CN109617479A - A kind of low-voltage, high-current servo-driver - Google Patents
A kind of low-voltage, high-current servo-driver Download PDFInfo
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Abstract
In order to overcome existing low voltage permanent magnetic synchronous motor servo-driver debugging process complexity cumbersome, it is not easy to the technical issues of user uses, the present invention provides a kind of low-voltage, high-current servo-drivers, including control circuit, power circuit and control software；It is characterized in that, when the control software is run, performs the steps of 1) motor number of pole-pairs and encoder digit Self-tuning System；2) rotor zero phase angle Self-tuning System；3) electric motor resistance and inductance Self-tuning System；4) control parameter Self-tuning System；5) winding back emf coefficient keWith torque coefficient ktSelf-tuning System；6) rotor rotary inertia Self-tuning System.This invention simplifies servo parameter debugging process, and user is made to be easier to use.
Description
Technical Field
The invention belongs to the field of industrial automation control, and relates to a permanent magnet synchronous motor servo driver.
Background
The servo driving technology is one of the key technologies for controlling numerical control machine tools, industrial robots and other machines, and with the development of power electronic technology, computer technology and control theory, the development of the servo driving technology is further promoted.
The current domestic servo drivers have more product types, and the general servo drivers in the industrial automation industry generally take commercial power (alternating current 220V or alternating current 380V) as power supply input and serve as a direct current bus power supply of the servo drivers after rectification; in the low voltage dc application field (such as dc 24V-100V), a brush dc motor, a brushless dc motor or a stepping motor is often used, and a corresponding driver is used in cooperation. The driver of the brush direct current motor generally adopts an H-bridge control mode, and the driver of the brushless direct current motor generally adopts a three-phase six-bridge square wave control mode of six-position commutation. Because the brush direct current motor adopts mechanical commutation, the brush is easy to wear in the long-term working process, and the efficiency of converting electric energy into mechanical energy is low, so the application field of the brush direct current motor is gradually reduced. Although the brushless direct current motor servo system adopts electronic commutation, the reliability problems of brush abrasion and the like do not exist, the control mode is that commutation is carried out for six times in each electric cycle, only short-time maximum torque control exists after each commutation, constant torque control and high-precision position servo control cannot be realized, and the efficiency of converting electric energy into mechanical energy also cannot reach the efficiency of a synchronous motor servo system. The stepping motor adopts pulse frequency control, and the position control precision of the stepping motor depends on the step angle of the stepping motor to a great extent, so that the higher the precision of the stepping motor is, the higher the design and production cost of the stepping motor is, and the stepping motor is not suitable for being applied to a high-precision position servo control system.
In recent years, manufacturers have proposed a low-voltage permanent magnet synchronous motor servo driver, but the function is simpler, the peak-to-peak output of the rated current of the driver is generally less than 30A, the input of the driver is generally pulse or analog quantity, or a low-speed serial bus, such as RS485 or CAN, does not have an EtherCAT bus interface based on 100M ethernet.
At present, most low-voltage permanent magnet synchronous motor servo drivers do not have a motor electrical parameter, mechanical parameter and current loop operation parameter self-tuning function, when a user uses the driver, the user needs to manually calculate parameters and formulas such as motor resistance and inductance provided by a motor manufacturer, then inputs the parameters and the formulas into the driver, obtains operation parameters through complex debugging, and the debugging process is complex and tedious and is not convenient for the user to use. For example:
patent document CN 107153366 a discloses a small-sized digital low-voltage ac servo based on EtherCAT, which has the following scheme: 1) comprises a controller for controlling the whole system; the EtherCAT bus communication is adopted for command input and data feedback; the input of the power supply is low-voltage direct-current voltage less than 100V; the driving circuit drives the switching tube to output low-voltage alternating voltage to drive the motor. The scheme has the advantages that: 1) the motor is light and small, and supports permanent magnet synchronous motors and wireless communication; 2) the method has absolute type and incremental type encoder input channels, and simultaneously supports three encoders; the status indicator lamp provides system running status indication; 3) the system is powered by an auxiliary power supply. However, this solution still has the following drawbacks: 1) the maximum operating current and the maximum driving frequency which can be supported by the driver are not described, and the maximum output current and the maximum operating frequency can be limited; 2) the motor parameter and operation parameter self-tuning function is not provided, and the driver parameter can be debugged manually to normally operate; 3) the feedforward control and interpolation control functions are not described.
