A DC brushless logistics sorting driver based on Ethernet control

Abstract

The present invention discloses a DC brushless logistics sorting driver based on Ethernet control, which relates to the technical field of logistics sorting. An H-bridge drive circuit, a Hall sensor, an I / O drive port, an Ethernet drive module, and a memory are respectively connected to a main control chip; the H-bridge drive circuit is connected to a three-phase output module, and the three-phase output module is connected to a motor for controlling the operation of the motor; a first network port and a second network port are connected to the Ethernet drive module, and the first network port and the second network port can be used to connect to an external host or an extended driver; a power supply for supplying power to the main control chip and the H-bridge drive circuit is further included. This driver uses Ethernet control and combines with PLC control to realize the intelligence of the express sorting system; the function of upgrading the firmware through Ethernet is added, which greatly facilitates the initial debugging and use and the later upgrade and maintenance of the cross-belt loop logistics sorting system.

Description

Technical Field

[0001] The present invention relates to the technical field of logistics sorting, and in particular to a DC brushless logistics sorting driver based on Ethernet control. Background Art

[0002] With the continuous innovation and advancement of technologies in the express sorting industry, the express sorting has transitioned from manual sorting to automated sorting. The sorting trolley is a core component of the cross-belt sorting system, and its sorting performance directly affects the performance of the entire sorting system. The traditional sorting trolley uses RS485 communication control. To ensure the reliability of communication and other factors, the communication rate can generally only be set at 9600bps. In actual applications, there are one or two hundred trolleys communicating simultaneously on a cross loop. The intensive interaction of multiple groups of data limits the operating efficiency of the sorting system. At the same time, the multi-device communication of RS485 increases the probability of communication conflicts, which also leads to a mis-sorting rate of no less than five per ten thousand in the sorting system using traditional communication. At the same time, the line speed of the cross-belt loop is limited within 2m / s. In such on-site applications, RS485 communication has problems such as incorrect wiring, inconvenient troubleshooting, and firmware upgrade.

[0003] In view of the above situation, there is an urgent need for a new technical solution to solve the above problems. Summary of the Invention

[0004] Aiming at the deficiencies of the prior art, the present invention proposes a DC brushless logistics sorting driver based on Ethernet control, which is applicable to the logistics sorting industry. It uses Ethernet control to improve the rate and stability of the cross-belt ring sorting system at the communication level, and nearly doubles the line speed of the cross-belt ring sorting system. Combined with PLC control, it can realize the intelligence of the express sorting system, with the advantages of high efficiency, high accuracy, and high automation. At the same time, an Ethernet upgrade firmware function is added to realize functions such as communication, control, debugging, and upgrade with a single cable, which greatly facilitates the initial commissioning and subsequent upgrade and maintenance of the cross-belt loop logistics sorting system.

[0005] To achieve the above-mentioned invention purpose, the present invention provides the following technical solutions:

[0006] A DC brushless logistics sorting driver based on Ethernet control includes a main control chip, to which an H-bridge drive circuit, a Hall sensor, an I / O drive port, an Ethernet drive module, and a memory are respectively connected; the H-bridge drive circuit is connected to a three-phase output module, and the three-phase output module is connected to a motor for controlling the operation of the motor; the Hall sensor is used to receive the Hall signal of the motor to monitor the motor; the I / O drive port is used to receive external control signals, and the control signals include a direction signal and an operation signal; the memory is used to store control programs and user information; the Ethernet drive module is connected to a first network port and a second network port, and the first network port and the second network port can be used to connect to an external host or an extended driver; it also includes a power supply for supplying power to the main control chip and the H-bridge drive circuit.

[0007] Preferably, the three-phase output module includes a U-phase inverter unit, a V-phase inverter unit, and a W-phase inverter unit; the motor includes a power line U, a power line V, a power line W, and a Hall signal line. There are five Hall signal lines, including three signal lines, one ground wire, and one power line; the power line U is connected to the U-phase inverter unit, the power line V is connected to the V-phase inverter unit, and the power line W is connected to the W-phase inverter unit; the signal lines are used to connect to the Hall sensor.

[0008] Preferably, the main control chip is an stm32 microcontroller chip.

[0009] Preferably, the host includes a host computer or a PLC device.

