A collection module and collection method of RS485 interface sensor

Abstract

The present invention relates to an acquisition module and an acquisition method of an RS485 interface sensor, which belongs to the field of industrial communication engineering and is applied to the structural safety and health monitoring industry. It includes a communication module, a multi-serial port microcontroller module, an isolated RS485 driver module, an interface protection module, a power management module, an isolated power module, a current sampling monitoring module, a data storage module, a power shunt module and an RS485 bus driver; the present invention solves the problems that RS485 network equipment in the current industry cannot remotely monitor the operating status, cannot be upgraded online, cannot self-diagnose, etc., realizes the intelligence of RS485 network equipment, improves the reliability and convenience of working RS485 on-site system integration, and has the ability to quickly locate faults with low maintenance costs.

Description

Technical Field

[0001] The invention relates to an acquisition module of an RS485 interface sensor and an acquisition method thereof, belongs to the field of industrial communication engineering, and is applied to the structural safety and health monitoring industry. Background Art

[0002] Prior art: Currently, RS485 sensor data collectors are being widely used in various industrial fields as industrial bus network equipment. RS485 sensor data collectors mainly optimize the network structure of RS485 bus, improve interface isolation, and thus improve the reliability of the entire network. The reliability of RS485 sensor data collectors plays a vital role in the stability and reliability of the entire system. If a certain RS485 sensor data collector in the network fails, the sensor data mounted on it will not be read, resulting in more serious consequences. At present, RS485 sensor data collectors are mostly stand-alone systems, that is, as a module with independent functions, such as only responsible for the logic control of the communication interface, transceiver control, channel expansion, etc., and cannot monitor the operating status and faults of the module in real time. When the module is abnormal, it cannot be restarted or reset remotely, and the system running firmware cannot be upgraded remotely, which is not conducive to the expansion and integration of module functions. Therefore, as a key network communication module in the industrial field, in addition to the reliability of the hardware, it is far from guaranteeing the reliable operation and maintenance of the entire system. At present, the fault operation status of the RS485 sensor data collector can only be observed on site through the status operation indicator light configured on the module. Personnel are required to go to the site to troubleshoot the fault, which indirectly increases the labor cost and fault resolution time. Summary of the invention

[0003] The present invention aims at solving the above-mentioned problems, and aims to solve the problem that the current RS485 sensor data collector cannot remotely monitor and control the module, and when a fault occurs, it is impossible to obtain the location and time of the fault, and personnel need to arrive at the site for investigation to locate the fault.

[0004] In order to achieve the above object, the present invention adopts the following technical scheme:

[0005] A collection module for RS485 interface sensors, comprising a communication module, a multi-serial port microcontroller module, an isolated RS485 driver module, an interface protection module, a power management module, an isolated power module, a current sampling monitoring module, a data storage module, a power shunt module and an RS485 bus driver;

[0006] The multi-serial port microcontroller module is respectively connected with the communication module, the current sampling monitoring module, the isolated RS485 driver module, the data storage module and the RS485 bus driver;

[0007] The communication module is connected to the power management module, and the power management module is respectively connected to the current sampling monitoring module and the isolation power supply module;

[0008] The isolated power module is connected to the power shunt module, the power shunt module is connected to the isolated RS485 driver module, and the isolated RS485 driver module is connected to the interface protection module.

[0009] Furthermore, the RS485 network host is connected to the RS485 type sensor via the RS485 cloud intelligent acquisition module;

[0010] The cloud monitoring platform communicates with the RS485 cloud intelligent acquisition module through the communication module.

[0011] Furthermore, the cloud monitoring platform is connected to the RS485 cloud intelligent acquisition module through a communication base station.

[0012] Furthermore, the multi-serial port microcontroller contains 5 serial ports, one of which is used as a main serial port for communicating with the RS485 bus, namely connected to the RS485 bus driver, and the other 4 serial ports are used as extended communication interfaces to connect to an external isolated RS485 driver module.

[0013] A collection method of the collection module of the RS485 interface sensor:

[0014] The communication module communicates with the multi-serial port microcontroller through the CMOS level serial port, sends the working status of the RS485 cloud intelligent acquisition module to the monitoring platform, and actively sends control commands, diagnostic information query commands, and system upgrade commands through the monitoring platform to remotely monitor and control the RS485 cloud intelligent acquisition module;

[0015] The multi-serial port microcontroller module has a microcontroller with multiple serial ports. The advantage of using a multi-serial port microcontroller is that the system can be upgraded and configured flexibly. In addition, the RS485 interface sensors of different protocol types mounted on the RS485 cloud intelligent acquisition module can be converted to unify communication protocols, reduce protocol conflicts, and indirectly improve network reliability.

