WO2009006172A2 - Dispositif de commande électronique de moteur et procédé de commande d'un moteur - Google Patents

Dispositif de commande électronique de moteur et procédé de commande d'un moteur Download PDF

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Publication number
WO2009006172A2
WO2009006172A2 PCT/US2008/068266 US2008068266W WO2009006172A2 WO 2009006172 A2 WO2009006172 A2 WO 2009006172A2 US 2008068266 W US2008068266 W US 2008068266W WO 2009006172 A2 WO2009006172 A2 WO 2009006172A2
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WIPO (PCT)
Prior art keywords
motor
voltage
microcontroller
controller
mosfet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2008/068266
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English (en)
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WO2009006172A3 (fr
Inventor
Wade Tai
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RWR ELECTRONICS LLC
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RWR ELECTRONICS LLC
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Publication of WO2009006172A2 publication Critical patent/WO2009006172A2/fr
Publication of WO2009006172A3 publication Critical patent/WO2009006172A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41B—WEAPONS FOR PROJECTING MISSILES WITHOUT USE OF EXPLOSIVE OR COMBUSTIBLE PROPELLANT CHARGE; WEAPONS NOT OTHERWISE PROVIDED FOR
    • F41B11/00—Compressed-gas guns, e.g. air guns; Steam guns
    • F41B11/60—Compressed-gas guns, e.g. air guns; Steam guns characterised by the supply of compressed gas
    • F41B11/62—Compressed-gas guns, e.g. air guns; Steam guns characterised by the supply of compressed gas with pressure supplied by a gas cartridge
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41A—FUNCTIONAL FEATURES OR DETAILS COMMON TO BOTH SMALLARMS AND ORDNANCE, e.g. CANNONS; MOUNTINGS FOR SMALLARMS OR ORDNANCE
    • F41A19/00—Firing or trigger mechanisms; Cocking mechanisms
    • F41A19/58—Electric firing mechanisms
    • F41A19/64—Electric firing mechanisms for automatic or burst-firing mode
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41A—FUNCTIONAL FEATURES OR DETAILS COMMON TO BOTH SMALLARMS AND ORDNANCE, e.g. CANNONS; MOUNTINGS FOR SMALLARMS OR ORDNANCE
    • F41A19/00—Firing or trigger mechanisms; Cocking mechanisms
    • F41A19/58—Electric firing mechanisms
    • F41A19/64—Electric firing mechanisms for automatic or burst-firing mode
    • F41A19/66—Electronic shot-velocity control
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41A—FUNCTIONAL FEATURES OR DETAILS COMMON TO BOTH SMALLARMS AND ORDNANCE, e.g. CANNONS; MOUNTINGS FOR SMALLARMS OR ORDNANCE
    • F41A19/00—Firing or trigger mechanisms; Cocking mechanisms
    • F41A19/58—Electric firing mechanisms
    • F41A19/69—Electric contacts or switches peculiar thereto
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41B—WEAPONS FOR PROJECTING MISSILES WITHOUT USE OF EXPLOSIVE OR COMBUSTIBLE PROPELLANT CHARGE; WEAPONS NOT OTHERWISE PROVIDED FOR
    • F41B11/00—Compressed-gas guns, e.g. air guns; Steam guns
    • F41B11/50—Magazines for compressed-gas guns; Arrangements for feeding or loading projectiles from magazines
    • F41B11/57—Electronic or electric systems for feeding or loading
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41B—WEAPONS FOR PROJECTING MISSILES WITHOUT USE OF EXPLOSIVE OR COMBUSTIBLE PROPELLANT CHARGE; WEAPONS NOT OTHERWISE PROVIDED FOR
    • F41B11/00—Compressed-gas guns, e.g. air guns; Steam guns
    • F41B11/70—Details not provided for in F41B11/50 or F41B11/60
    • F41B11/71—Electric or electronic control systems, e.g. for safety purposes

Definitions

  • the present invention relates to motor controllers generally, and more particularly to motor controllers incorporating logic-based switching and control.
  • AEG Airsoft Automatic Electric Gun
  • U.S. Pat. No. 5,261,384 to Hu incorporated herein by reference
  • U.S. Pat. No. 6,564,788 to Hu incorporated herein by reference.
  • Such devices attempt to replicate their real firearm counterparts in appearance and function.
  • These guns typically fire in single-shot semi-automatic mode, as well as fully-automatic mode. Some fire in a "burst" mode for a predetermined number of shots or period of time.
  • AEGs use a motor that is driven by a battery, switched on and off using one or more trigger switches, and may generally feature an electromechanical or timed cutoff to stop the motor after one or multiple shots.
  • the present invention may be applied to a variety of applications including AEGs, AEPs, AEG Boys, Electric Blowback (EBB) Pistols, Hybrids, Low/Medium Powered Electric Guns, mini electrics, and Radio Controlled Battle Tanks.
  • EBB Electric Blowback
  • an AEG's projectile- firing behavior does not mimic that of an automatic firearm.
  • An automatic firearm fires at a consistent rate from the first to last round, and can jam and stop firing from overheating if fired continuously.
  • the typical AEG rate of fire is relatively rapid. As the charge decreases, the rate of fire also drops proportionally with respect to the battery voltage. More specifically, the drop in the rate of fire is initially relatively sharp followed by a period of modest drop, and then finally by a period of sharp drop when the battery is near depletion.
  • the present invention can detect and stop the motor while it is still running (but slowing and nearing stall) to protect it from excess current, overheating, and damage to the controller and motor.
  • prior art AEGs do not employ means to protect against excess temperature.
  • configuration of sensors it is believed that prior art is either not configurable, or uses jumpers, potentiometers, and other controls to configure and adjust sensors. Further, the prior art is believed to be relatively limited with regard customization.
  • One aspect of the present invention permits motor control using a microcontroller, a MOSFET half H-bridge, and a low-side MOSFET switch.
  • the low- side MOSFET switch may advantageously provide reversed battery polarity protection, as it is not uncommon for RC battery packs (having opposite polarity) to be erroneously inserted in place of Airsoft battery packs.
  • Another aspect of the present invention permits the motor to be started and stopped with a low-voltage, low-current, microcontroller-debounced trigger switch to reduce power loss and contact wear caused by mechanically switching higher motor voltages and currents.
  • Another aspect of the invention permits an operation switch, which in one embodiment is a gun trigger, to function as a user interface, allowing the user to select between different modes of operation.
  • Another aspect of the present invention provides for a regulated, low- voltage power supply permitting use of optional sensors and optional external components requiring an external power supply.
  • Another aspect of the invention provides regulation of motor speed and performance using pulse-width modulation (PWM) to provide consistent motor performance, which maximizes battery life, and/or permits use of smaller, lighter, and/or lower-capacity batteries.
  • PWM pulse-width modulation
  • Still another aspect of the invention regulates motor speed by sensing power supply voltage through use of microcontroller analog-to-digital converter channels instead of costly and technically complex position and rotation sensors on the motor.
