Intelligent feedback type industrial control signal isolation adjusting system and method

Abstract

The invention discloses an intelligent feedback type industrial control signal isolation adjusting system and method, a signal transmission circuit between a control module and an actuator is divided into a primary section and a secondary section, and the two sections are electrically isolated through an isolation module, so that the secondary circuit can be prevented from being influenced by the fault of the primary circuit; meanwhile, interference signals of the secondary circuit are prevented from being transmitted back to the primary circuit. The feedback control module is arranged in the secondary circuit, the feedback industrial control signal transmitted to the actuator by the output circuit is collected, the feedback industrial control signal is compared with the sampling industrial control signal, and when the feedback industrial control signal is inconsistent with the sampling industrial control signal, the feedback industrial control signal is output. And a feedback industrial control signal transmitted to the execution module by the output circuit is adjusted until the feedback industrial control signal is consistent with the sampling industrial control signal, so that the accuracy of signal transmission is improved.

Description

Technical Field

[0001] The present invention relates to the field of electrical control, and in particular to an intelligent feedback-type industrial control signal isolation and regulation system and method. Background Art

[0002] In modern industrial and power systems, the reliability and stability of electrical control systems are crucial. With the development of electronic technology, electronic components in control systems are becoming more and more sophisticated, and the requirements for electromagnetic compatibility (EMC) are also becoming increasingly stringent. Traditional electrical control systems often have the following problems:

[0003] Due to the lack of effective electromagnetic interference protection measures, external electromagnetic interference can easily invade the system, causing signal distortion and inaccurate control, which in turn affects the operational stability of the entire system.

[0004] During signal transmission, there is no perfect isolation mechanism, which may lead to electrical connections between different circuit modules, which can easily cause faults to spread. For example, a short circuit in one module may affect the operation of other normal modules.

[0005] The control of current output is not precise enough, and there is a lack of effective closed-loop feedback adjustment mechanism, which results in the actuator's action not being able to accurately follow the preset requirements, affecting production efficiency and equipment performance.

[0006] When the system fails or experiences an abnormal situation, there is a lack of a timely and effective alarm mechanism, and operators cannot be quickly notified to handle the situation, which may lead to more serious equipment damage or production accidents.

[0007] Due to factors such as long on-site transmission distance and excessive load, the PLC's load capacity is insufficient, making it difficult to accurately transmit current signals, resulting in a significant decrease in signal accuracy and stability, seriously affecting the normal operation of the system and production efficiency. Summary of the Invention

[0008] The present invention provides an intelligent feedback type industrial control signal isolation and regulation system and method, which are used to solve the problems of low signal accuracy and poor stability in existing electrical control systems.

[0009] In order to solve the above technical problems, the technical solution proposed by the present invention is:

[0010] An intelligent feedback type industrial control signal isolation and regulation system, comprising: a control module, a primary circuit, an isolation module, a secondary circuit, an execution module and a power supply module connected in sequence;

[0011] The control module is used to generate an industrial control signal; and transmit the industrial control signal to the isolation module through the primary circuit;

[0012] The isolation module is used to electrically isolate the industrial control signal and generate a corresponding sampled industrial control signal to transmit to the secondary circuit;

[0013] The secondary circuit includes a feedback control module and an output circuit. The output circuit is used to transmit the sampled industrial control signal to the actuator. The feedback control module is used to collect the feedback industrial control signal transmitted to the actuator by the output circuit, and compare the feedback industrial control signal with the sampled industrial control signal. When the feedback industrial control signal is inconsistent with the sampled industrial control signal, the feedback industrial control signal transmitted by the output circuit to the execution module is adjusted until the feedback industrial control signal is consistent with the sampled industrial control signal.

[0014] Preferably, the output circuit includes a first digital-to-analog converter; the feedback control module includes a microcontroller and a sampling unit; the first input end of the microcontroller is connected to the output end of the isolation module; the first output end of the microcontroller is connected to the input end of the first digital-to-analog converter, the output end of the first digital-to-analog converter is respectively connected to the input end of the actuator and the input end of the sampling unit, and the output end of the sampling unit is connected to the second input end of the microcontroller.

[0015] Preferably, the sampling unit includes a first sampling circuit, a first amplifying circuit and a first analog-to-digital converter, the output end of the first digital-to-analog conversion unit is connected to the input end of the first sampling circuit, the output end of the first sampling circuit is connected to the input end of the first amplifying circuit, the output end of the first amplifying circuit is connected to the input end of the first analog-to-digital converter, and the output end of the first analog-to-digital converter is connected to the second input end of the microcontroller.