Patent document CN 204383200U discloses an AGV all-digital ac servo drive system based on CANopen bus, which has the following scheme: the system comprises a master station, a CANopen bus, a slave station, a low-voltage alternating current servo motor and a safety resistor; the master station comprises an AGV main control unit and a CANopen bus communication interface; the slave station comprises a servo drive controller, a master control chip and a direct current/alternating current inversion module; the system consists of a plurality of slave stations, and different slave stations respectively control left and right low-voltage alternating-current servo motors of the AGV; an AGV main control unit can be connected with 63 slave stations at most; the highest communication speed of the CANopen bus is 1M/s; the system power supply is 24V direct current voltage; the rated power of the low-voltage alternating current motor is 70W, and the rated rotating speed is 3000 r/min. The disadvantages of this solution are: 1) the technical scheme is mainly described for an AGV full digital alternating current servo driving system, namely the whole servo system consisting of a master station, a slave station, a motor, a power supply and the like, and the characteristics and the specific implementation scheme of a servo driver are not described in detail; 2) the rated power of the driving motor is 70W, the rated rotating speed is 3000 r/min, which is equivalent to that the driving current is less than 5A; 3) the servo driver described by the scheme has no motor parameter and operation parameter self-tuning function.
Disclosure of Invention
The invention provides a low-voltage high-current servo driver, aiming at solving the technical problems that the existing low-voltage permanent magnet synchronous motor servo driver is complex and fussy in debugging process and inconvenient for users to use.
The technical scheme of the invention is as follows:
a low-voltage high-current servo driver comprises a control circuit, a power circuit and control software; it is characterized in that the device is characterized in that,
when the control software runs, the following steps are realized:
1) self-tuning of pole pair number and encoder digit of motor
1.1) controlling the motor to work in a stator voltage vector rotation mode, wherein the voltage vector amplitude is a voltage value corresponding to the rated current;
1.2) in each cycle control period, increasing the stator voltage vector angle according to a given rule, starting the motor to rotate slowly in the forward direction, and detecting encoder data;
1.3) when the encoder data suddenly changes from a large value to a small value for the first time, recording the maximum value, calculating the number of bits of the encoder according to the maximum value, and simultaneously recording the vector angle of the reference voltage at the moment;
1.4) the motor continues to rotate, the number of pole pairs increases by 1 when the vector angle of the stator voltage increases by 2 pi, and when the sudden change from a large value to a small value occurs again, the number of times of 2 pi circulation experienced by the vector angle is the number of pole pairs of the motor;
2) zero phase angle self-tuning of motor rotor
2.1) controlling the motor to work in a stator current vector rotation mode, wherein the current vector amplitude is the rated current of the motor;
2.2) in each cycle control period, increasing a stator current vector angle according to a given rule, starting the motor to rotate slowly in the forward direction, and detecting encoder data;
2.3) when the encoder data has a sudden change from a large value to a small value, recording the current vector angle at the moment;
2.4) after the rotor rotates for a plurality of circles, recording a current vector angle every time when the encoder data suddenly changes from a large value to a small value;
2.5) averaging the recorded multiple groups of current vector angles, and converting the current vector angles into corresponding mechanical angles, namely the zero phase angle of the motor rotor;
3) self-tuning of motor resistance and inductance
3.1) carrying out vector control on the motor in a two-phase static coordinate system, and applying u to the motor according to a given ruleαAnd uβThe voltage vector records a corresponding current value when the current is stable;
3.2) according toThe resistance value of the motor can be obtained;
3.3) applying u to the electric machineαAnd uβDuring voltage vector, recording the time when the current reaches a stable value, and calculating to obtain the inductance of the motor through the time and the motor equivalent model;
4) control parameter self-tuning
After obtaining the resistance inductance, calculating a current loop proportion parameter k according to a motor current loop equivalent model and a bandwidth design method thereofpcCurrent loop integral parameter kic；
5) Back electromotive force coefficient k of motoreCoefficient of sum moment ktSelf-tuning
5.1) obtaining a current loop proportion parameter kpcAnd current loop integral parameter kicThen, the motor works in a current loop mode of a two-phase rotating d-q coordinate system;