  • Another aspect of the present invention provides a means to detect motor stall or impending motor stall and a means to interrupt the power supply in such circumstances to advantageously minimize motor heating and excess current generation.
  • Another aspect of the present invention reduces excess motor spin through braking, which permits a motor to stop in a predictable manner. Excess motor spin supplies current back to a rechargeable power source, both with and without the microcontroller in a deep sleep mode.
  • the present invention is applied to providing a more realistic and efficient operation of an AEG to permit the gun's trigger to function as a user interface allowing user selection between firing modes including timed, indexed, or continuous motor run modes with adjustable run times and index positions by using an optional sensor or back-EMF sensing.
  • the present invention also discloses two methods for fitting AEGs with the present inventive motor controller. Additionally, the present invention may permit a more refined motor starting to minimize AEG gear tooth breakage from sudden, full-voltage, high-torque motor starts by gradually increasing the voltage used to start the motor until it reaches a target voltage.
  • Prior art applies the full voltage or target duty cycle immediately at startup, or applies a duty cycle and repeatedly measures the motor feedback to adjust the duty cycle.
  • Motor speed and performance may be controlled using pulse-width modulation (PWM) to provide consistent firing rates, maximize battery life, and/or allow the use of smaller, lighter, and/or lower-capacity batteries to save size and weight.
  • PWM pulse-width modulation
  • the present invention provides a regulated, low-voltage power supply for an optional sensor or other optional external components that require such a power supply. Additionally, the present invention may reduce excess motor spin when higher- voltage batteries are used so that the air piston and projectile loader consistently start and stop in the same position during single and timed motor run modes, and optionally under indexed and continuous modes, and recharge the battery when the controller is slowing the motor by directing generated current and voltage back to the battery.
  • the controller can be easily adapted and fitted to existing gun designs. This characteristic is different from some prior art devices which require additional switches or compound switches to actuate or configure operating modes and parameters.
  • the present invention offers greater motor and battery regulation and protection without the need for redesign, added space, and added circuitry to accommodate additional switches and controls.
  • the controller permits incorporation of an additional, optional switch or sensor where desired.
  • battery readings are averaged over a plurality of ADC samples to filter noise, and the averaged result is stored in an multi-value circular buffer, with a running average of the buffer values is calculated by the microcontroller.
  • battery readings are averaged over 8 ADC samples to filter noise.
  • the averaged result is stored in a 8-value circular buffer, and a running average of the buffer values is calculated. This provides for a smoother, more predictable battery discharge curve for use in analysis by the controller. This differs from known prior art that utilize single, instantaneous samples.
  • Another aspect of the invention provides a safety timer cutoff. If no back-
  • a timer cuts power to the motor as a safety feature to prevent runaway firing when the trigger is released and no activity is detected causing the motor to continue running.
  • FIG. 1 is a schematic drawing of one embodiment of the motor controller.
  • FIG. 2 demonstrates top layer copper and placement of one embodiment of the controller.
  • FIG. 3 demonstrates bottom layer copper and placement of one embodiment of the controller.
  • FIG. 4 is a schematic demonstrating an embodiment bus-powered USB programming cable and module.
  • FIG. 5 demonstrates programming cable top layer copper and placement of one embodiment of the controller.
  • FIG. 6 demonstrates programming cable bottom layer copper and placement of one embodiment of the controller.
  • FIG. 7 is a block diagram depicting an embodiment plug-in location of the motor controller relative to the battery and trigger.
  • FIG. 8 is a block diagram depicting an embodiment hard-wired location of the motor controller relative to the battery and trigger.
  • FIG. 9 illustrates an alternative embodiment electronically controlled motor relay with brake.
  • FIG. 10 demonstrates top and bottom copper and placement for a motor relay embodiment.
  • FIG. 11 is a flow diagram demonstrating an embodiment controller initialization, configuration, and entering and exiting a sleep state.
  • FIG. 12 is a flow diagram demonstrating an embodiment main motor loop.
  • FIG. 13 is a flow diagram demonstrating an embodiment timer overflow interrupt: shot timing/counting, and trigger/sensor filtering.
  • FIG. 14 is an example embodiment sample output from the controller during configuration mode.
  • FIG. 1 illustrates one exemplar schematic diagram. It is important to note that the present invention should not be construed to be limited to the disclosed example embodiment.
  • B+ and B- are the battery positive and negative wire leads.
  • M+ and M- are the motor positive and negative leads.
  • Not shown in illustration 1 is a mini blade fuse and holder installed across pads B+l and F+. The holder is a pair of universal fuse clips, one soldered to each pad, and positioned horizontally to minimize thickness of the completed assembly.
  • T- and V- are digital signal ground pads for both trigger switch input T+ and switch/sensor input S+.
  • T+ and S+ are also used as a two-wire, serial interface with T+ as the receive pin and S+ as the transmit pin.
  • FIGS. 2 and 3 illustrate the copper layers, stop masks, and component placement on the circuit board.
  • IC2 is an STMicroelectronics LD2981 5 V, low-dropout, linear voltage regulator that provides power to a microcontroller (ICl) as well as any optional external sensors and components.
  • the LD2981 accepts up to 16V DC input which allows the use of standard 7.2V to 12V nickel-cadmium and nickel-metal-hydride rechargeable battery packs as well as 2- to 3-cell lithium-based battery packs.
  • the low-dropout feature helps the regulator provide clean 5 V power through the periods of low, depleted battery voltage levels as well as the voltage dip that occurs when the motor starts. Other regulators with similar or greater features and capabilities can be substituted.
  • Cl and C2 provide the recommended, manufacturer-specified noise filtering and dropout protection.
  • C3 provides filtering of the programming interface power supply or auxiliary 5 V supply provided by the controller to external components and sensors.
  • power from the connector is applied to the low-voltage regulated output side.
  • An optional protection diode may be required between the input and output pins of the regulator if it cannot tolerate higher voltage on the output side versus the input side.
  • Q 1 and Q2 are NXP/Philips PH4840S LFPAK N-channel, logic-level
  • MOSFETs that are used as a low-side, reverse battery switch and motor power switch, respectively. They are capable of handling large motor currents. Because of the compact size requirement, no additional heat sinking can be provided and therefore a greatly overrated part is used.
  • LFPAK and SOIC-8 form factors with the circuit board design shown above allow the board, battery leads, and motor leads to conduct heat away from the MOSFETs.
  • Other models and form factors of MOSFETs with similar or greater features and capabilities can be substituted.
  • a heavy-duty version of the controller can be constructed with International Rectifier IRL3713 TO-220 or TO- 262 MOSFETs, for example, for Ql and Q2. These larger MOSFETs can handle more current and dissipate more heat. In either version, multiple parallel MOSFETs can also be used for higher current-handling capability.
  • the gate pin of Ql is connected to the regulated, low- voltage output of
  • IC2 When the battery is properly connected, IC2 supplies a low voltage to the gate and the low-side MOSFET Ql is turned on causing the controller's ground to be connected to the battery negative terminal. When the battery terminals are reversed, the regulator is off and Ql stays off.
  • the gate pin of Q2 is connected to one of the PWM output pins of microcontroller ICl.