[0016] Preferably, the output circuit includes a first EMC protection circuit, and the output end of the first digital-to-analog conversion unit is connected to the actuator through the first EMC protection circuit;

[0017] and / or

[0018] The microcontroller is also used to filter the received sampled industrial control signal;

[0019] and / or

[0020] It also includes an alarm module, and the output end of the microcontroller is also connected to the alarm module.

[0021] Preferably, the primary circuit includes a second sampling unit, and the control module transmits the industrial control signal to the isolation module through the second sampling unit; the second sampling unit includes a second sampling circuit, a second amplifying circuit and a second analog-to-digital converter; the input end of the second sampling circuit is connected to the output end of the control module, the output end of the second sampling circuit is connected to the input end of the second amplifying circuit, the output end of the second amplifying circuit is connected to the input end of the second analog-to-digital converter, and the output end of the second analog-to-digital converter is connected to the input end of the digital isolation module.

[0022] Preferably, the primary circuit further includes a second EMC protection circuit, and the output end of the control module is connected to the input end of the second sampling unit through the second EMC protection circuit;

[0023] and / or

[0024] The isolation module is a digital isolator.

[0025] Preferably, the power supply module is a coupled power supply module, which includes a power supply and a power supply coupling circuit. The output end of the power supply is connected to the input end of the power supply coupling circuit, and the output end of the power supply coupling circuit is respectively connected to the input ends of the primary circuit and the secondary circuit. The power supply supplies power to the primary circuit and the secondary circuit respectively through the power supply coupling circuit.

[0026] Preferably, the coupled power supply module further includes a third EMC protection circuit, a DC / DC unit, a DC / AC unit, a first AC / DC unit, and a second AC / DC unit. The output end of the power supply is connected to the input end of the third EMC protection circuit, the output end of the third EMC protection circuit is connected to the input end of the DC / DC unit, the output end of the DC / DC unit is connected to the input end of the DC / AC unit, the output end of the DC / AC unit is connected to the input end of the power coupling circuit, the power coupling circuit is connected to the input end of the primary circuit through the first AC / DC unit, and the power coupling circuit is connected to the input end of the secondary circuit through the second AC / DC unit.

[0027] An intelligent feedback type industrial control signal isolation and regulation method is applied to the above-mentioned intelligent feedback type industrial control signal isolation and regulation system, comprising the following steps:

[0028] The feedback control module collects the feedback industrial control signal transmitted to the actuator by the output circuit of the secondary module, and compares the feedback industrial control signal with the sampled industrial control signal generated by the isolation module. When the feedback industrial control signal is inconsistent with the sampled industrial control signal, the feedback industrial control signal transmitted to the execution module by the output circuit is adjusted until the feedback industrial control signal is consistent with the sampled industrial control signal.

[0029] Preferably, the method comprises the following steps:

[0030] The feedback control module receives the sampled industrial control signal generated by the isolation module, and compares the sampled industrial control signal generated by the isolation module with the preset initial industrial control signal to determine whether the initial industrial control signal is consistent with the sampled industrial control signal:

[0031] If they are inconsistent, assigning the value of the sampled industrial control signal to the initial industrial control signal;

[0032] The feedback control module adjusts the feedback industrial control signal output by the output circuit;

[0033] The feedback control signal outputted by the output circuit is collected by the first sampling circuit and sent to the feedback control module;

[0034] The feedback control module compares the feedback industrial control signal with the assigned initial industrial control signal to determine whether the feedback industrial control signal is consistent with the assigned initial industrial control signal:

[0035] If they are inconsistent, the feedback control module adjusts the feedback industrial control signal output by the output circuit.

[0036] Preferably, before comparing the feedback industrial control signal with the assigned initial industrial control signal, the feedback control module further performs any of the following steps:

[0037] S1. Determine whether the feedback industrial control signal is less than a preset first threshold value. If so, control the alarm module to alarm and / or prompt the user that a circuit breaker fault has occurred in the system.

[0038] S2. Determine whether the feedback industrial control signal is greater than a preset second threshold value. If so, control the alarm module to sound an alarm and / or prompt a user that a system overload fault has occurred.

[0039] S3. When the initial industrial control signal is inconsistent with the sampled industrial control signal, start the timer to start timing, and when the feedback industrial control signal is inconsistent with the initial industrial control signal after assignment, compare the timing of the timer with the preset time threshold. When the timing of the timer is greater than the preset time threshold, control the alarm module to alarm and / or prompt the user that the system is abnormal.