[0016] The isolated RS485 driver module adopts an integrated isolation module;

[0017] The interface protection module is the anti-surge protection for the RS485 interface and the external power supply interface. The RS485 signal is a differential signal and adopts differential anti-surge protection. The external power supply adopts single-ended anti-surge protection. The anti-surge protection of the two interfaces adopts a two-level protection circuit. The first level adopts GDT and the second level adopts TVS tube after the decoupling device.

[0018] The power management module is responsible for providing energy to the communication module, multi-serial port MCU, isolated power supply and analog circuit, and converting the primary power provided by the external into the secondary power required by the system;

[0019] The isolated power supply module provides power to the RS485 type sensor;

[0020] The current sampling monitoring module monitors the current consumption of the external RS485 sensor load in real time. When an abnormality occurs, the RS485 cloud intelligent acquisition module can convert data through the analog-to-digital converter inside the current sampling monitoring module, and identify it through the microcontroller and convert it into a fault diagnosis message to send to the communication module;

[0021] The data storage module sends the data measured by the RS485 sensor to the RS485 bus. At the same time, the RS485 cloud intelligent acquisition module also makes a synchronous backup to avoid extreme situations. The RS485 cloud intelligent acquisition module can also automatically collect data according to the fault-tolerant mechanism configured by the system, temporarily replacing the role of the RS485 network host. After the RS485 bus returns to normal, the data in the data storage module will be sent to the host on the RS485 bus one by one. At the same time, the RS485 cloud intelligent acquisition module will also report abnormal faults of the RS485 bus to the cloud monitoring platform;

[0022] The power shunt module is used to divide the power provided by the isolation power module into multiple paths to provide to the external RS485 type sensor. Each path uses a separate self-recovery fuse and sampling resistor. In this way, when an external line fails, the faulty line will not affect the power supply of other lines. At the same time, this method can also reduce power modules, reduce costs and volume;

[0023] The RS485 bus driver is responsible for driving the RS485 signal on the RS485 bus side, mainly receiving commands from the RS485 network host and returning data packets from the collected RS485 sensors;

[0024] The RS485 network host is mainly responsible for sending data acquisition command frames and receiving data packets returned from sensors;

[0025] The main function of the cloud monitoring platform is to collect the diagnostic information reported by the RS485 cloud intelligent acquisition module and the operating status parameters of the RS485 cloud intelligent acquisition module in real time. At the same time, when the RS485 cloud intelligent acquisition module needs to be upgraded, the upgrade firmware is issued through the cloud monitoring platform to realize OTA remote online upgrade in the air and realize the intelligence of the RS485 cloud intelligent acquisition module.

[0026] Furthermore, the communication module adopts a built-in real-time clock type, which is set to a timed working and timed sleeping state to minimize the power consumption of the system.

[0027] Furthermore, the method for implementing the over-the-air online upgrade is as follows:

[0028] First, the internal Flash is 256Kb and the Flash is divided into two areas: boot area A, application area B, and backup area C;

[0029] The starting position of boot area A is 0x8000000, the ending address is 0x8006000, and it occupies 24Kb. The main function of the boot area is to download the upgrade file and write the upgrade file to the application area, which occupies 110KB. The backup area is used to store the issued upgrade file, which is 110KB in size.

[0030] The starting address of application area B is 0x8006000, occupying the remaining Flash size; the application area code implements the vibrating string collector function;

[0031] The upgrade process is:

[0032] a. After the device is powered on, it starts to execute from the boot area, reads the upgrade flag in the EEPROM in the boot area, and if it is determined to execute the upgrade process, it enters the boot area to execute the upgrade process; if it is determined not to upgrade, it executes the jump instruction and directly jumps to the application area to execute the code;

[0033] b. The application area code can accept upgrade instructions. When receiving the upgrade instruction, the EEPROM flag is written and then the device restarts;

[0034] c. After the device restarts, the boot program enters the upgrade process and sends the upgrade file to the backup area according to the protocol. After the upgrade is completed, the file is verified. If the acceptance is normal, the data in the backup area is copied to the application area. After the copy is completed, the upgrade mark in the EEPROM is cleared and the device restarts to execute the new firmware code; if the acceptance process fails or the verification fails, the backup area copy is not performed, and the upgrade mark in the EEPROM is cleared and restarted to continue executing the original firmware.

