Power management device based on nationwide components

Abstract

The invention relates to technical improvement of power management, in particular to a power management device based on national components, which adopts the national components, can receive voltage and current information reported by four PFC (power factor correction) modules in real time, and controls on-off of 390V direct current output to a direct current voltage conversion module by the PFC modules through a relay. Meanwhile, information such as voltage, current and temperature in the power supply device is reported to an upper computer through a serial port, a returned instruction is responded in time, the power supply device comprises an MCU module and a power supply module, the power supply module comprises a PFC module and a DC / DC module, and the MCU module is connected with a power supply, a clock, an isolator and a memory; the MCU module is further connected with the PFC module through a 485 serial port and a relay, the PFC module is further in IIC communication connection with the MCU module through a DC / DC module, an HYM32F407ZET6 is selected as a main control MCU chip, communication with an upper computer and the interior of a power supply is achieved through a communication bus, information such as voltage and current of the power module is monitored in real time for automatic turn-off, and a device manufacturer can give full-localization proof.

Description

Technical Field

[0001] This invention relates to a technological improvement in power management, specifically a power management device based on all domestically produced components. Background Technology

[0002] Controlling the on / off state of an external 220V AC power supply is crucial for both large industrial automated motor equipment and other small industrial control devices. In the event of an emergency, it concerns the safety of the operator and the entire equipment. Traditional power control devices often use fuses or circuit breakers for protection. When the circuit voltage or current exceeds the rated value of the device, the fuse or circuit breaker automatically shuts off the power to the downstream circuit to achieve the protection purpose. Currently, this method is widely used in the field of automation.

[0003] However, it has the following drawbacks: 1. Lack of information interaction and early warning functions: Conventional fuses and circuit breakers cannot interact with other modules. They only disconnect the power supply to the entire device immediately when the circuit voltage or current exceeds the rated value. The host computer cannot receive any fault information and cannot take timely and intelligent actions, which may result in occasional circuit overloads that cannot be identified. Alternatively, due to the complexity of analog circuits, the power module output voltage may fluctuate frequently even without triggering the fuse, significantly reducing the lifespan of downstream precision components. 2. Fault information is not stored and cannot be accurately located: When a traditional power control device fails, subsequent equipment repair or equipment replacement requires a series of troubleshooting steps, which cannot quickly and accurately locate the faulty part. Non-professionals find it difficult to maintain the device effectively. 3. No system self-test, the power supply itself may be faulty: Common power supply control devices cannot respond in time when there is a fault in the power supply front end, which may lead to unstable output voltage or no output voltage. Summary of the Invention

[0004] To address the aforementioned problems in existing technologies, this invention provides a power management device based on all domestically produced components. Employing all domestically produced components, it can receive voltage and current information reported in real time from four PFC modules and control the on / off switching of the 390V DC power output from the PFC modules to the DC-DC conversion module via relays. Simultaneously, it reports internal voltage, current, and temperature information to a host computer via a serial port and responds instantly to returned commands.

[0005] The technical solution adopted by this application to solve its technical problem is: a power management device based on all domestically produced components. The power module includes a PFC module and a DC / DC module, and includes an MCU module for managing the power module. The MCU module is connected to the power supply, clock, isolation, and storage. The MCU module is also connected to the PFC module through a 485 serial port and a relay. The PFC module is also connected to the MCU module through the DC / DC module via IIC communication. When the power module is powered on, the MCU module performs a self-test and tests the PFC module. If the PFC module is abnormal, the relay is disconnected, the SD card records the PFC module abnormality, and reports to the host computer. If the PFC module is normal, the relay is activated, the DC / DC module and the MCU module communicate through the IIC bus, and the MCU module monitors for abnormalities in real time. If an abnormality exists, the relay is disconnected, the SD card records the abnormality of a certain DC / DC module and reports to the host computer. If the voltage and current fluctuate frequently, the host computer is notified to issue another relay command.

[0006] Preferably, the drive pins of the MCU module are connected to the relay via a transistor amplifier circuit.

[0007] Preferably, the power module can convert 24V voltage to 12V voltage, and then use LDO to output 3.3V voltage, with 0.1uF and 10uF filter capacitors added on both sides of LDO.

[0008] Preferably, the MCU module is the HYM32F407ZET6 from the HYM32 series.

[0009] Preferably, the power module is Xi'an Weijing WK422812S-6G.