  • the PWM timer for switching the motor has multiple drive frequencies available allowing the user to select the best frequency for maximizing motor torque and efficiency.
  • Q3 is a Fairchild Semiconductor FDS668 IZ SOIC-8 P-channel MOSFET that is used as a regenerative brake connecting the motor terminals. It is also greatly overrated to withstand the current surge during fast braking without the need for additional heat sinking. Other models and form factors of MOSFETs having similar or greater features and capabilities may be substituted. Both Q2 and Q3 MOSFETs feature avalanche diodes and form a half H-bridge. Dl is a fly-back diode and provides additional brake current-handling capability. Use of the diode is recommended to absorb high transient voltages that can damage the MOSFETs.
  • TVS transient voltage suppression
  • snubber circuits of similar or greater capabilities
  • An additional TVS device can also be installed between M- and ground to protect against ground spikes.
  • Q3 is an STMicroelectronics P80PF55 TO-220 or TO-262 MOSFET, for example. In either version, multiple parallel MOSFETs can be used for higher current-handling capability.
  • Q4 is an NXP/Philips BSS 123 N-channel MOSFET that is used to switch the gate of Q3 at battery voltage.
  • Other logic-level MOSFETs with similar or greater features and capabilities can be substituted.
  • External pull-up resistors R2 and R3 are used because the internal pull-up resistors in the Atmel ATtiny85 microcontroller (ICl) are disabled while it is asleep and the microcontroller enters its deep sleep state before the motor can come to a full stop, and continued brake application is needed.
  • ICl Atmel ATtiny85 microcontroller
  • Rl ensures that the low-side motor switch is off whenever the controller is in a brownout condition and helps prevent both MOSFETs of the half bridge from conducting simultaneously, thereby causing a short circuit.
  • a diode in series with R3 and a capacitor across Q4 can be added to further prevent short circuits during low battery conditions. Further, although the brake is not driven by PWM in normal use, it could be PWM-driven if necessary. An optional dead time generator on the controller prevents Q2 and Q3 from activating simultaneously and allows conventional back-EMF sensing to be implemented.
  • R4 and R5 form a resistor divider to measure battery voltage and voltage at the positive terminal of the motor.
  • R6 and R7 form another resistor divider to measure voltage at the negative terminal of the motor.
  • Each resistor divider is connected to an analog-to-digital converter input pin on the microcontroller.
  • the resistors are sized so that the converters can measure the full range of battery voltages supported by the controller and MOSFETs.
  • Capacitors can be installed and stacked on top of R5 and R7 to reduce measurement noise from the running motor.
  • the Atmel ATtiny85 microcontroller features an internal temperature sensor connected to an analog-to-digital converter channel. Other microcontrollers with similar or greater features and capabilities can be substituted.
  • the MOSFETs Ql, Q2, and Q3 are mounted so that their heat spreaders face the circuit board and transfer their heat to the case of the microcontroller allowing a more accurate temperature measurement.
  • the trigger switch positive input T+ is connected to an external interrupt input pin (INTO) on the microcontroller.
  • INTO interrupt input pin
  • the external reset pin of the microcontroller is disabled so that it can be used as an input pin for the external sensor/switch (S+).
  • the internal pull-up resistor is enabled when the controller is configured for use with an active low sensor, and disabled when used with an active high sensor. An external pull-up resistor is not needed since the sensor can be disabled while the gun is not firing.
  • Optional resistors in series with the MOSFET gate pins provide microcontroller and regulator protection in case the MOSFETs fail.
  • Optional color LEDs can also be added to each gate circuit to indicate MOSFET switching, or as condition/status indicators during operation and configuration.
  • Optional resistor/capacitor filters provide noise suppression on the trigger and sensor inputs. The optional components can be omitted to satisfy space and other functional requirements of the controller depending on the application.
  • high- voltage, high-current pads connect wires directly to the MOSFET leads.
  • This configuration eliminates the need for wide traces such as those used in the standard version yet still allows for a compact circuit board.
  • silicone- insulated wires found in many AEGs PTFE/Teflon -insulated wires may be used to further minimize space requirements.
  • surface-mount and through-hole components are mounted to both sides of the circuit board to take advantage of available space.
  • the standard controller uses surface-mount components to save space.
  • Pads may be labeled to ease attachment of color coded wire segments or connectors.
  • the standard version has pads located on both ends to minimize the controller's space usage.
  • the completed assembly can be encased in epoxy or silicone with a moisture- and abrasion-resistant coating or sleeve around it.
  • a low-voltage, low-current, logic-level trigger switch is used to reduce power loss, contact wear, and pitting from arcing caused by a traditional switch that directly controls higher motor voltages and currents. With filtering, switch bounce from unintentional and intermittent switch contact, poor switch quality, and worn and pitted switch contacts is noticeably reduced. Switch operation is precise and reliable, and the AEG behaves more closely to the firearm that it attempts to replicate.
  • the trigger switch is also used to configure the controller to run the motor in timed, indexed, and continuous modes.
  • the controller prevents the motor from starting when the trigger switch is closed and the battery is connected. This safety feature allows the initial closure of the switch to toggle the controller between timed, indexed, and continuous motor run modes. It also reduces the chances of an accidental discharge if the trigger is pulled while the battery is installed.
  • the trigger switch is also used to adjust the timeout period for timed and indexed motor run modes.
  • the timeout is selected from a range of fixed time periods, but can also be a starting value that the controller uses as it measures the motor's behavior and adjusts itself accordingly. For example, the controller can measure the time elapsed for a single shot, and then extrapolate the time required for a burst of shots.
  • the controller can adapt to a variety of AEG motors, springs, and gear box designs.
  • 1.8 V may be used in order to save power, and especially in the case of battery-powered devices. It will be recognized by those skilled in the art, that although there are MOSFETs that respond to lower gate voltages, there are fewer higher-powered models that do. Therefore, a second smaller MOSFET may be required to drive the gate, not unlike the braking MOSFET used in the present invention. The same principle of adding a smaller MOSFET may be used on the motor MOSFET for lower-powered microcontrollers.
  • FIGS. 7 and 8 illustrate two methods for wiring AEGs with the subject electronic motor controller.
  • the first embodiment plug-in installation 700a provides installation places motor controller 225 a within the 3AG fuse holder typically used in an AEGs, and connects controller 225 a between the AEG and battery 702a using the existing electrical connectors.
  • the controller can be installed without disassembling the gun housing and without permanent changes to the wiring.
  • the controller provides limited braking function and the higher motor voltage passes through trigger switch 706a. Since there is a short delay from the time trigger switch 706a closes to the starting of motor 704a, switch arcing is reduced when controller 225 a is installed. Controller 225 a automatically detects the installation configuration.
  • controller 225 a When controller 225 a is connected between the gun and the battery 702a, the battery voltage does not appear on the negative motor terminal because the trigger switch 706a is in series with motor 704a and is open. In addition, this method will only work if the original trigger switch was installed on the negative, low-side wire. If the trigger switch is installed on the high side, the AEG will not fire when the trigger is pulled.