[0035] Beneficial effects of the present invention:

[0036] The patent of this invention solves the problems of RS485 network equipment (such as RS485 hub) in the current industry that cannot remotely monitor the operating status, cannot be upgraded online, and cannot self-diagnose. It realizes the intelligence of RS485 network equipment, improves the reliability and convenience of RS485 on-site system integration, and has the ability to low maintenance costs and quickly locate faults. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is a module connection block diagram of the present invention;

[0038] Figure 2 This is a schematic diagram of the network of the present invention;

[0039] Figure 3 This is a networking diagram of the entire monitoring system of the present invention;

[0040] Figure 4 This is a flowchart of the firmware upgrade program of the present invention. DETAILED DESCRIPTION

[0041] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments, and all other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making creative work are within the scope of protection of the present invention.

[0042] Embodiment 1:

[0043] A collection module for an RS485 interface sensor, comprising a communication module 1, a multi-serial port microcontroller module 2, an isolated RS485 driver module 3, an interface protection module 4, a power management module 5, an isolated power module 6, a current sampling monitoring module 7, a data storage module 8, a power shunt module 9 and an RS485 bus driver 10;

[0044] The multi-serial port microcontroller module 2 is respectively connected to the communication module 1, the current sampling monitoring module 7, the isolated RS485 driver module 3, the data storage module 8 and the RS485 bus driver 10;

[0045] The communication module 1 is connected to the power management module 5, and the power management module 5 is respectively connected to the current sampling monitoring module 7 and the isolation power supply module 6;

[0046] The isolated power supply module 6 is connected to the power shunt module 9 , the power shunt module 9 is connected to the isolated RS485 driver module 3 , and the isolated RS485 driver module 3 is connected to the interface protection module 4 .

[0047] The RS485 network host 13 is connected to the RS485 type sensor 12 via the RS485 cloud intelligent acquisition module 11;

[0048] The cloud monitoring platform 15 communicates with the RS485 cloud intelligent acquisition module 11 through the communication module 1 .

[0049] The cloud monitoring platform 15 is connected to the RS485 cloud intelligent acquisition module 11 through the communication base station 14 .

[0050] The multi-serial port microcontroller 2 has five serial ports, one of which is used as the main serial port for communicating with the RS485 bus, namely connected to the RS485 bus driver 10, and the other four serial ports are used as extended communication interfaces to connect to the external isolated RS485 driver module 3.

[0051] Example 2

[0052] A collection method of the collection module of the RS485 interface sensor:

[0053] The communication module 1 communicates with the multi-serial port microcontroller through the CMOS level serial port, sends the working status of the data RS485 cloud intelligent acquisition module to the monitoring platform, and actively sends control commands, diagnostic information query commands, and system upgrade commands through the monitoring platform to remotely monitor and control the RS485 cloud intelligent acquisition module;

[0054] The multi-serial port microcontroller module 2 has a microcontroller with multiple serial ports. The advantage of using a multi-serial port microcontroller is that the system can be upgraded and configured flexibly. In addition, the RS485 interface sensors of different protocol types mounted on the RS485 cloud intelligent acquisition module can be converted to unify communication protocols, reduce protocol conflicts, and indirectly improve network reliability.

[0055] The isolated RS485 driver module 3 adopts an integrated isolation module;

[0056] Interface protection module 4 is the anti-surge protection for RS485 interface and external power supply interface. RS485 signal is a differential signal, and adopts differential anti-surge protection. External power supply adopts single-ended anti-surge protection. Both interfaces adopt secondary protection circuit for anti-surge protection. The first stage adopts GDT and the second stage adopts TVS tube after decoupling device.