[0040] The present invention has the following beneficial effects:

[0041] 1. The present invention divides the signal transmission circuit between the control module and the actuator into two sections, a primary section and a secondary section, and electrically isolates the two sections through an isolation module. This prevents primary circuit failures from affecting the secondary circuit. Furthermore, to prevent interference in the secondary circuit, the interference signal from the secondary circuit is also prevented from being transmitted back to the primary circuit. The present invention provides a feedback control module in the secondary circuit. By collecting the feedback industrial control signal transmitted from the output circuit to the actuator and comparing the feedback industrial control signal with the sampled industrial control signal, the present invention adjusts the feedback industrial control signal transmitted from the output circuit to the actuator module until the feedback industrial control signal is consistent with the sampled industrial control signal, thereby improving the accuracy of signal transmission.

[0042] 2. In the preferred solution, in terms of power supply, the power coupling circuit adopts transformer coupling to isolate the primary and secondary power supplies, improve system stability and reliability, and solve the fault propagation problem caused by imperfect isolation in traditional systems.

[0043] 3. In the preferred solution, the system features multiple alarm mechanisms, including current threshold alarms, long-term regulation abnormality alarms, and circuit break alarms. Once an abnormality occurs, the alarm circuits immediately trigger audible and visual alarm signals, allowing operators to promptly identify and address the fault, ensuring safe and stable system operation.

[0044] 4. In the preferred solution, the isolation module's secondary stage features a separate power supply, providing stable and sufficient energy to the output module. The output module's DAC precisely adjusts the output current to accommodate varying load types and power requirements. Furthermore, the presence of a closed-loop feedback and alarm mechanism ensures real-time monitoring and adjustment of the output during load operation, enabling timely detection and resolution of abnormalities. This enables the isolation module to stably and reliably drive the actuator, effectively resolving the issue of weak on-site PLC load capacity.

[0045] In addition to the above-described objects, features and advantages, the present invention has other objects, features and advantages. The present invention will be further described in detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0047] Figure 1 This is a simplified structural diagram of the intelligent feedback type industrial control signal isolation and regulation system according to an embodiment of the present invention;

[0048] Figure 2 The figure is a flow chart of an intelligent feedback-type industrial control signal isolation and adjustment method according to an embodiment of the present invention. DETAILED DESCRIPTION

[0049] The embodiments of the present invention are described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered by the claims.

[0050] Example 1:

[0051] like Figure 1 As shown, the present invention provides an intelligent feedback type industrial control signal isolation and regulation system, comprising: a power supply module, a control module connected in sequence, a primary circuit, an isolation module, a secondary circuit and an execution module;

[0052] Among them, the power module provides power to the primary circuit and the secondary circuit;

[0053] The control module is used to generate an industrial control signal; and transmit the industrial control signal to the isolation module through the primary circuit;

[0054] The isolation module is used to electrically isolate the industrial control signal and generate a corresponding sampled industrial control signal to transmit to the secondary circuit;

[0055] The secondary circuit includes a feedback control module and an output circuit. The output circuit is used to transmit the sampled industrial control signal to the actuator. The feedback control module is used to collect the feedback industrial control signal transmitted to the actuator by the output circuit, and compare the feedback industrial control signal with the sampled industrial control signal. When the feedback industrial control signal is inconsistent with the sampled industrial control signal, the feedback industrial control signal transmitted by the output circuit to the execution module is adjusted until the feedback industrial control signal is consistent with the sampled industrial control signal.

[0056] Specifically, in a preferred embodiment, the power supply module is preferably a coupled power supply module, which includes a power supply and a power supply coupling circuit. The output end of the power supply is connected to the input end of the power supply coupling circuit, and the output end of the power supply coupling circuit is respectively connected to the input ends of the primary circuit and the secondary circuit. The power supply supplies power to the primary circuit and the secondary circuit respectively through the power supply coupling circuit.

[0057] The coupled power supply module further includes a third EMC protection circuit, a DC / DC unit, a DC / AC unit, a first AC / DC unit, and a second AC / DC unit. The output end of the power supply is connected to the input end of the third EMC protection circuit, the output end of the third EMC protection circuit is connected to the input end of the DC / DC unit, the output end of the DC / DC unit is connected to the input end of the DC / AC unit, the output end of the DC / AC unit is connected to the input end of the power coupling circuit, the power coupling circuit is connected to the input end of the primary circuit through the first AC / DC unit, and the power coupling circuit is connected to the input end of the secondary circuit through the second AC / DC unit.

[0058] In a preferred embodiment, the primary circuit includes a second sampling unit and a second EMC protection circuit; the second sampling unit includes a second sampling circuit, a second amplifying circuit and a second analog-to-digital converter; the output end of the control module is connected to the input end of the second sampling circuit through the second EMC protection circuit, the output end of the second sampling circuit is connected to the input end of the second amplifying circuit, the output end of the second amplifying circuit is connected to the input end of the second analog-to-digital converter, and the output end of the second analog-to-digital converter is connected to the input end of the digital isolation module.

[0059] In a preferred solution, the isolation module is preferably a digital isolator.

