电(dian)动车(che)无刷控(kong)制器工作原理(li)

电(dian)(dian)(dian)(dian)(dian)动车(che)无(wu)刷(shua)控(kong)制器(qi)主要(yao)(yao)由单片机主控(kong)电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、功率管前(qian)级驱动电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、电(dian)(dian)(dian)(dian)(dian)子换向器(qi)、霍(huo)尔(er)信(xin)号检测电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、转把信(xin)号电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、欠(qian)电(dian)(dian)(dian)(dian)(dian)检测电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、限流(liu)(liu)/过流(liu)(liu)检测电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、刹车(che)信(xin)号电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、限速电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)、电(dian)(dian)(dian)(dian)(dian)源电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)等部(bu)分组成，其原(yuan)理框图如图1所示，下面介绍(shao)主要(yao)(yao)电(dian)(dian)(dian)(dian)(dian)路(lu)(lu)(lu)(lu)的工作原(yuan)理。

1.  电子换向器

无(wu)刷(shua)(shua)电机(ji)与有(you)刷(shua)(shua)电机(ji)的根本区(qu)别(bie)就(jiu)在(zai)于无(wu)刷(shua)(shua)电机(ji)用电子(zi)换向器(qi)代(dai)替了(le)有(you)刷(shua)(shua)电机(ji)的机(ji)械换向器(qi)，因(yin)而控(kong)制方法(fa)也(ye)就(jiu)大不相(xiang)同(tong)，复杂程度明显(xian)提(ti)高。在(zai)无(wu)刷(shua)(shua)电机(ji)控(kong)制器(qi)中(zhong)，用6个功率 MOSFET管(guan)(guan)组(zu)成电子(zi)换向器(qi)，其(qi)结构(gou)如图2所示(shi)。图中(zhong)MOSFET管(guan)(guan)VT1、VT4构(gou)成无(wu)刷(shua)(shua)电机(ji)A相(xiang)绕(rao)(rao)组(zu)的桥(qiao)臂(bei)(bei)，VT3、VT6 构(gou)成无(wu)刷(shua)(shua)电机(ji)B相(xiang)绕(rao)(rao)组(zu)的桥(qiao)臂(bei)(bei)，VT5、 VT2构(gou)成无(wu)刷(shua)(shua)电机(ji)C相(xiang)绕(rao)(rao)组(zu)的桥(qiao)臂(bei)(bei)，在(zai)任何情况，同(tong)一桥(qiao)臂(bei)(bei)的上(shang)下(xia)两管(guan)(guan)不能 同(tong)时导通，否则要烧坏管(guan)(guan)子(zi)。

6只功(gong)率(lv)MOSFET管(guan)(guan)按一定要求顺(shun)次导(dao)通(tong)，就可实现无刷电(dian)(dian)(dian)(dian)机A、B、C三(san)相(xiang)绕(rao)组的(de)轮流通(tong)电(dian)(dian)(dian)(dian)，完成换相(xiang)要求，电(dian)(dian)(dian)(dian)机正(zheng)(zheng)常(chang)(chang)运(yun)(yun)转(zhuan)。在电(dian)(dian)(dian)(dian)动车(che)无刷电(dian)(dian)(dian)(dian)机控(kong)制(zhi)器中，这 6只功(gong)率(lv)管(guan)(guan)有(you)(you)二(er)二(er)通(tong)电(dian)(dian)(dian)(dian)方(fang)式(shi)(shi)和三(san)三(san)通(tong)电(dian)(dian)(dian)(dian)方(fang)式(shi)(shi)的(de)运(yun)(yun)用(yong)，二(er)二(er)通(tong)电(dian)(dian)(dian)(dian)方(fang)式(shi)(shi)即每(mei)一瞬间有(you)(you)两只功(gong)率(lv)管(guan)(guan)同时通(tong)电(dian)(dian)(dian)(dian)，三(san)三(san)通(tong)电(dian)(dian)(dian)(dian)方(fang)式(shi)(shi)即每(mei)一瞬间有(you)(you)三(san)只功(gong)率(lv)管(guan)(guan)同时通(tong)电(dian)(dian)(dian)(dian)。对于二(er)二(er)通(tong)电(dian)(dian)(dian)(dian)方(fang)式(shi)(shi)，功(gong)率(lv)管(guan)(guan)须(xu)(xu)按 VT1、VT2；VT2、VT3；VT3、VT4； VT4、VT5；VT5、VT6；VT6、VT1； VT1、VT2??的(de)通(tong)电(dian)(dian)(dian)(dian)顺(shun)序，电(dian)(dian)(dian)(dian)机才能 正(zheng)(zheng)常(chang)(chang)运(yun)(yun)转(zhuan)。对于三(san)三(san)通(tong)电(dian)(dian)(dian)(dian)方(fang)式(shi)(shi)，功(gong)率(lv)管(guan)(guan)须(xu)(xu)按VT1、VT2、VT3；VT2、VT3、 VT4；VT3、VT4、VT5；VT4、VT5、 VT6；VT5、VT6、VT1；VT6、  VT1、 VT2；VT1、VT2  、VT3??的(de)次序通(tong) 电(dian)(dian)(dian)(dian)，电(dian)(dian)(dian)(dian)机才能正(zheng)(zheng)常(chang)(chang)运(yun)(yun)转(zhuan)。

