Project Overview
This project is designed to automate gas pipeline welding using a BLDC motor control system. The system operates at 200 Watts, with a power input of 24V, and a peak current of 5A (running current: 2A). It uses an STM32F407G microcontroller to control motor operations, while a TI DRV808 driver IC manages power delivery to the motor. The primary objective is to control velocity and position, allowing the motor to run at precise RPMs and move to specific positions (e.g., 100 RPM to travel 100mm). The control commands are sent via Ethernet using an Android mobile app, providing a remote and convenient interface.
Technical Description
Hardware Arrangement: Two-Board Solution
1. Motherboard (Digital Control Board)
- Microcontroller (STM32F407G): This board serves as the brain of the system, managing motor control algorithms, feedback processing, and communication.
- Ethernet Interface: The motherboard integrates an Ethernet communication module, allowing the system to receive commands from the Android app and send motor status updates.
- Firmware: The STM32 runs custom firmware that handles real-time motor control using feedback from sensors (e.g., encoders). The firmware is responsible for interpreting remote commands to adjust motor speed and position.
- Sensors/Encoders: These provide real-time feedback for both velocity and position control. The system constantly adjusts motor behavior based on this feedback.
The motherboard separates the digital logic and manages motor control, ensuring precision and minimizing interference.
2. Power Board
- Motor Driver IC (TI DRV808): This IC manages the motor's power requirements, controlling current flow to maintain efficient operation. The driver can handle peak currents of 5A and is optimized for the 200W BLDC motor at 24V.
- Power Management: The power board is designed to deliver clean, stable power to the motor, ensuring protection against overcurrent, under-voltage, and thermal issues. It also includes appropriate protection circuits.
The power board manages and regulates power, ensuring efficient motor operation with necessary protections in place.
Design Approach
1. Hardware
- The system employs a two-board setup where the motherboard handles digital control and communication, while the power board manages the motor driver and power circuits.
- BLDC motor is driven through the TI DRV808 driver IC with feedback mechanisms like encoders for precise velocity and position control.
2. Firmware
- The STM32F407G firmware implements real-time control algorithms (like PID) for accurate speed and position adjustments based on user inputs from the app.
- Communication between the app and the system is handled through Ethernet, providing fast and reliable data transfer.
3. Mobile Application
- The Android Studio-developed app allows users to control and monitor the motor remotely, providing an intuitive interface for setting motor speed and position.
- The app enhances the system’s flexibility, enabling operators to manage the welding automation process from their smartphones, reducing setup times and improving workflow efficiency.
This solution offers a comprehensive and modular design that integrates efficient motor control with an easy-to-use mobile interface, streamlining the automation process for gas pipeline welding applications.