[0010] Preferably, it further includes a housing, and the main control chip, the H-bridge drive circuit, the Hall sensor, the Ethernet drive module, the memory, the three-phase output module, and the power supply are all arranged in the housing. The I / O drive port, the first network port, the second network port, the connection ports corresponding to the three-phase output module, and the connection ports corresponding to the Hall sensor are all arranged on the side of the housing.

[0011] Preferably, the motor is a BLDC logistics roller motor.

[0012] Preferably, the power supply is a low-voltage DC power supply, and the common values of the supply voltage are 36V or 48V.

[0013] Beneficial effects

[0014] A DC brushless logistics sorting driver based on Ethernet control provided by the present invention is applicable to the logistics industry. It uses Ethernet control to improve the speed and stability of the cross-belt ring sorting system at the communication level, doubling the linear speed of the cross-belt ring sorting system. Combined with PLC control, it can realize the intelligence of the express sorting system, with the advantages of high efficiency, high accuracy, and high automation. At the same time, an Ethernet upgrade firmware function is added to realize functions such as communication, control, debugging, and upgrading with a single cable, which greatly facilitates the initial debugging and use and subsequent upgrade and maintenance of the cross-belt ring logistics sorting system. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on the structures shown in these drawings.

[0016] Figure 1 It is a schematic structural diagram of a DC brushless logistics sorting driver based on Ethernet control according to the present invention;

[0017] Figure 2 It is the message verification process of a DC brushless logistics sorting driver based on Ethernet control according to the present invention;

[0018] Figure 3 It is the specific format of the UDP message of a DC brushless logistics sorting driver based on Ethernet control according to the present invention;

[0019] Figure 4 It is the broadcast communication process of a DC brushless logistics sorting driver based on Ethernet control according to the present invention.

[0020] Illustration marks:

[0021] 1 - Main control chip, 2 - Ethernet driver module, 3 - H-bridge drive circuit, 4 - Three-phase output module, 4-1 - U-phase inverter unit, 4-2 - V-phase inverter unit, 4-3 - W-phase inverter unit, 5 - Memory, 6 - Power supply, 7 - Hall sensor, 8 - I / O drive port, 9 - First network port, 10 - Second network port, 11 - Housing, 12 - Host, 13 - Expansion driver. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0023] As Figure 1 shown, a DC brushless logistics sorting driver based on Ethernet control is specifically a driver used to control and drive a BLDC logistics roller motor in a logistics sorting trolley (a brushless direct current motor (BLDCM) overcomes the congenital defects of a brushed direct current motor and replaces the mechanical commutator with an electronic commutator). It includes a main control chip 1, and an H-bridge drive circuit 3, a Hall sensor 7, an I / O drive port 8, an Ethernet drive module 2, and a memory 5 are respectively connected to the main control chip 1; the H-bridge drive circuit 3 is connected to a three-phase output module 4, and the three-phase output module 4 is connected to the motor for controlling the operation of the motor; the Hall sensor 7 is used to receive the Hall signal of the motor to monitor the position of the motor rotor; the I / O drive port 8 is used to receive external control signals, and the control signals include a direction signal and an operation signal; the memory 5 is used to store control programs and user information; a first network port 9 and a second network port 10 are connected to the Ethernet drive module 2, and the first network port 9 and the second network port 10 can be used to connect to an external host 12 or an extended driver 13; it further includes a power supply 6 for supplying power to the main control chip 1 and the H-bridge drive circuit 3.

[0024] Specifically, the main control chip 1 is an stm32 microcontroller chip, and the driver adopts three-phase full-bridge control based on the STM32 chip. Among them, the H-bridge drive circuit 3 is used to generate PWM pulses for control output (the H-bridge is a typical DC motor control circuit. Because its circuit shape resembles the letter H, it is named the "H-bridge". Four triodes form the four vertical legs of the H, and the motor is the crossbar in the H.), and outputs them to the motor through the three-phase output module 4 to achieve the purpose of controlling the movement of the motor. The host 12 in this embodiment includes a host computer or a PLC device; the power supply is a low-voltage DC power supply, and the common values of the supply voltage are 36V or 48V.

