A robust integrated measurement and control gate controller and its control method

Abstract

This invention discloses a robust integrated measurement and control gate controller and its control method, comprising: an input module for selecting a gate control mode and inputting a target state command under the selected control mode; a control module for generating control signals for a motor driver based on the selected control mode and the target state command; a data acquisition module for acquiring state data during gate operation via a sensor group; a processing module for determining the motor operating status, gate operating status, and solar power system operating status based on the correspondence between the state data and the sensor group's acquisition functions, and generating corresponding alarm information if an anomaly is determined; and an alarm module for acquiring the alarm information generated by the processing module and triggering an alarm. This invention incorporates a robust algorithm that analyzes gate data to set optimal parameters, ensuring that the motor, relays, and various sensors operate within a safe parameter range.

Description

Technical Field

[0001] This invention relates to the field of integrated measurement and control gate technology, specifically to a robust integrated measurement and control gate controller and its control method. Background Technology

[0002] The integrated measurement and control gate is powered by a solar power system, equipped with batteries and solar panels. It mainly includes: a gate controller, a solar power system, a sensor detection system, a power transmission system, and the gate body. This integrated measurement and control gate is a new type of gate that combines precise control and accurate measurement. Made of high-strength aluminum alloy, it features long service life, low energy consumption, strong environmental adaptability, reliable water sealing, and precise control and measurement. It is tailored for applications such as irrigation area expansion, information technology construction, and modernization.

[0003] Integrated monitoring and control gates often encounter problems such as siltation, blockage, and deformation of the aluminum alloy structure during application in irrigation areas. Gate malfunctions can easily lead to irrigation accidents. Because of spider webs or straw below the water level gauge, flow rate values ​​can deviate significantly and fluctuate greatly, making flow-based irrigation impossible or causing frequent up-and-down movements of the gate during flow-based irrigation, which can easily damage the gate and motor. The various sensors on the integrated monitoring and control gate are electronic components, and with a large number installed, there is a certain probability of failure. Sensor damage can easily cause the gate to erroneously execute control commands, leading to irrigation accidents. Summary of the Invention

[0004] Purpose of the invention: The purpose of this invention is to address the shortcomings of existing technologies by providing a robust integrated measurement and control gate controller and its control method, enabling the integrated measurement and control gate to operate more safely, minimizing or eliminating malfunctions, accurately identifying faults and providing timely alarms, thereby avoiding damage to personnel safety and socio-economic property.

[0005] Technical Solution: The robust integrated measurement and control gate controller of the present invention includes: an input module for selecting the gate's control mode and inputting a target state command in the selected control mode; a control module for generating a control signal for a motor driver based on the selected control mode and the target state command, so that the motor driver drives the motor according to the control signal, and the motor drives the gate to move to achieve the target state; a data acquisition module for acquiring state data during the gate's movement through a sensor group; and a processing module, which is communicatively connected to the input module, control module, and data acquisition module, for performing situation determination on the input module, control module, and data acquisition module, wherein the situation determination includes: based on... The processing module checks the communication connection with the input module and control module, determines the communication function status of the input module and control module, and generates alarm information for the input module or control module if an anomaly is detected. It acquires status data transmitted by the data acquisition module, and determines the functional status of the sensor group based on the correspondence between the status data and the sensor group's acquisition functions. If an anomaly is detected, alarm information for the corresponding sensor is generated. It also determines the operating status of the motor, gate, and solar power system based on the status data, and generates corresponding alarm information if an anomaly is detected. An alarm module is used to acquire the alarm information generated by the processing module and trigger an alarm.

[0006] To further improve the above technical solution, the gate control modes configured in the input module include direct control mode, fixed gate position control module, fixed flow control module, and fixed cumulative water volume control module. The target state commands of the direct control mode include motor forward rotation and motor reverse rotation; the target state commands of the fixed gate position control module include target opening degree; the target state commands of the fixed flow control module include gate set target flow rate; and the target state commands of the fixed cumulative water volume control module include gate set target cumulative water volume.

[0007] Furthermore, the input module can be configured for manual input or remote command input.

[0008] Furthermore, the status data collected by the sensor group includes solar charging voltage, battery voltage, solar charging current, battery discharging current, battery temperature, motor current, standby current, total encoder pulse count, water level before the gate, water level after the gate, flow rate, cumulative amount, and flow velocity.

[0009] Furthermore, the system acquires status data collected by the sensor group. Based on the parameter values ​​related to the current sensor, encoder, voltage sensor, upstream water level gauge, downstream water level gauge, temperature sensor, and flow meter in the status data, the system determines the status of each corresponding sensor. If a fault is determined, an alarm message for the corresponding sensor is output. The system also acquires the motor current and the total number of encoder pulses collected by the sensor group. If the motor current is greater than the current threshold, the motor is determined to be in an overload state. If the current sensor is faulty, the motor current value is calculated by back-calculating the battery voltage drop, and the motor stall coefficient is calculated by using the absolute value of the ratio of the motor current value to the encoder frequency. If the motor stall coefficient is greater than the maximum value, the motor is determined to be in a stall state. If the current sensor or encoder is faulty, the gate position information is estimated using a time estimation method. The system acquires the battery discharge current collected by the sensor group and calculates the battery performance indicators. If the battery performance indicators exceed the set threshold, an alarm message regarding the solar cell operating status is output. The system also acquires the upstream water level and battery discharge current collected by the sensors. Based on the upstream water level, gate basic parameters, and total battery discharge power, the system calculates the mechanical efficiency. If the mechanical efficiency is lower than the set threshold, an alarm message regarding the gate operating status is output.

