A kind of electric machine controller and independent MOS module thereof
Technical field
The present invention relates to Motor Control Field, be specifically related to a kind of electric machine controller.
Background technology
The electric bicycle of state's inner control three-phase direct-current brushless motor and the controller architecture of battery-operated motor cycle are as shown in Figure 1, mainly comprise power source conversion, various input/output interface, single-chip microcomputer (MCU), pre-driver part, reach the high-power driving part of forming by mos field effect transistor (Metal-Oxide-SemiconductorField-Effect Transistor is called for short MOSFET or metal-oxide-semiconductor).And motor has U, V, W three-phase, and this has just determined to have at least 6 metal-oxide-semiconductors to control motor, includes 6 metal-oxide-semiconductors in the electric vehicle motor controller at least.
The electric vehicle motor controller of market sale now, the power source conversion of its main control part, MCU, input/output interface, pre-driver part and metal-oxide-semiconductor all are unified on the printed circuit board.Metal-oxide-semiconductor can produce bigger heat when work, so must consider its heat dissipation problem.Manufacturer all helps its heat radiation by the aluminum shell of controller now.In conjunction with the drive principle of Electric Machine Control, when printed circuit board layout, all 6 metal-oxide-semiconductors are yi word pattern usually and arrange, be positioned at the plate end of printed circuit board (PCB).With the 250W controller is example, as shown in Figure 2, adopts metal-oxide-semiconductor and MCU and pre-driver to be integrated, the upright welding of 90 degree, the fundamental of practical products such as heating panel closely contacts with aluminum alloy casing, has reached the metal-oxide-semiconductor heat radiation more effectively, and the firm and production cost of shell is low.
There is following drawback in this kind mode:
1, controller is in work under the severe jolt environment throughout the year, because metal-oxide-semiconductor becomes continuing firmly of the 90 vertical welding of degree with pcb board, and metal-oxide-semiconductor is fastened on the aluminum alloy casing for heat radiation, from the mechanical structure angle, becoming the mechanical stress of 90 degree both directions to be easy to make the weld part generation metal fatigue that continues firmly to cause cracking, is to produce to burn one of major reason of metal-oxide-semiconductor and pcb board.
2, in the fault of electric motor car, having is that metal-oxide-semiconductor burns greatly, and the high temperature that produces when it burns can also burn control circuit board in the lump, thereby control circuit board is scrapped thereupon.During maintenance, can only change the monoblock control circuit board, maintenance cost is higher.
3, the 2nd pin of each metal-oxide-semiconductor and the 3rd pin all will bear electric current more than the 12A-35A in conducting moment maximum in the controller, are referred to as big electric current pin.Because of the flow of maximum current is directly proportional with sectional area of wire, and the spacing of the 2nd pin of metal-oxide-semiconductor and the 3rd pin has only 2.5 millimeters, the pin portion wiring that is to say PCB is limited in the thick 0.035 millimeter * double sided board of 1.5 millimeters * pcb board of live width Copper Foil=0.105 square millimeter, and the safety margins electric current of the Design Theory of this area has only 3 amperes.Therefore can only solve by the rough method that pin and PCB weld part are thickeied scolding tin during actual production.The thing followed is exactly that the welding of metal-oxide-semiconductor pin needs manual operations, be difficult to during manual welding guarantee that solder thickness is even, cause controller that the metal-oxide-semiconductor weld part can often take place thus and when operation, produce high temperature and burnt, and even pcb board is breakdown burns, cause the The whole control blackboard newspaper useless.
