CN117614318A - Servo driver based on DSP and FPGA dual processor - Google Patents

Servo driver based on DSP and FPGA dual processor Download PDF

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Publication number
CN117614318A
CN117614318A CN202311477868.6A CN202311477868A CN117614318A CN 117614318 A CN117614318 A CN 117614318A CN 202311477868 A CN202311477868 A CN 202311477868A CN 117614318 A CN117614318 A CN 117614318A
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CN
China
Prior art keywords
circuit
dsp
power supply
fpga
servo driver
Prior art date
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Pending
Application number
CN202311477868.6A
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Chinese (zh)
Inventor
吴文韬
高祥
葛宇
邱晨
张允志
邱静
赵乾
刘海马
乔客闲
孙硕
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Lianyungang Jierui Electronics Co Ltd
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Lianyungang Jierui Electronics Co Ltd
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Application filed by Lianyungang Jierui Electronics Co Ltd filed Critical Lianyungang Jierui Electronics Co Ltd
Priority to CN202311477868.6A priority Critical patent/CN117614318A/en
Publication of CN117614318A publication Critical patent/CN117614318A/en
Pending legal-status Critical Current

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Classifications

    • 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
    • H02P6/08—Arrangements for controlling the speed or torque of a single motor
    • H02P6/085—Arrangements for controlling the speed or torque of a single motor in a bridge configuration
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H7/00—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
    • H02H7/08—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for dynamo-electric motors
    • H02H7/0805—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for dynamo-electric motors for synchronous motors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H7/00—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
    • H02H7/08—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for dynamo-electric motors
    • H02H7/0822—Integrated protection, motor control centres
    • 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
    • H02P27/00—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
    • H02P27/04—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage
    • H02P27/06—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters
    • H02P27/08—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters with pulse width modulation
    • H02P27/085—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters with pulse width modulation wherein the PWM mode is adapted on the running conditions of the motor, e.g. the switching frequency
    • 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
    • H02P27/00—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
    • H02P27/04—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage
    • H02P27/06—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters
    • H02P27/08—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters with pulse width modulation
    • H02P27/12—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters with pulse width modulation pulsing by guiding the flux vector, current vector or voltage vector on a circle or a closed curve, e.g. for direct torque control
    • 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
    • H02P6/06—Arrangements for speed regulation of a single motor wherein the motor speed is measured and compared with a given physical value so as to adjust the motor speed
    • 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
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
    • H05K7/209—Heat transfer by conduction from internal heat source to heat radiating structure

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Control Of Motors That Do Not Use Commutators (AREA)

Abstract

The invention discloses a servo driver based on a DSP and an FPGA, which controls various motion functions of a motor in three modes of position, speed and moment, displays and processes system state faults, and reserves a software interface for later upgrade. After receiving enabling and command signals of the upper computer, the servo driver enters a driving working mode and controls the output of the MOSFET inverter circuit to drive the servo motor; meanwhile, a current sampling circuit collects current signals, and an FPGA executes an internal decoding program to collect speed and position signals to be used as feedback signals of a three-loop; the DSP performs closed-loop control on the operation of the servo motor through a PI control algorithm according to the command and the feedback data; and a logic processing circuit and a driving protection circuit are added at the front end of the MOSFET driving circuit, so that the driving protection, PWM logic level protection and STO protection of the MOSFET inverter circuit are realized.

Description

Servo driver based on DSP and FPGA dual processor
Technical Field
The invention belongs to the technical field of motor servo drive, and particularly relates to a servo driver based on a DSP and an FPGA.
Background
Servo systems have been widely used as one of the most important control and actuator mechanisms for industrial automation in the fields of machine tools, textile machines, printing machines, packaging machines, etc. Meanwhile, with the rapid expansion of industries such as industrial robots, electronic manufacturing equipment and the like in recent years, the application scale of a servo system in an emerging industry is rapidly increased, and the whole market scale is greatly increased. Modern servo systems are evolving towards full digitization, high integration, intelligence, networking and modularization. The servo driver is an important part of a servo system, is a crystal with multi-disciplinary technology crossing, and almost integrates various advanced technologies of modern industry, so the servo driver is always the research focus of students at home and abroad.
