统的BLDC电机控制器在UPS电源切换时产生冲击电流波形图；
图14是本发明的BLDC电机控制器在UPS电源切换时产生冲击电流波形图。
具体实施方式：
下面通过具体实施例并结合附图对本发明作进一步详细的描述。
实施例一:
如图4、图5、图6所示，本实施例提供的是一种三相电源缺相检测电路,其特征在于：包括3路的整流电路、降压电路和比较电路一，3路的整流电路的输入端分别连接三相输入电源U、V、W，3路的整流电路的输出端连接在一起作为降压电路的输入端，降压电路的输出端连接到比较电路一的输入端，比较电路一的输出端作为三相电源缺相信号Vdp的输出端，其特征在于：三相电源缺相信号Vdp通过二极管D561的分隔和滤波电路处理后作为比较电路二和比较电路三的信号输入，比较电路二的输出端用作为继电器控制信号Vdp-1输出，比较电路三的输出端作为快速响应的三相电源缺相信号Vdp-2输出。比较电路二的输出端的继电器控制信号Vdp-1可以作为BLDC电机控制器中浪涌保护电路里的继电器控制信号，使UPS电源切换前，能快速使BLDC电机控制器中的防浪涌保护电路中的继电器中的线圈RY释放完电能，使继电器中的电磁开关JK断开，避免UPS电源切换过程中产生的极大的冲击电流损坏电机控制器硬件。
上述的三相电源缺相信号Vdp连接二极管D561的正极，二极管D561的负极连接电阻R563的一端，电阻R563的另一端接地，滤波电路并联在电阻R563的两端。上述的滤波电路包括电容C561和电容C562，电容C561和电容C562分别并联在电阻R563的两端。
上述的比较电路二采用比较器芯片U56A，比较电路三采用比较器芯片U56B，比较电路二和比较电路三的参考电压Vref2输入由参考电压供电电路提供，使到比较电路二和比较电路三的输入信号相同，输出信号也相同。
上述参考电压供电电路包括电阻R561、电阻R562和电容C568，电阻R561和电阻R562串联后两端分别连接电源VCC1和地，电容C568并联在电阻R561的两端，电阻R561和电阻R562的中间引出参考电压Vref2。
当三相输入电源U、V、W在没有缺相的情况下，比较器一入端口的波形情况在限值线上分布，如图12所示，比较器一输出端Vdp是输出高电平；当三相输入电源U、V、W在缺相的情况下，比较器一入端口的波形情况有部分在限值线以下，如图12所示，比较器一输出端Vdp是输出交替的高低电平；滤波电路的主要作用是将比较器一输出端Vdp输出交替的高低电平进行处理去掉低电平信号，见图12所示，从而使比较电路二和比较电路三的入口端信号是稳定的，被拉直为一直线。
本发明在原有的三相电源缺相检测电路基础上通过新增几个元器件(一个二极管D561、三个电容、3个电阻，俩个比较器用于切换UPS电源时作为触发保护电路之用)可保护电机控制器在UPS电源切换过程中被冲击电流损坏，改造成本低，改造简单容易。可防止客户端在切换UPS电源过程发生空开跳开和电源跳闸的不良现象。关断继电器控制为纯硬件控制，可防止冲坏电机控制器里面的微处理器MCU。
实施例二：
如图7、图8、图9所示，本实施例提供BLDC电机由电机1和BLDC电机控制器2组成,所述的电机1包括定子组件12、转子组件13和机壳组件11，定子组件13安装在机壳组件11上，转子组件13套装在定子组件12的内侧，电机控制器2包括控制盒22和安装在控制盒22里面的控制线路板21。
如图10、图11A、图11B、图11C所示，BLDC电机控制器2里面的控制线 路板21集成三相电源缺相检测电路、三相整流电路、浪涌保护电路、母线充电电容C5、逆变电路、IGBT驱动电路和微处理器MCU，三相输入电源U、V、W连接到三相整流电路的输入端，三相整流电路的输出端连接浪涌保护电路后给母线充电电容C5充电，母线充电电容C5为逆变电路提供直流母线电压Vbus，浪涌保护电路包括继电器、继电器驱动电路和PTC电阻，继电器中的电磁开关JK与PTC电阻并联起来，微处理器MCU输出信号到继电器驱动电路来控制继电器中的线圈RY，以此控制电磁开关JK的吸合或者断开；三相电源缺相检测电路的信号输入端分别连接三相输入电源U、V、W，所述的三相电源缺相检测电路采用实施例一所述的一种三相电源缺相检测电路，三相电源缺相检测电路输出的三相电源缺相信号Vdp和快速响应的三相电源缺相信号Vdp-2输入到微处理器MCU，微处理器MCU的输出信号通过IGBT驱动电路控制逆变电路工作，三相电源缺相检测电路输出的继电器控制信号Vdp-1连接到继电器驱动电路的一个输入信号端，以便在UPS电源切换前，使继电器中的线圈RY提前放电，断开继电器中的电磁开关JK。
