A wireless remote control receiving method and device for a winch

Abstract

The present application relates to the technical field of electrical control, and particularly relates to a wireless remote control receiving control system of a winch and a control method thereof. The system constructs a four-level progressive safety protection framework: the first level, through the series connection of a relay (K1) and a MOS tube, prevents the MOS tube from losing control after breakdown; the second level, through the MCU detection of the sticking fault of K1 and alarm, avoids the unprotected operation of the system after the failure of K1; the third level, when K1 is stuck, the MCU does not immediately stop, but controls the bypass composed of a second relay (K2) and a resistor (R), so that the system enters a degraded operation mode, realizes controllable energy consumption braking, and greatly improves the availability under failure; the fourth level, a passive hardware backup circuit composed of a pressure sensitive element (TVS / MOV) and a normally closed thermal relay is additionally arranged in parallel with the MCU, when the MCU fails and the MOS tube breaks down, the total power supply is mechanically cut off through thermal driving, and the final and most reliable safety protection is provided. The present application realizes the comprehensive coverage from software intelligent fault tolerance to hardware intrinsic safety.

Description

Technical Field

[0001] This invention relates to the field of industrial control and safety system technology, and more specifically, to a control system and method with multi-level redundant safety protection mechanisms that is particularly suitable for high-power DC motors (such as winch drive motors). Background Technology

[0002] As a critical rescue and traction device, the reliability of the winch's control system is paramount. Existing wireless remote control drive solutions for winches have inherent flaws: relying solely on solid-state switches such as MOSFETs carries the risk of being damaged by the back electromotive force generated by the motor, leading to loss of control; relying solely on relays carries the risk of contact arcing, resulting in short lifespan and control failure. Therefore, this invention proposes a preliminary improvement: connecting the MOSFET and the relay in series, using the relay as a backup switch. However, this solution places the system's safety entirely on the relay; if the relay fails to connect first, the protection function will fail.

[0003] Furthermore, this invention introduces an MCU for relay status diagnosis and system locking in case of fault. While this prevents danger, it leads to the problem of equipment being "completely paralyzed due to minor faults," which is extremely disadvantageous in emergency situations. In addition, all solutions relying on an MCU (active component) share a common risk: the MCU itself may crash due to program errors, power supply interference, or other reasons. If a MOSFET fails at this time, the MCU will be unable to perform any protective actions, and the system will still face the risk of loss of control. Therefore, there is an urgent need in the field for a comprehensive solution that can achieve intelligent fault tolerance to maintain availability while providing ultimate hardware security protection independent of control software. Summary of the Invention

[0004] The purpose of this invention is to provide a winch wireless remote control receiving and control system and method, which completely solves the problem of not being able to balance security, availability and reliability in the prior art by constructing a multi-level defense-in-depth system that includes active intelligent control and passive hardware backup.

[0005] A winch wireless remote control receiver and control system, whose core innovation lies in the integration of four levels of safety protection: Level 1 (basic series protection): The main circuit is formed by the main control switching unit (such as a MOSFET) and the first relay (K1) connected in series. Under normal circumstances, the MOSFET performs precise PWM control, and K1 acts as the main switch.

[0006] Level 2 (Intelligent Fault Diagnosis): The controller (MCU) monitors the status of K1 in real time through the feedback circuit and can diagnose whether an adhesion fault has occurred.

[0007] Level 3 (Software Fault Tolerance and Degraded Operation): When the MCU detects K1 sticking, it does not immediately stop the machine. Instead, it activates a bypass consisting of the second relay (K2) and a power resistor (R), putting the system into "degraded operation mode." In this mode, the winch can still be started by a working MOSFET. When it needs to stop, the MCU controls K2 to engage, using resistor R to apply energy-dissipative braking to the motor, achieving a safe and controllable shutdown and maintaining basic availability under fault conditions.

[0008] Level 4 (Passive Hardware Ultimate Backup): This level operates in parallel with the MCU, providing independent protection. A varistor (MOV) or TVS diode is connected in parallel across the MOSFET. The heating coil of a normally closed thermal relay is connected in series with the varistor and then in parallel across the MOSFET. The normally closed contact of the thermal relay is connected in series in the main power supply circuit. When the MOSFET breaks down, the power supply voltage turns on the varistor, and a large current flows through the thermal relay coil, causing it to heat up and activate within seconds, mechanically disconnecting the main power supply. This process is entirely controlled by physical laws, independent of the MCU, providing the most fundamental safety guarantee.

