Ultra-small DC UPS based on supercapacitor

Abstract

The present invention discloses a supercapacitor-based ultra-small DC UPS, including UPS structural parts and an internal control mainboard, a charge and discharge battery safety protection circuit, an MCU logic control circuit, a charging control circuit, a USB communication control circuit, a power input EMC and protection circuit, a battery output boost control circuit, an output control and signal acquisition circuit, an IO input and output circuit and a status indicator light are mounted on the main control board through a patch process, a mode selection knob, a USB seat and an IO terminal are welded on the main control board through a wave soldering process, the main control board is fixed on the left aluminum shell, and the supercapacitor is mounted on the battery seat on the main control board; a grounding screw is installed on the right aluminum shell, the left aluminum shell and the right aluminum shell are fixed by left and right assembly screws, and a mask is affixed to the front of the shell composed of the left aluminum shell and the right aluminum shell; and a DIN buckle is installed on the back of the shell. The present invention has rich interfaces, powerful control functions, and modularization facilitates the replacement of different configurations and cost schemes.

Description

Technical Field

[0001] The present invention relates to the field of industrial control technology, and in particular to an ultra-small DC UPS based on a supercapacitor. Background Art

[0002] UPS, also known as Uninterruptible Power Supply, is a power electronic device that can provide continuous, stable and uninterrupted power supply. It is mainly composed of inverter and rectifier, and uses battery or capacitor as energy storage device. It can not only provide users with backup power to prevent important equipment from suffering losses due to power outages, but also improve power quality, protect equipment from high and low voltage, surge, noise, frequency instability and electromagnetic interference, and meet users' needs for power quality.

[0003] With the continuous advancement of UPS technology and the rapid development of industrialization and digitalization, traditional standardized UPS products are gradually unable to meet the needs of downstream customers. Products with advanced power conversion, automatic control, high frequency, high reliability power distribution, high stability and other characteristics are gradually becoming the main demand of the market and the development direction of the industry.

[0004] At present, high-end power supply (UPS) products are mainly used in rail transportation, chemical industry, nuclear power, finance, high-end manufacturing and other fields. Such application scenarios have very high requirements on the advanced technology, performance stability, quality reliability and adaptability of UPS product scenarios.

[0005] In the field of high-end manufacturing, as products are becoming increasingly miniaturized, such as AGV, the volume of controllers and other accessories are required to be controlled within an appropriate range. In addition, since lithium batteries have the risk of starvation if not charged for a long time, new energy storage components are also needed to replace them. Summary of the invention

[0006] In view of the deficiencies in the prior art, the purpose of the present invention is to provide an ultra-small DC UPS based on supercapacitors, which uses supercapacitors to replace commonly used lithium batteries, has rich interfaces, powerful control functions, and modularization to facilitate mutual replacement of different configurations and cost solutions.

[0007] In order to achieve the above-mentioned purpose, the present invention is implemented through the following technical solutions: an ultra-small DC UPS based on supercapacitors, including UPS structural parts and an internal control mainboard, wherein the control mainboard includes a charging and discharging battery safety protection circuit, an MCU logic control circuit, a charging control circuit, a USB communication control circuit, a power input EMC and protection circuit, a battery output boost control circuit, an output control and signal acquisition circuit, and an IO input and output circuit; the UPS structural parts include a supercapacitor, a mode selection knob, a USB socket, a status indicator light, an IO terminal, a main control board, left and right shell assembly screws, and a left aluminum shell. 、 The grounding screw, facial mask, DIN buckle and right aluminum shell, charging and discharging battery safety protection circuit, MCU logic control circuit, charging control circuit, USB communication control circuit, power input EMC and protection circuit, battery output boost control circuit, output control and signal acquisition circuit, IO input and output circuit and status indicator light are mounted on the main control board through the SMT process, the mode selection knob, USB socket and IO terminals are welded on the main control board through the wave soldering process, the main control board is fixed to the left aluminum shell through three 3M screws, and two supercapacitors are installed on the battery holder on the main control board; a grounding screw is installed on the right aluminum shell, the left aluminum shell and the right aluminum shell are fixed with left and right assembly screws, and a facial mask is affixed to the front of the shell composed of the left aluminum shell and the right aluminum shell; a DIN buckle is installed on the back of the shell.