  • the motor controller 225b is hard-wired, the battery voltage appears on both motor terminals.
  • the analog-to-digital sensors are described further below.
  • the present invention replaces the existing 3AG fuse with a commonly-available, automotive-type mini-blade fuse, such as the Littlefuse 897 (not shown).
  • a commonly-available, automotive-type mini-blade fuse such as the Littlefuse 897 (not shown).
  • circuit breakers, self-healing fuses, and other types of reusable, excess-current protection devices designed to replace mini-blade fuses can also be used in place of the supplied fuse.
  • the battery negative terminal is switched with a low-side, N-channel
  • MOSFET for reverse battery protection.
  • the gate of this MOSFET is connected to the output of the controller's voltage regulator such that when the battery is connected in reverse, the regulator is off and the MOSFET switch is open. Because the gate voltage is regulated, the MOSFET will not be damaged if a high voltage power source is connected that exceeds the maximum allowable gate threshold. In most cases, the same model MOSFET that is used as the low-side motor switch can be used because of the equivalent amount of current that it must handle.
  • the present invention regulates motor speed, including in one embodiment, the speed of an AEG motor using pulse-width modulation (PWM) in order to increase battery life and maintain realistic and consistent firing behavior.
  • Motor speed is regulated through analog-to-digital converter channels (ADC) of a microcontroller and a resistor divider to measure the battery voltage when the battery is first connected to the controller and just before each time that the motor is started.
  • ADC analog-to-digital converter channels
  • the microcontroller uses the ADC voltage value to determine the size of the battery installed and calculate the initial PWM duty cycle needed to run the motor at the appropriate speed for maximizing the life of the battery. Since the voltage applied to the motor is proportional to its speed, a voltage value close to the resting voltage of the battery is applied to the motor via PWM. It should be noted that various hardware PWM frequencies (and even multiple frequencies within the firing cycle) can be used to minimize MOSFET switching power loss and heat generation. The PWM frequency is scaled off of the microcontroller's system clock.
  • the microcontroller is programmed to contain tables of battery parameters for different standard battery types. If the user wants a faster or slower rate of fire, a higher or lower- voltage battery can be used, respectively.
  • the controller can also be configured by the user (described below) with the performance and battery parameters desired.
  • My invention differs from prior art in that it reduces initial motor speed to maximize battery life and realism, and analyzes the battery type and sets the controller operating parameters according to a list of known types.
  • the battery charge decreases at a higher rate as the load is increased, therefore monitoring the battery voltage before and during motor operation is a good way to determine the work that a motor has done. Since the load driven by an example AEG motor is identical for each rotation and a typical motor runs at 20,000 rpm or higher, the inventive method of monitoring the battery voltage to regulate the motor's speed is adequate for most AEGs.
  • the present invention starts the motor with the PWM duty cycle at 0% (or some other user-preset value) and increases it to the target level over a relatively short period of time. In one embodiment, it increases the duty cycle at a rate of roughly 0.39% per PWM cycle and this rate can be changed by the user. For example, as the duty cycle may range from 0 to 255, incrementing the cycle by 1 will yield a 0.39% or 1/256 increase.
  • the firmware may be changed to optimize the start and ramp values to most efficiently drive a particular motor and gearbox found in a specific AEG. By ramping the duty cycle, the moving parts engage more slowly and gradually. Since motor 704 startup period is brief and involves little initial motor movement, the added time, effort, and cost of removing power from motor 704 and monitoring rotation feedback is not worthwhile and detracts from applying continuously increasing power to start the initial rotation.
  • controller 225 When controller 225 reaches target duty cycle, controller 225 continues to monitor battery 702 voltage and adjust the duty cycle to compensate for decreasing voltage as battery 702 charge depletes. If the voltage drops below a preset threshold for a particular size of battery, then controller 225 stops motor 704 to prevent further charge depletion of battery 702. If motor 704 has not yet started but the user closes the trigger switch 706, then controller 225 prevents motor 704 from starting and draining the already depleted battery 702.
  • Nickel-metal hydride (NiMH), nickel-cadmium (NiCd), and lithium-based rechargeable batteries can be irreversibly damaged if they are allowed to discharge below a certain voltage. Over time, the battery capacity diminishes.
  • the low voltage threshold differs between battery types, and for NiMH and NiCd batteries is approximately equal to the number of cells in the battery.
  • the present invention uses the initial voltage of a fully- charged battery to determine motor's 704 optimal target duty cycle for maximizing battery life and the low voltage threshold of a depleted battery.
  • the microcontroller contains tables of depleted voltage thresholds and other battery parameters pertaining to each type of commonly-used AEG battery. The user can also specify these thresholds and parameters.
  • the controller 225 continues to monitor battery levels while the motor is running to maintain a consistent speed and shut off the motor if the battery is depleted.
  • the positive terminal of battery 702 is connected to the positive terminal of 704 motor, so the analog-to-digital converter described earlier also measures the voltage applied to the positive terminal of motor 704.
  • My invention uses a second analog- to-digital converter channel on the microcontroller to measure the voltage of the negative terminal of motor 704 after it has reached its target duty cycle.
  • the negative terminal is also connected to the drain of an N-channel, logic-level MOSFET which my invention uses as a low- side, high-current, low on-resistance power switch.
  • the source of the N- channel MOSFET is connected to the negative terminal of battery 702 (ground). The following formula is used to calculate voltage drop across a DC motor:
  • V(neg terminal) EMF(forward) - EMF(backward) - (I(motor) * R(motor))
  • V(neg terminal) EMF(forward)
  • Forward EMF is simply the voltage applied to a motor from a battery.
  • the voltage at the negative terminal is the same as the voltage at the positive terminal if a motor has stalled.
  • the present invention monitors the voltages at each motor terminal and when they are nearly equal, the controller 225 immediately cuts power to motor 704 to prevent high current from flowing through motor 704.
  • a threshold value defines when the voltages are nearly equal, and can be changed by the user.
  • the present invention may also utilize a temperature sensor to monitor the temperature of controller 225.
  • the temperature sensor is integrated into the microcontroller, but it may be a separate component. If the controller is mounted on or near the motor, then it can also monitor the motor temperature. If the temperature rises above a preset threshold, then the controller will stop the motor and enter a low power mode until the temperature drops below a lower threshold and a specified cool-down time period has elapsed. If the temperature is above the threshold and the user closes the trigger switch, then the controller will prevent the motor from starting so that both the motor and controller have the opportunity to cool and recover. Because many AEG housings are constructed of thermoplastics, limiting the temperature to a threshold below the melting point of these thermoplastics protects the integrity of the structural and decorative components. The temperature threshold can also be changed.
  • the present permits use of an optional sensor or switch to determine motor, gear, or actuator position.
  • the sensor may be necessary if the piston or projectile loader must start and stop in a position other than the default, forward resting position.
  • the installer can specify whether a sensor or switch is active high or active low, so a variety of switches and optical, magneto-resistive, and Hall-effect sensors can be used with the controller.
  • the controller provides a regulated, low- voltage supply for sensors and other optional components that require an external supply.