[0010] The gate control method using the aforementioned robust integrated measurement and control gate controller includes the following steps:

[0011] Acquire the selected control mode in the gate control mode and the target status command input in that control mode;

[0012] Based on the selected control mode and target state command, control signals for the motor driver are generated;

[0013] The motor driver drives the motor according to the control signal, and the motor controls the gate to move to achieve the target state;

[0014] The sensor array is used to acquire status data during the gate's operation.

[0015] Based on the status data, determine whether the sensor group, motor operation status, gate operation status, and solar power supply system operation status are within the safe parameter range, and make a situation judgment and equipment alarm.

[0016] The situation determination and equipment alarm include: generating multiple basic parameter values ​​based on the status data collected by the sensor group, and calculating multiple performance parameter values ​​based on one or more basic parameter values;

[0017] The multiple basic parameter values ​​correspond to the sensor devices in the sensor group. A sensor group judgment standard is established. When the basic parameter value in the sensor group judgment standard exceeds the safety parameter range, the sensor device corresponding to the basic parameter value is judged to be faulty, and the alarm information of the sensor device is output.

[0018] The multiple performance parameter values ​​correspond to the performance status of multiple devices. A device performance status judgment standard is established. When the device performance status judgment standard exceeds the safety parameter range, the device performance status corresponding to the performance parameter value is judged to be faulty, and the device alarm information is output.

[0019] When a sensor device is determined to be faulty, the basic parameter values ​​corresponding to the faulty sensor device are invalid, and the performance parameter values ​​associated with the invalid basic parameter values ​​are determined using compensation values.

[0020] Furthermore, the status data collected by the sensor group includes solar charging voltage, battery voltage, solar charging current, battery discharging current, battery temperature, motor current, standby current, total encoder pulse count, water level before the gate, water level after the gate, flow rate, cumulative amount, and flow velocity.

[0021] Furthermore, the situation determination and equipment alarm include:

[0022] Set an encoder frequency fluctuation threshold, calculate the encoder frequency and encoder frequency fluctuation value based on the total number of encoder pulses, and determine the encoder fault when the encoder frequency fluctuation value is greater than the encoder frequency fluctuation threshold;

[0023] Set a minimum value for the stall coefficient, calculate the stall coefficient based on the ratio of motor current to encoder frequency, and determine the current sensor fault when the stall coefficient is less than the minimum value.

[0024] A voltage range is set; if the voltage value collected by the voltage sensor exceeds the voltage range, the voltage sensor is deemed to be faulty.

[0025] Obtain the water level values ​​before and after the gate, set the fluctuation range of the water level before and after the gate, calculate the fluctuation value of the water level before and after the gate based on the water level values ​​before and after the gate, and determine that the water level fluctuation is abnormal when the fluctuation value of the water level before and after the gate exceeds the set fluctuation range of the water level before and after the gate.

[0026] Set the DTU communication interruption time. If no DTU data is received after the set time, the DTU is considered to be faulty.

[0027] Set the touch screen communication interruption time. If the refresh time of the touch screen test value exceeds the set time, the touch screen communication is judged to be faulty.

[0028] Set the temperature sensor communication interruption time. If the temperature value refresh time exceeds the set time, the temperature sensor communication is judged to be faulty.

[0029] Set the maximum value for battery performance indicators, calculate the voltage performance indicators of the solar cell, and determine that the solar cell is faulty if it exceeds the maximum value for battery performance indicators.

[0030] Set a minimum mechanical efficiency value for the gate, calculate the gate load, and calculate the gate mechanical efficiency based on the gate load. If the gate mechanical efficiency is less than the minimum mechanical efficiency value, the gate mechanical efficiency is determined to be too low.

[0031] Furthermore, the process for determining the operating status of the motor includes:

[0032] Set the current threshold, encoder frequency threshold, and maximum stall coefficient;

[0033] The motor current value is obtained. When the motor current value is greater than the current threshold, the motor is determined to be overloaded and an overload alarm message is output.

[0034] If the current sensor fails, the motor current value is calculated by back-calculating the battery voltage drop. The encoder frequency is calculated based on the total number of encoder pulses. The stall coefficient is calculated based on the ratio of the back-calculated motor current value to the encoder frequency. When the stall coefficient is greater than the maximum value, the motor is determined to be stalled, and a motor stall alarm message is output.

[0035] Furthermore, when the sensor device is determined to be faulty, the basic parameter value corresponding to the faulty sensor device is invalid, and the performance parameter value associated with the invalid basic parameter value is determined using a compensation value, including:

[0036] When both the current sensor and encoder fail, the gate position information is estimated using a time estimation method. This includes: first, reading the gate position information before the fault and storing it in the estimated pulse count register; if the current and voltage are normal, then increasing or decreasing the estimated pulse count register per second according to the normal motor speed; correspondingly, using the estimated gate position to replace the gate position information determined by the original encoder; if the current is too high and the voltage drop is too large when the motor is running, it indicates that the motor load is high, and the gate opening and closing speed under high load is used for estimation.

[0037] When the water level in front of the gate is greater than the maximum normal water level, it is determined that the water level fluctuation is abnormal, and the water level value of the previous second is used as the current water level value.

[0038] When the real-time flow rate exceeds the set range, the value calculated using the gate outlet flow formula is used instead of the flow rate value.

[0039] Beneficial effects: Compared with the prior art, the advantages of the present invention are as follows: The present invention provides a robust integrated measurement and control gate controller with multiple data interface interfaces, comprehensive data acquisition, and built-in robust algorithm. By analyzing the gate data, the optimal parameters are set, so that the motor and various sensors operate within a safe parameter range. In the event of hardware failure, the algorithm can intelligently locate the fault and use the "algorithm compensation" method to replace the function of the damaged sensor, maximize the correct execution of control commands, issue fault alarm information in a timely manner, minimize the occurrence of irrigation accidents, and improve the safety of irrigation operations.