2.  功率管前级驱动电路

功率(lv)(lv)管(guan)前级驱动(dong)(dong)(dong)电(dian)路(lu)用来驱动(dong)(dong)(dong) 电(dian)子(zi)换(huan)向器(qi)的(de)(de) 6 个(ge)(ge) MOSFET管(guan)，由于6 个(ge)(ge)MOSFET管(guan)组成了(le)  3个(ge)(ge)相(xiang)(xiang)同的(de)(de)桥臂(bei)， 对这3个(ge)(ge)相(xiang)(xiang)同的(de)(de)桥臂(bei)  的(de)(de)驱动(dong)(dong)(dong)电(dian)路(lu)是(shi)相(xiang)(xiang)同的(de)(de)，因而功率(lv)(lv)管(guan)前级驱动(dong)(dong)(dong)电(dian)路(lu)是(shi)由3组相(xiang)(xiang)同结构(gou)的(de)(de)电(dian)路(lu)组成，图3所示的(de)(de)是(shi)一典型的(de)(de)功率(lv)(lv)管(guan)前级驱动(dong)(dong)(dong)电(dian)路(lu)，对于一无刷控制器(qi)，有3个(ge)(ge)这样的(de)(de)电(dian)路(lu)，分别驱动(dong)(dong)(dong)3个(ge)(ge)桥臂(bei)。