[0060] In a preferred embodiment, the output circuit includes a first digital-to-analog converter and a first EMC protection circuit; the feedback control module includes a microcontroller and a sampling unit; the first input of the microcontroller is connected to the output of the isolation module; the first output of the microcontroller is connected to the input of the first digital-to-analog converter, the output of the first digital-to-analog converter is connected to the input of the actuator and the input of the sampling unit, respectively; and the output of the sampling unit is connected to the second input of the microcontroller. The sampling unit includes a first sampling circuit, a first amplifier circuit, and a first analog-to-digital converter; the output of the first digital-to-analog converter is connected to the input of the first sampling circuit, the output of the first sampling circuit is connected to the input of the first amplifier circuit, the output of the first amplifier circuit is connected to the input of the first analog-to-digital converter, and the output of the first analog-to-digital converter is connected to the second input of the microcontroller. The output of the first digital-to-analog converter is connected to the actuator via the first EMC protection circuit.

[0061] In a preferred embodiment, the intelligent feedback-type industrial control signal isolation and regulation system of the present invention further includes an alarm module, and the output end of the microcontroller is also connected to the alarm module.

[0062] In this embodiment, the main control unit may be a PLC or other controller.

[0063] In a preferred embodiment, the EMC protection circuit of the present invention uses multi-layer shielding technology, including metal shell shielding and electromagnetic shielding material wrapping of internal circuits. It can effectively filter out high-frequency and low-frequency electromagnetic interference, ensuring the purity of the signal entering the sampling circuit.

[0064] In this embodiment, the sampling circuit uses a low-value precision resistor divider and capacitor filtering network to accurately capture the PLC output signal. The PLC outputs a 4-20mA current signal, which the sampling circuit can accurately capture. The sampling frequency can be adjusted between 1kHz and 10kHz depending on the actual application scenario, ensuring that subtle signal changes can be captured.

[0065] The amplifier circuit uses a high-gain, low-noise operational amplifier. It can linearly amplify the weak signal collected by the sampling circuit, with an adjustable amplification factor between 10 and 100 times, meeting the conversion requirements of the subsequent analog-to-digital converter (ADC).

[0066] The analog-to-digital converter (ADC) uses a high-speed, high-precision analog-to-digital conversion chip that can quickly convert analog signals into digital signals and transmit them to the microcontroller MCU in a high-speed serial communication manner through a digital isolator.

[0067] The microcontroller (MCU) should feature high-performance processing capabilities and a rich set of peripheral interfaces. It receives digital signals from the primary circuit via a digital isolator and processes them according to a pre-set control algorithm. For example, in a motor speed control application, the MCU can precisely adjust the motor's speed based on the received digital signals using a PID control algorithm.

[0068] In this embodiment, the digital-to-analog converter (DAC) accurately adjusts the output current (4-20 mA) according to the adjustment signal transmitted by the MCU. This module directly controls the action of the actuator and achieves precise control of the actuator by adjusting the output current.

[0069] In a preferred embodiment, when the current signal collected by the sampling circuit exceeds the threshold value preset by the alarm module, the comparator will detect the abnormality, and the logic gate circuit will trigger the alarm to emit an audible and visual alarm signal.

[0070] If the output current cannot reach the PLC output set value for a long time (which can be set by the MCU internal timer), the MCU will send a signal to the alarm module, triggering an audible and visual alarm. This is because under normal control, if the current cannot reach the set value for a long time, there is a high possibility of potential fault.

[0071] When the output circuit is broken, the sampling circuit cannot detect the current. This state will be transmitted to the MCU, which will then trigger the alarm module to send an alarm signal so that the operator can detect and handle the fault in time.

[0072] Specifically, the workflow of the intelligent feedback industrial control signal isolation and regulation system in the present invention is as follows:

[0073] 1. System initialization and power supply

[0074] After power is turned on, the third EMC protection circuit begins to operate, filtering the wide-band input voltage for electromagnetic interference. The common-mode inductor suppresses common-mode interference signals, while the differential-mode capacitor filters out differential-mode interference, ensuring a relatively pure voltage signal before entering subsequent circuits.

[0075] The voltage from the third EMC protection circuit enters the DC / DC unit for transformation, then is converted to AC by the DC / AC unit. This is isolated and transmitted via the power coupling circuit before being converted to stable DC by the first and second AC / DC units, respectively, and output to the corresponding modules. This circuit, based on the system's preset voltage distribution scheme, converts the voltage to the different DC voltages required by the isolation module's primary and secondary circuits, for example, providing a 5V operating voltage for the primary circuit and a 12V operating voltage for the secondary circuit.