[0009] Beneficial effects: Defense in depth: It forms a four-level protection system from "component redundancy" to "intelligent diagnosis", "software fault tolerance" and "hardware backup", achieving an extremely high level of security.

[0010] High availability: By adopting the concept of "degraded operation", the traditional mindset of downtime due to failure is broken, which greatly enhances the value of equipment in critical missions.

[0011] Ultimate safety: The unique passive hardware backup circuit solves the common "crash" risk problem of electronic control systems, ensuring that there is still a reliable physical path to achieve safe shutdown in the event of any software failure.

[0012] Strong systemic nature: This invention is not a point improvement, but a systemic safety architecture design that can be extended to other motor control applications with high reliability requirements.

[0013] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0014] The above and other objects, features and advantages of the present invention will become clearer from the following description of embodiments of the invention with reference to the accompanying drawings, in which: Figure 1 This is a flowchart illustrating an exemplary wireless remote control receiving method for a winch in this application. Detailed Implementation

[0015] The present application is described below based on embodiments, but it is not limited to these embodiments. In the detailed description of the present application below, certain specific details are described in detail. Those skilled in the art can fully understand the present application without these details. To avoid obscuring the substance of the present application, well-known methods, processes, flows, elements, and circuits are not described in detail.

[0016] Furthermore, those skilled in the art should understand that the accompanying drawings provided herein are for illustrative purposes only and are not necessarily drawn to scale.

[0017] A winch wireless remote control receiver and control system includes a power supply, a winch motor (M), and a controller (MCU), characterized in that it further includes: a first-level protection module: including a main control switch unit and a first switch unit (K1), wherein the first switch unit (K1) and the main control switch unit are connected in series in the main power supply circuit of the winch motor (M); a second-level protection and third-level fault-tolerant module: including a second switch unit (K2) and an impedance element (R), wherein the branch formed by the second switch unit (K2) and the impedance element (R) connected in series is connected in parallel with the first switch unit (K1); the controller (MCU) is configured to detect the fault state of the first switch unit (K1) and to control the second switch unit (K2) to put the system into a degraded operation mode when a fault is detected; The fourth-level ultimate protection module includes a voltage-sensitive element and a thermally driven switch unit. The voltage-sensitive element is connected in parallel across the two ends of the main control switch unit. The thermal drive coil of the thermally driven switch unit is connected in series with the voltage-sensitive element and then in parallel across the two ends of the main control switch unit. The contacts of the thermally driven switch unit are connected in series in the total power circuit of the winch motor (M) and are normally closed.

[0018] In the degraded operation mode, the controller (MCU) is configured to: allow the winch motor (M) to be started by controlling the main control switch unit, and to stop the winch motor (M) by controlling the second switch unit (K2) to conduct energy-consuming braking using the impedance element (R).

[0019] In the fourth-level ultimate protection module, the voltage-sensitive element is a varistor (MOV) or a transient voltage suppressor diode (TVS); the thermally driven switch unit is a normally closed thermal relay or a mechanical switch in conjunction with a thermal fuse.

[0020] The method for the controller (MCU) to detect the fault status of the first switch unit (K1) includes: sending a disconnect command to the first switch unit (K1) while the main control switch unit is turned off, and detecting its actual status; if the actual status does not match the command, a fault is determined.

[0021] The main control switching unit is a MOSFET, IGBT, or thyristor.

[0022] The first switching unit (K1) and the second switching unit (K2) are electromechanical relays or contactors.

[0023] A multi-level safety control method for a winch wireless remote control receiving and control system as described in any one of claims 1-6, characterized by comprising the following steps: First-level protection step: coordinating motor control with a main control switch unit via a series-connected first switch unit (K1); Second-level monitoring step: monitoring whether the first switch unit (K1) experiences a sticking fault; Third-level fault-tolerance step: when a sticking fault is detected in the first switch unit (K1), controlling the second switch unit (K2) to activate, causing the system to enter a degraded operation mode for limited function control; Fourth-level backup step: through a passive hardware circuit, when the main control switch unit experiences a breakdown short circuit, disregarding the state of the controller (MCU), directly thermally driving a mechanical switch to disconnect the main power supply.