5.2) letting the d-axis current of the motor close loop to make id0; simultaneously, voltage is applied to the q axis according to a given rule, the motor rotates in an accelerated way, and the recording motor respectively reachesAnd wnormThe corresponding voltage value;
5.3) calculating the counter potential coefficient k of the motor according to the voltage value and the corresponding rotating speed obtained in the step 5.2)e；
5.4) according to the counter potential coefficient k of the motoreAnd coefficient of moment ktCalculating the moment coefficient kt；
6) Self-tuning of rotational inertia of motor rotor
6.1) applying a q-axis forward current i to the motorqThe motor begins to spin up, recording the motor fromAccelerate to wnormTime Δ t of1；
6.2) applying a negative q-axis current-i to the motorqWhen the motor starts to decelerate, the motor is recorded from wnormIs decelerated toTime Δ t of2；
6.3) according toCalculating the acceleration, and averaging the accelerations calculated in the acceleration process and the deceleration process;
6.4) according toCalculating the rotational inertia of the motor rotor;
further, in the step 3), the resistance value and the inductance value are measured for many times by adopting the methods of 3.1) to 3.3); and respectively averaging all the measured resistance values and inductance values to obtain the resistance and the inductance of the motor.
Further, in the step 4):
current loop ratio parameter
Current loop integral parameter
In the formula,
r is a motor resistor;
l is a motor inductor;
Tsthe current loop sampling period is equal to the current loop calculation period;
ωBthe cut-off frequency of an open-loop transfer function of a control model built in servo driver software;
MF is the open-loop transfer function phase margin of a control model built in servo driver software;
furthermore, the control circuit comprises a master control CPU, a parameter storage module, an EtherCAT bus communication module, a four-way SPI communication module and a plurality of communication interfaces;
the main control CPU is used for providing two current sampling data feedback channels for the motor, and simultaneously collecting U-phase current and W-phase current of the motor as feedback of a current loop;
the parameter storage module is used for storing the motor operation parameters;
the EtherCAT bus communication is used for realizing Ethernet communication and realizing data interaction with the master control CPU through an SPI interface;
a four-way SPI communication module comprising SPI1, SPI2, SPI3 and SPI 4; the main control CPU exchanges data with the EEPROM chip through the SPI1, carries out data interaction with a key/LED interface chip through the SPI2, is matched with a magnetic encoder interface through the SPI3, carries out bus data interaction with the ET1100 chip through the SPI4 and is configured with bus synchronous interruption;
the communication interface comprises an RS232 serial communication interface, an RS485 high-speed communication interface and a general RS485 communication interface.
Furthermore, the power circuit comprises a power supply conversion module, a drive circuit based on the MOSFET, a current sampling and conditioning module, a bus voltage sampling module, a temperature detection module and a fault protection module;
the power supply conversion module is used for selecting a working mode according to external input voltage and selecting a low-voltage power supply input source;
the driving circuit is used for driving the motor to work;
the current sampling and conditioning module comprises a current sampling unit and a conditioning unit; the current sampling unit uses a Hall type current sensor chip to sample current; the conditioning unit is a second-order active filter and is used for carrying out bias amplification and filtering on the sampling signal;
the bus voltage sampling module realizes voltage sampling by using a method of partial pressure sampling and isolation amplification;
the temperature detection module is used for acquiring the ambient temperature and the temperature of the power circuit;
and the fault protection module is used for protecting the driving circuit and the motor.
Further, the driving circuit is implemented using IR2136 and FQH90N 15.
Furthermore, the fault protection module realizes the overcurrent and short-circuit protection function by using the fault output signal of the current sensor chip, inputs the overcurrent fault signal of the current sampling and conditioning module into the main control CPU, and controls the PWM signal output of the main control CPU by the hardware register; when a fault occurs, the main control CPU prohibits the PWM pin from outputting an effective level, meanwhile, the control software outputs a low level signal to the EN pin of the IR2136, and prohibits the IR2136 from outputting an effective signal to the control end of the FQH90N15, so that the driving circuit and the motor are protected.
Furthermore, the control circuit also comprises a pulse/direction input interface, two isolated digital quantity input interfaces, two isolated digital quantity output interfaces and/or an incremental encoder interface which are connected with the main control CPU.