[0076] Initialize the isolation module's primary and secondary EMC protection circuits, sampling circuit, amplifier circuit, analog-to-digital converter (ADC), and microprocessor (MCU). For example, set the sampling frequency of the sampling circuit to 5kHz and the initial amplification factor of the amplifier circuit to 50x. The MCU then loads the preset control algorithm and initializes parameters such as the internal timer.

[0077] 2. Primary circuit workflow

[0078] After the PLC outputs a 4-20mA current signal, the second sampling circuit begins to collect signals. The resistor divider network in the second sampling circuit divides the current signal according to a predetermined ratio, and the capacitor filter network removes high-frequency noise from the signal to obtain a more stable analog voltage signal. This second sampling circuit uses a low-value precision resistor divider and a capacitor filter network to accurately collect the signal output by the PLC. Its sampling frequency can be adjusted between 1kHz-10kHz according to the actual application scenario to ensure that subtle changes in the signal can be captured. The second sampling circuit processes the signal through a low-value precision resistor divider and a capacitor filter network:

[0079] V 初级采样 =R 初级采样 ×I PLC

[0080] Where R初级采样 is the primary sampling resistor, I PLC Output current signal to PLC.

[0081] This circuit has high sampling accuracy and removes high-frequency clutter to ensure signal purity.

[0082] This analog voltage signal enters the second amplifier circuit, which linearly amplifies the signal according to a preset gain factor to meet the ADC input requirements. This amplifier circuit uses a high-gain, low-noise operational amplifier to linearly amplify the weak signal collected by the sampling circuit, with an adjustable gain factor between 10 and 100.

[0083] V 初级输出 =G 初级 ×V 初级采样

[0084] Where G 初级 It is the amplification factor of the primary operational amplifier, usually adjustable between 10-100 times.

[0085] The amplified analog signal is converted to a digital signal by a second analog-to-digital converter. This second analog-to-digital converter utilizes a high-speed, high-precision analog-to-digital conversion chip, rapidly converting the analog signal into a digital signal. This signal is then transmitted to the secondary circuit's MCU via a digital isolator via high-speed serial communication. The primary circuit's second EMC protection circuit utilizes multi-layer shielding technology, including a metal housing shield and electromagnetic shielding material surrounding the internal circuits. This effectively filters out both high- and low-frequency electromagnetic interference, ensuring a pure signal entering the sampling circuit. This circuit can effectively filter out external interference signals in industrial environments with high electromagnetic interference.

[0086] 3. Secondary circuit workflow

[0087] After receiving the digital signal, the MCU processes it according to its internal control algorithm. For example, in a valve opening control application, if the current value corresponding to the target opening is 12mA and the current sampled feedback current value is 8mA, the MCU calculates the required output current increase based on the algorithm and transmits the corresponding adjustment signal to the first digital-to-analog converter unit DAC.

[0088] After receiving the adjustment signal from the MCU, the voltage-to-current conversion circuit within the first digital-to-analog converter (DAC) changes the output current based on the signal. For example, the adjustment signal raises the reference voltage within the current source chip, increasing the output current and gradually approaching the target value of 12mA.

[0089] The first sampling circuit of the secondary circuit is similar to the second sampling circuit of the primary circuit. It collects the output current in real time. The low-value precision resistor converts the current signal into an analog voltage signal. The sampled voltage signal is amplified by the operational amplifier and sent to the high-precision first analog-to-digital converter ADC. The first analog-to-digital converter ADC converts the analog voltage signal into a digital signal and feeds it back to the MCU. The MCU continues to adjust the regulation signal according to the feedback signal to achieve precise closed-loop control of the output current.

[0090] V 次级输出 =G 次级 ×R 次级采样 ×I 输出

[0091] Where R 次级采样 is the secondary sampling resistor, I 输出 Output current signal for the current source chip of the output module, G 次级 is the amplification factor of the secondary operational amplifier. The error Error between the target value and the feedback signal is:

[0092]

[0093] The MCU adjusts the current source module based on the error, gradually adjusting the output current to match the target value. The system continuously monitors the error between the output current and the target value and dynamically adjusts the output signal to ensure a precise actuator response.

[0094] 4. Fault monitoring and alarm

[0095] The current signal collected by the first sampling circuit is transmitted to the MCU in real time. When the current signal exceeds the threshold preset by the alarm circuit, the MCU outputs a signal to trigger the alarm to emit an audible and visual alarm signal.

[0096] The internal timer of the MCU continuously monitors the output current adjustment time. When the output current cannot be adjusted to the target value within the preset time, there may be a potential fault, such as actuator jamming, load abnormality, etc. The MCU sends an alarm signal to the alarm circuit, triggering an audible and visual alarm.