3.  单片机主控电路

单(dan)片机(ji)(ji)(ji)(ji)主(zhu)控电(dian)(dian)(dian)(dian)(dian)(dian)(dian)路是无刷(shua)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)控制(zhi)(zhi)器的(de)(de)(de)(de)核心部(bu)分，电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)的(de)(de)(de)(de)霍尔信(xin)(xin)(xin)(xin)号、转把信(xin)(xin)(xin)(xin)号、过(guo)流检测(ce)信(xin)(xin)(xin)(xin)号、刹车(che)信(xin)(xin)(xin)(xin)号等都直接(jie)输(shu)(shu)(shu)入(ru)给(ji)单(dan)片机(ji)(ji)(ji)(ji)，由(you)单(dan)片机(ji)(ji)(ji)(ji)进行处理，并由(you)单(dan)片机(ji)(ji)(ji)(ji)输(shu)(shu)(shu)出电(dian)(dian)(dian)(dian)(dian)(dian)(dian)子换向器三个桥臂的(de)(de)(de)(de)前级驱(qu)动(dong)(dong)信(xin)(xin)(xin)(xin)号，以控制(zhi)(zhi)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)的(de)(de)(de)(de)运转，因(yin)而单(dan)片机(ji)(ji)(ji)(ji)主(zhu)控电(dian)(dian)(dian)(dian)(dian)(dian)(dian)路是无刷(shua)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)控制(zhi)(zhi)器的(de)(de)(de)(de)心脏部(bu)分。单(dan)片机(ji)(ji)(ji)(ji)PIC16F72是目(mu)(mu)前电(dian)(dian)(dian)(dian)(dian)(dian)(dian)动(dong)(dong)车(che)无刷(shua)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)控制(zhi)(zhi)器的(de)(de)(de)(de)主(zhu)流控制(zhi)(zhi)芯片，图4所示的(de)(de)(de)(de)是用PIC16F72构成(cheng)的(de)(de)(de)(de)无刷(shua)控制(zhi)(zhi)器的(de)(de)(de)(de)典型(xing)应用电(dian)(dian)(dian)(dian)(dian)(dian)(dian)路，它包括了(le)无刷(shua)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)控制(zhi)(zhi)器的(de)(de)(de)(de)各主(zhu)要输(shu)(shu)(shu)入(ru)、输(shu)(shu)(shu)出信(xin)(xin)(xin)(xin)号，如图 4中的(de)(de)(de)(de)SPSIG端信(xin)(xin)(xin)(xin)号，该(gai)信(xin)(xin)(xin)(xin)号经过(guo)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)阻R69和(he)R68组成(cheng)的(de)(de)(de)(de)网络送入(ru)单(dan)片机(ji)(ji)(ji)(ji)的(de)(de)(de)(de)第5脚，单(dan)片机(ji)(ji)(ji)(ji)根据该(gai)脚的(de)(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)压(ya)信(xin)(xin)(xin)(xin)号变化，决(jue)定输(shu)(shu)(shu)出驱(qu)动(dong)(dong)信(xin)(xin)(xin)(xin)号的(de)(de)(de)(de)脉宽，从而决(jue)定电(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)(ji)的(de)(de)(de)(de)转速。目(mu)(mu)前市面上电(dian)(dian)(dian)(dian)(dian)(dian)(dian)动(dong)(dong)车(che)的(de)(de)(de)(de)转把输(shu)(shu)(shu)出信(xin)(xin)(xin)(xin)号电(dian)(dian)(dian)(dian)(dian)(dian)(dian)压(ya)一般在1~4.2V，

它内部是(shi)由一个线(xian)性霍尔(er)元(yuan)(yuan)件和一个磁 体(ti)(ti)组成，转动转把、磁体(ti)(ti)移动，霍尔(er)元(yuan)(yuan) 件感应变(bian)化的磁场而输(shu)出变(bian)化的电压(ya)。

4.  限速电路

限速电(dian)路是(shi)通过分压电(dian)阻，减小送入单片(pian)机(ji)的(de)(de)转(zhuan)把(ba)最高电(dian)压信(xin)号(hao)，从(cong)而限制(zhi)了速度。如图4中把(ba)SPLIMT端接地，则R67与(yu)R68即组成分压电(dian)路，降(jiang)低转(zhuan)把(ba)信(xin)号(hao)（SPSIG）送入单片(pian)机(ji)的(de)(de)5 脚的(de)(de)电(dian)压，从(cong)而限制(zhi)了电(dian)动车的(de)(de)最高 转(zhuan)速。

5. 霍尔信号检测电路

在图4中，电(dian)阻(zu)R31~R36、电(dian)容 C16~C18组成霍尔(er)信号检(jian)(jian)测输入电(dian)路，电(dian)阻(zu)R34~R36形成上拉电(dian)位(wei)，电(dian)容C16~C18起滤波作用，抑制(zhi)干扰信号。单片机(ji)的15、16、17脚分别检(jian)(jian)测来自电(dian)机(ji)内的三路霍尔(er)位(wei)置信号，以决定换相时刻。

6.欠压检测电路

在图4中，元件R70、R71、R72、 C23组成(cheng)电(dian)(dian)池电(dian)(dian)压检(jian)测(ce)(ce)电(dian)(dian)路(lu)，检(jian)测(ce)(ce)值送(song)入单片机(ji)的(de)3脚(jiao)，当该脚(jiao)检(jian)测(ce)(ce)值低于(yu)某一(yi)数值时(shi)，可强(qiang)迫无刷电(dian)(dian)机(ji)控制器不工作，从而起到保护电(dian)(dian)池的(de)作用。