Today, most servo drives in the market are single-core control, and the control algorithm and the encoder decoding function are all integrated in one control chip. The control algorithm occupies longer time, so that the driver controlled by a single core has long control period, low parameter sampling frequency, low control precision and small closed-loop control tricyclic bandwidth. Meanwhile, the decoding function of the encoder occupies a larger storage space, and under the condition of single-core control, the compatibility of the driver to the encoder protocol is poor. Therefore, there is a need to design a servo driver with shorter control period, wider control bandwidth and compatibility with most encoders on the market.
Disclosure of Invention
The invention aims to solve the problems in the prior art and provides a low-voltage direct current servo driver based on a DSP and an FPGA dual processor, which has the advantages of small volume, strong environmental adaptability, quick dynamic response and high reliability.
The technical solution for realizing the purpose of the invention is as follows: the servo driver is designed by adopting a DSP and FPGA dual processor, the DSP is used as a main controller, the FPGA is used as an encoder decoding controller, various motion functions of a direct current brush, a brushless motor and a permanent magnet synchronous motor are precisely controlled in three modes of position, speed and moment, relevant system state faults are displayed and processed, and relevant software interfaces are reserved for later upgrading of alternating current servo control algorithm and functions; after receiving enabling and command signals of the upper computer, the servo driver enters a driving working mode and controls the output of the MOSFET inverter circuit to drive the servo motor; meanwhile, a current sampling circuit collects current signals, an FPGA executes an internal decoding program to collect speed and position signals of a servo motor, and the speed and position signals are used as feedback signals of a three-loop; the DSP performs closed-loop control on the operation of the servo motor through a PI control algorithm according to the command and the feedback data; the front end of the MOSFET driving circuit is connected with the logic processing circuit and the driving protection circuit and is used for realizing the driving protection of the MOSFET inverter circuit, the PWM logic level protection and the safe torque closing STO protection.
Further, the servo driver comprises a power supply unit, a main control unit, an inversion unit, a signal conditioning unit, a motor speed and angle measuring unit, a safe torque closing unit, a fault protection unit and a communication unit;
the main control unit comprises a DSP control circuit, an FPGA control circuit and a logic processing circuit; the DSP signal processor circuit is used for completing the following tasks, and comprises: instruction receiving, various signal acquisition, PWM signal generation, output torque control, speed tracking control and fault processing; the FPGA control circuit is used for realizing communication with each protocol encoder and safety torque closing; the logic processing circuit is used for realizing PWM output protection by controlling the logic protection signal level;
the power supply unit is used for providing required voltage for each unit of the servo driver;
the inversion unit comprises a MOSFET driving circuit and a MOSFET inversion circuit; the MOSFET driving circuit is used for realizing the switch driving of the MOSFET; the MOSFET inverter circuit is used for realizing driving control of the servo motor;
the signal conditioning unit is used for filtering and normalizing various analog input signals and sending the filtered analog input signals to the AD port of the DSP for ADC conversion; the system is also used for inputting various I/O signals to the DSP through optical coupling isolation treatment, and comprises a three-phase current sampling circuit, a direct-current bus voltage sampling circuit, an analog input interface circuit and an I/O signal interface circuit;
the motor speed and angle measuring unit is used for providing signal interfaces according to different feedback signals respectively;
the safety torque closing unit is used for closing the PWM signal output enabling of the driver after the motor torque exceeds a safety value;
the fault protection unit is used for protecting when the circuit fails and comprises an over-temperature protection circuit, a short-circuit protection circuit and an overvoltage protection circuit;
the communication unit is communicated with the upper computer, is used for realizing parameter setting and state monitoring, and is used for a digital speed control or torque current control mode.
Further, the power supply unit comprises four parts of a 12V driving power supply, a 5V external output power supply, a main control 3.3V power supply and a 1.9V power supply;
the main control 3.3V power supply and the 1.9V power supply circuit are used for generating power supply required by the operation of each control circuit;
the 12V driving power supply circuit is used for generating power supply required by the MOSFET driving circuit and supplying power for the next stage of power supply;
the 5V external output power supply is used for power supply transition, external encoder power supply and power supply of the rest part of the circuit.
Further, the input working main power range of the servo driver is 13.5-95V, the rated working condition is 85V, and the maximum output power is 1600W.