4, according to foregoing description, controller must have 6 metal-oxide-semiconductors at least, and will strengthen the power output of controller, and existing practice majority is that the quantity by corresponding increase metal-oxide-semiconductor realizes.Because of motor has U, V, W three-phase, so the quantity of the metal-oxide-semiconductor that increases is necessary for 3 multiple.According to the drive principle of Electric Machine Control, require the last bridge metal-oxide-semiconductor of the same phase of control to need to place nearby with following bridge metal-oxide-semiconductor.In conjunction with the heat radiation requirement, when printed circuit board layout, the existing practice is that all metal-oxide-semiconductors are in one line, is positioned at the plate end of printed circuit board (PCB).Desire is put into these metal-oxide-semiconductors, can only increase the length of printed circuit board (PCB) under above-mentioned theory.Basic money on the market is the controller of 6 metal-oxide-semiconductors, its length is generally 80-100mm, as shown in Figure 3, and the metal-oxide-semiconductor in the controller to be increased to 12, its controller length is generally at 180-200mm, as shown in Figure 4, increased the length of printed circuit board (PCB) certainly will will increase simultaneously the length of aluminum shell.So, production cost also significantly increases thereupon.
The drawback of above-mentioned electric machine controller not only exists in the electric motor car, and other use the equipment of three phase electric machines control, as automobile, elevator, the household electrical appliances of motor etc. are arranged, similar problem may occur equally in different occasions.
Summary of the invention
The technical problem that the present invention mainly solves provides a kind of electric machine controller and independent MOS module thereof, makes that the damage rate of metal-oxide-semiconductor reduces in the controller, even and metal-oxide-semiconductor also can avoid damaging control circuit board when being damaged, reduce the controller maintenance cost.
In order to solve the problems of the technologies described above, the invention provides a kind of electric machine controller, comprise independently MOS module of speed control unit, Hall element, control module and at least one;
Described control module comprises main control module and pre-driver module, described main control module is used for output result, and the position signalling of Hall element according to speed control unit, calculate required U/V/W phase sequence and corresponding pulse/carrier signal and the sequential of control motor rotation, export to described pre-driver module;
The conversion of signals that described pre-driver module is used for receiving is the gate pole control signal of driven MOS pipe, and exports to described MOS module;
Described MOS module comprises three at least and goes up bridge metal-oxide-semiconductor and three following bridge metal-oxide-semiconductors, control the U/V/W three-phase of motor respectively, described MOS module is used for according to the control signal that receives, and will rotate Shang Qiao and the following bridge metal-oxide-semiconductor and the power turn-on of institute's corresponding phase, drive motors rotation with motor.
As improvement of the technical scheme, the quantity that comprises metal-oxide-semiconductor in the described independently MOS module is 3 integral multiple.
As improvement of the technical scheme, the pin of each metal-oxide-semiconductor is arranged in two separate ranks in the described MOS module, be positioned at the positive and negative both sides of printed circuit board (PCB), two big electric current pins in described each metal-oxide-semiconductor lay respectively at different lines, be welded on the both sides of described printed circuit board (PCB), described MOS module is flexible coupling by split conductor and control module.
As improvement of the technical scheme, the face-off of the metal-oxide-semiconductor of bridge up and down of described MOS module is arranged.
As improvement of the technical scheme, described controller comprises aluminium shell, and described MOS module places the top or the bottom of described aluminium shell, is parallel to described control module.
Embodiments of the present invention also provide a kind of electric machine controller independent MOS module, and described MOS module comprises at least three at least and goes up bridge metal-oxide-semiconductor and three following bridge metal-oxide-semiconductors, controls the three-phase of motor respectively; Bridge metal-oxide-semiconductor face-off arrangement up and down in the described MOS module.
As improvement of the technical scheme, the pin of each metal-oxide-semiconductor is arranged in two separate ranks in the described MOS module, be positioned at the positive and negative both sides of printed circuit board (PCB), two big electric current pins of described each metal-oxide-semiconductor kind lay respectively at different lines, be welded on the both sides of described printed circuit board (PCB), control pin in described each metal-oxide-semiconductor and described big electric current pin are flexible coupling by split conductor.
As improvement of the technical scheme, the quantity that comprises metal-oxide-semiconductor in the described independently MOS module is 3 integral multiple.
