Design a universal motor control circuit that can operate any 3 or 4-wire AC 220V servo motor with an encoder for position feedback. The system should include a custom encoder, motor driver, and microcontroller, ensuring compatibility with various motor types. Key Design Features: A custom encoder will provide high-resolution position feedback using optical or magnetic-based encoder technology, depending on precision and cost requirements. The encoder feedback will determine motor position (up/down stop positions) and provide real-time RPM data for speed control. A custom motor driver will handle 220V AC servo motors (3 or 4 wires) with features like PWM control for speed variation, direction control (clockwise and counterclockwise), soft start/stop to avoid sudden jerks, and overcurrent/overvoltage protection. The universal microcontroller circuit, using STM32, Arduino, or ESP32, will process encoder feedback for position control, generate PWM signals for speed and direction control, and manage user-defined settings via buttons or display interfaces. It will include GPIO for buttons (speed, direction, and stop position setup), PWM output for motor control, Serial/UART communication for debugging, and EEPROM/Flash memory for saving settings. The circuit will support various servo motor configurations: 3-wire motors (power, neutral, and control wire) and 4-wire motors (power and control wires). It will handle motors up to 2-3 kW with adjustable speed and direction settings. Workflow: In setup mode, users configure speed (0–4200 RPM), direction (clockwise or counterclockwise), and stop positions (manually set up/down positions and save them). In operation mode, the motor starts via a Hall sensor or external signal, gradually accelerates to the set speed, decelerates, and stops when the signal is removed, returning to the saved stop position. Encoder feedback ensures real-time position and speed adjustments for precision. Hardware Requirements: The system requires a custom magnetic (Hall-effect-based) or optical encoder, an H-bridge or TRIAC-based driver circuit (with components like MOSFETs, IGBTs, or TRIACs), a microcontroller (e.g., STM32, ESP32, or Arduino Mega), a 7-segment or LCD display for settings and status, and 4-5 push buttons for adjustments (Up, Down, Enter, Set, Start). A reliable power supply for both control electronics (5V or 3.3V) and motor (220V AC) is essential. Example Workflow: During the setup process, users set speed, direction, and stop positions via buttons and save the settings in memory. During operation, the motor starts using a Hall sensor or external command, accelerates to the configured speed, and stops/returns to the last saved position when the stop command is received. Encoder feedback ensures precise control throughout. Summary: This universal circuit ensures compatibility with various AC 220V servo motors by integrating custom components like an encoder and motor driver with a programmable microcontroller. The system provides precise, reliable, and flexible motor control for industrial and personal projects.
Button Functions:
The Set Button (Settings) opens the settings menu, allowing navigation from S1 to S20, and also serves as an exit from the settings menu to the Home Screen. The Enter Button confirms a selection, such as entering a menu or saving changes, and returns the display to either the settings menu or the Home Screen after saving. The Up Button moves up in the menu or increases values during adjustments, while the Down Button moves down in the menu or decreases values.
Settings Menu Workflow:
To access the Settings Menu, press the Set Button, which displays options from S1 to S20. Use the Up Button to navigate upward and the Down Button to navigate downward through the settings. To enter a setting, highlight it and press the Enter Button. For value adjustments, the Up Button increases values, and the Down Button decreases them. Pressing the Enter Button saves changes and returns to the settings menu. To return to the Home Screen, press the Set Button.
Settings Overview:
S1: Speed Setting – Adjusts motor speed from 0 to 4200 RPM.
S2: Rotation Direction – Configures motor direction: clockwise (dot visible) or counterclockwise (no dot).
S3: Stop Position Mode – Sets the motor's stop position to either Up or Down.
S4: Set First Stop Position (Up) – After pressing Enter, rotate the motor manually to the desired Up position, then press Enter to save.
S5: Set Second Stop Position (Down) – Press Enter, rotate the motor to the desired Down position, and press Enter to save.
Home Screen Functionality:
After setup, the Home Screen displays the current speed and rotation direction, with a dot indicator showing clockwise rotation.
Operation Workflow:
To start and control speed, place a magnet near the Hall Effect Sensor, which initiates the motor and gradually increases its speed until it reaches the maximum set in S1. To stop and return to the preset position, move the magnet away or stop the motor; it will decelerate until it stops and then return to the user-defined stop position (Up or Down). This setup ensures precise stop position control, with the motor consistently returning to the specified stop position when stopped.
Hardware Requirements:
The system includes a microcontroller to manage motor control, settings, and feedback; a driver circuit to power the 220V AC servo motor; a custom encoder for precise position feedback; a Hall Effect Sensor to adjust speed based on the magnet's proximity; a 7-segment display to show current settings such as speed and rotation; and push buttons for control—Set for accessing settings, Enter for saving settings and returning, and Up/Down for navigation and adjustments.
Summary for Workers:
During setup, use the buttons to configure the speed (up to 4200 RPM), define stop positions (Up and Down), and set the rotation direction. For operation, speed control starts the motor as the magnet approaches the sensor, with the motor reaching maximum speed at full alignment. When stopping, the motor decelerates and returns to the preset position. Controls include a 7-segment display for monitoring and buttons for settings and adjustments.
NOTE
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