[0057] The power management module 5 is responsible for providing energy to the communication module, multi-serial port MCU, isolated power supply and analog circuit, and converting the primary power provided by the external into the secondary power required by the system;

[0058] The isolated power supply module 6 provides power to the RS485 type sensor;

[0059] The current sampling monitoring module 7 monitors the current consumption of the external RS485 sensor load in real time. When an abnormality occurs, the RS485 cloud intelligent acquisition module can convert data through the analog-to-digital converter inside the current sampling monitoring module, and identify it through the microcontroller and convert it into a fault diagnosis message and send it to the communication module;

[0060] The data storage module 8 sends the data measured by the RS485 sensor to the RS485 bus. At the same time, the RS485 cloud intelligent acquisition module 11 also makes a synchronous backup to avoid extreme cases. The RS485 cloud intelligent acquisition module can also automatically collect data according to the fault-tolerant mechanism configured by the system, temporarily replacing the role of the RS485 network host 13. After the RS485 bus returns to normal, the data in the data storage module is sent to the host on the RS485 bus one by one. At the same time, the RS485 cloud intelligent acquisition module also reports the abnormal fault of the RS485 bus to the cloud monitoring platform;

[0061] The power shunt module 9 is used to divide the power provided by the isolation power module 6 into multiple paths and provide them to the external RS485 type sensor. Each path uses a separate self-recovery fuse and sampling resistor. In this way, when an external line fails, the faulty line will not affect the power supply of other lines. At the same time, this method can also reduce power modules, reduce costs and volume;

[0062] The RS485 bus driver 10 is responsible for driving the RS485 signal on the RS485 bus side, mainly receiving commands from the RS485 network host 13 and returning data packets of the collected RS485 type sensors;

[0063] The RS485 network host 13 is mainly responsible for sending data acquisition command frames and receiving data packets returned from the sensors;

[0064] The cloud monitoring platform 15 mainly collects the diagnostic information reported by the RS485 cloud intelligent acquisition module and the operating status parameters of the RS485 cloud intelligent acquisition module in real time. At the same time, when the RS485 cloud intelligent acquisition module needs to be upgraded, the upgrade firmware is sent through the cloud monitoring platform to realize OTA remote online upgrade in the air, thereby realizing the intelligence of the RS485 cloud intelligent acquisition module.

[0065] The communication module 1 is of a built-in real-time clock type and is set to a timed working and timed sleeping state to minimize the power consumption of the system.

[0066] The method to achieve online upgrade over the air is as follows:

[0067] First, the internal Flash is 256Kb and the Flash is divided into two areas: boot area A, application area B, and backup area C;

[0068] The starting position of boot area A is 0x8000000, the ending address is 0x8006000, and it occupies 24Kb. The main function of the boot area is to download the upgrade file and write the upgrade file to the application area, which occupies 110KB. The backup area is used to store the issued upgrade file, which is 110KB in size.

[0069] The starting address of application area B is 0x8006000, occupying the remaining Flash size; the application area code implements the vibrating string collector function;

[0070] The upgrade process is:

[0071] a. After the device is powered on, it starts to execute from the boot area, reads the upgrade flag in the EEPROM in the boot area, and if it is determined to execute the upgrade process, it enters the boot area to execute the upgrade process; if it is determined not to upgrade, it executes the jump instruction and directly jumps to the application area to execute the code;

[0072] b. The application area code can accept upgrade instructions. When receiving the upgrade instruction, the EEPROM flag is written and then the device restarts;

[0073] c. After the device restarts, the boot program enters the upgrade process and sends the upgrade file to the backup area according to the protocol. After the upgrade is completed, the file is verified. If the acceptance is normal, the data in the backup area is copied to the application area. After the copy is completed, the upgrade mark in the EEPROM is cleared and the device restarts to execute the new firmware code; if the acceptance process fails or the verification fails, the backup area copy is not performed, and the upgrade mark in the EEPROM is cleared and restarted to continue executing the original firmware.

