How to handle the Reverse EMF (Regeneration)

How to handle the Reverse EMF (Regeneration)

In a modern industrial environment, industrial automation covers all aspects of the production process, from the handling of raw materials, the control of production equipment, the optimization of production processes, to the inspection and packaging of product quality. Automation can be achieved through a variety of automatic control systems, sensors, actuators, and computers to increase productivity and consistency, and reduce human error.

Under more and more industrial applications, it will also encounter a variety of phenomena and problems. For example, when applying DC stepper motor, there may be manual adjustment of the motor position, motor rotation to generate reverse EMF, reverse power to the controller, or in the application of vertical load, sudden automatic drop to produce spike current, or because of the linkage shaft relationship, linkage operation of the motor rotation and the phenomenon of reverse power generation, especially in the case of the motor with reducer, the instantaneous speed is high, the electromotive force or peak voltage generated may cause irreversible damage to the controller or power supply.

In response to this situation, the reverse power generation protection module (regeneration clamp) developed by our company can be effectively handled. First of all, let's verify the DC stepper motor reverse power generation just mentioned.

 
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Using synchronous wheels, connect the motor shafts of two 86 motors, and let the No. 1 motor drive the No. 2 motor to rotate. At the same time, let the No. 2 motor also connect to the No. 2 controller normally, but do not need to power up the No. 2 controller, through the test we found that when rotating the No. 1 motor, the No. 2 motor will also rotate, gradually increase the operating speed of the No. 1 motor, stabilize the speed for 1 minute, and check the positive and negative voltage values of the No. 2 controller with a multimeter. It was found that it was indeed possible to detect the voltage values of the positive and negative terminals of controller No. 2. And the voltage value changes linearly with the change of speed within a certain range.

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From the data, it can be seen that when the speed of the motor reaches 600RPM, the voltage value of the reverse power generation reaches 60V, which has exceeded the withstand voltage range of the controller protection diode, and the inspection found that the power circuit of the controller was damaged, and the MCU and DC-DC were also abnormal. It shows that when the motor shaft rotates, it will generate reverse power due to magnetic field cutting, and when the reverse power generation reaches a certain voltage value, it will cause irreversible damage to the controller or power supply.

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Replace the controller that has been damaged, and as if the connection method was just now, add a reverse power protection module to the power interface and the middle of the power line of controller No. 2 separately, and there is no need to turn on the power supply. Use the No. 1 motor to drive the No. 2 motor to rotate. Gradually increase the running speed of the No. 1 motor, stabilize the speed for 1 minute, and check the positive and negative voltage values of the No. 2 controller with a multimeter.

This test also detected that there are voltage values on the positive and negative poles of controller No. 2. And the voltage value changes linearly with the change of speed within a certain range.

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  The data shows that when the Regeneration clamp module is added, at the same speed, the size of the positive and negative voltage voltage values of the No. 2 motor has decreased significantly compared with before the protection module is added. The voltage value at 600RPM is only 40V, which is within the withstand voltage range of the controller. Besides, the test is to run at a stable speed of 1 minute, which will be better for the peak voltage. And there are different power options for different field conditions. If you are interested, you can learn about the situation on the official website of PUSIROBOT.

https://en.pusirobot.com/
 
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