[0040] This invention filters data, primarily addressing issues such as erroneous encoder and thermometer readings due to poor communication, erroneous water level readings due to debris in the water level gauge, and flow rate readings from the flow meter that significantly deviate from hydraulic calculations. This results in real-time and accurate gate operating parameters and water measurement data. In similar products, gate operation will malfunction if the encoder or gate position gauge is damaged. This invention employs time estimation and current-time estimation methods.

[0041] This invention innovatively uses a stall coefficient algorithm to determine the gate's operating status. This algorithm avoids the use of single current or speed thresholds by similar controllers to determine gate stall conditions. Instead, it correlates current values, voltage drop after motor startup, and motor speed, using the current-to-speed ratio to determine the motor's operating load, significantly improving accuracy. A mathematical model is established through multi-data analysis to eliminate noise interference and obtain the true values ​​of the sensors. If a true value cannot be obtained, it is identified as a false value, and a fault alarm is triggered promptly. Utilizing a robust algorithm, it ensures that all parts of the gate operate under safe parameters, achieving optimal gate operation and maximizing its lifespan. It accurately locates faults and intelligently alerts users to damage or nearing the end of the lifespan of batteries, motors, and sensors, allowing for timely replacement and minimizing the possibility of irrigation failures due to gate malfunctions. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the principle of the robust integrated measurement and control gate controller of the present invention;

[0043] Figure 2 This is a process diagram of the gate control method of the present invention. Detailed Implementation

[0044] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to the embodiments described.

[0045] Example 1: As Figure 1 The robust integrated measurement and control gate controller shown includes:

[0046] The input module is used to select the control mode of the gate and input the target state command in the selected control mode.

[0047] The control module generates control signals for the motor driver based on the selected control mode and target state command, so that the motor driver drives the motor according to the control signals, and the motor drives the gate to move to achieve the target state.

[0048] The data acquisition module acquires status data during the gate's operation through a sensor array;

[0049] The processing module communicates with the input module, control module, and data acquisition module. It is used to determine the status of these modules, including: assessing the communication function status of the input and control modules based on their communication connections; generating alarm information for the input or control module if an anomaly is detected; acquiring status data transmitted by the data acquisition module and determining the functional status of the sensor group based on the correspondence between the status data and the sensor group's acquisition functions; generating alarm information for the corresponding sensor if an anomaly is detected; and determining the operating status of the motor, gate, and solar power system based on the status data; generating corresponding alarm information if an anomaly is detected.

[0050] The alarm module is used to acquire alarm information generated by the processing module and to issue an alarm.

[0051] The input module can be manually input or remotely input via commands. The gate control modes configured in the input module include direct control mode, fixed gate position control module, fixed flow control module, and fixed cumulative water volume control module. The target status commands for the direct control mode include forward rotation of the motor and reverse rotation of the motor. The target status commands for the fixed gate position control module include the target opening degree. The target status commands for the fixed flow control module include the gate setting target flow rate. The target status commands for the fixed cumulative water volume control module include the gate setting target cumulative water volume.

[0052] The integrated measurement and control gate controller provided by this invention integrates multiple RS485, RS232, analog, and digital interfaces, which can be easily connected to industrial control protocols such as Modbus, SZY-206 water resource protocol, 0-5V signals, 4-20mA signals, and other analog signals. Custom protocols can also be developed. Through various data connection methods, it can acquire solar charging voltage, battery voltage, solar charging current, battery discharging current, battery temperature, motor current, standby current, encoder pulse count, inlet water level, outlet water level, flow rate, cumulative flow, and velocity.

[0053] The gate is equipped with multiple sensors, and data analysis allows for comprehensive analysis of battery performance, motor performance, and communication quality between various sensors and the controller. Battery performance is assessed through changes in battery discharge voltage and current. Motor performance is determined by factors such as motor speed stability, output power, and the gate's upward speed curve. Analysis is also conducted to address situations where excessive flow fluctuations affect flow control. Multi-dimensional fault analysis enables timely fault location and alarm activation, and a compensation algorithm allows the gate to continue executing commands even when certain sensors are damaged.

[0054] Acquire the status data collected by the sensor group, and determine the status of the corresponding sensor based on the parameter values ​​related to the current sensor, encoder, voltage sensor, upstream water level gauge, downstream water level gauge, temperature sensor, and flow meter in the status data. If a fault is determined, output the alarm information of the corresponding sensor.

[0055] The system acquires the motor current and encoder pulse count collected by the sensor group. If the motor current is greater than the current threshold, the motor is determined to be in an overload state. If the current sensor fails, the motor current value is calculated by back-calculating the battery voltage drop, and the motor stall coefficient is calculated by using the absolute value of the ratio of the motor current value to the encoder frequency. If the motor stall coefficient is greater than the maximum value, the motor is determined to be in a stall state. If the current sensor or encoder fails, the brake position information is estimated using the time estimation method, and alarm information about the motor's operating status is output.

[0056] The battery discharge current collected by the sensor group is used to calculate the battery performance indicators. If the battery performance indicators exceed the set threshold, an alarm message about the operating status of the solar cell is output.

[0057] The system acquires the inlet water level and battery discharge current collected by the sensors. Based on the inlet water level, gate basic parameters, and total battery discharge power, it calculates the mechanical efficiency. If the mechanical efficiency is lower than the set threshold, it outputs alarm information about the gate's operating status.