Further, a filter capacitor is arranged at the power input end of the servo driver, and a surge protection circuit is arranged at the power output end for supplying power to the encoder.
Further, the working principle of the safety torque closing unit is as follows: the safety torque signal is used for controlling the on-off of a rear-stage enabling signal through the optocoupler isolation chip, and is transmitted to the rear stage through the Schmidt buffer, so that the on-off of the driving PWM is controlled, and the safety torque closing state of the servo driver is transmitted.
Further, the motor speed and angle measuring unit circuit comprises two paths of sensor decoding circuits and one path of Hall sensor circuit, and the sensor decoding circuit converts an external encoder signal through RS485/RS422 level and then inputs the external encoder signal to the FPGA for processing; the Hall sensor circuit inputs a Hall signal to the FPGA for processing after passing through the Schmidt trigger inverter.
Further, the servo driver comprises a shell, a radiating bottom plate and a printed board, wherein the radiating bottom plate and the printed board are arranged in the shell, the printed board is designed to be 3 layers, a control board, a sampling board and a power board are sequentially arranged from top to bottom, the three boards are connected and fixed through pins, and the pins are connected with the printed board in a welding mode; the top layer of the power board is provided with 6 MOSFETs which are respectively arranged on two parallel lines, the bottom layer corresponding to the MOSFETs is provided with two heat dissipation welding rods with windows, the corresponding positions of the middle layer are subjected to heat dissipation through copper coating, and the heat dissipation welding rods with windows are connected with a heat dissipation bottom plate through reflow soldering.
Further, the heat dissipation bottom plate is made of aluminum metal, the surface of the heat dissipation bottom plate is plated with nickel, the shell is made of PPO plastic, the heat dissipation bottom plate is formed into a box shape in an injection molding mode, and the heat dissipation bottom plate is clamped on the edge of the heat dissipation bottom plate in a back fastening mode.
Further, the shell, the control board and the power board are provided with corresponding filling openings for glue filling treatment after the servo driver is assembled.
Compared with the prior art, the invention has the remarkable advantages that: the invention has the characteristics of simple hardware design, small volume, convenient maintenance, high dynamic response speed, wide control bandwidth, high compatibility of encoder protocols, high reliability and the like.
The invention is described in further detail below with reference to the accompanying drawings.
Drawings
Fig. 1 is a schematic block diagram of the operation of the drive.
Fig. 2 is a power supply structure diagram.
FIG. 3 is a flow chart illustrating the operation of the system main interrupt algorithm.
Fig. 4 is a diagram of an FPGA program framework.
Fig. 5 is a schematic block diagram of a safe torque shut-off.
Fig. 6 is a schematic diagram of a driver structure.
Detailed Description
In order to make the objects, technical solutions and advantages of the present application more apparent, the present application will be further described in detail with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the present application.
It should be noted that, if directional indications (such as up, down, left, right, front, and rear … …) are included in the embodiments of the present invention, the directional indications are merely used to explain the relative positional relationship, movement conditions, etc. between the components in a specific posture (as shown in the drawings), and if the specific posture is changed, the directional indications are correspondingly changed.
In one embodiment, in conjunction with FIG. 1, a low voltage DC servo driver employing segmented PI control based on a DSP and FPGA dual processor is provided.
The servo driver adopts a DSP+FPGA dual-processor design, can precisely control various motion functions of a direct current brush, a brushless motor and a permanent magnet synchronous motor in three modes of position, speed and moment, displays and processes related system state faults, and reserves related software interfaces for later upgrading of alternating current servo control algorithms and functions. After receiving enabling and command signals of the upper computer, the servo driver enters a driving working mode and controls the output of the MOSFET inverter circuit to drive the servo motor; meanwhile, a current sampling circuit collects current signals, and an FPGA executes an internal decoding program to collect speed and position signals to be used as feedback signals of a three-loop; the DSP performs closed-loop control on the operation of the servo motor through a PI control algorithm according to the command and the feedback data; and a logic processing circuit and a driving protection circuit are added at the front end of the MOSFET driving circuit, so that the driving protection of the MOSFET inverter circuit, the PWM logic level protection and the safety torque closing (STO) protection are realized.