7.刹车信号电路

对(dui)于(yu)电(dian)(dian)(dian)(dian)(dian)动(dong)(dong)(dong)自行车(che)(che)(che)(che)，当手(shou)把刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)时，单片机(ji)(ji)(ji)得到刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)，无刷电(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)控(kong)制(zhi)(zhi)器(qi)(qi)停止输出控(kong)制(zhi)(zhi)信(xin)号(hao)(hao)，电(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)断电(dian)(dian)(dian)(dian)(dian)，这称(cheng)为(wei)刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)断电(dian)(dian)(dian)(dian)(dian)，对(dui)于(yu)有些无刷控(kong)制(zhi)(zhi)器(qi)(qi)，当单片机(ji)(ji)(ji)得到刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)时，则输出控(kong)制(zhi)(zhi)信(xin)号(hao)(hao)，强制(zhi)(zhi)电(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)抱住，使电(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)不能(neng)转动(dong)(dong)(dong)，这称(cheng)为(wei)电(dian)(dian)(dian)(dian)(dian)刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)。目前市面上电(dian)(dian)(dian)(dian)(dian)动(dong)(dong)(dong)车(che)(che)(che)(che)的刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)有高电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)和低(di)(di)电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)两(liang)种(zhong)，对(dui)于(yu)单片机(ji)(ji)(ji)一般只识别其中(zhong)一种(zhong)信(xin)号(hao)(hao)，如果采用(yong)电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)转换(huan)电(dian)(dian)(dian)(dian)(dian)路(lu)，则可识别两(liang)种(zhong)电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)的刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)。在图4中(zhong)，当BK信(xin)号(hao)(hao)端(duan)为(wei)低(di)(di)电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)，则单片机(ji)(ji)(ji)第7 脚得到低(di)(di)电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)信(xin)号(hao)(hao)，通知无刷控(kong)制(zhi)(zhi)器(qi)(qi)完(wan)(wan)(wan)成刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)过程。当HBK端(duan)为(wei)高电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)时，通过电(dian)(dian)(dian)(dian)(dian)阻(zu)R66、R81、R88及三极管VT20完(wan)(wan)(wan)成电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)转换(huan)，三极管VT20 的集电(dian)(dian)(dian)(dian)(dian)极变(bian)为(wei)低(di)(di)电(dian)(dian)(dian)(dian)(dian)平(ping)(ping)(ping)，单片机(ji)(ji)(ji)第7脚为(wei)低(di)(di)，通知无刷控(kong)制(zhi)(zhi)器(qi)(qi)完(wan)(wan)(wan)成刹(cha)(cha)(cha)(cha)车(che)(che)(che)(che)动(dong)(dong)(dong)作。

8.  电源电路

在无刷电(dian)机(ji)(ji)控制器中，一(yi)般(ban)需两(liang)组(zu)电(dian)源(yuan)，一(yi)个是14V电(dian)源(yuan)供(gong)(gong)功率MOSFET驱动用，另一(yi)个是5V电(dian)源(yuan)，供(gong)(gong)单片机(ji)(ji)、电(dian)机(ji)(ji)霍尔(er)、转把霍尔(er)等电(dian)路用。14V电(dian)源(yuan)一(yi)般(ban)由(you)LM317调整管得到(dao)，5V电(dian)源(yuan)一(yi)般(ban)由(you)78L05得到(dao)，电(dian)路程式如(ru)图(tu)5所示。