The invention has the beneficial effects that:
1. the control software has a parameter self-tuning algorithm, can self-tune the number of pole pairs of the motor, the number of digits of the encoder, the zero phase angle of the rotor of the motor, the resistance, the inductance, the counter potential coefficient, the moment coefficient, the rotational inertia of the rotor and the current loop operation parameters, automatically stores the operation parameters obtained by self-tuning into the parameter storage module, automatically reads the obtained parameters from the parameter storage module to control the motor to operate after next power-on, simplifies the debugging process of the servo parameters and enables a user to use the servo parameters more easily.
2. The power circuit adopts a power driving mode of IR2136+ FQH90N15, and under the condition that the voltage of a direct-current bus is 100V, the rated output amplitude of the phase current reaches 50A.
3. The power circuit adopts the power supply conversion module, and can realize power supply in a wide power supply range (12V-100V).
4. The invention configures the EtherCAT bus communication function, can realize the network operation, makes the wiring in the application of a plurality of drivers simpler, and can realize the multi-axis synchronous control; the communication rate reaches 100 Mbps.
5. The invention has the current, voltage and temperature sampling functions and various protection functions such as short circuit, overcurrent, undervoltage, overvoltage, overtemperature and the like.
6. The invention can be applied to occasions with only low-voltage direct current power supply or occasions with battery power supply, such as battery cars, vehicle-mounted refrigerators, vehicle-mounted compressors, power-assisted carts, low-voltage automation equipment, field operation and the like, and can greatly improve the efficiency of a servo system and save the electric quantity of a mobile power supply compared with the traditional brushless direct current driving mode.
7. Besides the EtherCAT bus and the serial bus, the device also has pulse, digital quantity and analog quantity input interfaces, can be matched with various instruction modes, and has good universality.
Drawings
FIG. 1 is a block diagram of a control circuit according to the present invention.
Fig. 2 is a block diagram of a power circuit according to the present invention.
Fig. 3 is a functional block diagram of a driving circuit in the present invention.
Fig. 4 is a current loop equivalent model.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
The low-voltage high-current servo driver provided by the invention adopts an FOC control algorithm, the amplitude of rated output phase current reaches 50A, and the low-voltage high-current servo driver comprises a control circuit, a power circuit and control software.
Control circuit
The control circuit comprises a main control CPU, a parameter storage module, an EtherCAT bus communication module, a four-way SPI communication module, a plurality of communication interfaces, a pulse/direction input interface, two-way isolated digital quantity input and two-way isolated digital quantity output (corresponding to I/O & AIn in the attached figure 1);
the main control CPU adopts STM32F 405; the main control CPU provides two current sampling data input channels for the motor, and simultaneously collects the U-phase current and the W-phase current of the motor as the feedback of a current loop.
The parameter storage module is used for storing motor operation parameters and specifically adopts an EEPROM chip;
the EtherCAT bus communication adopts an ET1100 chip to realize Ethernet communication and realizes data interaction with a main control CPU through an SPI interface;
a four-way SPI communication module comprising SPI1, SPI2, SPI3 and SPI 4; the main control CPU exchanges data with the EEPROM chip through the SPI1, carries out data interaction with a key/LED interface chip through the SPI2, is matched with a magnetic encoder interface through the SPI3, carries out bus data interaction with the ET1100 chip through the SPI4 and is configured with bus synchronous interruption; and hardware synchronous interruption is realized by connecting the SYNC pin of the ET1100 chip with the IO pin of the main control CPU.
The communication interface comprises a path of RS232 serial communication interface, a path of RS485 high-speed communication interface with the highest speed up to 2.5Mbps and capable of being matched with an SmartABS encoder interface of Morgan, and a path of RS485 communication interface adopting a Modbus protocol;
in a main control CPU of the control circuit, a Timer1 is configured through software to output 6 paths of PWM control signals, a TIM1_ BKIN is configured to be used as a fault input control port, and when a fault occurs, a hardware register triggers and prohibits PWM signal output.
In addition, the driver is separately configured with a parameter debugging serial port, and the parameter debugging serial port interface is RS232 in the attached figure 1.