[0008] Preferably, the control mainboard is connected to the host computer software for communication; the control mainboard adopts MCUSTM32F103RCT6.

[0009] Preferably, the host computer software includes a main control embedded program and a host computer program.

[0010] Preferably, the battery output boost control circuit adopts MPQ4214.

[0011] The workflow of the host computer software is as follows:

[0012] 1. First, initialize the hardware parameters, load the user configuration parameters, and configure the communication parameters;

[0013] 2. Data collection and control;

[0014] 3. If data collection is successful, check whether the external power supply is currently on; if data collection fails, an error prompt alarm is issued;

[0015] 4. If the current external power supply is detected, Uout output tracking: when the external power supply voltage changes, Uout output remains lower than the external voltage value to prevent abnormal battery power consumption; battery charging control: when the battery power is lower than the set value, repeated charging is automatically started. When charging is abnormal, charging is automatically stopped and an alarm signal is output.

[0016] 5. If there is no external power supply, an operation warning prompt will be given. If there is a charging abnormality in the battery charging control, an operation warning prompt will also be given. If there is no abnormality, the battery charging control will be performed;

[0017] 6. If the current external power supply is not detected in step 4, check whether it is in continuous power supply mode. If not, perform external power-off output control: determine whether the shutdown current is off. If so, and the current is lower than the set value, Uout output is powered off, the UPS is ready to shut down, execute the shutdown process and power on again, keep Uout power off for 5 seconds, re-power Uout and restart, and re-enter step 2; if not, directly skip the judgment that the current is lower than the set value; if the shutdown process is executed and the power is not re-powered, the program ends;

[0018] 7. If it is continuous power supply mode, the UPS output will be maintained until the battery is exhausted and the program ends.

[0019] The step 2 comprises:

[0020] 2.1. Collect input and output current, voltage and power;

[0021] 2.2. Read the user band switch position setting.

[0022] The external power-off output control in step 6 includes:

[0023] 6.1. The user sets the delay of power off to maintain output;

[0024] 6.2. The device is ready to power off and outputs a shutdown signal;

[0025] 6.3. Determine whether the device is turned off based on the settings.

[0026] The beneficial effects of the present invention are as follows: compared with the traditional solution, it has the advantages of rich interfaces, powerful control functions, modularization and convenient replacement of different configurations and cost solutions. The control mainboard is designed based on MCU STM32F103RCT6, and is implemented using C language as the basic language of embedded programs; MPQ4214 is the buck-boost main control chip. In addition, the present invention has high integration and is the UPS product with the lowest power of 60W on the market that can standby for more than 10 minutes. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments;

[0028] Figure 1 It is a front view of the present invention;

[0029] Figure 2 for Figure 1 AA section view;

[0030] Figure 3 for Figure 1 DD section view;

[0031] Figure 4 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0032] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0033] Reference Figure 1-4 The present specific implementation adopts the following technical scheme: an ultra-small DC UPS based on supercapacitors, including UPS structural parts and an internal control mainboard, wherein the control mainboard includes a charge and discharge battery safety protection circuit 1, an MCU logic control circuit 2, a charging control circuit 3, a USB communication control circuit 4, a power input EMC and protection circuit 5, a battery output boost control circuit 6, an output control and signal acquisition circuit 7, and an IO input and output circuit 8; the UPS structural parts include a supercapacitor 9, a mode selection knob 10, a USB seat 11, a status indicator light 12, an IO terminal 13, a main control board 14, left and right shell assembly screws 15, and a left aluminum shell 16. 、 The grounding screw 17, the mask 18, the DIN buckle 19 and the right aluminum shell 20, the charging and discharging battery safety protection circuit 1, the MCU logic control circuit 2, the charging control circuit 3, the USB communication control circuit 4, the power input EMC and protection circuit 5, the battery output boost control circuit 6, the output control and signal acquisition circuit 7, the IO input and output circuit 8 and the status indicator light 12 are mounted on the main control board 14 through the patch process, the mode selection knob 10, the USB seat 11 and the IO terminal 13 are welded on the main control board 14 through the wave soldering process, the main control board 14 is fixed to the left aluminum shell 16 through three M3 screws, and two 21700 super capacitors 9 are installed on the battery seat on the main control board 14; the grounding screw 17 is installed on the right aluminum shell 20, the left aluminum shell 16 and the right aluminum shell 20 are fixed by the left and right assembly screws 15, and the front of the shell composed of the left aluminum shell 16 and the right aluminum shell 20 is affixed with a mask 18; the back of the shell is installed with a DIN buckle 19.