The present invention compared with prior art, the main distinction and effect thereof are: metal-oxide-semiconductor part in the controller is partly separated with control module, make the wiring of MOS module placement satisfy the designing technique standard of high power device to greatest extent, improved the product electrical characteristic, when even metal-oxide-semiconductor burns, the printed circuit board (PCB) of control module is also unaffected, and only is that the printed circuit board (PCB) of MOS module may relatedly burn.Because of electronic devices and components on the printed circuit board (PCB) of MOS module seldom (only comprise 6 metal-oxide-semiconductors and corresponding electric capacity and resistance), even burnt, can not bring too big loss yet, worst case is changed this MOS module and is got final product, economic loss is reduced to minimum, significantly reduce maintenance cost.
Because the printed circuit board (PCB) and the metal-oxide-semiconductor part of control module part are discrete, the area of the printed circuit board (PCB) of control module part just can not increase because of the increase of metal-oxide-semiconductor.And the principle basically identical of the control module of different controllers part (comprising main control module and pre-driver module), so controller power output size no matter, main control module and pre-driver module section size are almost equal, reduce because of the different product inventories that cause plurality of specifications of power.
Description of drawings
Below in conjunction with the drawings and specific embodiments the present invention is described in further detail.
Fig. 1 is the electric bicycle of domestic three-phase direct-current brushless motor in the background technology and the controller architecture schematic diagram of battery-operated motor cycle;
Fig. 2 is the upright welding of metal-oxide-semiconductor 90 a degree schematic diagram in the background technology middle controller;
Fig. 3 is structure and the length schematic diagram that comprises the controller of 6 metal-oxide-semiconductors in the background technology;
Fig. 4 is structure and the length schematic diagram that comprises the controller of 12 metal-oxide-semiconductors in the background technology;
Fig. 5 is the electric machine controller structure chart of first embodiment of the invention;
Fig. 6 is 6 pipe MOS module diagrams in the electric vehicle motor controller of second embodiment of the invention;
Fig. 7 is pre-driver module and the connection diagram between the MOS module independently in the electric vehicle motor controller of second embodiment of the invention;
Fig. 8 is 12 pipe MOS module diagrams in the electric vehicle motor controller of second embodiment of the invention;
Fig. 9 is metal-oxide-semiconductor pin apportion arrangement architecture figure in the electric vehicle motor controller of second embodiment of the invention;
Figure 10 is bridge metal-oxide-semiconductor face-off arrangement architecture figure up and down in the electric vehicle motor controller of second embodiment of the invention;
Figure 11 is 12 pipe MOS modular structure figure in the electric vehicle motor controller of second embodiment of the invention;
Figure 12 comprises 2 independently schematic diagrames of MOS module in the electric vehicle motor controller of second embodiment of the invention.
Embodiment
For making the purpose, technical solutions and advantages of the present invention clearer, embodiments of the present invention are described in further detail below in conjunction with accompanying drawing.
First embodiment of the invention relates to a kind of electric machine controller, comprises independently MOS module of speed control unit, Hall element, control module and at least one, as shown in Figure 5.
Control module comprises main control module and pre-driver module, main control module is used for output result, and the position signalling of Hall element according to speed control unit, calculate required U/V/W phase sequence and corresponding pulse/carrier signal and the sequential of control motor rotation, export to the pre-driver module;
The conversion of signals that the pre-driver module is used for receiving is the gate pole control signal of driven MOS pipe, and exports to the MOS module;
The MOS module comprises three at least and goes up bridge metal-oxide-semiconductor and three following bridge metal-oxide-semiconductors, control the U/V/W three-phase of motor respectively, the MOS module is used for according to the control signal that receives, and will rotate Shang Qiao and the following bridge metal-oxide-semiconductor and the power turn-on of institute's corresponding phase, drive motors rotation with motor.The quantity that independently comprises metal-oxide-semiconductor in the MOS module is 3 integral multiple.The pin of each metal-oxide-semiconductor is arranged in two separate ranks in the MOS module, is positioned at the positive and negative both sides of printed circuit board (PCB), and two big electric current pins in each metal-oxide-semiconductor lay respectively at different lines, are welded on the both sides of printed circuit board (PCB), and the MOS module is flexible coupling by split conductor and control module.