[0058] The built-in robust algorithm implements the following functions:

[0059] 1. Ensure all hardware systems operate within safe parameter ranges. Collect component operating data according to different component categories. Collect motor voltage, current, and speed data, analyze the logical relationships between data to establish a data model, accurately determine motor stall and overcurrent conditions, and provide timely shutdown protection and alarms. Prevent frequent shutdowns caused by overprotection and prevent motor burnout due to protection failure. When the gate is under excessive load, analyze the impact of lowering the voltage value on the sensor to avoid sensor malfunction.

[0060] 2. Based on solar charging power statistics, battery discharge power statistics, temperature data, and approximate static voltage values ​​under conditions of no charging at night and extremely low standby power consumption, predict battery health and lifespan, and promptly issue alarms for control system malfunctions caused by battery performance.

[0061] 3. Monitor data from various sensors in real time, and use multi-data modeling algorithms to verify data anomalies in real time. If a value is lost or significantly abnormal, input data such as gate running time, voltage information, current information, temperature value, motor speed, water level information, real-time flow rate, and real-time flow velocity into the algorithm model to identify the fault and perform emergency repair, and trigger an alarm.

[0062] Example 2: A gate control method using the robust integrated measurement and control gate controller provided in Example 1, comprising the following steps:

[0063] Acquire the selected control mode in the gate control mode and the target status command input in that control mode;

[0064] Based on the selected control mode and target state command, control signals for the motor driver are generated;

[0065] The motor driver drives the motor according to the control signal, and the motor controls the gate to move to achieve the target state;

[0066] The sensor array is used to acquire status data during the gate's operation.

[0067] Based on the status data, determine whether the sensor group, motor operation status, gate operation status, and solar power supply system operation status are within the safe parameter range, and make a situation judgment and equipment alarm.

[0068] Situation determination and equipment alarm include: generating multiple basic parameter values ​​based on the status data collected by the sensor group, and calculating multiple performance parameter values ​​based on one or more basic parameter values;

[0069] Multiple basic parameter values ​​correspond to the sensor devices in the sensor group. A sensor group judgment standard is established. When the basic parameter value in the sensor group judgment standard exceeds the safety parameter range, the sensor device corresponding to the basic parameter value is judged to be faulty, and the alarm information of the sensor device is output.

[0070] Multiple performance parameter values ​​correspond to the performance status of multiple devices. A standard for judging device performance status is established. When the standard for judging device performance status exceeds the safety parameter range, the performance status of the device corresponding to the performance parameter value is judged as faulty, and alarm information of the device is output.

[0071] When a sensor device is determined to be faulty, the basic parameter values ​​corresponding to the faulty sensor device are invalid, and the performance parameter values ​​associated with the invalid basic parameter values ​​are determined using compensation values.

[0072] The status data collected by the sensor group includes solar charging voltage, battery voltage, solar charging current, battery discharging current, battery temperature, motor current, standby current, total encoder pulse count, water level before gate, water level after gate, flow rate, cumulative flow, and flow velocity.

[0073] like Figure 2 As shown, the status judgment and equipment alarm based on the status data collected by the sensor group include:

[0074] Set an encoder frequency fluctuation threshold, calculate the encoder frequency and encoder frequency fluctuation value based on the total number of encoder pulses, and determine the encoder fault when the encoder frequency fluctuation value is greater than the encoder frequency fluctuation threshold;

[0075] Set a minimum value for the stall coefficient, calculate the stall coefficient based on the ratio of motor current to encoder frequency, and determine the current sensor fault when the stall coefficient is less than the minimum value.

[0076] A voltage range is set; if the voltage value collected by the voltage sensor exceeds the voltage range, the voltage sensor is deemed to be faulty.

[0077] Obtain the water level values ​​before and after the gate, set the fluctuation range of the water level before and after the gate, calculate the fluctuation value of the water level before and after the gate based on the water level values ​​before and after the gate, and determine that the water level fluctuation is abnormal when the fluctuation value of the water level before and after the gate exceeds the set fluctuation range of the water level before and after the gate.

[0078] Set the DTU communication interruption time. If no DTU data is received after the set time, the DTU is considered to be faulty.

[0079] Set the touch screen communication interruption time. If the refresh time of the touch screen test value exceeds the set time, the touch screen communication is judged to be faulty.

[0080] Set the temperature sensor communication interruption time. If the temperature value refresh time exceeds the set time, the temperature sensor communication is judged to be faulty.

[0081] Set the maximum value for battery performance indicators, calculate the voltage performance indicators of the solar cell, and determine that the solar cell is faulty if it exceeds the maximum value for battery performance indicators.

[0082] Set a minimum mechanical efficiency value for the gate, calculate the gate load, and calculate the gate mechanical efficiency based on the gate load. If the gate mechanical efficiency is less than the minimum mechanical efficiency value, the gate mechanical efficiency is determined to be too low.

[0083] When both the current sensor and encoder fail, a time-based estimation method is used to estimate the gate position information. First, the gate position information before the fault is read and stored in the estimated pulse count register. If the current and voltage are normal, the estimated pulse count register is incremented or decremented per second according to the normal motor speed. Correspondingly, the estimated gate position information replaces the original encoder gate position information. If the current is too high and the voltage drop is too large during motor operation, it indicates a high motor load; in this case, the gate opening and closing speed under high load is used for estimation.

[0084] When the water level in front of the gate is greater than the maximum normal water level, it is determined that the water level fluctuation is abnormal, and the water level value of the previous second is used as the current water level value.

[0085] When the real-time flow rate exceeds the set range, the value calculated using the gate outlet flow formula is used instead of the flow rate value.