[0034] It is worth noting that the control mainboard 14 is connected to the upper computer software for communication; the control mainboard 14 adopts MCU STM32F103RCT6.

[0035] It is worth noting that the host computer software includes a main control embedded program and a host computer program;

[0036] It is worth noting that the battery output boost control circuit 6 adopts MPQ4214.

[0037] In addition, the workflow of the host computer software is as follows:

[0038] 1. First, initialize the hardware parameters, load the user configuration parameters, and configure the communication parameters;

[0039] 2. Data collection and control:

[0040] 2.1. Collect input and output current, voltage and power;

[0041] 2.2. Read the user band switch position setting.

[0042] 3. If data collection is successful, check whether the external power supply is currently on; if data collection fails, an error prompt alarm is issued;

[0043] 4. If the current external power supply is detected, Uout output tracking: when the external power supply voltage changes, Uout output remains lower than the external voltage value to prevent abnormal battery power consumption; battery charging control: when the battery power is lower than the set value, repeated charging is automatically started. When charging is abnormal, charging is automatically stopped and an alarm signal is output.

[0044] 5. If there is no external power supply, an operation warning prompt will be given. If there is a charging abnormality in the battery charging control, an operation warning prompt will also be given. If there is no abnormality, the battery charging control will be performed;

[0045] 6. If the current external power supply is not detected in step 4, check whether it is in continuous power supply mode. If not, perform external power-off output control: determine whether the shutdown current is off. If so, and the current is lower than the set value, Uout output is powered off, the UPS is ready to shut down, execute the shutdown process and power on again, keep Uout power off for 5 seconds, re-power Uout and restart, and re-enter step 2; if not, directly skip the judgment that the current is lower than the set value; if the shutdown process is executed and the power is not re-powered, the program ends;

[0046] 7. If it is continuous power supply mode, the UPS output will be maintained until the battery is exhausted and the program ends.

[0047] The external power-off output control in step 6 includes:

[0048] 6.1. The user sets the delay of power off to maintain output;

[0049] 6.2. The device is ready to power off and outputs a shutdown signal;

[0050] 6.3. Determine whether the device is turned off based on the settings.

[0051] The hardware installation method of this specific implementation is as follows: using the patch process to mount the charging and discharging battery safety protection circuit (1), MCU logic control circuit (2), charging control circuit (3), USB communication control circuit (4), power input EMC and protection circuit (5), battery output boost control circuit (6), output control and signal acquisition circuit (7), IO input and output circuit (8) and status indicator light (12) related electronic components on the main control board (14); using the wave soldering process to mount the mode selection knob (10), The USB socket (11) and the IO terminal (13) are welded to the main control board (14); the main control board (14) is fixed to the left aluminum shell (16) using three M3 three-combination screws; two 21700 supercapacitors (9) are installed on the battery holder on the main control board (14); the grounding screw (17) is installed on the right aluminum shell (20); the left aluminum shell (16) and the right aluminum shell (20) are assembled and fixed with the left and right assembly screws (15); a mask (18) is attached to the front of the product; and the DIN buckle (19) is installed on the back of the product. The product installation is now complete.

[0052] The host computer software exists as the communication control between the UPS product and the controller. In the host computer, you can set the UPS shutdown mode to be time mode or power mode, and you can set the shutdown duration and alarm power value; provide variable definitions to customers, and customers can embed UPS related functions into the PLC.

[0053] This specific implementation method uses supercapacitors to replace common lithium batteries in order to solve the problem of lithium battery starvation. It mainly focuses on the field of high-end production, industrialization, digitization, automatic control, high stability, small size; rich interfaces, powerful control functions, modularization and high integration. It is the UPS product with the smallest power of 60W on the market and can standby for more than 10 minutes.

