A data acquisition device, method and industrial computer based on switch technology

Abstract

The application provides a data acquisition device, method and industrial computer based on switch technology, the data acquisition device comprises a clock module, a sensor interface module, a network switch and an upper computer; the sensor interface module comprises a plurality of sensor interfaces, which are used for connecting digital signal sensors or analog signal sensors; the clock module comprises a clock generator and a clock board, the clock generator is used for generating a digital clock signal, and the plurality of sensor interfaces are connected to the clock generator through network cables respectively; the clock generator is electrically connected to the clock board, the network switch is a serial server, the upper computer is a user computer, and the network switch is used for establishing interactive communication. The application realizes a multi-channel, multi-speed, high-integration and high-subsystem interchangeability data acquisition system based on common network protocols and synchronous clock hardware.

Description

Technical Field

[0001] This invention belongs to the field of industrial control systems, and in particular relates to a data acquisition device, method and industrial control computer based on switch technology. Background Technology

[0002] Currently, most common data acquisition systems on the market use a single MUC to perform multiple complex acquisition tasks. In low-speed acquisition, microcontroller or FPGA solutions are commonly used. These hardware-supported acquisition cards are mostly self-timed, meaning the system time is determined by the microcontroller's own operating precision. This is inaccurate in high-speed acquisition, and the data acquisition rate of this solution is relatively low, with a maximum of only 16 MSa / s. In high-end acquisition, such as NI's PXI data acquisition system, there are integrable multi-functional acquisition boxes. Their performance is undoubtedly very powerful, but they are expensive and have a high learning curve, making it difficult for general technical personnel to master their use in a short period of time.

[0003] The problems with using a single-chip microcomputer system are: complex development, poor performance, low acquisition speed, and poor scalability. The problems with using a single acquisition card system are: limited functionality, often relying on analog signals as the main acquisition method, poor scalability, complex to learn, requiring a lot of secondary development work, and the acquired data requiring extensive processing by a host computer. The problems with using an acquisition chassis system are: high cost and redundant functions, many functions are not needed but still must be purchased, inflexible expansion, and the acquired data requiring extensive processing by a host computer. Invention Content

[0004] In view of this, the present invention aims to propose a data acquisition device, method and industrial control computer based on switch technology, so as to realize a multi-channel, multi-speed, highly integrated and highly interchangeable data acquisition system based on common network protocols and synchronous clock hardware.

[0005] To achieve the above objectives, the technical solution created by this invention is implemented as follows:

[0006] A data acquisition device based on switch technology includes a clock module, a sensor interface module, a network switch, and a host computer;

[0007] The sensor interface module includes multiple sensor interfaces, which are used to connect digital signal sensors or analog signal sensors.

[0008] The clock module includes a clock generator and a clock board. The clock generator is used to generate digital clock signals, and multiple sensor interfaces are respectively connected to the clock generator via network cables. The clock generator is electrically connected to the clock board, which is a microcontroller, and multiple sensor interfaces are respectively connected to the clock board via network cables.

[0009] The network switch is a serial port server, and multiple digital signal sensors and / or analog signal sensors establish connections with the network switch through the sensor interfaces; the host computer is a user terminal computer that establishes interactive communication with the network switch.

[0010] Furthermore, the clock board uses an STM32F407 chip, and the clock generator uses an STM32F407168MHz chip.

[0011] Furthermore, the clock board is equipped with an RJ45 interface, 1 to 8 front COM interfaces, 1 to 8 rear COM interfaces, 1 422 interface, 1 24V power supply interface, and 1 clock closed-loop communication line.

[0012] Furthermore, the sensor interface module includes 4 I2C interfaces, 3 tension interfaces + I2C interface, torque and speed interface, AD interface, and spare control interface.