Two, power circuit
The power circuit mainly comprises a power supply conversion module, a drive circuit based on the MOSFET, a current sampling and conditioning module, a bus voltage sampling module, a temperature detection module, a fault protection module and a fan control module; the power circuit composition block diagram is shown in fig. 2.
The power supply conversion module is used for selecting a working mode according to external input voltage and selecting a low-voltage power supply input source; the power supply conversion module can convert 9-36V or 30-100V input power supply voltage into 15V, 5V and 3.3V used in the servo driver, and respectively supplies power to the control circuit and the power circuit;
the driving circuit is realized by adopting IR2136 and FQH90N15, a PWM signal from the control circuit enters an IR2136 input port after being isolated by magnetic coupling, and then drives the MOSFET power tube of the three-phase six-bridge to be switched on and off, as shown in figure 3;
the current sampling and conditioning module comprises a current sampling unit and a conditioning unit; the current sampling unit uses a Hall type current sensor chip to sample current; the conditioning unit is a second-order active filter and is used for carrying out bias amplification and filtering on the sampling signal, so that the bias amplification processing can be carried out on the sampling signal, high-frequency noise in the current signal is filtered, and the current sampling range and precision meet the use requirements.
The bus voltage sampling module realizes voltage sampling by using a method of partial pressure sampling and isolation amplification;
the temperature detection module is used for sampling the temperature by the sampling temperature sensor, and when the sampling temperature (the temperature of the acquired radiator attached to the three-phase six-bridge) exceeds a set threshold value, the control software limits the output power of the driving circuit; the temperature sensor can specifically adopt an NTC thermistor;
the fault protection module realizes overcurrent and short-circuit protection functions by using fault output signals of the current sensor chip, inputs overcurrent fault signals of the current sampling and conditioning module into the main control CPU, and controls PWM (pulse width modulation) signal output of the main control CPU by the hardware register; when a fault occurs, the main control CPU prohibits the PWM pin from outputting an effective level, meanwhile, the software outputs an EN signal to the IR2136 enabling end, and prohibits the IR2136 from outputting an effective signal to the MOSFET control end, so that the driving circuit and the motor are protected.
The specific method for realizing current sampling conditioning and fault protection of the power circuit comprises the following steps:
u, V, W three-phase output of the driving circuit passes through the current sampling unit, and U-phase and V-phase current sampling values are taken to enter the conditioning unit; an overcurrent fault output function of the current sampling unit is utilized to configure overcurrent fault threshold values Voc and Ioc for U, V, W three phases, and fault output signals of the current sampling unit enter a main control CPU after being processed by AND logic; when the current sampling unit detects that the current exceeds a set threshold value, the fault pin outputs a low level, the low level triggers a TIM _ BKIN event, and a hardware register prohibits PWM signal output, so that a driving circuit and a motor are protected.
The working principle of the power circuit is as follows:
the power circuit receives the PWM signal of the control circuit from the pin header, the IR2136 carries out logic and level conversion on the PWM signal, drives six MOSFET power devices to be switched on and switched off according to a given sequence, and outputs a U/V/W power signal for driving the motor to rotate. Meanwhile, the power circuit samples the U-phase current and the W-phase current through the current IC, detects whether the UVW three-phase current is over-current or not, and outputs a FAULT FAULT signal if the over-current occurs. The current sampling signal is filtered and biased and amplified by a second-order filter, and then is sent to the control circuit together with the fault detection signal through the pin header. The power circuit samples the bus voltage and temperature at the same time, sends the sampled bus voltage and temperature into the pin header, receives a fan control signal from the pin header and controls the external fan; DC1+, DC2+ and GND are two low-voltage power supply input interfaces, and can respectively input 9V-36V direct-current power supply signals and 30V-100V direct-current power supply signals.
Third, control software
The control software as the core component of the servo driver mainly has the following remarkable functions:
and 3.1, adopting a FreeRTOS real-time operating system and an interrupt processing mechanism to allocate and schedule resources for a fast real-time task, a slow real-time task, a monitoring task and a background task of the driver.