Further, in one embodiment, the servo driver circuit mainly comprises a power supply unit, a main control unit, an inversion unit, a signal conditioning unit, a motor speed and angle measuring unit, a safety torque closing unit, a fault protection unit and a communication unit. The units are specifically as follows:
(1) Power supply unit
The power supply comprises a 12V driving power supply, a 5V external output power supply, a main control 3.3V power supply and a 1.9V power supply.
The main control 3.3V power supply and the 1.9V power supply circuit are used for generating power supply required by the operation of the control circuit.
The 12V drive power supply circuit is used to generate the power supply required by the MOSFET drive circuit and to supply power to the next stage of power supply.
The 5V external output power supply is used for power supply transition, external encoder power supply and power supply of the rest of the circuit.
The filter capacitor and the surge protection circuit which are composed of TVS, fuse, inductance and the like and are needed by the power input end of the driver can be realized in the driver circuit, a large number of higher harmonics generated by the power supply main circuit due to high-power high-frequency carrier waves can be effectively restrained, and the interference to other equipment and internal control circuits of the power supply circuit is reduced.
(2) Main control unit
The main control unit mainly comprises a DSP control circuit, an FPGA control circuit and a PWM hardware enabling circuit.
The DSP signal processor circuit mainly completes tasks such as instruction receiving, various signal acquisition, PWM signal generation, output torque control, speed tracking control, fault processing and the like, and is the core of the whole system.
The FPGA control circuit mainly completes the task of communicating with each protocol encoder.
The PWM hardware enabling circuit mainly realizes the hardware enabling of the PWM output path.
(3) Inverter unit
The inversion unit mainly comprises a MOSFET driving circuit and a MOSFET inversion circuit.
The MOSFET driving circuit mainly realizes the switch driving of the MOSFET.
The MOSFET inverter circuit is mainly used for realizing driving control of the servo motor.
(4) Signal conditioning unit
The signal conditioning unit mainly comprises a three-phase current sampling circuit, a direct current bus voltage sampling circuit, an analog input interface circuit and an I/O signal interface circuit.
The conditioning circuit filters and normalizes various analog input signals and sends the signals to the AD port of the DSP for ADC conversion.
The conditioning circuit inputs and outputs various I/O signals into the DSP through optical coupling isolation processing.
(5) Motor speed and angle measuring unit
The motor speed and angle measuring unit provides signal interfaces according to different feedback signals respectively.
(6) Safety torque closing unit
The safety torque closing unit ensures that the PWM signal output enable of the driver is closed after the motor torque exceeds a safety value.
(7) Fault protection unit
The fault protection unit mainly comprises an over-temperature protection circuit, a short-circuit protection circuit, an overvoltage protection circuit and the like.
(8) Communication unit
And two groups of communication interfaces including RS232 and CAN are provided, and the communication interfaces CAN be configured to communicate with an upper computer, are used for system parameter setting and state monitoring, and are used for digital speed control or torque current control modes.
Further, in one embodiment, the range of the input working main power supply (control power and power) of the servo driver is 13.5-95V, the rated working condition is 85V, and the maximum output power is 1600W; the filter circuit and the surge protection circuit are implemented in the peripheral circuit of the servo driver device.
Further, in one embodiment, the servo driver interface includes: the device comprises a power interface, a motor interface, an encoder interface, a communication interface (RS 232, CAN), an analog interface, a digital interface and a safety torque closing interface.
Further, in one embodiment, the printed board of the servo driver is designed to be 3 layers, namely an upper layer control board, a lower layer power board and an intermediate layer sampling board, the three boards are connected and fixed through pins, and the pins are connected with the printed board in a welding mode; the power board is provided with 6 MOSFETs, the MOSFETs are respectively arranged on two parallel lines, two heat dissipation welding rods with windows are designed on the bottom layer corresponding to the MOSFETs, heat dissipation is carried out on the corresponding position of the middle layer through copper coating, and the heat dissipation welding rods with windows are connected with the bottom heat dissipation plate through reflow soldering.