[0097] When the output circuit is broken, the first sampling circuit cannot detect the current, and the current sensor outputs a zero signal. The signal is transmitted to the MCU. After identification, the MCU triggers the alarm circuit to send an alarm signal. The operator then troubleshoots and handles the system based on the alarm information.

[0098] In summary, the primary circuit and the secondary circuit of the present invention are electrically isolated by a digital isolator. In terms of signal transmission, from the primary ADC to the secondary MCU, the digital isolator effectively blocks the electrical connection, preventing the influence of the primary circuit fault on the secondary circuit, and also preventing the interference signal of the secondary circuit from being transmitted back to the primary circuit. In terms of power supply, the power supply part adopts a transformer coupling method through the power coupling circuit to isolate the primary and secondary power supplies, so that the fluctuation and interference of the primary power supply will not be transmitted to the secondary power supply, and vice versa, thereby improving the stability and reliability of the entire system and effectively solving the problem of fault propagation caused by imperfect isolation in traditional systems.

[0099] In addition, if Figure 2 As shown, based on the above system, the present invention also provides an intelligent feedback type industrial control signal isolation and adjustment method, including:

[0100] 1. Startup: After the system is powered on, each module is initialized, including the initialization of the hardware circuit and the setting of software parameters such as sampling frequency, amplification factor, etc., and then enters the signal processing process.

[0101] 2.PLC signal output: PLC outputs 4-20mA current signal S PLC ,This signal serves as the input signal of the system and will be received by the primary circuit for subsequent processing.

[0102] 3. Primary Sampling and Filtering: The secondary sampling circuit in the primary circuit begins sampling and filtering the PLC's output current signal using a low-precision resistor divider and capacitor filtering network. The resistor divider converts the current signal into a voltage signal, and the capacitor filter removes high-frequency noise from the signal, resulting in a stable analog voltage signal, ready for subsequent amplification. The sampling frequency can be adjusted between 1kHz and 10kHz to ensure accurate capture of signal changes.

[0103] 4. Signal Amplification: The amplifier circuit uses a high-gain, low-noise operational amplifier to linearly amplify the sampled and filtered analog voltage signal. The amplification factor is adjustable between 10-100 times, amplifying weak signals to a range suitable for ADC processing and ensuring accurate conversion to digital signals.

[0104] 5. ADC Conversion: A high-speed, high-precision analog-to-digital converter (ADC) chip converts the amplified analog signal into a digital signal. Digital signals are easy to transmit, process, and store, providing the foundation for subsequent digital signal processing and control. The converted digital signal is transmitted via high-speed serial communication to the MCU on the secondary side of the isolation module via a digital isolator.

[0105] 6. Digital isolator: Digital isolators achieve electrical isolation between primary and secondary circuits, effectively blocking electrical connections and preventing primary circuit faults from affecting the secondary circuit. They also prevent interference signals from the secondary circuit from being transmitted back to the primary circuit, ensuring safe and reliable transmission of digital signals and improving system stability and reliability.

[0106] 7. Digital filtering and obtaining stable samples: Further digital filtering is performed on the received digital signal in the MCU.

[0107] Remove possible noise and interference to obtain stable and reliable sampling industrial control signals (hereinafter referred to as signal samples S 采样 ),

[0108] Provide accurate data basis for subsequent signal judgment and control algorithm execution.

[0109] 8. Signal judgment: Compare the DAC module output to set the initial industrial control signal S 初始 And the digitally filtered signal sample S 采样 .

[0110] If the two are equal, the system proceeds directly to the next step: DAC output and actuator control. If they are not equal, timer T is started and the countdown is initialized. The signal sample is assigned to the relevant variables before proceeding to the next step. This judgment process is a key step in achieving precise control in the system. Through real-time comparison and adjustment, the output signal is ensured to be consistent with the set value.

[0111] 9. DAC Output and Actuator Control: The DAC module converts digital signals into analog signals. These signals are then processed by the EMC module to enhance their immunity to electromagnetic interference, ultimately driving the actuator module to complete its intended action. During this process, the output module's current source chip precisely adjusts the output current based on the MCU's regulation signal, enabling precise control of the actuator.

[0112] 10. Control and adjust the closed-loop feedback link: collect the DAC module output signal in real time and trigger the feedback link (secondary sampling).

[0113] After the signal is amplified and converted by ADC, the DAC module feedback industrial control signal S is obtained. 反馈 , used to adjust system parameters. Through closed-loop control, the system continuously adjusts the output based on the feedback signal to ensure that the actuator's action is carried out accurately according to the preset requirements.

[0114] 11. Open circuit check: If the feedback industrial control signal S 反馈 If it is 0, the circuit breaker alarm is triggered immediately and the process ends; if it is not 0, it goes to the next step. The circuit breaker alarm can promptly remind the operator of the circuit breaker fault so that it can be checked and repaired in time.