[0054] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. Ultra-small DC UPS based on supercapacitor, characterized by: The invention comprises UPS structural parts and an internal control mainboard, wherein the control mainboard comprises a charge and discharge battery safety protection circuit (1), an MCU logic control circuit (2), a charge control circuit (3), a USB communication control circuit (4), a power input EMC and protection circuit (5), a battery output boost control circuit (6), an output control and signal acquisition circuit (7), and an IO input and output circuit (8); the UPS structural parts comprise a super capacitor (9), a mode selection knob (10), a USB socket (11), a status indicator light (12), an IO terminal (13), a main control board (14), left and right shell assembly screws (15), and a left aluminum shell (16). 、 The grounding screw (17), the mask (18), the DIN buckle (19) and the right aluminum shell (20), the charging and discharging battery safety protection circuit (1), the MCU logic control circuit (2), the charging control circuit (3), the USB communication control circuit (4), the power input EMC and protection circuit (5), the battery output boost control circuit (6), the output control and signal acquisition circuit (7), the IO input and output circuit (8) and the status indicator light (12) are mounted on the main control board (14) through the patch process, and the mode selection knob (10), the USB socket (11) and The IO terminal (13) is welded on the main control board (14) by wave soldering process, the main control board (14) is fixed on the left aluminum shell (16) by three M3 screws, and two 21700 super capacitors (9) are installed on the battery holder on the main control board (14); a grounding screw (17) is installed on the right aluminum shell (20), the left aluminum shell (16) and the right aluminum shell (20) are fixed by left and right assembly screws (15), and a mask (18) is attached to the front of the shell composed of the left aluminum shell (16) and the right aluminum shell (20); and a DIN buckle (19) is installed on the back of the shell.

2. The ultra-small DC UPS based on supercapacitor according to claim 1, characterized in that: The control mainboard (14) is connected to the host computer software for communication; the control mainboard (14) adopts MCU STM32F103RCT6.

3. The ultra-small DC UPS based on supercapacitor according to claim 2, characterized in that: The host computer software includes a main control embedded program and a host computer program.

4. The ultra-small DC UPS based on supercapacitor according to claim 1, characterized in that: The battery output boost control circuit (6) adopts MPQ4214.

5. The ultra-small DC UPS based on supercapacitor according to claim 2 or 3, characterized in that: The workflow of the host computer software is as follows: (1) First, initialize hardware parameters, load user configuration parameters, and configure communication parameters; (2) Data collection and control; (3) If data collection is successful, it detects whether the current external power supply is on; if data collection fails, it issues an error prompt alarm; (4) If the current external power supply is detected, the Uout output is tracked: when the external power supply voltage changes, the Uout output remains lower than the external voltage value to prevent abnormal battery power consumption; battery charging control: when the battery power is lower than the set value, repeated charging is automatically started. When charging is abnormal, charging is automatically stopped and an alarm signal is output; (5) If there is no external power supply, an operation warning prompt will be given. If there is a charging abnormality in the battery charging control, an operation warning prompt will also be given. If there is no abnormality, the battery charging control will be performed; (6) If the current external power supply is not detected in step (4), then check whether it is in the continuous power supply mode. If it is not in the continuous power supply mode, perform external power-off output control: determine whether the shutdown current is present. If so, and the current is lower than the set value, the Uout output is powered off, the UPS is ready to shut down, execute the shutdown process and power on again, keep Uout powered off for 5 seconds, re-power Uout and start the machine, and re-enter step (2); if not, directly skip the judgment that the current is lower than the set value; if the shutdown process is not performed and the power is not re-powered, the program ends; (7) If it is continuous power supply mode, the UPS output will be maintained until the battery is exhausted and the program ends.

6. The ultra-small DC UPS based on supercapacitor according to claim 5, characterized in that: The step (2) comprises: (2.1) Collect input and output current, voltage and power; (2.2) Read the user band switch position setting.

7. The ultra-small DC UPS based on supercapacitor according to claim 5, characterized in that: The external power-off output control in step (6) includes: (6.1) The user sets the delay of power off to maintain output; (6.2) The device is ready to power off and output a shutdown signal; (6.3) Determine whether the device is turned off based on the settings.

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