[0024] The degraded operation mode in the third-level fault-tolerant step includes: starting the motor through the main control switch unit, and using the series impedance element (R) to perform energy-consuming braking by turning on the second switch unit (K2).

[0025] The specific process of the fourth-level backup step is as follows: When the main control switch unit breaks down, the power supply voltage is applied to the parallel voltage sensitive element, causing it to conduct and generate a large current. This current flows through the coil of the thermal drive switch unit to generate heat. After a preset delay, it drives its normally closed contact to open.

[0026] See Figure 1 The system operates according to the following logic: Step 100: System initialization and continuous monitoring loop.

[0027] Step 110 (Level 1 Protection): When the system is working normally, MCU 1 coordinates and controls MOSFET and K1 to realize various operations of the motor.

[0028] Step 120 (Second-level protection): MCU 1 performs diagnostics periodically (e.g., upon power-up). It first turns off the MOSFET, then commands K1 to disconnect, and uses feedback to determine if K1 is stuck.

[0029] Step 130: Determine if K1 is normal? If normal, return to normal monitoring; if stuck, proceed to step 140.

[0030] Step 140 (Third-level protection activated): MCU 1 triggers an audible and visual alarm and prepares to enter degrade mode. It can first turn on K2 and determine whether the MOSFET has also broken down by detecting the current on resistor R (dual fault detection).

[0031] Step 150 (Degradation Operation): If only K1 fails while the MOSFET is intact, the system enters degradation mode.

[0032] Start-up: The user command turns on the MOSFET of MCU1, and the motor starts running.

[0033] Stop: When the user issues a stop command, MCU 1 executes: 1) Turn off the MOSFET; 2) Immediately engage K2. The motor's kinetic energy is dissipated through resistor R via K1 (already engaged) and K2 (just engaged), achieving rapid braking. In this mode, complex functions can be disabled, retaining only "Start" and "Brake Stop".

[0034] Step 160 (Level 4 protection, working independently in parallel): This level of protection is completely independent of MCU 1.

[0035] Under normal conditions: the TVS diode is in a high-resistance state, the current flowing through the heating coil Coil is extremely small, and the K_thermal contact of the thermal relay remains closed.

[0036] When MOSFET 2 breaks down (regardless of whether the MCU is working): the power supply voltage is directly applied to the TVS diode and the heating coil. The TVS diode quickly breaks down and conducts, generating a large current of several amperes flowing through the heating coil.

[0037] Thermally driven action: The heating coil (Coil) heats up within a short time (e.g., 2-5 seconds), causing the bimetallic strip to deform and mechanically disconnecting the normally closed contact of the thermal relay (K_thermal), completely cutting off the power supply to the entire machine. This is the final and most reliable protection.

[0038] The basic principles of this disclosure have been described above with reference to specific embodiments. However, it should be noted that the advantages, benefits, and effects mentioned in this disclosure are merely examples and not limitations, and should not be considered as essential features of each embodiment of this disclosure. Furthermore, the specific details disclosed above are for illustrative and facilitative purposes only, and are not limitations. These details do not limit the scope of this disclosure to the specific details described above.

[0039] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For system embodiments, since they largely correspond to method embodiments, the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments.

[0040] The block diagrams of devices, apparatuses, devices, and systems disclosed herein are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As those skilled in the art will recognize, these devices, apparatuses, devices, and systems can be connected, arranged, and configured in any manner. Words such as “comprising,” “including,” “having,” etc., are open-ended terms meaning “including but not limited to,” and are used interchangeably with them. The terms “or” and “and” as used herein refer to the terms “and / or,” and are used interchangeably with them unless the context clearly indicates otherwise. The term “such as” as used herein refers to the phrase “such as but not limited to,” and is used interchangeably with it.