Further, in one embodiment, the bottom heat dissipation plate of the servo driver is made of aluminum, the surface of the bottom heat dissipation plate is plated with nickel, the upper shell is made of PPO plastic, the bottom heat dissipation plate is made into a box shape in an injection molding mode, and the bottom heat dissipation plate is clamped on the bottom heat dissipation plate in a mode that the edges of the bottom heat dissipation plate are made into a back buckle. Two filling openings are reserved on the shell, the control board and the power board respectively and are used for glue filling treatment after assembly.
The present invention will be described in detail below.
The working principle block diagram of the servo driver of the invention is shown in figure 1:
1) The DSP is used as a main controller, the FPGA is used as an encoder decoding controller, the instruction receiving and feedback signal acquisition and processing of the upper computer are completed, and the control and fault monitoring of the current loop, the speed loop and the position loop are realized.
2) A high-speed logic AND gate is used as a logic protection circuit to logically protect PWM output, and logic protection signals are divided into an enabling signal and a safety torque closing signal.
3) And a MOS inverter circuit is adopted to realize a power driving function.
4) Three-phase current is collected by adopting a precise mΩ -level sampling resistor, bus voltage sampling is carried out by adopting a resistor voltage dividing circuit, and reference voltage is provided by adopting a voltage dividing reference circuit.
5) An optocoupler is used as a digital input and output isolation device, and an operational amplifier is used for constructing an amplifying circuit to realize differential analog input.
6) And an RS485 chip and an RS422 chip and a Schmidt inverter are adopted as motor speed and angle feedback signal conversion devices.
7) And the CAN and RS232 chips are adopted to complete the level conversion of the corresponding communication protocol.
8) The SRAM chip is used for storing temporary data such as signal waveforms, and the EEPROM chip is used for storing nonvolatile data such as driver parameters, motor parameters and the like.
9) The bottom heat dissipation plate is made of aluminum metal, the surface of the bottom heat dissipation plate is plated with nickel, the upper shell is made of PPO plastic, the bottom heat dissipation plate is made into a box shape in an injection molding mode, and the bottom heat dissipation plate is clamped on the bottom heat dissipation plate in a mode that the edges of the bottom heat dissipation plate are made into back buckles.
The main components are designed as follows.
1. Power supply unit
The power supply unit structure is shown in fig. 2, and comprises a 12V power supply, a 5V decoding circuit, an external power supply, a main control 3.3V power supply and a 1.9V power supply, wherein the power supply unit structure is designed as a non-isolated power supply, and the peripheral circuit is built to remove interference among I/O signals. Considering that the driver has a volume requirement, a non-isolated switching power supply chip is selected to build a power supply circuit; in order to ensure the reliability and safety of the power supply, a surge protection circuit composed of a TVS tube, a capacitor, an inductor and the like is added at the power supply input and output end.
2. Main control unit
The main control unit mainly comprises a DSP signal processor circuit, an FPGA circuit and a logic processing circuit. The DSP signal processing circuit mainly completes tasks such as instruction receiving, various signal acquisition, PWM signal generation, output torque control, speed tracking control, fault processing and the like, and is the core of the whole system. The FPGA circuit mainly completes the work of encoder decoding, safety torque closing and the like. The logic processing circuit mainly completes PWM output protection work by controlling the logic protection signal level.
In the DSP signal processor, a control closed-loop algorithm is realized in a Timer0 interrupt program, an FPGA is used as a peripheral main body, information interaction is carried out with the DSP in each interrupt period, information interaction is carried out with an external sensor continuously, and partial functional signal processing is participated. The flow chart of the system main interrupt algorithm operation and the time required by each step are shown in fig. 3, and the FPGA program framework chart is shown in fig. 4.
3. Inverter unit
The inversion unit adopts a currently mainstream linear PWM driving method, the method can realize four-quadrant operation of the motor, is suitable for motor position control, speed control and torque control, and can be applied to alternating current motors and direct current brushless motors.
4. Signal conditioning unit
The signal conditioning unit mainly comprises a three-phase current sampling circuit, a direct current bus voltage sampling circuit, an analog input interface circuit and an I/O signal interface circuit. The conditioning circuit normalizes and digitizes various digital-analog input/output signals and sends the signals to the DSP.
Here, the reference voltage of the signal conditioning unit is provided by a divided reference circuit.