The interrupt is generated by a PWM hardware register configuration inside the CPU, the frequency of a PWM signal is configured to be 8KHz, and a central symmetry mode is adopted, so that the interrupt is generated every 125 us. The interrupt has the highest priority, and a fast real-time task is executed once when the interrupt responds; the slow real-time task is executed every two interrupts. The task scheduling of the real-time operating system is controlled by a timer, the priority is lower than the interrupt priority, the monitoring task is executed once every 1ms, and the background task (the lowest priority) is executed at the rest time, namely when the CPU is idle. The fast real-time task and the slow real-time task can preempt the resources of the monitoring task and the background task.
3.2, the self-tuning control algorithm function of the electrical parameters, the mechanical parameters and the operation parameters of the motor is realized.
The control software sets the rated working current and rated rotating speed of the motor and operates according to a preset working mode, so that the pole pair number, the encoder bit number, the zero phase angle of the motor rotor, the resistance, the inductance and the current loop proportion parameter k of the motor can be setpcAnd an integral parameter kicCounter potential coefficient keCoefficient of moment ktAnd the rotor rotational inertia, and automatically storing the self-setting obtained operation parameters into an EEPROM, and automatically reading the obtained parameters from the EEPROM after the next power-on to control the operation of the motor.
3.2.1) self-tuning of the number of pole pairs of the motor and the number of the encoder bits.
The algorithm is described here by way of an absolute encoder interface. The driver controls the motor to work in a stator voltage vector rotation mode, the voltage vector amplitude is a voltage value corresponding to the rated current, the stator voltage vector angle is increased according to a given rule in each cycle control period, the motor starts to rotate slowly in the forward direction (anticlockwise), and meanwhile, encoder data are detected. When the sudden change from a large value to a small value occurs in the encoder data for the first time, the maximum value is recorded, and the number of encoder bits is calculated according to the maximum value. And simultaneously recording the vector angle of the reference voltage at the moment. The motor continues to rotate, the number of pole pairs is increased by 1 when the stator voltage vector angle is increased by 2 pi, when the large value and the small value are suddenly changed again, namely the motor rotates for a mechanical whole circle, the vector angle undergoes 2 pi cycles for many times, and the number of the 2 pi cycles is the number of pole pairs of the motor.
3.2.2) self-adjusting the zero phase angle of the motor rotor.
The algorithm is described by taking an absolute encoder interface as an example. The driver controls the motor to work in a stator current vector rotation mode, the current vector amplitude is the rated current of the motor, the stator current vector angle is increased according to a given rule in each cycle control period, the motor starts to rotate slowly in the forward direction (anticlockwise), and meanwhile, encoder data are detected. The current vector angle at that moment is recorded when a large to small jump in the encoder data occurs. After the rotor rotates for multiple circles, each sudden change of the encoder data from a large value to a small value corresponds to a current vector angle, multiple groups of recorded current vector angles are averaged, and then the current vector angles are converted into corresponding mechanical angles, namely the zero phase angle of the motor rotor.
3.2.3) self-tuning of the motor resistance and inductance.
Vector control is carried out on the motor in a two-phase static coordinate system, and u is applied to the motor according to a given ruleαAnd uβVoltage vector, when the current is stable, recording the corresponding current value according toThe motor resistance can be obtained; also applying u to the motorαAnd uβAnd during voltage vector, recording the time when the current reaches a stable value, and calculating the inductance of the motor through the time and the motor equivalent model. The self-setting method is used for measuring the resistance value and the inductance value for multiple times, and the average value is taken as the resistance and the inductance of the motor after the multiple measurements.
3.2.4) self-tuning of current loop control parameters.
After obtaining the resistance inductance, the current loop proportion parameter k can be calculated according to the motor current loop equivalent model and the bandwidth design method thereofpcCurrent loop integral parameter kic。
Current loop equivalent model as shown in fig. 4, considering the sampling delay and the delay of the zero-order hold,whereinR, L motor resistance and inductance, TsThe current loop sampling period (equivalent to the current loop calculation period).
The PI controller model is as follows:
the open loop transfer function is:
cut-off frequency omega of open-loop transfer function of control model built in servo driver softwareBAnd a phase margin MF, which can be calculated:
current loop integral parameter kic：
Then, a current loop proportion parameter k is obtained according to the definition of cut-off frequencypc：
Wherein,
r: a motor resistance;
l is the motor inductance;
ωB: current loop open loop transfer function cutoff frequency;
MF: current loop phase margin
Kic: current loop integral parameter
Kpc: current loop ratio parameter
Ts: current loop calculation period
3.2.5) counter electromotive force coefficient k of motoreCoefficient of sum moment ktAnd self-tuning.