[0086] Based on the relationship between the downstream water depth and the size of the contraction section, hydraulic jumps are classified into three types: a hydraulic jump occurring downstream of the contraction section (distant-drive hydraulic jump); a hydraulic jump occurring at the contraction section (critical hydraulic jump); and a hydraulic jump occurring upstream of the contraction section (submerged hydraulic jump). The downstream water level corresponding to a distant-drive orifice or critical hydraulic jump does not affect the flow capacity of the gate opening, and is called free outflow. The downstream water level corresponding to a submerged hydraulic jump reduces the flow capacity of the gate opening, and is called submerged outflow.

[0087] The outflow from the gate openings on a flat-topped weir can be calculated and determined using the following method:

[0088] Shrink water depth Water depth after the jump at the contraction section The downstream water depth is ,like For free flow; , to submerge the outflow;

[0089] The formula for the flow rate of the gate outlet is:

[0090]

[0091] In the formula: -Submergence coefficient, - Flow coefficient; n - Number of gate openings; b - Net width of gate openings; e - Gate opening height; g - Gravitational acceleration. -Water head acting in front of the gate;

[0092] When the number of gate openings, the gate height, and the gate opening size are constant, the factor affecting the flow rate Q through the gate is the water head acting upstream of the gate. Flow coefficient Submersion coefficient Q and the water head acting in front of the gate It is proportional to the square root. It is the main factor affecting the flow rate through the gate; Reflecting the influence of downstream water level on Q, free outflow =1.0, submerged outflow <1.0; Influencing factors include the vertical contraction coefficient. Flow velocity coefficient φ and relative gate opening height e / H.

[0093] Example 3: This example provides a specific application process of a robust integrated measurement and control gate controller for gate control.

[0094] Begin

[0095] Input: U0, US. / / Battery voltage, solar charging voltage, continuously collected.

[0096] Input: IM, ID, IC. / / Motor current, standby current, solar charging current, continuously collected.

[0097] Input: C251. / / Total encoder pulse count, continuously acquired.

[0098] Input: H1, H2. / / Water level before and after the sluice gate, collected continuously.

[0099] Input: TD. / / Battery temperature, continuously collected.

[0100] Input: D438, D440 / / Maximum gate opening, maximum opening corresponds to encoder pulse count, parameter input.

[0101] Input: Q, QZ / / Real-time flow rate of the flow meter, the flow meter measures the total water volume, and the data is collected when the flow meter is powered on.

[0102] HZ: =D438*C251 / D440 / / Gate position value

[0103] I. Basic Operation Controls:

[0104] Mode 1, direct control

[0105] Input: D39. / / Control mode selection, D39=1 direct control mode, D39=2 fixed gate position control mode, D39=3 fixed flow control mode, D39=4 fixed cumulative water volume control mode, manual or remote command input.

[0106] Input: M17, M18, M19. / / D39=1 In direct control mode, M17=1 the motor rotates forward and the gate rises, M18=1 the motor rotates in reverse and the gate falls. Manual or remote command input.

[0107] If (D39 = 1, M17 = 1) then M0 = 1, Y1 = 0 / / When M0 = 1, the motor driver powers on, the motor runs, and Y1 = 0 means the motor rotates forward.

[0108] If (D39 = 1, M19 = 1) then M0 = 1, Y1 = 1 / / When M0 = 1, the motor driver powers on, the motor runs, and Y1 = 1 means the motor rotates backward.

[0109] If (D39 = 1, M18 = 1) then M0 = 0, Y1 = 0, M17 = 0, M19 = 0, M18 = 0 / / When M18 = 1, the motor driver powers off, and then M17, M19, M18 are reset.

[0110] Mode 2, fixed gate position control

[0111] Input: D39. / / Control mode selection.

[0112] Input: D42, M80 / / In the fixed gate position control mode where D39 = 2, D42 is the set target opening degree, and the command is executed when M80 = 1.

[0113] If (D39 = 2, D42 > HZ, M80 = 1) then M0 = 1, Y1 = 0 / / When the target opening degree D42 is greater than the current opening degree HZ, the motor driver powers on, the motor runs, and Y1 = 0 means the motor rotates forward.

[0114] If (D39 = 2, D42 < HZ, M80 = 1) then M0 = 1, Y1 = 1 / / When the target opening degree D42 is less than the current opening degree HZ, the motor driver powers on, the motor runs, and Y1 = 1 means the motor rotates backward.

[0115] If (D39 = 2, D42 = HZ, M80 = 1) then M0 = 0, Y1 = 0, M80 = 0, D42 = 0 / / When the target opening degree D42 is equal to the current opening degree HZ, the motor driver powers off and the parameters are reset.

[0116] Mode 3, fixed flow control

[0117] Input: D39. / / Control mode selection.

[0118] Input: D43, M80, M82 / / In the fixed flow control mode where D39 = 3, D43 is the set target flow of the gate, the command is executed when M80 = 1, and the command execution stops when M82 = 1.

[0119] If (D39 = 3, D43 > Q, M80 = 1) then M0 = 1, Y1 = 0 / / When the target flow D43 is greater than the current flow Q, the motor driver is powered on, the motor runs, and Y1 = 0 for forward motor rotation.

[0120] If (D39 = 3, D43 < Q, M80 = 1) then M0 = 1, Y1 = 1 / / When the target flow D43 is less than the current flow Q, the motor driver is powered on, the motor runs, and Y1 = 1 for reverse motor rotation.

[0121] If (D39 = 3, D43 = Q, M80 = 1) then M0 = 0, Y1 = 0 / / When the target flow D43 is equal to the current flow Q, the motor driver is powered off.

[0122] If (D39 = 3, M82 = 1) then M0 = 0, Y1 = 0, M80 = 0, D43 = 0 / / The motor driver is powered off and the current command execution is stopped.