[0013] Furthermore, the clock board is also equipped with a 24V / IOS24 power supply and an IOS24 / 12V power supply. The 24V / IOS24 power supply provides power to the clock generator, clock board, AD interface, pull force interface +12C interface, torque and speed interface, four 12C interfaces, and spare control interface, respectively. The IOS24 / 12V power supply provides power to the network switch. The 24V / IOS24 power supply and the IOS24 / 12V power supply are integrated with the clock generator and clock board on the same motherboard.

[0014] A data acquisition method based on switch technology, applied to the aforementioned data acquisition device based on switch technology, includes the following steps:

[0015] S1, the clock generator generates a digital clock signal, which is sent to the sensor through the sensor interface module; and the digital clock signal is also sent to the clock board;

[0016] S2, the sensor collects sensor signals and obtains the digital clock signal, and sends the sensor signal with clock information to the network switch according to the set transmission frequency;

[0017] S3, the network switch collects the sensor signals with clock information in a cyclical manner according to a set timing sequence;

[0018] S4, the clock board acquires the synchronization clock signal of the sensor and the digital clock signal;

[0019] S5, the clock board compares the digital clock signal with the synchronous clock signal of the sensor to determine whether the sensor is delayed. If the delay exceeds the set value, then S6 to S8 are executed.

[0020] S6, when the delay exceeds the set value, the clock sends a frame count abnormality signal to the network switch; the host computer obtains the frame count abnormality signal through the network switch;

[0021] S7, the network switch sends a feedback signal to the clock generator based on the acquired abnormal signal;

[0022] S8, the clock generator adjusts the digital clock signal according to the acquired feedback signal.

[0023] Furthermore, the clock generator produces a 1kHz digital clock, and the clock generator transmits at a frequency of 460,800 baud.

[0024] Furthermore, the host computer checks every 5000 frames whether any module is sending an abnormal number of frames.

[0025] Furthermore, the sensor interface module sends a pulse signal to the clock board every 1000 frames received. The clock board calculates the arrival time error of each pulse, and if the difference is 300µs, it reports an anomaly.

[0026] An industrial control computer for data acquisition based on switch technology includes the aforementioned data acquisition device based on switch technology, and also includes an industrial control computer chassis, which houses the clock generator, clock board, sensor interface module and network switch.

[0027] Compared with existing technologies, the data acquisition device, method, and industrial control computer based on switch technology described in this invention have the following advantages:

[0028] (1) The invention creates a clock module, sensor interface module, network switch and host computer, which makes the total acquisition speed and the acquisition speed of each channel of the system more flexible. The maximum acquisition speed of a single channel is only limited to the upper limit of the network communication speed. Under the current mature technology of 10 Gigabit switches, its acquisition speed is faster.

[0029] (2) The clock module described in this invention supports the system to have accurate time after power-on. Through the clock generator, clock board and sensor interface module, the real-time and synchronization of all channels can be achieved by triggering each channel. Attached Figure Description

[0030] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0031] Figure 1 A structural diagram of the data acquisition device described in the embodiments of the present invention;

[0032] Figure 2 The data acquisition device structure diagram of Embodiment 1 of the present invention is shown below;

[0033] Figure 3 The data acquisition device structure diagram of Embodiment 2 of the present invention is shown below;

[0034] Figure 4 Power supply topology diagram of the data acquisition device described in the embodiments of the present invention;

[0035] Figure 5 A flowchart illustrating the data acquisition method described in the embodiments of the present invention;

[0036] Figure 6 A timing diagram of the data acquisition method described in the embodiments of the present invention.

[0037] Explanation of reference numerals in the attached figures:

[0038] 1-Sensor interface module; 2-Clock generator; 3-Clock board; 4-Network switch; 5-Host computer; 6-24V / IOS24 power supply and IOS24 / 12V power supply; 101-4-channel I2C interface; 102-3-channel tension interface + I2C interface; 103-Torque speed interface; 104-AD interface; 105-Spare control interface; 201-COM2-7 Clock closed-loop control; 202-COM1 Throttle and other command forwarding; 203-COM1-8 24VPOE power output; 204-COM2-8 Input / output; 205-1-channel PWM output; 211-Main control board; 212-Dual-channel full-bridge board; 213-Dual-channel ADC board; 214-2-channel relay acquisition board; 215-485 system. Detailed Implementation

[0039] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0040] The invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0041] like Figure 1 As shown, the data acquisition device based on switch technology includes a clock module, a sensor interface module 1, a network switch 4, and a host computer 5.