[0115] 12. Overload check: If the feedback industrial control signal S 反馈 If the value exceeds the threshold, an overload alarm is triggered immediately, and the process ends. If the value does not exceed the threshold, the process proceeds to the next step. The overload alarm prevents damage to the system due to overload and ensures safe operation of the system.

[0116] 13. Signal tracking: If the feedback industrial control signal S 反馈 With the initial industrial control signal S 初始 When the ADC is equal, the timer is stopped and a countdown is initiated. The output is continuously corrected to track the input signal, and then the ADC conversion is resumed. This process ensures that the system can operate continuously and stably, tracking signal changes in real time and making adjustments.

[0117] 14. Abnormal alarm: If the feedback industrial control signal S 反馈 With the initial industrial control signal S 初始 are not equal, and the timer T exceeds the set value,

[0118] If an abnormal alarm is triggered, the process ends; if it does not exceed the set value, it goes to the next step and the MCU performs control and adjustment.

[0119] Then enter the DAC output and actuator control link. The abnormal alarm mechanism can detect abnormal conditions in the system operation in time.

[0120] Prevent potential failures from causing more serious problems.

[0121] In summary, from the perspective of structural design, the present invention achieves electrical isolation between the primary circuit and the secondary circuit through a digital isolator, and cooperates with the transformer coupling method adopted by the power coupling circuit to form a complete electrical isolation structure, which solves the problem of incomplete isolation and easy fault propagation in the existing technology. In terms of the power module, the wide input design and the EMC protection circuit composed of common-mode inductors and differential-mode capacitors broaden the application range of the power supply and improve the anti-interference ability, which is difficult to achieve with traditional power input and protection; the DC / DC transformer circuit adopts high-frequency switching power supply technology to ensure stable operation under a wide input voltage, surpassing the performance limitations of ordinary transformer circuits. In the signal processing part, the primary multi-layer shielding EMC protection technology of the isolation module, combined with the sampling circuit with adjustable sampling frequency, the amplifier circuit with adjustable amplification factor, and the high-speed, high-precision ADC using high-speed serial communication, realizes the optimization of the entire process from signal acquisition, processing to transmission. The isolation module's secondary high-performance MCU, coupled with a rich set of peripheral interfaces, enables precise signal processing using pre-set control algorithms. The output module's DAC precisely regulates output current, and combined with a closed-loop feedback sampling and regulation mechanism, enables precise control of the actuator and dynamic error adjustment, addressing shortcomings in existing technologies in terms of control accuracy and dynamic regulation. Furthermore, the alarm mechanism, a major innovation of this invention, integrates current threshold alarms, long-term regulation anomaly alarms, and circuit breaker alarms, reversing the existing single alarm mechanism and ensuring safe and stable system operation.

[0122] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. An intelligent feedback industrial control signal isolation and regulation system, characterized in that: include: A control module, a primary circuit, an isolation module, a secondary circuit, an execution module, and a power module connected in sequence; The control module is used to generate an industrial control signal; and transmit the industrial control signal to the isolation module through the primary circuit; The isolation module is used to electrically isolate the industrial control signal and generate a corresponding sampled industrial control signal to transmit to the secondary circuit; The secondary circuit includes a feedback control module and an output circuit. The output circuit is used to transmit the sampled industrial control signal to the actuator. The feedback control module is used to collect the feedback industrial control signal transmitted to the actuator by the output circuit, and compare the feedback industrial control signal with the sampled industrial control signal. When the feedback industrial control signal is inconsistent with the sampled industrial control signal, the feedback industrial control signal transmitted by the output circuit to the execution module is adjusted until the feedback industrial control signal is consistent with the sampled industrial control signal.

2. The intelligent feedback industrial control signal isolation and regulation system according to claim 1, characterized in that: The output circuit includes a first digital-to-analog converter; the feedback control module includes a microcontroller and a sampling unit; the first input end of the microcontroller is connected to the output end of the isolation module; the first output end of the microcontroller is connected to the input end of the first digital-to-analog converter, the output end of the first digital-to-analog converter is respectively connected to the input end of the actuator and the input end of the sampling unit, and the output end of the sampling unit is connected to the second input end of the microcontroller.

3. The intelligent feedback type industrial control signal isolation and regulation system according to claim 1 is characterized in that: The sampling unit includes a first sampling circuit, a first amplifying circuit and a first analog-to-digital converter. The output end of the first digital-to-analog conversion unit is connected to the input end of the first sampling circuit, the output end of the first sampling circuit is connected to the input end of the first amplifying circuit, the output end of the first amplifying circuit is connected to the input end of the first analog-to-digital converter, and the output end of the first analog-to-digital converter is connected to the second input end of the microcontroller.