[0123] Mode 4, fixed cumulative water volume control

[0124] Input: D39. / / Control mode selection.

[0125] Input: D44, M80, M82 / / In the fixed cumulative water volume control mode with D39 = 4, D44 is the target cumulative water volume set for the gate, the command is executed when M80 = 1, and the command execution is stopped when M82 = 1.

[0126] If (D39 = 4, D44 > QZ, M80 = 1) then M0 = 1, Y1 = 0 / / When the target cumulative water volume D44 is greater than the current cumulative water volume QZ, the motor driver is powered on, the motor runs, and Y1 = 0 for forward motor rotation.

[0127] If (D39 = 4, D44 <= QZ, M80 = 1) then M0 = 1, Y1 = 1 / / When the target cumulative water volume D44 is less than or equal to the current opening HZ, the motor driver is powered on, the motor runs, and Y1 = 1 for reverse motor rotation.

[0128] If (D39 = 4, M82 = 1) then M0 = 0, Y1 = 0, M80 = 0, D43 = 0 / / The motor driver is powered off and the current command execution is stopped.

[0129] II. Situation determination and equipment alarm:

[0130] Input: IY, fY. / / Current threshold, encoder frequency threshold. Manually input according to the rated power of the motor.

[0131] Fb:=C251(current value)-C251(previous second value). / / Encoder frequency, calculated continuously.

[0132] (1) Motor overload judgment

[0133] If (IM>IY) then M26=1, M0=0.

[0134] Printf "Motor overload protection, please check if the gate is blocked, and if the motor and driver are intact." / / Overload detection: When the motor current exceeds the current threshold, the motor is protected and stops working. Overload detection is the primary basis for motor protection, while stall detection is a backup auxiliary basis.

[0135] (2) Motor stall determination

[0136] Input KMAX. / / Maximum stall coefficient, manually input.

[0137] K:=abs(IM / fb). / / Locked rotor coefficient, the absolute value of the ratio of motor current to encoder frequency.

[0138] If ((K<>0,K>KMAX) ||fb>fY) then M25=1, M0=0.

[0139] Printf: "Motor speed and current mismatch, stall protection activated. Please check if the gate is blocked, and if the motor and driver are intact." / / During motor operation, if the encoder frequency is not 0, the stall coefficient K is greater than KMAX, or the encoder pulse frequency is lower than fY, the motor is de-energized. Stall is detected.

[0140] (3) Encoder damage determination

[0141] fB:=fb(current value)-fb(previous second value) / / encoder frequency fluctuation value.

[0142] Input: fBY / / Encoder frequency fluctuation threshold, manually input according to motor speed.

[0143] If ((T21>5,M0=1,fb=0)||(T21>5,M0=1,fBY>fB) then M43=1 / / T21 motor start time.

[0144] Printf "Encoder output pulse is abnormal. Temporarily using time estimation method to evaluate gate opening. Please check encoder wiring or replace encoder as soon as possible." / / Timing starts after motor power-on. When the driver is powered on and the current increases, the load is under normal operating conditions. The encoder pulse frequency is 0, or the current value indicates that the motor is operating stably. The encoder pulse fluctuates too much. The motor driver starts the start judgment 0.5s after starting.

[0145] (4) Determination of current sensor damage

[0146] Input: KMIN. / / Minimum stall coefficient, manually entered.

[0147] If ((M0=1, IM=0)||(M0=1, K) <KMIN)) then M44=1

[0148] Printf "Current sensor malfunction. Please check the sensor wiring or replace the current sensor as soon as possible." / / The motor driver has zero current or a stall coefficient less than the minimum value after power-on.

[0149] (5) Determination of voltage sensor damage

[0150] If ((U0>28800)||(U0<18000)) then M44=1 / / Voltage value exceeds the possible range.

[0151] The print message reads: "Voltage value exceeds the possible range. Please check the voltage sensor wiring or replace the voltage sensor as soon as possible."

[0152] (6) Judgment of abnormal water level fluctuations (there may be debris under the water level gauge)

[0153] FS1: = H1 (current value) - H1 (previous second value) / / Water level fluctuation value in front of the gate

[0154] FS2: =H2(current value) - H2(previous second value) / / Water level fluctuation value after sluice gate

[0155] If ((FS1>50)||(FS2>50)) then M37=1 / / If the water level value increases or decreases by more than 50mm compared to the previous second, the water level fluctuation is considered abnormal.

[0156] Printf: "Abnormal water level fluctuations. There may be spider webs or grass under the water level gauge. Please check and clean it as soon as possible."

[0157] (7) DTU communication interruption determination

[0158] If (T24>3600) then M46=1 / / No data was received from the DTU for 6 minutes.

[0159] Print message: "If you have not received data from the DTU for an extended period, please check your DTU connection and SIM card for expiration and outstanding fees as soon as possible."

[0160] (8) Touchscreen communication interruption determination

[0161] If (T27>600) then M47=1 / / The test value from the touch screen to the controller does not refresh for 1 minute.

[0162] Printf "Touch screen communication interrupted. Please check the touch screen wiring as soon as possible, check if the touch screen is frozen, or replace the touch screen."

[0163] (9)Abnormal communication of temperature sensor

[0164] If (T28>600) then M48=1 / / The temperature value does not refresh for 1 minute.

[0165] Printf "Temperature sensor communication interrupted. Please check the temperature sensor wiring or replace the temperature sensor as soon as possible."

[0166] (10)Battery performance evaluation

[0167] QD = QD (previous second) + P / / QD discharge amount statistics, P is the current power.

[0168] PD := a * w * (U60 - UQ) / / The voltage value U60 after 60 minutes of charging stop, minus the voltage value UQ after discharging 18000 joules, multiplied by the temperature correction coefficient w, multiplied by the voltage correction coefficient a, and the voltage performance index PD.

