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TheDesignofMotorDrivewithSpeedControlforanElectricBicycleTze-YeeHo,Wei-ChiehChen,Chih-HaoChiang,Wei-ChangHungDept.ofElectricalEngineeringFengChiaUniversityTaichung,Taiwan,R.O.C.tw,,,.twMu-SongChenDept.ofElectricalEngineeringDa-YehUniversityChangHua,Taiwan,R.O.C..twAbstractThispaperpresentsasimplemethodtodesignthespeedcontrolsystemofmotordriveforanelectricbicycle.Byproperlyselectingthecurrentcontrollertimedelayandspeedcontrollertimedelay,thecrossoverfrequencyofcurrentcontrollerandthe3-dBcornerfrequencyofPIcontrollercanbefound,respectively.Therotorfrequencyisdesignedintherangebetweenthesetwofrequenciesforproperoperation.Thesimplemethodtodeterminetherangeofoperatingspeedwithappropriatelytuningcontrollerparameters,cannotonlyspeedupthedesignandimplementationofspeedcontrolledmotordrivebutalsoreducethedevelopmenttime.Anelectricbicyclebasedonablushlessdcmotordrivewhichhashighefficiency,zeropollution,cleanandconvenient,isthendesignedandimplementedinthispaper.Thehardwaredesignbasedonamicrocontrollerisanalyzedanddiscussed.ThesoftwareprogrammingisdevelopedinMPLABintegrateddevelopmentenvironment.Finally,aprototypeofblushlessdcmotordriveforanelectricbicycleisrealizedanddemonstrated.Theexperimentalresultsshowthefeasibilityandfidelityofthecompletedesignedsystem.Keywords-electricbicycle,microcontroller,speedcontrolI.INTRODUCTIONInordertogainthehighperformanceoftheinjustrialmotordrive,mostoftheindustrialdrivesystemhavePIcontrollersinthecurrentcontrolandspeedcontrolfortuningprocess1.TheZiegler-Nicholsmethodswhicharebasedontheempiricalresearchoftryanderror,arecommonlyusedtodesigntheindustrialspeeddrive.However,theovershootphenomenonofthesystemcouldoccurifthedelaytimeisnotsufficienttodeterminethesppedcontrolerparamenters2.AmodificationofZiegler-NicholsmethodsbasedonBodesfrequencydiagramisaddressedandprovedtoreducetheovershoot3.Thismethodiscomplicatedandisnoteasytodeterminetherotoroperatingfrequency.Withtheapproximationofcurrentcontrolloopbyconsideringtheoperatingrotorfrequency,thespeedcontrolsystemcanreducetothefirstordersystem.Thecrossoverfrequencyofcurrentcontrollerandthe3-dBcornerfrequencyofPIcontrollercanbefoundwithproperselectionoftimedelaysofbothcurrentandspeedcontrollers,respectively.Therotorfrequencyisdesignedintherangebetweenthesetwofrequenciesforproperoperation.Thesimplemethodtodeterminetherangeofoperatingspeedwithappropriatelytuningcontrollerparameters,cannotonlyspeedupthedesignandimplementationofspeedcontrolledmotordrivebutalsoreducethedevelopmenttime.Theelectricbicyclewhichdoesnotproducetheexhaustgasandgeneratetheairpollutionhasbecomeoneofthemostefficientandeconomictrafficvehiclesinthemetropolitancity1.Recentyears,duetothehighlydevelopmentofpowerelectronicdevicesandmicrocontrollers,thedesignandimplementationoftheelectricbicyclehavebeenstudiedintheacademicfieldandwidelyappliedtotheindustryaswell.Inordertorealizethecompletesystem,thebasicconfigurationofanelectricbicycledrivewhichconsistsofacontroller,batterycharger,batteryandelectricmotorisfirstlyaddressedinthispaper.Acontrollerisbasicallybasedonamicrocontrollerthatcontrolsthepowerfromthebatterytotheelectricmotorandtheauxiliarydevicessuchasthebrake,thesignallightsaswell.Therefore,inordertodesignandimplementanelectricbicyclewithspeedcontrol,abrushlessdcmotordrivebasedonamicrocontrollerispresentedinthispaper.Bothdesigncriterionandrequirementsofthedesignedsystemmeetthestandardofelectric-auxiliarybicyclesCNS14126inTaiwan4.Thispaperisorganizedasfollowing.ThesectionIIofthispaperdescribesthehardwareofthedesignedsystem,whichincludesamicrocontroller,powerbreakcircuit,voltageregulator,halfbridgegatedrive,currentsensingcircuit,andphotoisolatorcircuit.The120-degreeconductionpulsewidthmodulation(PWM)controlmethodisemployedtotheblushlessdc(BLDC)motordriveaccordingtotherotorpositionfromthemeasurementsofHalleffectmagneticpolesensing.ThesectionIIIpresentsthesystemcontroldesign.ThePIcontrolalgorithmisappliedtoachievethebestperformanceofsystemresponse.ThesoftwareprogramsarewritteninClanguageandprogrammedbasedontheMPLABintegrateddevelopmentenvironment(IDE)toolbyMicrochiptechnologyincorporatedinthissection5.Finally,thecompletesystemissuccessfullydesignedandimplementedinthispaper.Theexperimentalresultsshowthesystemrealizationandverifythesystemperformance,whicharepresentedinthesectionIVandV.II.THESYSTEMSTRUCTUREOFELECTRICBICYCLEThesystemstructurewithcontrolalgorithmofmotordriveforanelectricbicyclebasedonaBLDCmotordriveisshowninFig.1.ItconsistsofadsPIC30F4011microcontroller,protectioncircuit,opticalcoupling2014InternationalSymposiumonComputer,ConsumerandControl978-1-4799-5277-9/14$31.002014IEEEDOI10.1109/IS3C.2014.228864isolation,inverter,currentsensor,encoder,andcommunicationinterface.ThemicrocontrollerdsPIC30F4011manufacturedbyMicrochiptechnologyincorporateisthecorecontrolleroftheelectricbicycle.Itisa16-bitCPUwiththecapabilityofdigitalsignalprocessing.Moreover,itsupportsmanypowerfulmodulessuchasbuilt-inPWMmodule,addressableencoderinterfacemodule,andinputcapturemodule,thesemakethedesignfriendlyandthusshortenthedevelopmentschedule.Thethree-phasebridgeinvertercomprisessixpowerMOSFETsforswitchingasshowninFig.2.ThephotocouplerTLP250manufacturedbyToshibasemiconductorcompany,isusedforelectricalisolationbetweenthemicrocontrollersystemandbusvoltage.ThemotorcurrentsfromtheDCbusaresensedthroughthecurrentdetectioncircuit.ThemagnetpoleandrotorpositionaredetectedbytheHalleffectsensor.Insuchaway,thespeedandrotorpositioncanbecalculatedandpreciselycontrolled,subsequently.The120-degreeconductionofpulsewidthmodulationtechniqueforMOSFETsswitching,isappliedtodrivethethee-phaseinverter.aiFigure1.Thesystemstructureofelectricbicycle.Thestatorphasevoltageequations(Van,Vbn,Vcn)relatedtothestatorphasecurrents(ia,ib,ic)andbackelectromotiveforce(ea,eb,ec)foraBLDCmotor,canbeexpressedby(1)5-6.ccccbcbacacccnbcbcbbbababbbnacacbabaaaaaanedtdiLdtdiLdtdiLiRVedtdiLdtdiLdtdiLiRVedtdiLdtdiLdtdiLiRVg14g14g14g14g32g14g14g14g14g32g14g14g14g14g32g3g3g11g20g20g12g3WhereRa,Rb,Rc,representthephaseresistanceforeachphase,Laa,Lbb,LccrepresenttheselfinductanceforeachphaseandLab,Lbc,Lcarepresentthemutualinductancebetweeneitheroftwophases,ea,eb,ec,representthebackEMFforeachphase.Ifathree-phasebalancedsystemisconsidered,thestatorvoltagein(1)canberearrangedtog187g187g187g188g186g171g171g171g172g170g14g187g187g187g188g186g171g171g171g172g170g187g187g187g188g186g171g171g171g172g170g14g187g187g187g188g186g171g171g171g172g170g187g187g187g188g186g171g171g171g172g170g32g187g187g187g188g186g171g171g171g172g170cbacbassscbassscnbnaneeeiiiL000L000LdtdiiiR000R000RVVV(2)Theelectromagnetictorquecanbeexpressedbyg3ateiKTg32(3)Theelectromagnetictorqueexpressedin(3)indicatesthatitcanbecontrolledbythestatorcurrentwiththetorqueconstant,Kt.Thisisverysimilartothecontrolofseparatelydcmotordrive.Theloadmodelcanbeexpressedintermsofamomentofinertia,JL,inkg-m2/sec2withaviscousfrictionBL,inN-m/rad/sec.Theelectromagnetictorque,Te,inN-mthendrivestheloadtorque,TL,inN-mcanbeexpressedbyrLLeLg550Bdtrdg550J)T(T2Pg14g32g16(4)III.THESYSTEMCONTROLDESIGNForaspeed-controlledmotordrive,thetimeconstantsofthecurrentloopareusuallymuchsmallerthanthatoftheloadandthespeedcontroller.Insuchsituation,thecontrolsystemwithsimplifiedcurrentloopforamotordrive,isshowninFig.2.ThecurrenttransferfunctionofPIcontrolappliedtoacurrentcontrollercanbeexpressedbycsT1iK(s)*asi(s)asi(s)iGg14g32g32(5)Ifthegaincrossoverfrequencyforthecurrentcontrolloopisproperlyselected,thentheGi(s)canbeapproximatedascsT11(s)iGg14g35(6)AssumethatTcisverysmallintheoperatingfrequency,thenGi(s)isapproximatetobeunity.ThePIcontrolisusuallyemployedtothespeedcontrolledmotordrivesystemandhasprovedtoachievegoodperformance.Thetransferfunctionofspeedcontroller,Gs(s),isthenexpressedassisKpsK(s)sGg14g32(7)WhereKpsistheproportionalgainandKisistheintegratorgain.Asweobservethespeedcontrolloop,theopen-looptransferfunctionofthespeedresponsehasthreepoleswhichcanbeobtainedfromtheintegratortimedelayconstant,currentlooptimedelayandtheloadtimeconstant,respectively.csT11g14tK*rg550rg550Figure2.Thesimplifiedcurrentloopforspeedcontrolloop.Forthespeed-controlleddrivesystem,thecrossoverfrequency,g90cgeneratedfromthecurrentlooptimedelayisalwaysdesignedtobehigherthantherotorfrequency,g90r.Inaddition,the3-dBfrequency,g90swhichisobtainedfrom865theintegratortimedelayofPIcontrollerisusuallychosentobesmallerthantheg90r.FromtheapproximationofcurrentloopcrossoverfrequencyandthecornerfrequencyofPIcontroller,thecompletespeed-controlleddrivesystemisredrawninFig.3.The3-dBfrequency,g90rcoftheoverallclosedloopspeedcontrolledsystemcanbefoundtobe,g90rc=(BL+KpsKt)/JL.Therotorfrequencyshouldbedesignedtobeintherangebetweeng90sandg90rcinordertoachievethebetterperformance.Thesystemisinherentlystablesincethemaximumphaseangleofthecompletecontrolsystemis-90o.Adjustingtheproportionalgainofspeedcontroller,Kps,canbeappliedtomeettherequirementsoftheovershootfortheoverallcontrolsystem.ThesystemsoftwareprogramisdevelopedunderMPLABIDEsoftwareplatformandwritteninClanguage.Mostofthefunctionsofelectricbicycleareprogrammedinthemicrocontrollerfirmwarewhichincludesthecircuitprotectionmechanism,PWMgeneration,motorcurrentscalculation,rotorpositionandspeedcalculationandrotorpoleposition7-8.TheflowchartofmainprogramformicrocontrollerfirmwareisshowninFig.4.TheinitializationsforI/Oconfiguration,Timer1,Timer2,ADCandPWMsettingsarefirstlyprocessedinthemainprogram.LsJLB1g14tK*rg550rg550psKFigure3.Theoverallsystemofspeed-controlledmotordrive.Figure4.TheflowchartofmainprogramFig.5showsthePWMinterruptroutine.Thesensingcurrentisfirstlycalculatedandfedtothecurrentcontroller.SincethePWMfrequencyis20kHz,thecurrentcontrollerisupdatedforevery50us.Afterthecalculationofcurrentcontroller,thespeedcalculationisthenperformedbyspeedcontroller.Thespeedisconstrainedbythelimiterfortheoperatingspeedrange.Figure5.ThePWMinterruptroutine.IV.THEEXPERIMENTALRESULTSTheprototypeofthemotordriveforanelectricbicyclewithspeedcontrolbasedonthedsPICmicrocontroller,istestedunderdifferentloadconditionswhicharefulfilledwiththedynamometer.Fig.6showstheprintedcircuitboardofcontrolboardfortheelectricbicycledesignedinthispaper.ThemotorparametersfortheexperimentsareKt=0.0761021N-m/A,JL=0.000245Kgm2,andBL=0.00731N-ms/rad.Thus,theg90rccanbefoundtobe1553rad/secwithKps=5.Figure.ThemagnitudefrequencyresponseofBodeplotwithdifferentKpsisshowninFig.7.ObservingtheFig.7,itcanbefoundthatthewrcisaround800rad/sec.ItconcludesthattheKpscannotbechosenlessthanKps=1.Fig.8showsthespeedcannotreachthecommandspeedifKpsistoosmall.Fig.9showsthestepresponseofthespeedfromzeroto200rpmundertheloadof10kg-cm.Itcanbeobservedthatthemotordrivecanreachthecommandspeedwithinthe1.5seconds.Thephasecurrentsundertheloadof10kg-cmisshowninFig.10,wherech1,ch2andmathrepresentphasecurrentsA,B,andC,respectively.Figure6.TheprintedcircuitboardofBLDCmotordrivefortheelectricbicycle.866050010001500200025003000-10-9-8-7-6-5-4-3-2-10g55020log(w/w*)Kps=5Kps=1Kps=0.5Figure7.TheBodefrequencyresponseofg90r.Figure8.Thestepspeedresponseprofile.Figure9.Thestepresponseofspeedundertheloadof10kg-cmFigure10.Thephasecurrentsundertheloadof10kg-cm.V.CONCLUSIONSThespeedcontrolofmotordriveforanelectricbicycleisdesignedandimplementedinthispaper.Thehardwarestructureincludingamicrocontroller,protectioncircuit,opticalcouplingisolation,three-phaseinverter,currentsensorandcommunicationinterfaceiswelldesigned.Further,thesystemsoftwareandfirmwareofmicrocontrollerareprogrammedanddescribedindetail.Basedontheproposedsimplemethodtofindthewrc,theproportionalgain,Kpsofspeedcontrollercanbeeasilyfound.TherangeofKpsisalsocanbelocatedsoastoavoidthesystemoscillation.Thissimplemethodtodeterminetherangeofoperatingspeedwithappropriatelytuningcontrollerparameters,cannotonlyspeedupthedesignandimplementationofspeedcontrolledmotordrivebutalsoreducethedevelopmenttime.Fromtheexperimentalresults,itcanbeseenthatthegoodperformanceofspeedresponseprofileverifiedthedesignedsystemovertheoperatingspeedrange.Finally,aBLDCdriveforanelectricbicycleisreal

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