  • the controller detects a level change on the sensor input to the microcontroller. Like the trigger switch input, the sensor input is filtered by the microcontroller to reduce bounce and noise.
  • the controller will continue to detect changes and stop the motor when the shot index has reached the maximum index, or if the trigger was released during indexed or continuous fire, when the shot index is incremented. If the index is not reached in the expected amount of time while in indexed mode, the controller stops the motor to prevent runaway.
  • the maximum index and time limit can be changed using the trigger switch as described earlier.
  • the controller When the controller is in the timed/index mode and the trigger switch is held closed for a specified time period after the motor has stopped, the controller will advance to the next higher timeout and index value. Repeat the procedure to advance to the next timeout and index value. When the highest timeout and index value is reached, the controller reverts to the lowest timeout and index value.
  • the microcontroller enters a deep sleep state to conserve battery power. During sleep, battery consumption is far below that of the self-discharge rate of conventional rechargeable batteries.
  • the present invention may also be connected to a personal or handheld computer or serial terminal to configure its parameters at startup and to update the firmware.
  • Examples of possible interfaces include: RS-232, SPI, TWI, OWI, or USB.
  • the motor and battery characteristics can be configured before the controller is installed into a gun, or the controller can be removed in the field, configured, and replaced.
  • Timed, indexed, or continuous run modes; PWM on/off; timed/index cutoff; low voltage cutoff; baseline duty cycle; high temperature threshold; motor braking on/off; stall cutoff point; sensor active high/low; and all other aspects of the controller can be configured through the interface.
  • the trigger and sensor input pins are used as a bidirectional interface.
  • the controller detects whether it is connected to a host if the battery is disconnected and no voltage is detected at both motor terminals. Power is supplied through the programming module/cable, for example, 5V through a bus- powered USB interface or from another external, regulated 5 V supply. If a microcontroller having more I/O pins is substituted, those additional pins can be used as a dedicated interface (for example, for an external port on the gun housing) or to specify entry into configuration mode. Once in configuration mode, the user can send commands via the connected host to configure the various aspects of controller behavior, to view controller status, and to diagnose controller operation.
  • Power is supplied through the programming module/cable, for example, 5V through a bus- powered USB interface or from another external, regulated 5 V supply. If a microcontroller having more I/O pins is substituted, those additional pins can be used as a dedicated interface (for example, for an external port on the gun housing) or to specify entry into configuration mode. Once in configuration mode, the user can send commands via the connected host to configure the various aspects
  • FIGS. 7 and 8 illustrate the typical AEG wiring diagram on top.
  • FIG. 8 represents a wiring diagram of electronic motor controller (EMC) installed in the hard-wired configuration. Again, the illustration shows the typical AEG wiring diagram on top. For a retrofit, hard- wired installation of an EMC into an AEG, the following steps are recommended:
  • the EMC switch/sensor input is 5V active low by default. That is, the switch or sensor must pull the input low to ground to signal full auto fire or the end of the firing cycle has been reached, respectively.
  • the actual voltage depends on the regulator used.
  • the EMC operates in burst mode with a minimum timed burst or a minimum fixed number of shots if the sensor or back-EMF counting is enabled.
  • the selector switch With the selector switch in the semi-auto position, the AEG fires a single shot with each pull of the trigger, as before the installation.
  • the selector switch in the full auto position the AEG will fire a burst of shots up to the minimum burst period, or up to the minimum burst count if a sensor is installed, with each pull of the trigger.
  • the user can change the maximum burst time within the full range of available times or within the full range of shot counts if a sensor is used. In burst mode, continue to hold the trigger for 3 seconds (or another user-specified timeout period) after a burst is fired.
  • the EMC will increase the burst time by 0.1 seconds (or another user- specified timeout period), or if a sensor is installed, by 1 shot. To increment the burst time by another 0.1 seconds or another 1 round, fire another burst and hold the trigger for 3 seconds.
  • the EMC exceeds the maximum burst time or the maximum burst count, it will revert back to time minimum time and count. Repeat until the desired burst time or shot count is reached.
  • the selected burst time and shot count are retained in EEPROM memory even if you remove and replace the battery.
  • the microcontroller is programmed with firmware before the controller is assembled.
  • the firmware resides in non- volatile flash memory within the microcontroller and is protected from viewing and modification using development tools from the microcontroller manufacturer.
  • the firmware may contain a method for the user to update the microcontroller with new firmware through the programming module/cable.
  • the ATtiny85 microcontroller can run at a maximum system clock speed of 16MHz using the PLL clock. From the system clock, the firmware instructs the microcontroller to generate a PWM clock frequency and a timer clock frequency.
  • Various clock frequencies can be used depending on the type of motor and MOSFET used to maximize torque and efficiency.
  • alternative brands and types of microcontrollers can also be substituted so long as they have similar size, power requirements, and hardware capabilities.
  • FIGS. 11-13 there are two loops in the example embodiment firmware: the main loop and the firing loop.
  • the firing loop is nested within the main loop.
  • Point A is the entry into the main loop.
  • the controller waits for the trigger, releases the brake, starts the motor, goes into the nested loop to monitor the trigger and firing.
  • the controller shuts off the motor, applies the brake, looks at the trigger to see if the trigger is held, and repeats the loop at point A.
  • Point B marks the exit from the firing loop. The steps following the exit lie within the main loop.
  • Controller initialization and configuration is addressed by FIG. 11.
  • PWM pin OCOB is configured as the motor low- side switch output control and PWM pin OCOA is configured as the brake output control. Unused features are shut off for power savings and input pin pull-up resistors are enabled.
  • all configurable parameters of the controller such as fire mode, index mode, sensor active state, burst count limit, PWM enable, soft start enable, stall detection enable, and low voltage threshold are loaded from non- volatile EEPROM.
  • a delay of up to several seconds can be employed to test for trigger pull and interface connected. In one particular embodiment, no delay is specified to minimize controller start-up delay.
  • the operator must disconnect the battery and restart the controller for the new settings to take effect. This is a safety feature to prevent accidental AEG firing.
  • the computer interface is enabled.
  • an interrupt-driven software RS-232 interface is implemented that allows communications at 4800 baud, 8 bits, no parity, 1 stop bit through the RS-232 or USB port of a PC.
  • the PCINTO interrupt is used to detect a low status on the RX pin which indicates that data is ready to be sent from the host to the controller.
  • TIMERl is configured to transmit and received bits at the specified rate and stop bits.
  • the battery is tested for being above a high and below a low voltage threshold. High voltages can damage electronic components and the motor. If the voltage is out of range, the controller becomes inactive until the battery is replaced with one having suitable voltage. Likewise, the temperature is also tested for being above or below certain thresholds. At lower temperatures, lubricant can become much more viscous and hinder mechanical operation. In one particular embodiment, the battery range is 6-15V and the temperature is 0-80C.
  • the battery readings at blocks 1145, 1175, and 1242 are averaged over 8 ADC samples to filter noise. Furthermore, the averaged result is stored in a 8-value circular buffer and a running average of the buffer values is calculated. This provides for a smoother, more predictable battery discharge curve for use in analysis by the controller. Smaller or larger buffers or sample sizes can be used.