After the current loop control parameters are obtained, the motor can work in a d-q axis current loop mode. Let the d-axis current of the motor be closed-loop to make id0; simultaneously, voltage is applied to the q axis according to a given rule, the motor rotates in an accelerated way, and the motor is recorded to respectively reachAnd wnormCalculating the counter electromotive force coefficient k of the motor according to the corresponding voltage value and the corresponding rotation speedeThen according to the motor back electromotive force coefficient keAnd the moment systemNumber ktCalculating the moment coefficient k according to the specific relationshipt。wnormThe rated rotating speed of the motor and the motor parameters used by users.
3.2.6) self-adjusting the rotational inertia of the motor rotor.
Applying a q-axis forward current i to the motorq(d, q-axis current are both closed-loop, id0), the motor starts to rotate at an increased speed, and the motor is recorded fromAccelerate to wnormThen q-axis negative current is applied to the motor, the motor starts to decelerate, and the motor speed from w is recordednormIs decelerated toAccording to the time ofCalculating the acceleration based onAnd calculating the rotational inertia of the motor rotor.
Claims (8)
1. A low-voltage high-current servo driver comprises a control circuit, a power circuit and control software; it is characterized in that the preparation method is characterized in that,
when the control software runs, the following steps are realized:
1) self-tuning of pole pair number and encoder digit of motor
1.1) controlling the motor to work in a stator voltage vector rotation mode, wherein the voltage vector amplitude is a voltage value corresponding to the rated current;
1.2) in each cycle control period, increasing the stator voltage vector angle according to a given rule, starting the motor to rotate slowly in the forward direction, and detecting encoder data;
1.3) when the encoder data suddenly changes from a large value to a small value for the first time, recording the maximum value, calculating the number of bits of the encoder according to the maximum value, and simultaneously recording the vector angle of the reference voltage at the moment;
1.4) the motor continues to rotate, the number of pole pairs increases by 1 when the vector angle of the stator voltage increases by 2 pi, and when the sudden change from a large value to a small value occurs again, the number of times of 2 pi circulation experienced by the vector angle is the number of pole pairs of the motor;
2) zero phase angle self-tuning of motor rotor
2.1) controlling the motor to work in a stator current vector rotation mode, wherein the current vector amplitude is the rated current of the motor;
2.2) in each cycle control period, increasing a stator current vector angle according to a given rule, starting the motor to rotate slowly in the forward direction, and detecting encoder data;
2.3) when the encoder data has a sudden change from a large value to a small value, recording the current vector angle at the moment;
2.4) after the rotor rotates for a plurality of circles, recording a current vector angle every time when the encoder data suddenly changes from a large value to a small value;
2.5) averaging the recorded multiple groups of current vector angles, and converting the current vector angles into corresponding mechanical angles, namely the zero phase angle of the motor rotor;
3) self-tuning of motor resistance and inductance
3.1) carrying out vector control on the motor in a two-phase static coordinate system, and applying u to the motor according to a given ruleαAnd uβThe voltage vector records a corresponding current value when the current is stable;
3.2) according toThe resistance value of the motor can be obtained;
3.3) applying u to the electric machineαAnd uβDuring voltage vector, recording the time when the current reaches a stable value, and calculating to obtain the inductance of the motor through the time and the motor equivalent model;
4) control parameter self-tuning
After obtaining the resistance inductance, calculating a current loop proportion parameter k according to a motor current loop equivalent model and a bandwidth design method thereofpcCurrent loop integral parameter kic；
5) Back electromotive force coefficient k of motoreCoefficient of sum moment ktSelf-tuning
5.1) obtaining a current loop proportion parameter kpcAnd current loop integral parameter kicThen, the motor works in a current loop mode of a two-phase rotating d-q coordinate system;
5.2) letting the d-axis current of the motor close loop to make id0; simultaneously, voltage is applied to the q axis according to a given rule, the motor rotates in an accelerated way, and the recording motor respectively reachesAnd wnormThe corresponding voltage value;
5.3) calculating the counter potential coefficient k of the motor according to the voltage value and the corresponding rotating speed obtained in the step 5.2)e；
5.4) according to the counter potential coefficient k of the motoreAnd coefficient of moment ktCalculating the moment coefficient kt；
6) Self-tuning of rotational inertia of motor rotor
6.1) applying a q-axis forward current i to the motorqThe motor begins to spin up, recording the motor fromAccelerate to wnormTime Δ t of1；
6.2) applying a negative q-axis current-i to the motorqWhen the motor starts to decelerate, the motor is recorded from wnormIs decelerated toTime Δ t of2；
6.3) according toCalculate the sumSpeed, averaging the accelerations calculated in the acceleration process and the deceleration process;
6.4) according toAnd calculating the rotational inertia of the motor rotor.