[0041] It should also be noted that in the apparatus, devices, and methods of this disclosure, the components or steps are decomposable and / or recombinable. Such decomposition and / or recombination should be considered equivalent to the present disclosure. The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use this disclosure. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other aspects without departing from the scope of this disclosure. Therefore, this disclosure is not intended to be limited to the aspects shown herein, but rather to be carried out within the widest scope consistent with the principles and novel features disclosed herein.

[0042] The above description has been given for purposes of illustration and description. Furthermore, this description is not intended to limit the embodiments of this disclosure to the forms disclosed herein. Although numerous exemplary aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, alterations, additions, and sub-combinations therein.

[0043] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A winch wireless remote control receiver and control system, comprising a power supply, a winch motor (M), and a controller (MCU), characterized in that, Also includes: The first-level protection module includes a main control switch unit and a first switch unit (K1). The first switch unit (K1) and the main control switch unit are connected in series in the main power supply circuit of the winch motor (M). The second-level protection and third-level fault-tolerant module includes a second switch unit (K2) and an impedance element (R). The branch formed by the second switch unit (K2) and the impedance element (R) connected in series is connected in parallel with the first switch unit (K1). The controller (MCU) is configured to detect the fault state of the first switching unit (K1) and to control the second switching unit (K2) to put the system into a degraded operation mode when a fault is detected; the fourth-level ultimate protection module includes a voltage-sensitive element and a thermally driven switching unit; The voltage-sensitive element is connected in parallel across the two ends of the main control switch unit; the thermal drive coil of the thermal drive switch unit is connected in series with the voltage-sensitive element and then in parallel across the two ends of the main control switch unit, and the contacts of the thermal drive switch unit are connected in series in the total power supply circuit of the winch motor (M) and are normally closed.

2. The winch wireless remote control receiver and control system according to claim 1, characterized in that, In the degraded operation mode, the controller (MCU) is configured to: allow the winch motor (M) to be started by controlling the main control switch unit, and to stop the winch motor (M) by controlling the second switch unit (K2) to conduct energy-consuming braking using the impedance element (R).

3. The winch wireless remote control receiver and control system according to claim 1, characterized in that, In the fourth-level ultimate protection module, the voltage-sensitive element is a varistor (MOV) or a transient voltage suppressor diode (TVS); the thermally driven switch unit is a normally closed thermal relay or a mechanical switch in conjunction with a thermal fuse.

4. The winch wireless remote control receiver and control system according to claim 1, characterized in that, The method for the controller (MCU) to detect the fault status of the first switch unit (K1) includes: sending a disconnect command to the first switch unit (K1) while the main control switch unit is turned off, and detecting its actual status; if the actual status does not match the command, a fault is determined.

5. The winch wireless remote control receiver and control system according to claim 1, characterized in that, The main control switching unit is a MOSFET, IGBT, or thyristor.

6. The winch wireless remote control receiver and control system according to claim 1, characterized in that, The first switching unit (K1) and the second switching unit (K2) are electromechanical relays or contactors.

7. A multi-level safety control method for a winch wireless remote control receiver control system as described in any one of claims 1-6, characterized in that, Includes the following steps: The first level of protection involves coordinating the control of the motor with the main control switch unit via a series-connected first switch unit (K1); the second level of monitoring involves monitoring whether the first switch unit (K1) experiences a sticking fault; the third level of fault tolerance involves controlling the second switch unit (K2) to activate when a sticking fault is detected in the first switch unit (K1), causing the system to enter a degraded operation mode for limited function control; the fourth level of backup involves using a passive hardware circuit to directly thermally drive a mechanical switch to disconnect the main power supply when the main control switch unit experiences a breakdown short circuit, regardless of the state of the controller (MCU).

8. The method according to claim 7, characterized in that, The degraded operation mode in the third-level fault-tolerant step includes: starting the motor through the main control switch unit, and using the series impedance element (R) to perform energy-consuming braking by turning on the second switch unit (K2).

9. The method according to claim 7, characterized in that, The specific process of the fourth-level backup step is as follows: When the main control switch unit breaks down, the power supply voltage is applied to the parallel voltage sensitive element, causing it to conduct and generate a large current. This current flows through the coil of the thermal drive switch unit to generate heat. After a preset delay, it drives its normally closed contact to open.

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