电动自行车控制器,有刷控制器原理详解-KIA MOS管

有刷控制器电路原理

电(dian)动(dong)车控制器以功(gong)(gong)率(lv)(lv)大(da)小(xiao)可(ke)分(fen)为大(da)功(gong)(gong)率(lv)(lv)、中功(gong)(gong)率(lv)(lv)、小(xiao)功(gong)(gong)率(lv)(lv)三类。电(dian)动(dong)自(zi)行车使(shi)用(yong)小(xiao)功(gong)(gong)率(lv)(lv)的，货(huo)运三轮车和电(dian)摩托要使(shi)用(yong)中功(gong)(gong)率(lv)(lv)和大(da)功(gong)(gong)率(lv)(lv)的。从配合电(dian)机分(fen)，可(ke)分(fen)为有刷(shua)、无刷(shua)两大(da)类。

有刷控制器电路

电路原理

电(dian)(dian)(dian)(dian)(dian)路(lu)原(yuan)理图见图2所示，该控制器由稳压电(dian)(dian)(dian)(dian)(dian)源电(dian)(dian)(dian)(dian)(dian)路(lu)、PWM产生电(dian)(dian)(dian)(dian)(dian)路(lu)、电(dian)(dian)(dian)(dian)(dian)机驱(qu)动电(dian)(dian)(dian)(dian)(dian)路(lu)、蓄(xu)电(dian)(dian)(dian)(dian)(dian)池放(fang)电(dian)(dian)(dian)(dian)(dian)指示电(dian)(dian)(dian)(dian)(dian)路(lu)、电(dian)(dian)(dian)(dian)(dian)机过流(liu)及蓄(xu)电(dian)(dian)(dian)(dian)(dian)池过放(fang)电(dian)(dian)(dian)(dian)(dian)保护电(dian)(dian)(dian)(dian)(dian)路(lu)等(deng)组成。

稳压(ya)电(dian)(dian)源(yuan) 由V3（TL431），Q3等元件组成(cheng)，从36V蓄电(dian)(dian)池经过串联稳压(ya)后(hou)得到+12V电(dian)(dian)压(ya)，给控制电(dian)(dian)路供电(dian)(dian)，调节VR6可(ke)校准+12V电(dian)(dian)源(yuan)。

PWM电路(lu) 以脉(mai)宽调制 器(qi)TL494为核心组成。R3、C4与内部电路(lu)产(chan)生(sheng)振荡(dang)，频率大约为12kHz。

H是高(gao)(gao)变低(di)型霍尔速度控制转(zhuan)把，由松(song)开到旋紧时，其输(shu)出(chu)端可得到4V—1V的(de)电(dian)压(ya)(ya)。该电(dian)压(ya)(ya)加到TL494的(de)②脚(jiao)，与①脚(jiao)电(dian)压(ya)(ya)进行(xing)比较，在⑧脚(jiao)得到调(diao)(diao)(diao)宽(kuan)(kuan)脉冲(chong)。②脚(jiao)电(dian)压(ya)(ya)越低(di)，⑧脚(jiao)输(shu)出(chu)的(de)调(diao)(diao)(diao)宽(kuan)(kuan)脉冲(chong)的(de)低(di)电(dian)平(ping)部分越宽(kuan)(kuan)，电(dian)机转(zhuan)速越高(gao)(gao)，电(dian)位器VR2用于零速调(diao)(diao)(diao)节(jie)，调(diao)(diao)(diao)节(jie)VR2使转(zhuan)把松(song)开时电(dian)机停转(zhuan)再(zai)过一(yi)点。