[0169] If (PD > PDmax) then printf "Battery performance has dropped too much. Please replace the battery"

[0170] (11)Mechanical efficiency evaluation

[0171] If (Y0 = 0) then FH := b * H1 + FM + FZ / / The rising load FH of the gate is equal to the value of the water level before the gate multiplied by the coefficient b plus the frictional force FM plus the weight FZ of the gate plate.

[0172] If (Y0 = 1) then FH := b * H1 + FM - FZ / / The falling load FH of the gate is equal to the value of the water level before the gate multiplied by the coefficient b plus the frictional force FM minus the weight FZ of the gate plate.

[0173] Jx := FH * V / (U0 * I0) / / The mechanical efficiency Jx is equal to the gate load multiplied by the gate speed divided by the total battery discharge power.

[0174] If (Jx < Jxmin) then printf "Mechanical efficiency is too low. Please check if there is poor lubrication"

[0175] III. Fault compensation mechanism

[0176] (1) When the current sensor is damaged, the current can be calculated by the battery voltage drop to determine the stall condition; when the motor is powered on, the circuit is open, and the voltage drop UD=RN*U0 / (R0+RN). As the motor current IM increases, the battery internal resistance RN and the motor comprehensive load RO decrease, so UD is an increasing function of IM. Through data analysis, the corresponding values ​​of the current value and voltage drop can be obtained.

[0177] When the encoder is damaged, the encoder value is handed over using the alternative estimated pulse number D442.

[0178] If (M43=1, M0=1, Y1=0) then C251:=D442 D442=D442+2*T21

[0179] If (M43=1, M0=1, Y1=1) then C251:=D442 D442=D442-2*T21

[0180] / / When the encoder is damaged, the time estimation method is used to estimate the gate position information, and the stall determination is made by the relationship between voltage drop and current.

[0181] (2) The water level is a key parameter for calculating the flow rate. Abnormal fluctuations in the water level will lead to inaccurate flow meter readings. Under normal water discharge conditions, the water level change per second should not exceed 50 mm. A sudden increase in the water level or the water level exceeding the maximum water level H1MAX or H2MAX indicates that there are spider webs or weeds under the water level gauge.

[0182] Input H1max, H2max / / Maximum normal water level values ​​before and after the gate.

[0183] If ((FS1>50)||H1>H1max) then H1(current value) = H1(previous second value)

[0184] If ((FS2>50)||H2>H2max) then H2(current value) = H2(previous second value)

[0185] / / If the water level fluctuates too much or the water level value exceeds the maximum threshold, replace it with the true value of the previous second.

[0186] The flow rate value is significantly incorrect.

[0187] If ((Qj / Q>1.4)||(Qj / Q<0.7)) then Q:=Qj

[0188] Printf "Flow meter data error. Please check if the flow meter transducer is faulty."

[0189] / / Qj is calculated using the gate outlet formula. Although its accuracy is not as high as that of the flow meter under normal circumstances, the accuracy deviation will be within a certain range. As an electronic product, the flow meter has a certain failure rate in liquid level testing. When a failure occurs, Qj is used to replace Q.

[0190] As described above, although the invention has been shown and described with reference to specific preferred embodiments, it should not be construed as limiting the invention itself. Various changes in form and detail may be made without departing from the spirit and scope of the invention as defined in the appended claims.

Claims

1. A robust integrated measurement and control gate controller, characterized in that, include: The input module is used to select the control mode of the gate and input the target state command in the selected control mode. The control module generates control signals for the motor driver based on the selected control mode and target state command, so that the motor driver drives the motor according to the control signals, and the motor drives the gate to move to achieve the target state. The data acquisition module acquires status data during the gate's operation through a sensor array; The processing module is communicatively connected to the input module, control module, and data acquisition module. It is used to determine the status of these modules, including: judging the communication function status of the input and control modules based on their communication connections; generating alarm information for the input or control module if an anomaly is detected; acquiring status data transmitted by the data acquisition module; judging the functional status of the sensor group based on the correspondence between the status data and the sensor group's acquisition functions; generating alarm information for the corresponding sensor if an anomaly is detected; and judging the operating status of the motor, gate, and solar power system based on the status data; generating corresponding alarm information if an anomaly is detected. The status data collected by the sensor group includes solar charging voltage, battery voltage, solar charging current, battery discharging current, battery temperature, motor current, standby current, total encoder pulse count, water level before the gate, water level after the gate, flow rate, cumulative amount, and flow velocity. Acquire the status data collected by the sensor group, and determine the status of the corresponding sensor based on the parameter values ​​related to the current sensor, encoder, voltage sensor, upstream water level gauge, downstream water level gauge, temperature sensor, and flow meter in the status data. If a fault is determined, output the alarm information of the corresponding sensor. The system acquires the motor current and encoder pulse count from the sensor group. If the motor current is greater than the current threshold, the motor is determined to be in an overload state. If the current sensor fails, the motor current value is calculated by back-calculating the battery voltage drop, and the motor stall coefficient is calculated by using the absolute value of the ratio of the motor current value to the encoder frequency. If the motor stall coefficient is greater than the maximum value, the motor is determined to be in a stall state. If the current sensor or encoder fails, the brake position information is estimated using the time estimation method. The system acquires the battery discharge current collected by the sensor array and calculates the battery performance indicators. If the battery performance indicators exceed the set threshold, it outputs alarm information about the operating status of the solar cells. The system acquires the water level value in front of the gate and the battery discharge current collected by the sensor. Based on the water level value in front of the gate, the gate's basic parameters, and the total battery discharge power, the system calculates the mechanical efficiency. If the mechanical efficiency is lower than the set threshold, the system outputs alarm information about the gate's operating status. The alarm module is used to acquire alarm information generated by the processing module and to issue an alarm.