9.  限流/过流保护电路

限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)保(bao)护是(shi)(shi)(shi)控制无(wu)(wu)(wu)刷电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)控制器 在某一最大限(xian)(xian)(xian)(xian)定(ding)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)值下(xia)(xia)(xia)工(gong)作，对于 36V控制器，限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)值一般在14±1A，对于48V控制器限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)值一般在17±1A。限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)保(bao)护其实又(you)是(shi)(shi)(shi)过(guo)(guo)(guo)(guo)载保(bao)护，当(dang)上坡、载重(zhong)必然引起(qi)负(fu)载加重(zhong)、电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)增大，但电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)增大的(de)(de)(de)极限(xian)(xian)(xian)(xian)就是(shi)(shi)(shi)限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)值。如图(tu)4中，IC6B（LM358）的(de)(de)(de)运(yun)(yun)放与(yu)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)阻R73、R74、R75、R76及RT 构成(cheng)(cheng)限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)信(xin)号(hao)检测(ce)(ce)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)路(lu)。R T为串接于 MOSFET管上的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)阻丝，如图(tu)2所(suo)示，因为电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)通过(guo)(guo)(guo)(guo)MOSFET管，也就流(liu)(liu)(liu)(liu)(liu)(liu)(liu)  过(guo)(guo)(guo)(guo)R  T，当(dang)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)过(guo)(guo)(guo)(guo)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)变化，反(fan)应在 R  T上就是(shi)(shi)(shi)R  T两(liang)端电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)压(ya)(ya)的(de)(de)(de)变化。当(dang)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)过(guo)(guo)(guo)(guo)RT 的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)大到限(xian)(xian)(xian)(xian)定(ding)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)时(shi)，此时(shi)IC6的(de)(de)(de)第(di) 7脚输(shu)出(chu)约(yue)3V的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)压(ya)(ya)，单片(pian)机(ji)(ji)(ji)PIC16F72 的(de)(de)(de) 2脚得(de)到3V电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)压(ya)(ya)时(shi)，则降(jiang)低MOSFET 驱(qu)动输(shu)出(chu)信(xin)号(hao)的(de)(de)(de)占空(kong)比，迫使(shi)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)过(guo)(guo)(guo)(guo)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji) 的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)下(xia)(xia)(xia)降(jiang)，即R  T上的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)下(xia)(xia)(xia)降(jiang)，同时(shi) R  T上的(de)(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)压(ya)(ya)下(xia)(xia)(xia)降(jiang)，使(shi)得(de)IC6的(de)(de)(de)第(di)7脚输(shu)出(chu)下(xia)(xia)(xia)降(jiang)，如此动态调节，保(bao)证(zheng)无(wu)(wu)(wu)刷电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)控制器工(gong)作于限(xian)(xian)(xian)(xian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)值以下(xia)(xia)(xia)。过(guo)(guo)(guo)(guo)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)保(bao)护是(shi)(shi)(shi)当(dang)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)达(da)到限(xian)(xian)(xian)(xian)定(ding)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)时(shi)，无(wu)(wu)(wu)刷电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)控制器电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)仍在上升，则强迫停止电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)机(ji)(ji)(ji)供电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)。IC6A的(de)(de)(de)运(yun)(yun)放和(he)R59、R61、R62及R T构成(cheng)(cheng)过(guo)(guo)(guo)(guo)流(liu)(liu)(liu)(liu)(liu)(liu)(liu)保(bao)护检测(ce)(ce)电(dian)(dian)(dian)(dian)(dian)(dian)(dian)(dian)路(lu)，见图(tu)4。检测(ce)(ce)信(xin)号(hao)由IC6的(de)(de)(de)1 脚输(shu)出(chu)，送入单片(pian)机(ji)(ji)(ji)的(de)(de)(de)21脚。

维修要点

根据笔者在(zai)实际工作中的(de)经验， 要修好无刷(shua)控制(zhi)器，可按(an)如下步骤进 行，将会(hui)收(shou)到事半功倍的(de)效(xiao)果(guo)。

第一步:正确判断(duan)无刷电机(ji)控制器的各引(yin)出(chu)线(xian)功能 无刷电机(ji)控制器一般具备如下引(yin) 出(chu)线(xian)。

1.电机线（图6中A线(xian)）无刷电机控制器电机线(xian)有(you)3根(gen)，称(cheng)为(wei)A、B、C相线(xian)，一般黄(huang)线(xian)为(wei)A相，蓝线(xian)为(wei)B相，绿(lv)线(xian)为(wei)C相，但也有(you)例外，这(zhei)就要求维修者试着调(diao)换(huan)3根(gen)线(xian)的(de)次序(xu)，直(zhi)到电机运转正常(chang)。