2. A low voltage high current servo driver according to claim 1, wherein: in the step 3), the resistance value and the inductance value are measured for many times by adopting the methods of 3.1) to 3.3); and respectively averaging all the measured resistance values and inductance values to obtain the resistance and the inductance of the motor.
3. A low voltage high current servo driver according to claim 1 or 2, wherein in step 4):
current loop ratio parameter
Current loop integral parameter
In the formula,
r is a motor resistor;
l is a motor inductor;
Tsthe current loop sampling period is equal to the current loop calculation period;
ωBthe cut-off frequency of an open-loop transfer function of a control model built in servo driver software;
the MF is a control model open-loop transfer function phase margin built in servo driver software.
4. A low voltage high current servo driver according to claim 3, wherein: the control circuit comprises a master control CPU, a parameter storage module, an EtherCAT bus communication module, four paths of SPI communication modules and a plurality of communication interfaces;
the main control CPU is used for providing two current sampling data feedback channels for the motor, and simultaneously collecting U-phase current and W-phase current of the motor as feedback of a current loop;
the parameter storage module is used for storing the motor operation parameters;
the EtherCAT bus communication is used for realizing Ethernet communication and realizing data interaction with the master control CPU through an SPI interface;
a four-way SPI communication module comprising SPI1, SPI2, SPI3 and SPI 4; the main control CPU exchanges data with the EEPROM chip through the SPI1, carries out data interaction with a key/LED interface chip through the SPI2, is matched with a magnetic encoder interface through the SPI3, carries out bus data interaction with the ET1100 chip through the SPI4 and is configured with bus synchronous interruption;
the communication interface comprises an RS232 serial communication interface, an RS485 high-speed communication interface and a general RS485 communication interface.
5. A low voltage high current servo driver according to claim 4, wherein: the power circuit comprises a power supply conversion module, a drive circuit based on the MOSFET, a current sampling and conditioning module, a bus voltage sampling module, a temperature detection module and a fault protection module;
the power supply conversion module is used for selecting a working mode according to external input voltage and selecting a low-voltage power supply input source;
the driving circuit is used for driving the motor to work;
the current sampling and conditioning module comprises a current sampling unit and a conditioning unit; the current sampling unit uses a Hall type current sensor chip to sample current; the conditioning unit is a second-order active filter and is used for carrying out bias amplification and filtering on the sampling signal;
the bus voltage sampling module realizes voltage sampling by using a method of partial pressure sampling and isolation amplification;
the temperature detection module is used for acquiring the ambient temperature and the temperature of the power circuit;
and the fault protection module is used for protecting the driving circuit and the motor.
6. A low voltage high current servo driver according to claim 5, wherein: the driver circuit is implemented using IR2136 and FQH90N 15.
7. A low voltage high current servo driver according to claim 6, wherein: the fault protection module realizes overcurrent and short-circuit protection functions by using fault output signals of the current sensor chip, inputs overcurrent fault signals of the current sampling and conditioning module into the main control CPU, and controls PWM (pulse width modulation) signal output of the main control CPU by the hardware register; when a fault occurs, the main control CPU prohibits the PWM pin from outputting an effective level, meanwhile, the control software outputs a low level signal to the EN pin of the IR2136, and prohibits the IR2136 from outputting an effective signal to the control end of the FQH90N15, so that the driving circuit and the motor are protected.
8. A low voltage high current servo driver according to claim 7, wherein: the control circuit also comprises a pulse/direction input interface, two isolated digital quantity input interfaces, two isolated digital quantity output interfaces and/or an incremental encoder interface which are connected with the main control CPU.
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