[0042] like Figure 1 As shown, the sensor interface module 1 includes multiple sensor interfaces, which are used to connect digital signal sensors or analog signal sensors;

[0043] like Figure 1 As shown, the clock module includes a clock generator 2 and a clock board 3. The clock generator 2 is used to generate digital clock signals, and multiple sensor interfaces are respectively connected to the clock generator 2 via network cables. The clock generator 2 is electrically connected to the clock board 3, which is a microcontroller, and multiple sensor interfaces are respectively connected to the clock board 3 via network cables.

[0044] like Figure 1 As shown, the network switch 4 is a serial port server, and multiple digital signal sensors and / or analog signal sensors are respectively connected to the network switch 5 through the sensor interface 1; the host computer 5 is a user terminal computer, which establishes interactive communication with the network switch 4.

[0045] As one of the preferred embodiments of the present invention, such as Figure 3 As shown, the clock board 3 uses an STM32F407 chip, and the clock generator 2 uses an STM32F407 168MHz chip. The STM32F407 chip's processor has timestamping and local clock frequency adjustment functions. The clock board is equipped with an RJ45 interface, 1 to 8 front COM interfaces, 1 to 8 rear COM interfaces, one 422 interface, one 24V power supply interface, and one clock closed-loop communication line; wherein, as... Figure 3 As shown, COM2-7 is the clock closed-loop control 201; COM1 is the throttle and other command forwarding 202; COM1-8 is the 24V POE power output 203; COM2-8 is the input / output 204; 1-channel PWM output 205 and ACDC power supply 206; the main control board 211, dual-channel full-bridge board 212, dual-channel ADC board 213, 2-channel relay acquisition board 214 and existing 485 system 215 are used to support the connection of peripherals.

[0046] As one of the preferred embodiments of the present invention, such as Figure 2 As shown, the sensor interface module includes a 4-channel I2C interface 101, a 3-channel tension interface + I2C interface 102, a torque and speed interface 103, an AD interface 104, and a spare control interface 105.

[0047] As one of the preferred embodiments of the present invention, such as Figure 4As shown, the clock board is also equipped with a 24V / IOS24 power supply and an IOS24 / 12V power supply 6. The 24V / IOS24 power supply provides power to the clock generator 2, clock board 3, AD interface 104, 3-channel tension interface + 12C interface 102, torque and speed interface 103, 4-channel 12C interface 101, and spare control interface 105, respectively. The IOS24 / 12V power supply provides power to the network switch 4. The 24V / IOS24 power supply and the IOS24 / 12V power supply 6 are integrated with the clock generator 2 and the clock board 3 on the same motherboard.

[0048] like Figure 5 As shown, a data acquisition method based on switch technology, applied to a data acquisition device based on switch technology, includes the following steps: S1, the clock generator 2 generates a digital clock signal and sends it to the sensor through the sensor interface module 1; and sends the digital clock signal to the clock board 3; S2, the sensor acquires sensor signals and obtains the digital clock signal, and sends sensor signals with clock information to the network switch 4 according to a set transmission frequency; S3, the network switch 4 cyclically acquires the sensor signals with clock information according to a set timing sequence; S4, the clock board 3 obtains the synchronization clock signal of the sensor and obtains the digital clock signal; S5, the clock board 3 compares the digital clock signal with the synchronization clock signal of the sensor to determine whether the sensor is delayed. If the delay exceeds a set value, steps S6 to S8 are executed.

[0049] S6, when the delay exceeds the set value, the clock 3 sends a frame count abnormal signal to the network switch 4; the host computer obtains the frame count abnormal signal through the network switch 4; S7, the network switch 4 sends a feedback signal to the clock generator 2 according to the obtained abnormal signal; S8, the clock generator 2 adjusts the digital clock signal according to the obtained feedback signal.