The voltage dividing reference circuit provides a reference lift for each sampling circuit. Firstly, carrying out resistance voltage division on a reference voltage of a voltage reference source to obtain a reference lifting voltage; and then the output is sent to each sampling circuit after passing through a follower circuit, and the follower circuit plays a role in buffering reference voltage.
The three-phase current sampling circuit is used for detecting three-phase current of the motor. Firstly, partial pressure acquisition of phase current is carried out through an mΩ -level sampling resistor, and then the phase current is input into a DSP after conversion for current feedback closed-loop operation.
The DC bus voltage sampling circuit is used for sampling bus voltage. Firstly, converting bus voltage into small voltage by a large-resistance voltage division method, and then inputting the small voltage into an AD port of the DSP for sampling by a first-order active filter circuit.
The servo driver is provided with a path of differential analog signal input interface, a path of unipolar analog input interface, a six-path digital input interface, a 2-path digital output isolation interface and a 2-path digital output non-isolation interface. The digital input/output isolation signal interface adopts an optical coupler isolation chip to provide electric shock signals, realizes the isolation of input/output signals of the servo driver, and sends the signals into the DSP for processing or sends the signals out of the DSP, wherein the IN5 and IN6 digital input ports can be used as PWM signal input, and the two interfaces adopt high-speed optical couplers. The 2-path digital output non-isolation interface is directly driven by an FPGA output level signal. The differential analog signal input sampling circuit converts a-10V to +10V differential analog signal by adopting an operational amplifier circuit and inputs the converted differential analog signal into an AD port of the DSP for sampling. The unipolar analog input is directly sent to the AD port of the DSP for sampling after being filtered by the resistance-capacitance filter.
5. Motor speed and angle measuring unit
The motor speed and angle measuring unit circuit comprises two paths of sensor decoding circuits and one path of Hall sensor circuit. The sensor decoding circuit converts the external encoder signal through RS485/RS422 level and inputs the converted signal to the FPGA for processing; the Hall signal of the Hall sensor circuit is input to the FPGA for processing after passing through the Schmidt trigger inverter.
6. Safety torque closing unit
The driver is designed with a two-way safety torque closing unit, when the motor torque exceeds the safety torque range, the external safety torque signal jumps to a low level, and when the low level of the external safety torque signal lasts for a period of time, the driver closes PWM driving enabling, and the motor is not driven any more. The schematic block diagram of the safety torque closing is shown in fig. 5, the safety torque signal controls the on-off of a rear-stage enabling signal through an optocoupler isolation chip, and is transmitted to the rear stage through a schmitt buffer, and controls the on-off of the driving PWM and informs the driver of the safety torque closing state.
7. Fault protection unit
The fault protection unit mainly comprises a software protection function and a hardware protection function. For the application environment of the servo driver, the design software protection function comprises: software operation fault reporting, overcurrent, over-temperature, overspeed, power protection, encoder fault, speed feedback fault and communication fault. Because the hardware fault processing circuit responds and is effective in time, the short-circuit protection function adopts the hardware circuit to realize fault protection, and after the fault occurs, the driver realizes drive disabling through the hardware circuit and feeds back a fault signal to the upper computer through the communication interface.
And the over-temperature protection function adopts a thermistor voltage dividing circuit as a temperature sensor, the thermistor is arranged at a power board radiating pad, and divided voltage is sent to an AD interface of the DSP for temperature monitoring. And the short-circuit protection function is realized by adopting a current monitoring chip to monitor bus current and output sampling current, outputting sampling voltage through a grounding resistor, comparing the sampling voltage with a reference value through a comparator and sending the sampling voltage to a trigger pin of the DSP. And the overvoltage protection function is realized by comparing a busbar voltage sampling value with a reference value through a comparator and sending output to a DSP trigger pin for judgment. And the reset monitoring function is realized by adopting a reset monitoring chip.
The protection of other faults, such as software operation fault reporting, overcurrent, overspeed, power supply protection, speed feedback faults, communication faults and the like, is realized through software design. The software operation error reporting is realized by monitoring overflow or messy codes of certain key data through a program; overcurrent, overspeed and power protection are realized by monitoring corresponding sampling voltages; the speed feedback fault monitoring is realized by monitoring speed information abnormality in a program; communication fault monitoring is achieved by detecting whether the driver is connected normally or not at regular time.