[0025] In this embodiment, the three-phase output module 4 includes a U-phase inverter unit 4-1, a V-phase inverter unit 4-2, and a W-phase inverter unit 4-3; the motor includes a power line U, a power line V, a power line W, and Hall signal lines. There are five Hall signal lines, including three signal lines, one ground line, and one power line; the power line U is connected to the U-phase inverter unit 4-1, the power line V is connected to the V-phase inverter unit 4-2, and the power line W is connected to the W-phase inverter unit 4-3; the signal lines are used to connect to the Hall sensor 7, facilitating the main control chip 1 to obtain the Hall signal of the motor in real time.

[0026] It further includes a housing 11. The main control chip 1, the H-bridge drive circuit 3, the Hall sensor 7, the Ethernet drive module 2, the memory 5, the three-phase output module 4, and the power supply 6 are all arranged inside the housing 11. The I / O drive port 8, the first network port 9, the second network port 10, the connection ports corresponding to the three-phase output module 4, and the connection ports corresponding to the Hall sensor 7 are all arranged on the side of the housing 11.

[0027] As the control methods of this driver for the motor, there are the following two:

[0028] Method 1: The Ethernet drive module 2 conducts Ethernet communication with the host through the first network port or the second network port, transmits control and monitoring instructions output by the host to the main control chip 1. The main control chip 1 receives the instructions to complete the setting of the driver parameters, and stores the relevant parameters in the memory 5 (or overwrites and updates the historical data). The main control chip 1 outputs the adjusted PWM pulse signal to the H-bridge drive circuit 3 to complete the control of the BLDC motor.

[0029] Method 2: Connect to the external PLC through the I / O drive port 8, receive the instructions issued by the PLC, transmit control and monitoring instructions output by the PLC to the main control chip 1. The main control chip 1 receives the instructions to complete the setting of the driver parameters, and stores the relevant parameters in the memory 5 (or overwrites and updates the historical data). The main control chip 1 outputs the adjusted PWM pulse signal to the H-bridge drive circuit 3 to complete the control of the BLDC motor.

[0030] Each driver is preset with a default IP address at the factory. Users can set the IP by themselves as the identifier of different drivers in the same local area network. Each driver is assigned a unique MAC address as the network flag of the driver. The drive station number is added in the broadcast communication as the identifier of different drivers.

[0031] As the communication types of this driver, three communication functions of TCP, UDP, and broadcast communication can be implemented to meet different functional requirements. Each communication protocol uses different network communication ports and corresponding Modbus communication protocol message frame identifiers, specifically as follows:

[0032] TCP communication: TCP communication is mainly used for communication between the driver and the host computer and Ethernet upgrade. The data frame message format is the standard Modbus / TCP format, including 0x03 read register instruction, 0x06 write register instruction, 0x10 write multiple registers instruction, etc. When the host computer reads the driver register through the Ethernet drive interface, it sends the corresponding read register instruction message. After receiving the message, the driver checks the data and returns the data in the accessed register; when the host computer writes data to the register through the driver, it corresponds to sending a write register instruction message to the driver. After receiving the instruction message and passing the check, the driver updates the response data to the register parameters; the message check process is as Figure 2 shown;

[0033] UDP communication: UDP communication is mainly used for point-to-point communication between the driver and peripheral devices. The data frame message format is the custom Modbus / UDP format, with the instruction flag bit 0x17, including read and write registers. The instruction message check process is as shown in the appendix Figure 2 shown, and the specific format of the UDP message is as Figure 3 shown;

[0034] Broadcast communication: It is mainly used for PLC broadcast polling to selectively control specific drivers in the same local area network to form an automated logistics sorting system. The data frame message format is the custom Modbus / UDP format, and the instruction flags include broadcast write register instruction and broadcast read register instruction. In broadcast communication, the PLC sends a broadcast message with the driver station number identifier. All drivers in the same network segment receive the broadcast message, and only the driver corresponding to the driver station number identifier responds to the broadcast message. This response can be to drive the motor to act or broadcast back monitoring information. At the same time, a driver action identifier is added as the identification identifier for each broadcast. In actual applications, when the PLC receives the upper and lower package processing signals of the express sorting system, it can broadcast control signals to all drivers in the same network segment and selectively control the drivers that need to act in the sorting system to complete the corresponding express information processing and update the current action identifier of the driver. The PLC can query the execution result of each instruction through the driver station number and the driver action identifier. Such a processing method can query the result of each sub-packet instruction and easily detect that the system has mis-sorted the express, reducing the mis-sorting rate of the system, as Figure 4 shown.