2.  电源线（图6中B线(xian)(xian)）无刷电机(ji)控制器电源线(xian)(xian)一般用3根线(xian)(xian)，其中一根细一些的线(xian)(xian)为(wei)锁线(xian)(xian)，它是给无刷电机(ji)控制器14V及 5V电源供电的，另外 两根粗线(xian)(xian)（红、黑）给功率管供电。

3. 限速线（图6中C线）国家标(biao)(biao)准规定电(dian)动(dong)车(che)(che)的(de)最高限速 为20km/h，因(yin)此各无(wu)刷电(dian)机控(kong)制器厂(chang) 家生产(chan)的(de)控(kong)制器出厂(chang)时都留有(you)如(ru)(ru)图7 中的(de)D号线，当插头插上，则电(dian)动(dong)车(che)(che) 限速为20km/h，符合国家标(biao)(biao)准，如(ru)(ru)断(duan) 开，则电(dian)动(dong)车(che)(che)速度将大于20km/h，方 便用户选择。

4.  刹车线（图(tu)6中D线(xian)）刹(cha)车(che)(che)线(xian)连接到电动车(che)(che)的把(ba)手开(kai)关(guan)上，当刹(cha)车(che)(che)时开(kai)关(guan)动作，刹(cha)车(che)(che)信号送入单(dan)片机，执行刹(cha)车(che)(che)断电或刹(cha)车(che)(che)抱死动作。

5.速度线（图6中(zhong)(zhong)E线(xian)）速(su)度(du)线(xian)与(yu)电(dian)(dian)(dian)动车仪(yi)表盘(pan)中(zhong)(zhong)的(de)速(su)度(du)表相(xiang)(xiang)(xiang)连，在无(wu)刷电(dian)(dian)(dian)机(ji)(ji)控(kong)制器内它通过(guo)一限流电(dian)(dian)(dian)阻与(yu)电(dian)(dian)(dian)机(ji)(ji)的(de)某(mou)一根相(xiang)(xiang)(xiang)线(xian)相(xiang)(xiang)(xiang)连。电(dian)(dian)(dian)机(ji)(ji)速(su)度(du)变化(hua)，反(fan)应在电(dian)(dian)(dian)机(ji)(ji)相(xiang)(xiang)(xiang)线(xian)中(zhong)(zhong)电(dian)(dian)(dian)流变化(hua)，则(ze)在速(su)度(du)线(xian)中(zhong)(zhong)电(dian)(dian)(dian)流也变化(hua)，反(fan)应在仪(yi)表盘(pan)中(zhong)(zhong)就是速(su)度(du)的(de)变化(hua)。

6.转把线（图(tu)6中F线(xian)）转(zhuan)把(ba)(ba)(ba)线(xian)连接到电动(dong)车转(zhuan)把(ba)(ba)(ba)内(nei)(nei)的(de)霍尔(er)(er)上(shang)，转(zhuan)把(ba)(ba)(ba)线(xian)有(you)3根线(xian)，分别为(wei)(wei)(wei)电源(yuan)(yuan)正(zheng)、电源(yuan)(yuan)负和信(xin)号(hao)线(xian)，一般红线(xian)为(wei)(wei)(wei)电源(yuan)(yuan)正(zheng)，黑(hei)线(xian)为(wei)(wei)(wei)电源(yuan)(yuan)负，信(xin)号(hao)线(xian)为(wei)(wei)(wei)蓝色。当转(zhuan)把(ba)(ba)(ba)转(zhuan)动(dong)时，转(zhuan)把(ba)(ba)(ba)内(nei)(nei)磁铁(tie)相对霍尔(er)(er)运(yun)动(dong)，产生由低到高的(de)感应电压信(xin)号(hao)，该信(xin)号(hao)送(song)入单片机，执(zhi)行调速指令。