The metal-oxide-semiconductor of the bridge up and down face-off of MOS module is arranged.As improvement of the technical scheme, controller comprises aluminium shell, and the MOS module places the top or the bottom of aluminium shell, is parallel to control module.
Speed control unit among the present invention is used for output speed commands for controlling motor speed, and its output can be parameters such as voltage, electric current, power; Implementation can be various wired or wireless modes such as handle, pedal, single-chip microcomputer, potentiometer, remote controller, switch according to the type and the application scenario of motor.
Second embodiment of the invention relates to a kind of electric vehicle motor controller, comprises independently MOS module of speed control unit, Hall element, control module and at least one, and wherein speed control unit is the rotating speed joystick.Each part mentioned above adds three-phase DC motor, constitutes a complete movement system
Control module comprises main control module (generally can be single-chip microcomputer) and pre-driver module, main control module is used for according to detected rotating speed joystick output voltage and detects the position signalling of the attached Hall element of motor, calculate required U/V/W phase sequence and corresponding pulse/carrier signal and the sequential of control motor rotation, export to the pre-driver module;
The conversion of signals that the pre-driver module is used for receiving is the gate pole control signal of driven MOS pipe, and exports to the MOS module;
The MOS module is used for according to the control signal that receives, and will rotate Shang Qiao and the following bridge metal-oxide-semiconductor and the power turn-on of institute's corresponding phase with motor, reaches the purpose of drive motors rotation.The MOS module comprises three at least and goes up bridge metal-oxide-semiconductor and three following bridge metal-oxide-semiconductors, controls the U/V/W three-phase of motor respectively, and the circuit diagram of 6 pipe MOS modules as shown in Figure 6.Main control module in the present embodiment in the control module and pre-driver module are same as the prior art, pre-driver module and being connected as shown in Figure 7 between the MOS module independently.
By the metal-oxide-semiconductor part is discrete with the control module part, make the wiring of MOS module placement satisfy the designing technique standard of high power device to greatest extent, improved the product electrical characteristic, when even metal-oxide-semiconductor burns, the printed circuit board (PCB) of control module is also unaffected, and only is that the printed circuit board (PCB) of MOS module may relatedly burn.Because of electronic devices and components on the printed circuit board (PCB) of MOS module seldom (only comprise 6 metal-oxide-semiconductors and corresponding electric capacity and resistance), even burnt, can not bring too big loss yet, worst case is changed this MOS module and is got final product, economic loss is reduced to minimum, significantly reduce maintenance cost.
And because the printed circuit board (PCB) and the metal-oxide-semiconductor part of control module part are discrete, the area of the printed circuit board (PCB) of control module part just can not increase because of the increase of metal-oxide-semiconductor.And the principle basically identical of the control module of different controllers part (comprising main control module and pre-driver module), so controller power output size no matter, main control module and pre-driver module section size are almost equal, reduce because of the different product inventories that cause plurality of specifications of power.
Controller in the present embodiment can use aluminium shell equally, the MOS module of separating can place the top or the bottom of described aluminium shell, be parallel to control module,, reduce the cumulative volume of controller by effectively utilizing top or bottom with larger area aluminum shell.
According to the demand of different electric motor cars to the controller power output, generally can comprise 6,9,12,15,18 even 24 metal-oxide-semiconductors in the MOS module, the metal-oxide-semiconductor quantity that comprises in the MOS module is 3 integral multiple, to control the three-phase of motor respectively.In actual applications, can be provided with 6 pipe/9-12 pipe/15-18 pipe/21-24 pipe (and the like) several separate modules, 6 pipe MOS modules comprise 3 and go up bridge metal-oxide-semiconductors, 3 following bridge metal-oxide-semiconductors; 9 pipe MOS modules comprise 6 and go up bridge metal-oxide-semiconductor, 3 following bridge metal-oxide-semiconductors; 12 pipe MOS modules comprise 6 and go up bridge metal-oxide-semiconductor, 6 following bridge metal-oxide-semiconductors; 15 pipe MOS modules comprise 9 and go up bridge metal-oxide-semiconductor, 6 following bridge metal-oxide-semiconductors; 18 pipe MOS modules comprise 9 and go up bridge metal-oxide-semiconductor, 9 following bridge metal-oxide-semiconductors; Fig. 6 and Fig. 8 show the structure chart of 6 pipe MOS modules and 12 pipe MOS modules respectively in the present embodiment, and other each MOS modular structures are similar with it.Both can contain the controller of nearly all electric bicycle/battery-operated motor cycle/beach buggy/electro-tricycle by these discrete MOS modules, and reduce cost significantly.