  • the controller does not sleep if it is installed using the plug-in method at the expense of higher power consumption. This is necessary since the presence of voltage at the motor terminal is used to signal firing rather than the trigger input pin.
  • FIG. 12 represents the main firing loop.
  • the trigger is released and a single complete motor cycle has not been detected, stop firing immediately. This behavior is required in a situation where the piston is fully retracted and on the brink of release.
  • the factory switch cut-off lever actuates before the controller can analyze enough back-EMF data points to determine whether a shot was fired.
  • a timer cuts power to the motor if no back-EMF activity is detected. This is a safety feature to prevent runaway firing if the trigger is released and no activity is detected causing the motor to continue running.
  • full auto fire is interrupted only immediately after piston release is detected or if the shot timer runs out in block 1218.
  • the motor is allowed to continue to run.
  • the TOIEl flag is checked to see if the interrupt is still enabled.
  • the interrupt handler compares OCRlA (current duty cycle 0-255) against the target duty cycle and if OCRlA is smaller, increments OCRlA. Once the duty cycle is equal to the target, the interrupt is disabled. IfPWM is configured as disabled, PWM is stopped and then the motor is turned on fully. If PWM is configured as enabled and an alternate PWM rate is configured, then once the target duty cycle is reached, the PWM rate is switched to the alternate rate. In one particular embodiment, a higher PWM rate of 3906.25Hz is used to start the motor turning, then once it is spining, a PWM rate of 976.56Hz is selected.
  • blocks 1230 through 1248 are placed in an
  • ADC interrupt handler for sampling at more regular intervals during the firing cycle. Just before the motor firing loop, the ADC is put in a timer-driven or free-running mode and the interrupt handler is executed whenever ADC sampling is complete. Immediately after execution of the handler, the ADC automatically samples at the next interval. The intervals can be timed with PWM frequency to sample whenever there is either an on or off pulse sent to the motor switch.
  • target duty cycle is analyzed and compared to battery voltage.
  • motor performance is only evaluated after each firing cycle. Motor performance cannot be evaluated within the cycle because changes to the PWM duty cycle affect back-EMF analysis and detection of cusps in the voltage curve corresponding to piston release.
  • FIG. 13 represents the timer, sensor shot counter, and filter interrupt handler.
  • the value used to test the sensor input buffer can be one of three values depending on the input configuration chosen. The value is ObIOOOOOOO if an active-high sensor is installed and configured, ObOl 111111 if an active-low sensor is installed and configured, and ObOOOOOOOO if the sensor input is used as a burst/full selector switch input. If configured as a selector switch, a step is executed before block 1203 to determine the state of the switch and the set the corresponding burst or full-auto mode.
  • FIG. 14 represents sample output from the controller during configuration mode.
  • the output can be viewed using a host terminal program such as HyperTerminal in Microsoft Windows XP configured at 4800 baud, 8 bits, no parity, and 1 stop bit.
  • the USB module/cable is connected to the controller and the entire assembly plugged into a USB port.
  • the operator presses the ? key to display the menu from the controller.
  • the controller redisplays the menu showing the newly-changed parameter.
  • exit the host terminal program unplug the assembly from the USB port, and disconnect the USB module/cable.
  • the microcontroller executes the external interrupt handler (for INTO).
  • the handler disables sleep mode and disables the external interrupt from triggering again so that the handler is not repeatedly executed as the user continues to hold the trigger switch closed.
  • Firmware execution continues from after the point of entering sleep mode.
  • an overflow interrupt handler for the PWM timer increments the PWM duty cycle from the initial value until it has reached the target duty cycle.
  • the firmware disables the overflow interrupt to stop further incrementing the duty cycle.
  • the motor terminal voltages are analyzed for sudden speed increases and load decreases that indicate piston release.
  • the changes in ADC voltage differential readings from both motor terminals are sampled and averaged in order to filter motor brush noise.
  • the samples are stored in a circular buffer and averaged. As the motor compresses the spring, back-EMF voltage decreases. When the piston is released, back-EMF will suddenly increase.
  • the state of back-EMF changes is stored in another 8-bit circular buffer.
  • the state of back-EMF changes is stored in another 8-bit circular buffer.
  • the motor is approaching stall and the controller stops the motor immediately.
  • the left 4 bits are decreasing and the right 4 bits are increasing, a sudden directional change in back-EMF has occurred and indicates that the piston was released.
  • These changes in back-EMF rate can be counted in order to implement indexed burst and continuous fire modes. This method of shot counting is optional and must be carefully tuned to motor, gear, and spring characteristics.
  • the buffer length and the number of bits sampled can be increased or decreased to adapt to a variety of motors and microcontrollers.
  • the battery voltage and temperature are checked to see if they are within the operating threshold. If not, or if the motor has stalled, the controller enters a sleep state for a specified time period in order to let the controller and motor cool. If the battery voltage is out of range, the controller enters a sleep state until the battery is replaced.
  • a lower temperature threshold can be specified so that the controller must reach this temperature before it wakes and enables firing again.
  • the hysteresis range is adjustable and allows for longer firing periods between over- temperature and stall conditions. It also helps the user distinguish between controller failure and when it is actively protecting itself, the motor, and the battery.
  • the 62.5Khz timer is configured to interrupt 244 times per second, so after the shot time counter is incremented 244 times, the firmware increments the seconds counter and resets the shot time counter. Other timer frequencies can also be used but the shot time counter limit must be adjusted accordingly for accurate timing. [0088] Most automatic firearms fire the full string of timed or indexed mode shots within one second in order to provide the user with better control of recoil and minimize waste of ammunition when recoil has shifted the weapon out of alignment with the intended target.
  • the overflow handler also left shifts the current trigger and sensor pin states into two 8-bit circular buffers. Since the pull-up resistor on the trigger input pin is enabled and closing the trigger switch shorts the pin to ground, the firmware specifies that the trigger switch is closed only when all eight bits in the trigger state buffer are zero. Any switch bounce that occurs during the initial switch closure is ignored. Likewise, the firmware specifies that the trigger switch is open only when all eight bits in the buffer are one. The buffer length and the number of bits sampled can be increased or decreased to adapt to a variety of switches and switch quality.
  • the firmware checks the sensor state buffer for a leftmost one bit followed by seven zeros for an active high switch or sensor, and a leftmost zero bit followed by seven ones for an active low switch or sensor. Thus, the firmware checks for the trailing level change after the switch or sensor is triggered. When it detects a change, the shot index is incremented and a longer timeout threshold is set that is appropriate for indexed mode. If the shot index exceeds the threshold for indexed mode, then the firmware signals for motor rotation to stop. Again, the buffer length and number of bits sampled can be increased or decreased.