[0074] The above is only a preferred specific implementation of the present invention; however, the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solution and its improved conception within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A collection method for a collection module of an RS485 interface sensor, characterized in that: The communication module (1) communicates with the multi-serial port microcontroller through the CMOS level serial port, and sends the working status of the data RS485 cloud intelligent acquisition module to the monitoring platform. The platform actively sends control commands, diagnostic information query commands, and system upgrade commands to remotely monitor and control the RS485 cloud intelligent acquisition module; The multi-serial port microcontroller module (2) has a microcontroller with multiple serial ports. The advantage of using a multi-serial port microcontroller is that the system can be upgraded and configured flexibly, and the RS485 interface sensors of different protocol types mounted on the RS485 cloud intelligent acquisition module can be converted to unify the communication protocol, reduce protocol conflicts, and indirectly improve the reliability of the network; The isolated RS485 driver module (3) adopts an integrated isolation module; The interface protection module (4) is an anti-surge protection for the RS485 interface and the external power supply interface, wherein the RS485 signal is a differential signal and adopts a differential anti-surge protection, and the external power supply adopts a single-ended anti-surge protection. The anti-surge protection of the two interfaces adopts a two-level protection circuit, the first level adopts a GDT and the second level adopts a TVS tube after a decoupling device; The power management module (5) is responsible for providing energy to the communication module, multi-serial port MCU, isolated power supply and analog circuit, and converting the primary power provided by the external into the secondary power required by the system; The isolated power supply module (6) provides power to the RS485 type sensor; The current sampling monitoring module (7) monitors the current consumption of the external RS485 sensor load in real time. When an abnormality occurs, the RS485 cloud intelligent acquisition module can convert data through the analog-to-digital converter inside the current sampling monitoring module, and identify and convert it into a fault diagnosis message through the microcontroller and send it to the communication module; The data storage module (8) sends the data measured by the RS485 sensor to the RS485 bus. At the same time, the RS485 cloud intelligent acquisition module (11) also makes a synchronous backup to avoid extreme situations. The RS485 cloud intelligent acquisition module can also automatically collect data according to the fault tolerance mechanism configured by the system, temporarily replacing the role of the RS485 network host (13). After the RS485 bus returns to normal, the data in the data storage module is sent to the host on the RS485 bus one by one. At the same time, the RS485 cloud intelligent acquisition module also reports the abnormal fault of the RS485 bus to the cloud monitoring platform; The power distribution module (9) is used to divide the power provided by the isolation power module (6) into multiple paths and provide them to the external RS485 type sensor. Each path uses a separate self-recovery fuse and sampling resistor. In this way, when an external line fails, the faulty line will not affect the power supply of other lines. At the same time, this method can also reduce the number of power modules, reduce costs and volume; The RS485 bus driver (10) is responsible for driving the RS485 signal on the RS485 bus side, mainly receiving commands from the RS485 network host (13) and returning data packets from the collected RS485 type sensors; The RS485 network host (13) is mainly responsible for sending data acquisition command frames and receiving data packets returned from sensors; The cloud monitoring platform (15) is mainly used to collect the diagnostic information reported by the RS485 cloud intelligent acquisition module and the operating status parameters of the RS485 cloud intelligent acquisition module in real time. At the same time, when the RS485 cloud intelligent acquisition module needs to be upgraded, the upgrade firmware is sent through the cloud monitoring platform to realize OTA remote online upgrade in the air, thereby realizing the intelligence of the RS485 cloud intelligent acquisition module.

2. The acquisition method of the acquisition module of the RS485 interface sensor according to claim 1, characterized in that: The communication module (1) is of a built-in real-time clock type and is set to a timed working state and a timed sleeping state, thereby maximally reducing the power consumption of the system.

3. The acquisition method of the acquisition module of the RS485 interface sensor according to claim 1, characterized in that: The method to achieve online upgrade over the air is as follows: First, the internal Flash is 256Kb and the Flash is divided into two areas: boot area A, application area B, and backup area C; The starting position of boot area A is 0x8000000, the ending address is 0x8006000, and it occupies 24Kb. The main function of the boot area is to download the upgrade file and write the upgrade file to the application area, which occupies 110KB. The backup area is used to store the issued upgrade files, and its size is 110KB; The starting address of application area B is 0x8006000, occupying the remaining Flash size; the application area code implements the vibrating string collector function; The upgrade process is: a. After the device is powered on, it starts to execute from the boot area, reads the upgrade flag in the EEPROM in the boot area, and if it is determined to execute the upgrade process, it enters the boot area to execute the upgrade process; If it is determined not to be upgraded, the jump instruction is executed and the code is directly jumped to the application area; b. The application area code can accept upgrade instructions. When receiving the upgrade instruction, the EEPROM flag is written and then the device restarts; c. After the device restarts, the boot program enters the upgrade process and sends the upgrade file to the backup area according to the protocol. After the upgrade is completed, the file is verified. If the acceptance is normal, the data in the backup area is copied to the application area. After the copy is completed, the upgrade mark in the EEPROM is cleared and the device restarts to execute the new firmware code. If the acceptance process fails or the verification fails, the backup area copy is not performed, and the upgrade mark in the EEPROM is cleared and restarted to continue executing the original firmware.

Images