8. Communication unit
The driver provides two communication interfaces of RS232 and CAN, and CAN be configured to communicate with an upper computer for system parameter setting and state monitoring.
9. Structural process design
The driver consists of a radiating bottom plate, a printed board and a shell, wherein the printed board is designed into three boards, namely an upper control board, a middle sampling board and a lower power board, the three boards are connected and fixed through pins, the pins are connected and fixed with the printed board through a welding mode, and a structural schematic diagram is shown in fig. 6. The top layer of the power board is provided with 6 MOSFETs which are respectively used for inflow and outflow of the high and low ends of three-phase current of the motor, the power board is divided into two groups and is respectively arranged on two parallel lines, the bottom layer corresponding to the power board is provided with two heat dissipation welding rods with the width of 7mm, and heat dissipation is increased through copper coating in the middle layer. Preferably, the heat dissipation bottom plate is made of aluminum metal, the surface of the heat dissipation bottom plate is plated with nickel, and the heat dissipation welding rod is connected with the heat dissipation bottom plate in a reflow soldering mode. Preferably, the driver housing is made of PPO plastic, is made into a box shape by injection molding, and is clamped on the heat dissipation base plate by making a back buckle at the edge.
2 potting openings with the diameter of 2mm are reserved on the shell, the control board and the power board respectively, three printed boards are connected through pin welding during assembly, then are connected with the radiating bottom board through reflow soldering, and finally the shell is clamped. After the assembly is completed, glue filling treatment is carried out through two filling and sealing openings on the shell, so that the shock resistance vibration characteristic and the heat dissipation effect of the driver are enhanced.
The foregoing has outlined and described the basic principles, features, and advantages of the present invention. It will be understood by those skilled in the art that the foregoing embodiments are not intended to limit the invention, and the above embodiments and descriptions are meant to be illustrative only of the principles of the invention, and that various modifications, equivalent substitutions, improvements, etc. may be made within the spirit and scope of the invention without departing from the spirit and scope of the invention.

Claims (10)

1. The servo driver is characterized in that the servo driver adopts a DSP+FPGA dual-processor design, the DSP is used as a main controller, the FPGA is used as an encoder decoding controller, various motion functions of a direct current brush, a brushless motor and a permanent magnet synchronous motor are precisely controlled in three modes of position, speed and moment, relevant system state faults are displayed and processed, and relevant software interfaces are reserved for later upgrading of alternating current servo control algorithm and functions; after receiving enabling and command signals of the upper computer, the servo driver enters a driving working mode and controls the output of the MOSFET inverter circuit to drive the servo motor; meanwhile, a current sampling circuit collects current signals, an FPGA executes an internal decoding program to collect speed and position signals of a servo motor, and the speed and position signals are used as feedback signals of a three-loop; the DSP performs closed-loop control on the operation of the servo motor through a PI control algorithm according to the command and the feedback data; the front end of the MOSFET driving circuit is connected with the logic processing circuit and the driving protection circuit and is used for realizing the driving protection of the MOSFET inverter circuit, the PWM logic level protection and the safe torque closing STO protection.
2. The servo driver based on the DSP and the FPGA according to claim 1, wherein the servo driver comprises a power supply unit, a main control unit, an inversion unit, a signal conditioning unit, a motor speed and angle measuring unit, a safe torque closing unit, a fault protection unit and a communication unit;
the main control unit comprises a DSP control circuit, an FPGA control circuit and a logic processing circuit; the DSP signal processor circuit is used for completing the following tasks, and comprises: instruction receiving, various signal acquisition, PWM signal generation, output torque control, speed tracking control and fault processing; the FPGA control circuit is used for realizing communication with each protocol encoder and safety torque closing; the logic processing circuit is used for realizing PWM output protection by controlling the logic protection signal level;
the power supply unit is used for providing required voltage for each unit of the servo driver;
the inversion unit comprises a MOSFET driving circuit and a MOSFET inversion circuit; the MOSFET driving circuit is used for realizing the switch driving of the MOSFET; the MOSFET inverter circuit is used for realizing driving control of the servo motor;
the signal conditioning unit is used for filtering and normalizing various analog input signals and sending the filtered analog input signals to the AD port of the DSP for ADC conversion; the system is also used for inputting various I/O signals to the DSP through optical coupling isolation treatment, and comprises a three-phase current sampling circuit, a direct-current bus voltage sampling circuit, an analog input interface circuit and an I/O signal interface circuit;
the motor speed and angle measuring unit is used for providing signal interfaces according to different feedback signals respectively;
the safety torque closing unit is used for closing the PWM signal output enabling of the driver after the motor torque exceeds a safety value;
the fault protection unit is used for protecting when the circuit fails and comprises an over-temperature protection circuit, a short-circuit protection circuit and an overvoltage protection circuit;
the communication unit is communicated with the upper computer, is used for realizing parameter setting and state monitoring, and is used for a digital speed control or torque current control mode.