7.  电机霍尔线（图6中G线(xian)(xian)）电(dian)(dian)机(ji)霍尔线(xian)(xian)与(yu)电(dian)(dian)机(ji)内(nei)霍尔相(xiang)(xiang)连(lian)(lian)(lian)，以决(jue)定电(dian)(dian)机(ji)换相(xiang)(xiang)时刻。霍尔线(xian)(xian)有5根线(xian)(xian)：红为正，黑为负，其余3根线(xian)(xian)为3 个霍尔信号，这(zhei)3根线(xian)(xian)与(yu)电(dian)(dian)机(ji)相(xiang)(xiang)连(lian)(lian)(lian)，必须次序(xu)正确，否则电(dian)(dian)机(ji)不能正常运转(zhuan)，有时需反复调换这(zhei)3根线(xian)(xian)与(yu)电(dian)(dian)机(ji)相(xiang)(xiang)连(lian)(lian)(lian)次序(xu)，直(zhi)到电(dian)(dian)机(ji)运转(zhuan)正常。

第二步：目视(shi)检查(cha)(cha)打开(kai)无(wu)刷电(dian)机控(kong)制器，如图(tu)7所(suo)示(shi)，目视(shi)检查(cha)(cha)有无(wu)不良，重点检查(cha)(cha)各导线是否焊接良好，功率MOS管、14V 稳压管、大电(dian)解(jie)电(dian)容、单片机、振荡器是否焊接良好，如图(tu)7中A、B、C、 D、E标注(zhu)的所(suo)示(shi)，要排除不良点。

第三步:在不通电情况下(xia)用万用表检查(cha)

1. 先用万(wan)用表量外接(jie)电(dian)源端对地 阻抗是否正常(chang)，一般应大于 2kΩ。

2.分(fen)别测6个(ge)MOS管引脚间(jian)有无短(duan)路现象，此(ci)点(dian)较为重要，无刷电机控制器(qi)（如MOS管）较差，过流(liu)保(bao)护控制不(bu)佳或散热做得(de)不(bu)好，往(wang)往(wang)会引起MOS管击穿，如图7中(zhong)A部分(fen)。

3. 检查电(dian)源稳压管LM317引(yin)脚间 有(you)无(wu)短(duan)路现象(xiang)。

4. 测(ce)78L05与地间阻(zu)抗(kang)是否正 常，一般(ban)应大于1.5 kΩ。

第四步:在(zai)通电情况下测直流工作点 测 LM317 输(shu)出 （ 应为 14V ）、 78L05输(shu)出（应为5V）、转把线(xian)(xian)霍(huo)尔线(xian)(xian)、助力(li)线(xian)(xian)、红线(xian)(xian)与黑线(xian)(xian)间(jian)电源(yuan)（应 为5V）。

第五步:尝试通电运转

1. 只连(lian)接电机线(xian)、霍尔线(xian)、转把(ba)(ba)线(xian)，保证正(zheng)(zheng)确连(lian)接后(hou)通(tong)电试着(zhe)转动转把(ba)(ba)，先(xian)慢慢转动一小段(duan)位(wei)置（低(di)速(su)），看电机运转状态是否正(zheng)(zheng)常(chang)，如(ru)不正(zheng)(zheng)常(chang)，立即停机，重(zhong)新(xin)检(jian)查。只有电机低(di)速(su)正(zheng)(zheng)常(chang)，方可(ke)逐(zhu)渐提高速(su)度，否则易损坏器件。

2.  在电机运(yun)转正常(chang)情况下，检查 刹(cha)车、助力(li)、速度(du)表(biao)、欠压、限流等(deng)功能是否正常(chang)。

第六步：故(gu)障(zhang)排(pai)除有时(shi)故(gu)障(zhang)现(xian)象是多(duo)方面因(yin)(yin)素(su)造成(cheng)的，因(yin)(yin)此，我们要善于(yu)透(tou)过现(xian)象看本质，逐一排(pai)除点(dian)(dian)，最后问题便迎刃而解(jie)，附表是故(gu)障(zhang)现(xian)象与原因(yin)(yin)的几(ji)点(dian)(dian)总结。

总之(zhi)，在初步(bu)掌握无(wu)刷控制器(qi)基本(ben)原理(li)的基础上，按照以上所介绍(shao)的几点步(bu)骤维(wei)修(xiu)，将会(hui)收到事半功倍的效果。本(ben)文旨在抛砖引玉，许多(duo)维(wei)修(xiu)技巧还要靠不断实践才能融(rong)会(hui)贯通(tong)。

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