上述的直流母线电压Vbus还连接到DC-DC降压电路输入端，DC-DC降压电路的输出端提供不同的供电电压为逆变电路和微处理器MCU供电。
如图11C所示，继电器驱动电路包括电阻R192、电阻R123、电阻R6、三极管Q8、三极管Q9组成推挽式驱动电路以驱动继电器中的线圈RY，+15V电源通过稳压管ZD7、电阻R116、二极管D223、电阻R192到达三极管Q8的基极，二极管D223与电阻R192之间连接电容C99一端，电容C99的另一端接地GND，三相电源缺相检测电路输出的继电器控制信号Vdp-1连接电容C99与电阻R192之间。当继电器控制信号Vdp-1为低电平信号时，三极管Q8和三极管Q9都关闭，继电器中的线圈RY断电，使继电器中的电磁开关JK断开；当继电器控制信号Vdp-1为高电平信号时，三极管Q8和三极管Q9都导通，继电器中的线圈RY得电，使继电器中的电磁开关JK闭合。在电阻R116与二极管D223之间连接一个三极管Q18的集电极，三极管Q18的基极连接电阻R144作为微处理器MCU的输 出信号K1的入口端；三极管Q18的发射极接地GND。这样利用二极管D223的分隔使微处理器MCU的输出信号K1与继电器控制信号Vdp-1互补影响，均可独立控制驱动继电器。地GND与+15V还连接电容C98，电阻R144与三极管Q18的基极之间连接电阻R146的一端，电阻R146的另一端接地GND。
本发明的工作原理是：假设本发明的电机控制器是运行在UPS电源供电的条件下，如图3所示，在市电三相交流输入正常(不缺相)情况下，BLDC电机控制器2控制电机1正常运作，外部电源处于额定电压范围内时，Vdp为稳定的高电平，比较电路三的输出信号Vdp-2和比较电路二的输出信号Vdp-1都为高电平，继电器保存吸合状态，电机保持原正常运作状态。
当市电三相交流输入处于缺相的非正常情况下，三相电源缺相检测电路输出的三相电源缺相信号Vdp是交替高低电平方波信号，通过二极管D561的分隔和滤波电路处理后形成稳定平直信号作为比较电路三和比较电路二的输入信号，且给参考电压Vref2大，因此，比较电路三的输出信号Vdp-2和比较电路二的输出信号Vdp-1都为高电平，继电器保存吸合状态，电机进入缺相保护运作状态，微处理器MCU输出6路封锁脉冲信号去关闭逆变电路中的6只IGBT电子开关管(即关闭图11B中三极管Q1、三极管Q2、三极管Q3、三极管Q4、三极管Q5和三极管Q6)。微处理器MCU有2个输入端口接收三相电源缺相信号Vdp和快速响应的三相电源缺相信号Vdp-2；而且微处理器MCU内部设定信号Vdp-2优先于信号Vdp的级别。因为Vdp为高低电平交替的不稳定电压，微处理器MCU需要检测多个周期的高低电平交替才确定其处于缺相状态。但本发明的当外部电源缺相时，信号Vdp为高低电平交替的不稳定电压，当微处理器MCU需要检测Vdp为低电平时且信号Vdp-2为高电平时立即进入缺相保护状态。提高电源缺相时反应速度，缩短反应时间。
当市电三相交流输入处于断电情况下，信号Vdp为稳定的低电平，比较电路二和比较电路三的参考电压Vref2输入由参考电压供电电路提供，参考电压Vref2比零电压大得多，比较电路三的输出信号Vdp-2和比较电路二的输出信号 Vdp-1都为低电平且在断电前，继电器的电磁开关JK就处于断开状态，电机停机，这时在500ms-1秒左右切换为UPS电源时，继电器处于断开状态，电流流经PTC电阻进入母线充电电容C5，PTC电阻的作用是防止电流突变，这时可有效的解决切换电源造成的大电流，保护BLDC电机继电器的电子元器件不受大电流冲击。