  • the controller checks the shot index count to see if it has been incremented by the sensor filter or through back-EMF sensing. An index greater than one indicates that a sensor is installed or back-EMF changes are detectable, and that a single shot was fired but not in semi-automatic mode. If a sensor is installed or back-EMF is active and the controller is in indexed mode, then the motor will continue to rotate until the next index or the timeout period is reached. The controller then turns off the motor. If a sensor is not installed or back-EMF changes are not detected, then the controller stops the motor as soon as the trigger switch is opened. [0092] Once the motor has stopped and the controller turns off the N-channel
  • the controller turns on the P-channel MOSFET to brake the motor and send generated voltage and current back to the positive terminal of the battery.
  • the P- channel MOSFET is driven by a small N-channel MOSFET which provides adequate gate voltage to the larger MOSFET.
  • the gates have pull-up resistors to ensure that the brake is still applied when the microcontroller enters its sleep state.
  • the two large MOSFETs form a half H-bridge.
  • the low-voltage, low-current trigger switch can operate at other low voltages as long as they are higher than the gate threshold voltage of the low- side MOSFET used in the H-bridge.
  • Logic-level MOSFETs with sufficient high-voltage and high-current capabilities to drive a motor but with equivalent or lower gate threshold voltages can be substituted.
  • a different voltage regulator can be substituted that provides higher current capability for driving external components and accessories.
  • the reverse battery protection MOSFET can be disabled or omitted if protection is not needed and/or space for the controller is limited.
  • a FET bridge can be added in place of the reverse battery protection MOSFET to allow Airsoft batteries of any polarity configuration to be used.
  • the AEG motor will always be driven in the correct direction and there is no risk of damaging the controller, motor, or gears.
  • Other embodiments include higher current and power handling MOSFETs with similar or different packages can be substituted for motor, brake, and reverse battery protection MOSFETs to create a heavy-duty controller.
  • a corresponding change to the circuit board layout may be required to accommodate packages other than SOIC-8 and LFPAK.
  • the motor speed regulation can be disabled or omitted if the MOSFETs cannot dissipate the heat generated by PWM switching and/or space for the controller is limited.
  • the motor switch PWM frequency can also be changed to reduce MOSFET heating and adjust efficiency.
  • ADC sampling of motor voltages could be performed when a timer compare match interrupt has occurred.
  • the ADC sampling occurs whenever the PWM output pin for the low-side motor switch has been high for some time, that is, when the voltage pulse applied to the motor has stabilized at a high level.
  • the motor brake can be disabled or omitted to make the controller smaller if the braking and regeneration functions are not needed, or if the MOSFET and/or fly-back diode cannot dissipate the heat generated by braking.
  • a different microcontroller with equivalent or greater features, speed, and capabilities can be substituted.
  • a microcontroller with more I/O pins can be used to provide a dedicated serial interface allowing the controller to be permanently installed in an AEG while still allowing the user to configure its parameters. The controller's status can then be viewed and parameters changed in real time as the gun operates.
  • the pins can be used to select configuration mode or set some application-specific parameter.
  • MOSFET gate and half H-bridge driver ICs can be used to further prevent both MOSFETs from conducting simultaneously. These ICs may be more costly and require more circuit board space. Some ICs feature dead time generators and additional overload and over-temperature protection. Some may even allow a lower-cost. N-channel MOSFET to be used for braking.
  • the overload and thermal protection devices and their firmware routines can be removed, resulting in less or no protection and less space requirement for the controller. Protection may be unnecessary in cases where a light load is driven such as if the motor and gearing capabilities far exceed the load that it drives or if the piston is driven by a lighter spring.
  • An optional external switch can be added allowing more convenient selection between timed/indexed and continuous run modes. The switch shorts the S+ input to ground and can be enabled using the serial interface.
  • a switch can also be added to the positive battery lead to simulate battery disconnection and reconnection in order to ease mode changes using the mode change procedure described earlier.
  • the switch can also be used as a master power switch to prevent excessive battery drain.
  • serial interface, firmware upgrade, and their associated firmware routines can be omitted if configurability and updating are not needed.
  • firmware monitoring of the ADC channels during the firing cycle can be interrupt-driven and removed from the main firing loop.
  • the microcontroller's ADC unit can be placed into a timer driven interrupt mode or into a free-running mode so that voltage readings are taken at preset times or continuously. For example, it could be synchronized with the motor PWM cycle. This method provides greater accuracy from more frequent and regular samplings. Where this monitoring is utilized, it may be advantageous to utilize a microcontroller with storage capabilities exceeding that of the ATtiny 85.
  • Braking intensity can be reduced or modulated using PWM.
  • the H-bridge can be configured for PWM so that both MOSFETs are switched in an alternating fashion allowing conventional back-EMF measurements to be made during the firing cycle.
  • the present invention could also be installed in other motor-driven, projectile-firing, recreational guns, including but not limited to paintball, pellet, and metallic BB guns.
  • the controller can also be used in hybrid guns, such as gas-electric guns that use one or more electric motors to actuate loading and gas valves, and a pressurized gas to propel the projectile.
  • the controller can also trigger ignition components if the gun uses a combustible liquid or gas fuel to propel the projectile.
  • TVS transient voltage suppressors
  • snubber circuits instead of diodes, can be used to absorb motor voltage spikes.
  • Additional transient protection may be required on the battery terminals of the invention to prevent MOSFET damage and microcontroller glitches due to spikes.
  • a single SPDT relay instead of using separate MOSFETs to switch and brake the motor, a single SPDT relay can be used.
  • the Panasonic/NAIS CPl- 12V "1 Form C" relay (component Rl in the diagram) is an example of a compact 12V automotive relay that can be used to replace the two TO-220 sized MOSFETs while still providing high-current-switching capabilities.
  • Either the CP1-12V or the CP1A-12V surface mount relay can be mounted to the circuit board.
  • PWM can no longer be used to modulate motor speed and braking, PWM can still be employed to reduce coil power consumption after the relay is initially switched on.
  • a common, low-cost transistor is used to switch the coil.
  • a TVS is installed on the relay coil to protect the transistor.
  • the contact resistance of the relay is often less than the on resistance of the MOSFETs, and when combined with the coil power dissipation, the overall power dissipation of the relay is still less than that of the MOSFETs. Relays can be more rugged, less static sensitive, and more cost effective than MOSFETs. Unlike MOSFETs that have built-in diodes, relays are not prone to damage when the battery polarity is reversed or when the terminals are handled. The polarity protection MOSFET can thus be omitted. The motor negative terminal voltage sensing circuit was also omitted to save board space. The parts reduction offers additional cost savings during production. [0107] By using an SPDT relay, the braking function is automatically applied whenever the relay coil is deenergized. No additional control is required from the microcontroller and the extra pin can remain disconnected or can be used for other functions.
  • the electronic control circuitry can optionally be separated and operated remotely from the relay switching circuitry.
  • the circuit board layouts below show where the invention can be separated into two smaller modules. Separation allows this invention to be fitted to AEGs that have limited internal space and cannot accommodate the larger module. It also provides the option of no microprocessor control in applications where burst fire is not needed but trigger reliability and longevity are.
  • the TVS devices on the relay coil and motor terminals reduce contact sparking and prolong switch and relay life.