电(dian)(dian)(dian)机驱(qu)动(dong)电(dian)(dian)(dian)路 由(you)Q1、Q2、Q4等元件组成。电(dian)(dian)(dian)机MOTOR为永磁直(zhi)流有刷电(dian)(dian)(dian)机。TL494的(de)(de)(de)⑧脚(jiao)(jiao)输(shu)出(chu)(chu)的(de)(de)(de)调宽脉冲，经Q1反相放(fang)大驱(qu)动(dong)VDMOS管Q2。TL494的(de)(de)(de)⑧脚(jiao)(jiao)输(shu)出(chu)(chu)的(de)(de)(de)调宽脉冲低电(dian)(dian)(dian)平(ping)(ping)(ping)部分越(yue)宽，则Q2导(dao)通(tong)(tong)时间越(yue)长，电(dian)(dian)(dian)机转速(su)越(yue)高。D1是电(dian)(dian)(dian)机续流二极(ji)管，防止(zhi)Q2击穿。TL494的(de)(de)(de)⑧脚(jiao)(jiao)输(shu)出(chu)(chu)低电(dian)(dian)(dian)平(ping)(ping)(ping)时，Q1、D2导(dao)通(tong)(tong)，Q4截止(zhi)，Q2导(dao)通(tong)(tong)；TL494的(de)(de)(de)⑧脚(jiao)(jiao)输(shu)出(chu)(chu)高电(dian)(dian)(dian)平(ping)(ping)(ping)时，Q1、D2截止(zhi)，Q4导(dao)通(tong)(tong)，迅速(su)将Q2栅极(ji)电(dian)(dian)(dian)荷泄放(fang)，加速(su)Q2的(de)(de)(de)截止(zhi)过(guo)程(cheng)，对降低Q2温(wen)度有十分重要的(de)(de)(de)作用。

蓄电(dian)(dian)(dian)(dian)(dian)池(chi)放电(dian)(dian)(dian)(dian)(dian)指(zhi)示电(dian)(dian)(dian)(dian)(dian)路(lu) 由(you)(you)LM324组成四(si)(si)个比(bi)较(jiao)器，12V由(you)(you)R24、VR1、VR4、VR3、VR5、R21分(fen)(fen)压(ya)(ya)形(xing)成四(si)(si)个不(bu)同基(ji)准电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)分(fen)(fen)别(bie)加到(dao)四(si)(si)个比(bi)较(jiao)器的(de)(de)(de)反相(xiang)端(duan)。蓄电(dian)(dian)(dian)(dian)(dian)池(chi)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)经R23和(he)R22分(fen)(fen)压(ya)(ya)加到(dao)每个比(bi)较(jiao)器的(de)(de)(de)同相(xiang)端(duan)，该电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)和(he)蓄电(dian)(dian)(dian)(dian)(dian)池(chi)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)成比(bi)例。VA=VB*R22/（R22+R23）。当蓄电(dian)(dian)(dian)(dian)(dian)池(chi)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)不(bu)低(di)于38V时(shi)，LED1、LED2、LED3均点亮；当电(dian)(dian)(dian)(dian)(dian)池(chi)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)低(di)于38V时(shi)，LED3熄灭(mie)；当电(dian)(dian)(dian)(dian)(dian)池(chi)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)低(di)于35V时(shi)，LED2熄灭(mie)；当电(dian)(dian)(dian)(dian)(dian)池(chi)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)低(di)于33V时(shi)，LED1熄灭(mie)，此时(shi)应给电(dian)(dian)(dian)(dian)(dian)池(chi)充电(dian)(dian)(dian)(dian)(dian)。调节VR1、VR4、VR3可(ke)分(fen)(fen)别(bie)设定LED3、LED2、LED1熄灭(mie)时(shi)的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)压(ya)(ya)。LED4用作电(dian)(dian)(dian)(dian)(dian)源指(zhi)示，LED5用作欠压(ya)(ya)切断(duan)控制器输出(chu)指(zhi)示。

蓄电(dian)(dian)池过放电(dian)(dian)保(bao)护(hu) 当(dang)蓄电(dian)(dian)池放电(dian)(dian)到31.5V时.LM324的①脚(jiao)输出(chu)低电(dian)(dian)平，三极(ji)管(guan)Q5导通，约5V电(dian)(dian)压(ya)加到TL494的死区控制端④脚(jiao)。该(gai)脚(jiao)电(dian)(dian)位≥3.5V，就会迫(po)使TL494内部(bu)调宽脉冲(chong)输出(chu)管(guan)截止，从而使三极(ji)管(guan)Q1、Q2截止，电(dian)(dian)机停(ting)止运转，蓄电(dian)(dian)池放电(dian)(dian)停(ting)止，进入(ru)电(dian)(dian)池保(bao)护(hu)状态(tai)。此(ci)时LED5点亮，指(zhi)示出(chu)该(gai)状态(tai)。VR5用(yong)于设(she)定电(dian)(dian)池保(bao)护(hu)点电(dian)(dian)压(ya)。