2. The robust integrated measurement and control gate controller according to claim 1, characterized in that: The gate control modes configured in the input module include direct control mode, fixed gate position control module, fixed flow control module, and fixed cumulative water volume control module. The target status commands of the direct control mode include motor forward rotation and motor reverse rotation; the target status commands of the fixed gate position control module include target opening degree; the target status commands of the fixed flow control module include gate set target flow rate; and the target status commands of the fixed cumulative water volume control module include gate set target cumulative water volume.

3. The robust integrated measurement and control gate controller according to claim 1 or 2, characterized in that: The input module can be used for manual input or remote command input.

4. A gate control method using the robust integrated measurement and control gate controller as described in claim 1, characterized in that, Includes the following steps: Acquire the selected control mode in the gate control mode and the target status command input in that control mode; Based on the selected control mode and target state command, control signals for the motor driver are generated; The motor driver drives the motor according to the control signal, and the motor controls the gate to move to achieve the target state; The sensor array is used to acquire status data during the gate's operation. Based on the status data, determine whether the sensor group, motor operation status, gate operation status, and solar power supply system operation status are within the safe parameter range, and make a situation judgment and equipment alarm. The situation determination and equipment alarm include: generating multiple basic parameter values ​​based on the status data collected by the sensor group, and calculating multiple performance parameter values ​​based on one or more basic parameter values; The multiple basic parameter values ​​correspond to the sensor devices in the sensor group. A sensor group judgment standard is established. When the basic parameter value in the sensor group judgment standard exceeds the safety parameter range, the sensor device corresponding to the basic parameter value is judged to be faulty, and the alarm information of the sensor device is output. The multiple performance parameter values ​​correspond to the performance status of multiple devices. A device performance status judgment standard is established. When the device performance status judgment standard exceeds the safety parameter range, the device performance status corresponding to the performance parameter value is judged to be faulty, and the device alarm information is output. When a sensor device is determined to be faulty, the basic parameter values ​​corresponding to the faulty sensor device are invalid, and the performance parameter values ​​associated with the invalid basic parameter values ​​are determined using compensation values.

5. The gate control method according to claim 4, characterized in that: The situation determination and equipment alarm include: Set an encoder frequency fluctuation threshold, calculate the encoder frequency and encoder frequency fluctuation value based on the total number of encoder pulses, and determine the encoder fault when the encoder frequency fluctuation value is greater than the encoder frequency fluctuation threshold; Set a minimum value for the stall coefficient, calculate the stall coefficient based on the ratio of motor current to encoder frequency, and determine the current sensor fault when the stall coefficient is less than the minimum value. A voltage range is set; if the voltage value collected by the voltage sensor exceeds the voltage range, the voltage sensor is deemed to be faulty. Obtain the water level values ​​before and after the gate, set the fluctuation range of the water level before and after the gate, calculate the fluctuation value of the water level before and after the gate based on the water level values ​​before and after the gate, and determine that the water level fluctuation is abnormal when the fluctuation value of the water level before and after the gate exceeds the set fluctuation range of the water level before and after the gate. Set the DTU communication interruption time. If no DTU data is received after the set time, the DTU is considered to be faulty. Set the touch screen communication interruption time. If the refresh time of the touch screen test value exceeds the set time, the touch screen communication is judged to be faulty. Set the temperature sensor communication interruption time. If the temperature value refresh time exceeds the set time, the temperature sensor communication is judged to be faulty. Set the maximum value for battery performance indicators, calculate the voltage performance indicators of the solar cell, and determine that the solar cell is faulty if it exceeds the maximum value for battery performance indicators. Set a minimum mechanical efficiency value for the gate, calculate the gate load, and calculate the gate mechanical efficiency based on the gate load. If the gate mechanical efficiency is less than the minimum mechanical efficiency value, the gate mechanical efficiency is determined to be too low.

6. The gate control method according to claim 5, characterized in that: The process for determining the operating status of the motor includes: Set the current threshold, encoder frequency threshold, and maximum stall coefficient; The motor current value is obtained. When the motor current value is greater than the current threshold, the motor is determined to be overloaded and an overload alarm message is output. If the current sensor fails, the motor current value is calculated by back-calculating the battery voltage drop. The encoder frequency is calculated based on the total number of encoder pulses. The stall coefficient is calculated based on the ratio of the back-calculated motor current value to the encoder frequency. When the stall coefficient is greater than the maximum value, the motor is determined to be stalled, and a motor stall alarm message is output.

7. The gate control method according to claim 6, characterized in that: When the sensor device is determined to be faulty, the basic parameter value corresponding to the faulty sensor device is invalid, and the performance parameter value associated with the invalid basic parameter value is determined using a compensation value, including: When both the current sensor and encoder fail, the gate position information is estimated using a time estimation method. This includes: first, reading the gate position information before the fault and storing it in the estimated pulse count register; if the current and voltage are normal, then increasing or decreasing the estimated pulse count register per second according to the normal motor speed; correspondingly, using the estimated gate position to replace the gate position information determined by the original encoder; if the current is too high and the voltage drop is too large when the motor is running, it indicates that the motor load is high, and the gate opening and closing speed under high load is used for estimation. When the water level in front of the gate is greater than the maximum normal water level, it is determined that the water level fluctuation is abnormal, and the water level value of the previous second is used as the current water level value. When the real-time flow rate exceeds the set range, the value calculated using the gate outlet flow formula is used instead of the flow rate value.

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