[0050] like Figure 2 As shown in the preferred embodiment of the present invention, the clock generator 2 generates a 1kHz digital clock, and the clock generator 2 transmits at a frequency of 460800 baud. The host computer 5 checks every 5000 frames whether any module is sending abnormal frames. The sensor interface module 1 sends a pulse signal to the clock board 3 every 1000 frames received. The clock board 3 calculates the arrival time error of each pulse, and if the difference is 300µs, it reports an anomaly.

[0051] like Figure 6The diagram shows the timing of the data acquisition method. The digital clock signal refers to the digital clock signal generated by clock generator 2. Modules 1, 2, and 3 refer to the sensor interface modules and the sensors connected to them. The clock generator 2 is set to a baud rate of 460800; transmitting one byte takes approximately 20µs. With one byte of parity, the clock transmission to the clock board takes 60µs. Since the modules are connected to the clock board via network cables, the distance is relatively far, so the baud rate is set to 460800; the time required for the clock to be transmitted to each module is 60µs. Modules 1, 2, and 3 acquire data in real time, with each module sending 25 bytes to the serial port server at a baud rate of 460800; the transmission time is 540µs; therefore, the program execution time for each module is less than 300µs.

[0052] like Figure 1 As shown, a data acquisition industrial control computer based on switch technology includes the data acquisition device and an industrial control computer chassis 10. The industrial control computer chassis 10 carries a clock generator 2, a clock board 3, a sensor interface module 1, and a network switch 4.

[0053] The working principle of the data acquisition device, method, and industrial control computer based on switch technology of this invention is as follows: A purely digital acquisition device is formed by the clock module, sensor interface module, network switch, and host computer. The front-end sensor is the acquisition end, and the sensor includes commonly used digital signal sensors or analog signal sensors. The sensor types include analog quantity, pulse quantity, I2C, SPI, and 485 Modbus. The clock module, including the clock generator and clock board, serves as the front end of the data acquisition device, transmitting the processed data with clock information to the network switch, i.e., the server, thereby realizing the digitization and real-time synchronization of the sensors at the front end. Based on the mature switch technology, this system can achieve 10 Gigabit communication with the PC host computer. At this speed, the system can arbitrarily expand the sensor channels. For example, at low speeds, multiple sensors can be connected in series via the EtherCar protocol without worrying about compatibility issues or the most important signal processing issues in ordinary acquisition. The switch only needs to handle communication, with clear division of labor and unparalleled scalability. At high speeds, for example, an 8 / 16-port switch can be used to connect 16 high-speed sensors to communicate with the host computer individually, maximizing the acquisition speed. These two operating modes transform the system into a real-time system capable of operating at high speed with few channels or at low speed with many channels.

[0054] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A data acquisition device based on switch technology, characterized in that, It includes a clock module, a sensor interface module (1), a network switch (4), and a host computer (5); The clock module includes a clock generator (2) and a clock board (3). Multiple sensor interface modules (1) are connected to the clock generator (2) via network cables. The clock generator (2) is electrically connected to the clock board (3). The clock board (3) is a microcontroller. Multiple sensor interface modules (1) are connected to the clock board (3) via network cables. The clock generator (2) is used to generate a digital clock signal, which is sent to the sensor via the sensor interface module (1) and sent to the clock board (3). The clock generator (2) is also used to adjust the digital clock signal according to the obtained feedback signal. The clock board (3) is used to obtain the synchronous clock signal of the sensor and obtain the digital clock signal. The digital clock signal is compared with the synchronous clock signal of the sensor to determine whether the sensor is delayed. When the delay exceeds a set value, a frame count abnormal signal is sent to the network switch (4). The host computer (5) obtains the frame count abnormal signal through the network switch (4). The sensor interface module (1) includes multiple sensor interfaces. The sensor interfaces are used to connect digital signal sensors or analog signal sensors. The sensors are used to collect sensor signals and obtain the digital clock signal. The sensor signals with clock information are sent to the network switch (4) according to the set transmission frequency. The network switch (4) is a serial port server. Multiple digital signal sensors and / or analog signal sensors establish connections with the network switch (4) through the sensor interface (1). The host computer (5) is a user terminal computer that establishes interactive communication with the network switch (4). The network switch (4) is used to collect the sensor signals with clock information in a cyclic manner according to a set time sequence. The network switch (4) is also used to send feedback signals to the clock generator (2) based on the acquired abnormal signals.