4. The intelligent feedback type industrial control signal isolation and regulation system according to claim 2, characterized in that: The output circuit includes a first EMC protection circuit, and the output end of the first digital-to-analog conversion unit is connected to the actuator through the first EMC protection circuit; and / or The microcontroller is also used to filter the received sampled industrial control signal; and / or It also includes an alarm module, and the output end of the microcontroller is also connected to the alarm module.

5. The intelligent feedback industrial control signal isolation and regulation system according to any one of claims 1 to 4, characterized in that: The primary circuit includes a second sampling unit, and the control module transmits the industrial control signal to the isolation module through the second sampling unit; the second sampling unit includes a second sampling circuit, a second amplifying circuit and a second analog-to-digital converter; the input end of the second sampling circuit is connected to the output end of the control module, the output end of the second sampling circuit is connected to the input end of the second amplifying circuit, the output end of the second amplifying circuit is connected to the input end of the second analog-to-digital converter, and the output end of the second analog-to-digital converter is connected to the input end of the digital isolation module.

6. The intelligent feedback type industrial control signal isolation and regulation system according to claim 5, characterized in that: The primary circuit further includes a second EMC protection circuit, and the output end of the control module is connected to the input end of the second sampling unit through the second EMC protection circuit; and / or The isolation module is a digital isolator.

7. The intelligent feedback type industrial control signal isolation and regulation system according to claim 1, characterized in that: The power supply module is a coupled power supply module, comprising a power supply and a power coupling circuit, wherein the output end of the power supply is connected to the input end of the power coupling circuit, and the output end of the power coupling circuit is connected to the input ends of the primary circuit and the secondary circuit respectively, and the power supply supplies power to the primary circuit and the secondary circuit respectively through the power coupling circuit; The coupled power supply module further includes a third EMC protection circuit, a DC / DC unit, a DC / AC unit, a first AC / DC unit, and a second AC / DC unit. The output end of the power supply is connected to the input end of the third EMC protection circuit, the output end of the third EMC protection circuit is connected to the input end of the DC / DC unit, the output end of the DC / DC unit is connected to the input end of the DC / AC unit, the output end of the DC / AC unit is connected to the input end of the power coupling circuit, the power coupling circuit is connected to the input end of the primary circuit through the first AC / DC unit, and the power coupling circuit is connected to the input end of the secondary circuit through the second AC / DC unit.

8. An intelligent feedback type industrial control signal isolation and regulation method, applied to the intelligent feedback type industrial control signal isolation and regulation system according to any one of claims 1 to 7, characterized in that: The following steps are involved: The feedback control module collects the feedback industrial control signal transmitted to the actuator by the output circuit of the secondary module, and compares the feedback industrial control signal with the sampled industrial control signal generated by the isolation module. When the feedback industrial control signal is inconsistent with the sampled industrial control signal, the feedback industrial control signal transmitted to the execution module by the output circuit is adjusted until the feedback industrial control signal is consistent with the sampled industrial control signal.

9. The intelligent feedback type industrial control signal isolation and adjustment method according to claim 8, characterized in that: The following steps are involved: The feedback control module receives the sampled industrial control signal generated by the isolation module, and compares the sampled industrial control signal generated by the isolation module with the preset initial industrial control signal to determine whether the initial industrial control signal is consistent with the sampled industrial control signal: If they are inconsistent, assigning the value of the sampled industrial control signal to the initial industrial control signal; The feedback control module adjusts the feedback industrial control signal output by the output circuit; The feedback control signal outputted by the output circuit is collected by the first sampling circuit and sent to the feedback control module; The feedback control module compares the feedback industrial control signal with the assigned initial industrial control signal to determine whether the feedback industrial control signal is consistent with the assigned initial industrial control signal: If they are inconsistent, the feedback control module adjusts the feedback industrial control signal output by the output circuit.

10. The intelligent feedback type industrial control signal isolation and adjustment method according to claim 9, characterized in that: Before comparing the feedback industrial control signal with the assigned initial industrial control signal, the feedback control module further performs any of the following steps: S1. Determine whether the feedback industrial control signal is less than a preset first threshold value. If so, control the alarm module to alarm and / or prompt the user that a circuit breaker fault has occurred in the system. S2. Determine whether the feedback industrial control signal is greater than a preset second threshold value. If so, control the alarm module to sound an alarm and / or prompt a user that a system overload fault has occurred. S3. When the initial industrial control signal is inconsistent with the sampled industrial control signal, start the timer to start timing, and when the feedback industrial control signal is inconsistent with the initial industrial control signal after assignment, compare the timing of the timer with the preset time threshold. When the timing of the timer is greater than the preset time threshold, control the alarm module to alarm and / or prompt the user that the system is abnormal.

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