Abstract: This paper takes a new energy sedan as the research object, researches and develops the drive motor system, determines the drive control schematic diagram, and determines the selection of key components of the controller by analyzing its controller composition and function analysis. The AC permanent magnet motor current optimal control method calculates the id and iq current values ​​under various speed and torque demands, and controls the actual output current as the command value.
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1 drive motor control principle
The permanent magnet synchronous motor rotor is a permanent magnet, and the rotary transformer is used as the motor position sensor. The motor phase current is used as the feedback amount, and the control mode is the torque closed-loop control. The principle of the control system is shown in Fig. 1.
The high-voltage DC power supply is converted into a three-phase alternating current with adjustable voltage amplitude and frequency by the motor controller DC/AC to drive the permanent magnet synchronous motor; meanwhile, by detecting the current rotor position signal and real-time sampling the phase current of the motor, And sent to the motor control unit. The motor control unit communicates with the vehicle controller through the CAN bus, obtains the current torque command, operation mode and rotation direction from the vehicle controller, and obtains the current and motor position signals according to the feedback, and controls the motor controller to generate the required three. AC power to achieve normal motor operation.
2 controller hardware function description and composition
2.1 Motor controller has the following functions
(1) Protection functions such as overcurrent, overvoltage, overtemperature, undervoltage, overspeed, and power polarity connection error;
(2) Torque monitoring function;
(3) with CAN circuit interface for communication, 232 communication interface for program programming, monitoring and calibration;
(4) Control the operation of the permanent magnet synchronous motor.
2.2 Controller hardware components
The controller hardware is mainly composed of a low-voltage DC-DC control power supply unit, a DSP control unit, a power conversion unit, an interface circuit, and a detection unit (temperature sensor, current sensor). Controller hardware block diagram.
2.3 DC-DC control power unit
The DC-DC control power supply provides multiple isolated power supplies for the DSP and drive and control circuits over a wide range of input voltages. According to the actual needs of the controller, the DC-DC control power supply uses multiple flyback switching power supplies to meet the demand.
2.4 DSP control unit
The DSP control unit drives the S320LF2407 as the main control chip, and adopts the permanent magnet synchronous motor variable voltage frequency conversion vector control method to realize the torque closed-loop control of the permanent magnet synchronous motor.
The main functions of the DSP control unit include: the realization of the control algorithm; the generation of the SVPWM signal; the sampling and calculation of the current, voltage and temperature signals; the detection and calculation of the rotor position and speed of the motor; the reception of the vehicle control command via the CAN bus communication; The realization of protection functions (undervoltage, overvoltage, overcurrent, overtemperature, etc.).
The circuit of the DSP control unit mainly includes: clock circuit; reset circuit; JTAG interface circuit; external interrupt circuit, PWM drive control circuit; AD sampling circuit, resolve signal detection circuit; CAN/232 interface circuit; D/A conversion circuit; Expanded EEPROM circuit; I/O control circuit.
2.5 power conversion unit
The power conversion unit of the controller is composed of a DC filter capacitor, a high power device IGBT and its driving circuit.
The power module drive circuit mainly receives the DSP switch information and feeds back relevant information (protection signal); amplifies the switch signal and drives the IGBT; provides voltage isolation and protection functions. The controller driving circuit takes the isolated driving chip as the core, isolates and amplifies the PWM signal provided by the control unit, drives the high-power device IGBT, and realizes DC-AC conversion. The controller uses Infineon's FS400R07A1E3 (400A/650V, PinFin structure) as a high-power switching device. The DC filter capacitor adopts the domestic leading AAEV42872 membrane capacitor, which is matched with the IGBT module to form a modular structure.
2.6 Detection circuit
The detection circuit mainly includes the motor phase current (A/C phase), bus current, bus voltage, motor temperature, controller temperature and motor position and speed for real-time detection, and sends the collected information to the DSP control unit, which is the motor drive. The guarantee of reliable operation of the system.
3 controller key device selection
3.1 DSP control unit
Electronic control technology has evolved from analog control to digital control with a highly integrated microprocessor. Compared with traditional analog control technology, digital control has the following advantages:
(1) small size, light weight, low energy consumption, low hardware cost;
(2) less hardware line connection, no faulty working time, and higher reliability;
(3) It is less affected by changes in temperature and other parameters;
(4) Improve the ability of the entire system to store, monitor, diagnose and real-time information;
(5) The complex algorithm function can be realized through software programming, which makes the system have higher adaptability, and it is easy to apply modern control theory and improve the comprehensive performance of the system.
With the digital development of power electronic control technology as a condition, the motor control system has also undergone great changes in hardware structure. In particular, the emergence and rapid development of DSP not only simplifies the hardware structure of motor control, but also achieves high performance, low cost and high reliability of motor control. This system uses TI TMS320LF 2407 DSP as the main controller chip.
3.2 Power Conversion Unit
The driving circuit of the power conversion unit selects an automotive-level isolated IGBT driving chip, which can realize the functions of amplifying the SVPWM signal, electrical isolation of strong and weak electricity, and short circuit protection of the IGBT.
IGBT (Insulated Gate Bipolar Transistor), insulated gate bipolar transistor, is a composite fully controlled voltage-driven power semiconductor device composed of BJT (bipolar transistor) and MOS (insulated gate field effect transistor), and has MOSFET The high input impedance and the low on-voltage drop of the GTR have the advantages of low drive power and reduced saturation voltage. It is ideal for automotive motors and their control systems with DC voltages of 600V and above.
This system power module uses Infineon automotive IGBT FS400R07A1E3 (400A/650V, PinFin structure) as a high-power switching device.
3.3 Filter Capacitor
The motor controller DC filter capacitor is mainly used to filter out high frequency ripple of 10 kHz, instantaneous function and harmonic compensation. DC filter capacitors are required to have high rms current and surge immunity, as well as a compact size.
The membrane capacitor has the characteristics of high dielectric constant, small volume, large capacity and good stability. It can withstand high RMS current, can withstand twice the rated voltage, can withstand reverse voltage, and can withstand peaks. Value current, with a long service life. Compared with electrolytic capacitors, the same function is achieved, and the required capacitance is much lower than that of electrolytic capacitors, which can greatly reduce the size of the system.
4 drive motor selection
Due to the frequent start-up and acceleration and deceleration of new energy cars, low-speed and high-torque, high-speed and high-power operating conditions, the technical requirements for drive motors are summarized as follows:
(1) to meet the maximum energy utilization of the battery: high efficiency and wide efficiency interval characteristics, optimal space volume and high density requirements;
(2) Meet the performance requirements: high speed and wide speed performance, large starting torque and strong overload capability, fast torque corresponding and high speed and high power specific;
(3) to meet the vehicle comfort and reliability requirements: motor torque fluctuation is small, control is mature, motor structure is simple and reliable;
(4) Meet the cost requirements: the motor manufacturing process is simple and the price is reasonable.
Domestic permanent magnet synchronous motor technology continues to develop, and China's rare earth resources are also relatively abundant. Permanent magnet synchronous motors meet all the requirements of new energy car technology requirements: high efficiency, high power density, high torque density, mature control, and wide efficiency range. And the technical characteristics of speed regulation performance, compared with the DC motor structure is simple and reliable, the manufacturing process is mature, the process is simple, and the cost is moderate.
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