2. The data acquisition device based on switch technology according to claim 1, characterized in that: The clock board (3) uses an STM32F407 chip, and the clock generator (2) uses an STM32F407 168MHz chip.

3. The data acquisition device based on switch technology according to claim 2, characterized in that: The clock board (3) is equipped with an RJ45 interface, 1 to 8 front COM interfaces, 1 to 8 rear COM interfaces, 1 422 interface, 1 24V power supply interface and 1 clock closed-loop communication line.

4. The data acquisition device based on switch technology according to claim 2, characterized in that: The sensor interface module (1) includes 4 I2C interfaces (101), 3 tension interfaces + I2C interface (102), torque and speed interface (103), AD interface (104), and spare control interface (105).

5. The data acquisition device based on switch technology according to claim 4, characterized in that: The clock board (3) is also equipped with a 24V / IOS24 power supply and an IOS24 / 12V power supply (6). The 24V / IOS24 power supply provides power to the clock generator (2), the clock board (3), the AD interface (104), the 3-channel tension interface + 12C interface (102), the torque speed interface (103), the 4-channel 12C interface (101), and the backup control interface (105), respectively. The IOS24 / 12V power supply provides power to the network switch (4). The 24V / IOS24 power supply and the IOS24 / 12V power supply (6) are integrated with the clock generator (2) and the clock board (3) on the same motherboard.

6. A data acquisition method based on switch technology, applied to a data acquisition device based on switch technology as described in any one of claims 1 to 5, characterized in that, Includes the following steps: S1, the clock generator (2) generates a digital clock signal and sends it to the sensor through the sensor interface module (1); and sends the digital clock signal to the clock board (3). S2, the sensor collects sensor signals and obtains the digital clock signal, and sends the sensor signal with clock information to the network switch (4) according to the set transmission frequency; S3, the network switch (4) collects the sensor signals with clock information in a cyclic manner according to the set timing sequence; S4, the clock board (3) acquires the synchronous clock signal of the sensor and the digital clock signal; S5, the clock board (3) compares the digital clock signal with the synchronous clock signal of the sensor to determine whether the sensor is delayed. If the delay exceeds the set value, S6 to S8 are executed. S6, when the delay exceeds the set value, the clock board (3) sends a frame count abnormal signal to the network switch (4); the host computer obtains the frame count abnormal signal through the network switch (4); S7, the network switch (4) sends a feedback signal to the clock generator (2) based on the acquired abnormal signal; S8, the clock generator (2) adjusts the digital clock signal according to the acquired feedback signal.

7. The data acquisition method based on switch technology according to claim 6, characterized in that: The clock generator (2) generates a 1KZ digital clock and transmits at a frequency of 460800 baud.

8. The data acquisition method based on switch technology according to claim 6, characterized in that: The host computer (5) checks every 5000 frames whether there is an abnormal number of frames sent by a module.

9. The data acquisition method based on switch technology according to claim 6, characterized in that: The sensor interface module (1) sends a pulse signal to the clock board (3) every 1000 frames. The clock board (3) calculates the arrival time error of each pulse. If the difference is 300us, an anomaly is reported.

10. A data acquisition industrial control computer based on switch technology, characterized in that, The device includes the apparatus according to any one of claims 1 to 5, and further includes an industrial control chassis (10), which carries the clock generator (2), clock board (3), sensor interface module (1) and network switch (4).

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