[0035] This driver combines Ethernet communication control with traditional BLDC control drivers, effectively solving problems such as easy communication interference, low communication rate, and redundant wiring in traditional RS485 communication when hundreds of drivers are densely communicating. For a single driver, the Ethernet control rate is much higher than RS485 communication, which also improves the responsiveness of each driver to the PLC. By adding the identification of the driver station number and the identification of the number of actions in the broadcast communication, automated, efficient, and highly reliable express sorting is achieved under the cooperative control of the PLC.

[0036] In addition, when upgrading the firmware of traditional RS485 communication, the driver needs to be unplugged from the system and connected to the host for updating. Considering on-site wiring and driver installation issues, this causes inconvenience to the firmware update of the driver; during the use of this driver, Ethernet communication is adopted, and the driver update uses self-update based on Ethernet / TCP. Combined with the debugging upper computer, the Ethernet self-update function of the software can be completed only by accessing the driver local area network. The update process is as follows:

[0037] The upper computer accesses the local area network where the driver is located, connects to the driver, selects the update function and the firmware update package, and then starts the update. The upper computer actively connects to the driver to complete the firmware update function. The automatic communication update includes the following:

[0038] The upper computer uses Modbus / TCP to connect to the driver and send a firmware update instruction to the driver. After receiving the firmware update instruction, the driver jumps to the Boot to establish a TCP connection. The upper computer connects to the driver again to complete the handshake communication. After the handshake is successful, the firmware is sent, verified, and updated in packets according to the agreed process between the two parties. After the firmware update is completed, the new firmware program starts to run. Before the update, different drivers can be connected by modifying the IP. The entire process can complete the update of all drivers in the local area network with only one network cable.

[0039] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A brushless DC logistics sorting driver based on Ethernet control, characterized in that: It includes a main control chip (1), and a H-bridge drive circuit (3), a Hall sensor (7), an I / O drive port (8), an Ethernet drive module (2) and a memory (5) are respectively connected to the main control chip (1); the main control chip (1) is an stm32 microcontroller chip; The H-bridge drive circuit (3) is connected to a three-phase output module (4), and the three-phase output module (4) is connected to a motor for controlling the operation of the motor; the three-phase output module (4) includes a U-phase inverter unit (4-1), a V-phase inverter unit (4-2) and a W-phase inverter unit (4-3); the motor includes a power line U, a power line V, a power line W and Hall signal lines, and there are five Hall signal lines, including three signal lines, one ground wire and one power line; the power line U is connected to the U-phase inverter unit (4-1), the power line V is connected to the V-phase inverter unit (4-2), and the power line W is connected to the W-phase inverter unit (4-3); the signal lines are used to be connected to the Hall sensor (7); The Hall sensor (7) is used to receive the Hall signal of the motor to monitor the position of the motor rotor; The I / O drive port (8) is used to receive external control signals, and the control signals include a direction signal and an operation signal; The memory (5) is used to store control programs and user information; A first network port (9) and a second network port (10) are connected to the Ethernet drive module (2), and the first network port (9) and the second network port (10) can be used to connect to an external host (12) or an expansion driver (13); the Ethernet drive module (2) supports a self-update function based on Modbus / TCP to complete firmware upgrade through a local area network; It also includes a power supply (6) for supplying power to the main control chip (1) and the H-bridge drive circuit (3).

2. The DC brushless logistics sorting driver based on Ethernet control according to claim 1, wherein: The host (12) includes a host computer or a PLC device.

3. The DC brushless logistics sorting driver based on Ethernet control according to claim 1, wherein: It also includes a housing (11), and the main control chip (1), the H-bridge drive circuit (3), the Hall sensor (7), the Ethernet drive module (2), the memory (5), the three-phase output module (4) and the power supply (6) are all arranged in the housing (11), and the I / O drive port (8), the first network port (9), the second network port (10), the connection ports corresponding to the three-phase output module (4) and the connection ports corresponding to the Hall sensor (7) are all arranged on the side of the housing (11).

4. The DC brushless logistics sorting driver based on Ethernet control according to claim 1, characterized in that: The motor is a BLDC logistics roller motor.

5. The DC brushless logistics sorting driver based on Ethernet control according to claim 1, wherein: The power supply (6) is a low-voltage DC power supply, and the common value of the supply voltage is 36V or 48V.

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