如图13所示，经过实验，传统的BLDC电机控制器在切换UPS电源过程中承受148安的电流冲击，如图14所示，本发明的BLDC电机控制器在切换UPS电源过程中承受56安的电流冲击，从实验可知，本发明的技术方案可大幅降低切换UPS电源过程中电流冲击，有效保护电机控制器的电子元器件。
以上实施例为本发明的较佳实施方式，但本发明的实施方式不限于此，其他任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均为等效的置换方式，都包含在本发明的保护范围之内。

Claims (7)

  1. 一种三相电源缺相检测电路,其特征在于：包括3路的整流电路、降压电路和比较电路一，3路的整流电路的输入端分别连接三相输入电源U、V、W，3路的整流电路的输出端连接在一起作为降压电路的输入端，降压电路的输出端连接到比较电路一的输入端，比较电路一的输出端作为三相电源缺相信号Vdp的输出端，其特征在于：三相电源缺相信号Vdp通过二极管D561的分隔和滤波电路处理后作为比较电路二和比较电路三的信号输入，比较电路二的输出端用作为继电器控制信号Vdp-1输出，比较电路三的输出端作为快速响应的三相电源缺相信号Vdp-2输出。
  2. 根据权利要求1所述的一种三相电源缺相检测电路,其特征在于：三相电源缺相信号Vdp连接二极管D561的正极，二极管D561的负极连接电阻R563的一端，电阻R563的另一端接地，滤波电路并联在电阻R563的两端。
  3. 根据权利要求2所述的一种三相电源缺相检测电路,其特征在于：滤波电路包括电容C561和电容C562，电容C561和电容C562分别并联在电阻R563的两端。
  4. 根据权利要求1或2或3所述的一种三相电源缺相检测电路,其特征在于：比较电路二采用比较器芯片U56A，比较电路三采用比较器芯片U56B，比较电路二和比较电路三的参考电压Vref2输入由参考电压供电电路提供，使到比较电路二和比较电路三的输入信号相同，输出信号也相同。
  5. 根据权利要求4所述的一种三相电源缺相检测电路,其特征在于：参考电压供电电路包括电阻R561、电阻R562和电容C568，电阻R561和电阻R562串联后两端分别连接电源VCC1和地，电容C568并联在电阻R561的两端，电阻R561和电阻R562的中间引出参考电压Vref2。
  6. 一种BLDC电机控制器，包括三相电源缺相检测电路、三相整流电路、浪涌保护电路、母线充电电容C5、逆变电路、IGBT驱动电路和微处理器MCU，三相输入电源U、V、W连接到三相整流电路的输入端，三相整流电路的输出端 连接浪涌保护电路后给母线充电电容C5充电，母线充电电容C5为逆变电路提供直流母线电压Vbus，浪涌保护电路包括继电器驱动电路、继电器和PTC电阻，继电器中的电磁开关JK与PTC电阻并联起来，微处理器MCU输出信号到继电器驱动电路来控制继电器中的线圈RY，以此控制电磁开关JK的吸合或者断开；三相电源缺相检测电路的信号输入端分别连接三相输入电源U、V、W，其特征在于：所述的三相电源缺相检测电路采用权利要求1至5任意一项所述的一种三相电源缺相检测电路，三相电源缺相检测电路输出的三相电源缺相信号Vdp和快速响应的三相电源缺相信号Vdp-2输入到微处理器MCU，微处理器MCU的输出信号通过IGBT驱动电路控制逆变电路工作，三相电源缺相检测电路输出的继电器控制信号Vdp-1连接到继电器驱动电路的一个输入信号端，以便在UPS电源切换前，使继电器中的线圈RY提前放电，断开继电器中的电磁开关JK。
  7. 根据权利要求6所述的一种BLDC电机控制器，其特征在于：直流母线电压Vbus还连接到DC-DC降压电路输入端，DC-DC降压电路的输出端提供不同的供电电压为逆变电路和微处理器MCU供电。
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