电(dian)(dian)(dian)(dian)机过(guo)流(liu)保护(hu) R30为电(dian)(dian)(dian)(dian)机电(dian)(dian)(dian)(dian)流(liu)取样(yang)电(dian)(dian)(dian)(dian)阻，当过(guo)流(liu)时(shi)，取样(yang)电(dian)(dian)(dian)(dian)压经R14加(jia)到TL494的⑩脚(jiao)。当⑩脚(jiao)电(dian)(dian)(dian)(dian)位高于⑩脚(jiao)电(dian)(dian)(dian)(dian)位时(shi)，TL494内(nei)部运放2输出高电(dian)(dian)(dian)(dian)平，迫使(shi)TL494内(nei)部调宽脉(mai)冲(chong)输出管截(jie)止(zhi)，从而(er)使(shi)Q1、Q2截(jie)止(zhi)，电(dian)(dian)(dian)(dian)机停止(zhi)运转，从而(er)保护(hu)了电(dian)(dian)(dian)(dian)机。

制(zhi)(zhi)动保护(hu) 当刹车制(zhi)(zhi)动时，KEY2接(jie)通.5V电压(ya)加(jia)到TL494的死区控制(zhi)(zhi)端④脚，迫(po)使TL494内部调宽脉冲(chong)输出(chu)管截止，从而使Q1、Q2截止，电机停止运转，实(shi)施制(zhi)(zhi)动保护(hu)。

调试

调速(su)(su)(su)电(dian)(dian)路零速(su)(su)(su)调试：速(su)(su)(su)度(du)转(zhuan)把完全松开。调节VR2使(shi)电(dian)(dian)机停转(zhuan)并(bing)再调过一点以保证(zheng)可靠(kao)置零速(su)(su)(su)。制动调试：转(zhuan)动速(su)(su)(su)度(du)转(zhuan)把，电(dian)(dian)机旋转(zhuan)。此时闭合制动开关(guan)KEY2，Q2栅(zha)极(ji)应立即变(bian)为低电(dian)(dian)平0V。过流保护调试：转(zhuan)动速(su)(su)(su)度(du)转(zhuan)把，Q2栅(zha)极(ji)为高电(dian)(dian)平12V。此时在源(yuan)极(ji)对地之间加上(shang)0.8V左(zuo)右(you)的电(dian)(dian)压，栅(zha)极(ji)应很快(kuai)变(bian)为低电(dian)(dian)平。

蓄电(dian)池(chi)放电(dian)指(zhi)示电(dian)路(lu)用(yong)可(ke)调电(dian)源(yuan)代(dai)替(ti)蓄电(dian)池(chi)。电(dian)压(ya)为38V时(shi)(shi)，调节VR1，使(shi)LED3刚(gang)好(hao)熄灭(mie)；电(dian)压(ya)为35V时(shi)(shi)，调节VR2，使(shi)LED2刚(gang)好(hao)熄灭(mie)；电(dian)压(ya)为33V时(shi)(shi)，调节VR3，使(shi)LED1刚(gang)好(hao)熄灭(mie)；电(dian)压(ya)为31V时(shi)(shi)，调节VR5，使(shi)LED5刚(gang)好(hao)点亮(liang)，此时(shi)(shi)TL494的(de)④脚应(ying)为高(gao)电(dian)平5V左右，进入电(dian)池(chi)欠压(ya)保(bao)护(hu)状态。通(tong)过上述设置，仅LED1点亮(liang)时(shi)(shi)，电(dian)压(ya)为33V-34V，应(ying)及时(shi)(shi)给蓄电(dian)池(chi)充(chong)电(dian)，不过LED1熄灭(mie)至(zhi)LED5点亮(liang)这(zhei)(zhei)段时(shi)(shi)间(jian)，蓄电(dian)池(chi)还可(ke)维持(chi)运行(xing)，但(dan)LED5点亮(liang)时(shi)(shi)，进入欠压(ya)保(bao)护(hu)状态。此时(shi)(shi)应(ying)注意(yi)，过一(yi)会儿电(dian)池(chi)电(dian)压(ya)因电(dian)机停转而(er)回升(sheng)，保(bao)护(hu)解除(chu)，又恢(hui)复工作。如此反复保(bao)护(hu)-工作-保(bao)护(hu)的(de)结果会损坏电(dian)池(chi)和控制器，故应(ying)避免出(chu)现这(zhei)(zhei)种状况。

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