3. The DSP and FPGA dual processor based servo driver of claim 2, wherein the power supply unit comprises four parts of a 12V driving power supply, a 5V external output power supply, a main control 3.3V power supply, and a 1.9V power supply;
the main control 3.3V power supply and the 1.9V power supply circuit are used for generating power supply required by the operation of each control circuit;
the 12V driving power supply circuit is used for generating power supply required by the MOSFET driving circuit and supplying power for the next stage of power supply;
the 5V external output power supply is used for power supply transition, external encoder power supply and power supply of the rest part of the circuit.
4. A DSP and FPGA dual processor based servo driver as in claim 3 wherein said servo driver input operates as a main power source in the range of 13.5V-95V, rated condition 85V, maximum output power 1600W.
5. The dual processor DSP and FPGA based servo driver of claim 4 wherein a filter capacitor is provided at the power input of the servo driver and a surge protection circuit is provided at the power output for supplying power to the encoder.
6. The servo driver based on the dual processors of the DSP and the FPGA according to claim 2, wherein the working principle of the safe torque closing unit is as follows: the safety torque signal is used for controlling the on-off of a rear-stage enabling signal through the optocoupler isolation chip, and is transmitted to the rear stage through the Schmidt buffer, so that the on-off of the driving PWM is controlled, and the safety torque closing state of the servo driver is transmitted.
7. The servo driver based on the DSP and the FPGA according to claim 2, wherein the motor speed and angle measuring unit circuit comprises two paths of sensor decoding circuits and one path of Hall sensor circuit, and the sensor decoding circuit converts an external encoder signal through an RS485/RS422 level and inputs the external encoder signal to the FPGA for processing; the Hall sensor circuit inputs a Hall signal to the FPGA for processing after passing through the Schmidt trigger inverter.
8. The servo driver based on the DSP and the FPGA is characterized by comprising a shell, a radiating bottom plate and a printed board, wherein the radiating bottom plate and the printed board are arranged in the shell, the printed board is designed to be 3 layers, a control board, a sampling board and a power board are sequentially arranged from top to bottom, the three boards are connected and fixed through pins, and the pins are connected with the printed board in a welding mode; the top layer of the power board is provided with 6 MOSFETs which are respectively used for flowing in and out of the high end and the low end of the three-phase current of the motor, the power board is divided into two groups and arranged on two parallel lines, two heat dissipation welding rods with windows are designed at the bottom layer corresponding to the power board, heat dissipation is carried out at the corresponding position of the middle layer through copper coating, and the heat dissipation welding rods with windows are connected with a heat dissipation bottom plate through a reflow soldering mode.
9. The servo driver based on the DSP and the FPGA according to claim 8, wherein the heat dissipation base plate is made of aluminum metal, the surface of the heat dissipation base plate is plated with nickel, the shell is made of PPO plastic, the shell is formed into a box shape in an injection molding mode, and the shell is clamped on the heat dissipation base plate at the edge in a back-fastening mode.
10. The servo driver based on the DSP and the FPGA, according to claim 9, wherein the shell, the control board and the power board are provided with corresponding filling openings for filling glue after the servo driver is assembled.
CN202311477868.6A 2023-11-08 2023-11-08 Servo driver based on DSP and FPGA dual processor Pending CN117614318A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118137924A (en) * 2024-05-06 2024-06-04 宁德时代新能源科技股份有限公司 Motor control system, control method, servo system and battery production line

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118137924A (en) * 2024-05-06 2024-06-04 宁德时代新能源科技股份有限公司 Motor control system, control method, servo system and battery production line

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