  • an STMicroelectronics SMA6J18CA Transil SMA device rated at 600W and 18V is installed across the relay coil, and a Diodes Incorporated 1.5KE24CA DO-201 device rated at 1500W and 24V is installed across the motor terminals. They are bidirectional devices to prevent damage due to accidental battery polarity reversal. Since less power is consumed by the relay than the MOSFETs, the temperature sensing function of the microcontroller is less critical to reliable operation of the switching. The microcontroller can still be located in proximity to the motor for motor temperature sensing.
  • a Littlefuse 897 Low Profile MINI fuse and Keystone 3557 fuse clips are used to further reduce space requirements. These components can be installed on all versions of this invention.
  • the fuse and clips are installed vertically next to the relay so that the top of the fuse is at the same height as the top of the relay and the overall length of the controller is reduced when compared to a horizontally- positioned fuse.
  • the microcontroller is placed in a low-power sleep state, idle power consumption by the relay-based invention can be eliminated entirely by placing the regulator and the battery voltage sensing circuit behind the trigger switch.
  • the software algorithm must be changed so that the accidental discharge safety feature and power-on configuration are disabled, and the trigger input is ignored and the motor started immediately. Other unused features can be disabled in the firmware configuration. The simpler mode of operation is more appropriate for a cost-cut product.
  • the present invention includes a method of providing consistent motor drive.
  • This method comprises: providing a microcontroller having a first analog-to-digital converter channel and a second analog-to-digital converter channel, said microcontroller having an integrated temperature sensor.
  • the method next provides a resistor divider capable of producing an output voltage, and measuring an initial output voltage value of a power source derived through said resistor divider connected to said analog-to digital channel.
  • the method calculates a target pulsed-width-modulation duty cycle based upon said voltage value of said power source, and starts a pulsed- width- modulation duty cycle at a predetermined starting value, and actuating a motor where said output voltage value is greater than a predetermined depletion value.
  • the method measures for a voltage stall detection value of the negative terminal of said motor, derived through said second analog-to-digital channel after said target duty cycle is reached.
  • the method measures a temperature value.
  • the pulsed-width-modulation duty cycle is increased at a preset ramp value.
  • the method re-measures a subsequent battery voltage value derived through said first analog-to-digital channel just prior to each motor actuation.
  • the duty cycle is adjusted based upon the subsequent battery voltage value derived through said first analog-to-digital channel.
  • the motor is stopped where said re- measured subsequent battery voltage value derived through said first analog-to-digital channel is less than a predetermined depletion value.
  • Power to said motor is interrupted where the difference between said measured negative terminal voltage stall detection value and said power source voltage value is less than a predetermined imminent stall threshold value.
  • the motor is stopped where measured temperature value exceeds a temperature threshold value.

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Abstract

La présente invention concerne un dispositif de commande de moteur et un procédé destiné à fournir une commande de moteur présentant un commutateur anti-rebond de microcontrôleur qui peut fonctionner comme une interface utilisateur permettant de sélectionner différents modes de fonctionnement. Le dispositif de commande de moteur présente un moyen pour détecter un arrêt du moteur et pour fournir une performance de moteur constante indépendante de la tension d'alimentation. Des modes de réalisation comportent un moyen de protection de polarité utilisant un commutateur MOSTEC à bas potentiel, un moyen de protection de surintensité, un moyen de protection de haute et basse tensions, un moyens de protection de haute et basse températures, et un pont en demi-H MOSTEC pour fournir commande et freinage. D'autres modes de réalisation utilisent un relais. Des modes de réalisation du dispositif de commande de moteur comportent un moyen de détection de charge mesurant la force contre-électromotrice et comportant un moyen de temporisation pour couper le moteur et empêcher le moteur de s'emballer. La présente invention concerne également un procédé destiné à pourvoir des lanceurs automatiques d'un dispositif de commande de moteur.
PCT/US2008/068266 2007-06-28 2008-06-26 Dispositif de commande électronique de moteur et procédé de commande d'un moteur Ceased WO2009006172A2 (fr)

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US8723464B2 (en) 2011-05-24 2014-05-13 Regal Beloit America, Inc. Permanent magnet motor system
WO2014142605A1 (fr) * 2013-03-15 2014-09-18 Song Soo-Min Dispositif de commande pour pistolet airsoft électrique
CN109365535A (zh) * 2018-11-20 2019-02-22 湖北新冶钢特种钢管有限公司 一种顶管机齿条电气控制保护电路及其保护方法
CN114167433A (zh) * 2021-12-06 2022-03-11 中煤科工集团沈阳研究院有限公司 一种激光雷达续流保护结构及其电机本安性能的检测方法
EP4414652A1 (fr) 2023-02-07 2024-08-14 GF Corp Spolka z Ograniczona Odpowiedzialnoscia Spolka Komandytowa Procédé de commande d'un moteur d'un dispositif de propulsion de projectile électrique, contrôleur pour un dispositif de propulsion de projectile électrique
CN119445782A (zh) * 2024-11-04 2025-02-14 广州市微眸医疗器械有限公司 一种手术机器人的警报处理方法、装置及电子设备
DE102023213060A1 (de) * 2023-12-20 2025-06-26 Volkswagen Aktiengesellschaft Traktionsnetz und Mikroprozessor

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JPH0374189A (ja) * 1989-08-14 1991-03-28 Nec Corp モータ制御ｉｃの駆動回路
JP2001169552A (ja) * 1999-12-08 2001-06-22 Sony Corp 電子機器の電源装置
JP2006300464A (ja) * 2005-04-22 2006-11-02 Tokyo Marui:Kk 電動ガン

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8723464B2 (en) 2011-05-24 2014-05-13 Regal Beloit America, Inc. Permanent magnet motor system
WO2014142605A1 (fr) * 2013-03-15 2014-09-18 Song Soo-Min Dispositif de commande pour pistolet airsoft électrique
KR101492158B1 (ko) * 2013-03-15 2015-02-10 송수민 전동건 제어 장치
CN109365535A (zh) * 2018-11-20 2019-02-22 湖北新冶钢特种钢管有限公司 一种顶管机齿条电气控制保护电路及其保护方法
CN109365535B (zh) * 2018-11-20 2024-06-04 大冶特殊钢有限公司 一种顶管机齿条电气控制保护电路及其保护方法
CN114167433A (zh) * 2021-12-06 2022-03-11 中煤科工集团沈阳研究院有限公司 一种激光雷达续流保护结构及其电机本安性能的检测方法
EP4414652A1 (fr) 2023-02-07 2024-08-14 GF Corp Spolka z Ograniczona Odpowiedzialnoscia Spolka Komandytowa Procédé de commande d'un moteur d'un dispositif de propulsion de projectile électrique, contrôleur pour un dispositif de propulsion de projectile électrique
DE102023213060A1 (de) * 2023-12-20 2025-06-26 Volkswagen Aktiengesellschaft Traktionsnetz und Mikroprozessor
CN119445782A (zh) * 2024-11-04 2025-02-14 广州市微眸医疗器械有限公司 一种手术机器人的警报处理方法、装置及电子设备

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