As further improvement, the pin of each metal-oxide-semiconductor is arranged in two separate ranks in this MOS module, be positioned at the positive and negative both sides of printed circuit board (PCB), two big electric current pins (the 2 3rd pin) of each metal-oxide-semiconductor kind lay respectively at different lines, transverse weld is in the both sides of printed circuit board (PCB), the MOS module is flexible coupling by split conductor and control module, as shown in Figure 9, and the metal fatigue of the hard continual-connecting-part of avoiding mechanical stress to greatest extent and being caused.
And, when every metal-oxide-semiconductor pin is arranged in two separate ranks, with bridge metal-oxide-semiconductor face-off arrangement up and down in this MOS module, after metal-oxide-semiconductor is arranged as shown in figure 10, as can be seen from the figure this distribution mode has given pin by big electric current with sufficient wiring space, guaranteed that high power device had both reached the theoretic safety standard of electrical design, again can the shortest distribution, improve the product electric property to greatest extent, reduced the metal-oxide-semiconductor weld part when operation, to produce high temperature and burnt may, solved the damage problem of the metal-oxide-semiconductor of conventional controller to greatest extent, and realized producing cheaply.And by this mode, do not need painstakingly metal-oxide-semiconductor pin and PCB weld part to be thickeied scolding tin, only weld normally and get final product guaranteed quality.
Arrange bridge metal-oxide-semiconductor up and down by face-off in MOS module independently, volume in the MOS module volume ratio prior art after can making independently in controller dwindles greatly, and then make the controller overall volume dwindle 2/5 to 1/2, undoubtedly further reduced production cost.
Figure 11 shows the front elevation and the back view of the MOS module that comprises 12 metal-oxide-semiconductors, as can be seen, utilize the solution of the present invention, comprise under 12 metal-oxide-semiconductor situations at controller, its length only is equal to the length that comprises 6 metal-oxide-semiconductor controllers on the market, has cut down production cost greatly.
In addition, can increase at the weld of metal-oxide-semiconductor pin and pcb board and regulate auxiliary sheet copper thickness, as shown in figure 11, make the maximum current that passes through to reach tens of amperes, further avoided metal-oxide-semiconductor excessive by electric current when moving because of the pin weld part, produce high temperature and, reduce the probability of damage of metal-oxide-semiconductor the possibility that metal-oxide-semiconductor burns.
As further improvement, more for a long time, as greater than 12 the time, can use 2 independently MOS modules at the required metal-oxide-semiconductor of controller, two MOS modules face-offs are distributed in the top and the bottom of aluminium shell, as shown in figure 12.
In sum, compare with conventional controller, the electrical security of electric vehicle motor controller of the present invention is higher, and maintenance cost is lower, and production and assembly are simpler and more direct, and product design is short, little, light, thin more, adapts to the tendency of the day of energy-conserving and environment-protective more.
Disclosed electric machine controller of the present invention and MOS module thereof, main use but be not limited to electric vehicle motor controller field, also can be applicable to automobile, elevator, have on the equipment of a lot of Electric Machine Control such as household electrical appliances of motor, particularly relate to the three phase electric machine controller of high-power driving module, realize discreteization design.
Though pass through with reference to some of the preferred embodiment of the invention, the present invention is illustrated and describes, but those of ordinary skill in the art should be understood that and can do various changes to it in the form and details, and without departing from the spirit and scope of the present invention.