[0010] The beneficial effects of this invention are as follows: It uses a microcontroller and its peripheral circuits to communicate with both the host computer and the internal components of the power supply via a communication bus, enabling real-time monitoring of the power module's voltage, current, and other information for automatic shutdown. Simultaneously, it sends an early warning to the host computer when the power output is unstable, receives and parses instructions from the host computer, performs corresponding operations, and can store fault information in an SD card and report it to the host computer. Furthermore, it selects the HYM32F407ZET6 as the main control MCU chip, a microcontroller chip based on the ARM Cortex-M4 core launched by Chengdu Honglixin. This chip features fast response speed, a wide operating temperature range, and the manufacturer can provide proof of complete domestic production, resulting in a high level of independent controllability. Attached Figure Description

[0011] Figure 1 This is a hardware block diagram of the power management device of the present invention; Figure 2 This is the system control logic diagram of the present invention; Figure 3This is the MCU circuit diagram of the present invention; Figure 4 This is a circuit diagram of the relay module of the present invention; Figure 5 This is the power supply circuit diagram of the present invention; Figure 6 This is a circuit diagram of the storage circuit of the present invention; Figure 7 This is a CAN communication circuit diagram of the present invention; Figure 8 This is a 485 communication circuit diagram of the present invention; Figure 9 This is a circuit diagram of the IIC communication circuit of the present invention; Figure 10 This is a reset circuit diagram of the present invention; Figure 11 This is the clock circuit diagram of the present invention; Figure 12 This is the input isolation circuit diagram of the present invention; Figure 13 This is the output isolation circuit diagram of the present invention. Detailed Implementation

[0012] The main technical problems to be solved by this invention are as follows: I. Lack of Information Interaction and Early Warning Functions: The device of this invention has two CAN buses that can communicate with a host computer, uploading the voltage and current information read by the MCU from the four DC-DC voltage conversion modules via the IIC bus to the host computer in real time. When the voltage and current output by the DC-DC voltage conversion modules exceed the threshold, the four PFC modules can be controlled by four relays, thereby controlling the shutdown of the DC-DC voltage conversion modules. If the voltage and current of a certain power module fluctuate frequently but do not reach the threshold, the operator can control whether the power module is shut down via the host computer according to the actual usage situation.

[0013] II. Fault information not stored, fault cannot be accurately located, no system self-test: This power control device can read the voltage, current, temperature, and other information of the PFC module in real time via serial port. When the PFC module fails, the PFC module input is directly shut off via a relay to achieve system self-test. Simultaneously, the fault information of the PFC module and the abnormal information of the DC voltage conversion module are stored on an SD card. During subsequent troubleshooting, the data on the SD card can be directly read to locate the corresponding module.

[0014] A schematic diagram of the hardware structure of the power management device based on domestically produced components of the present invention is shown below. Figure 1As shown, the system includes an MCU module and a power supply module. The power supply module includes a PFC module and a DC / DC module. The MCU module is connected to the power supply, clock, isolation, and storage. The MCU module is also connected to the PFC module via a 485 serial port and a relay. The PFC module is also connected to the MCU module via the DC / DC module for I2C communication. Its control logic is as follows: Figure 2 As shown, when the power module is powered on, the MCU module performs a self-test and checks the PFC module. If the PFC module malfunctions, the relay disconnects, the SD card records the PFC module malfunction, and the host computer is notified. If the PFC module is normal, the relay is activated, and the DC / DC module communicates with the MCU module via the IIC bus. The MCU module monitors for abnormalities in real time. If an abnormality is found, the relay disconnects, the SD card records the abnormality of a specific DC / DC module, and the host computer is notified. If the voltage and current fluctuate frequently, the host computer is notified to issue another relay command. The core chip of this device is the HYM32F407ZET6 chip from Chengdu Honglixin. The device interacts with the host computer via the CAN bus, with the PFC module via the 485 serial port, and with the DC-DC module via the IIC bus. A relay module is also included. When the power board is powered on, the MCU module performs a self-test by reading the voltage, current, and temperature information of the PFC module. If the PFC module malfunctions, the fault information is stored in the SD card, the relay is turned off, and the host computer is notified. If the PFC module is functioning correctly, the drive pins PG4, PG5, PG6, and PG7 will activate the relays, enabling the DC-DC converter module to operate. The MCU will read the four DC-DC data channels via the IIC bus. If an anomaly is detected, the relays will be deactivated, and the corresponding fault information will be stored on the SD card. If the voltage or current fluctuates repeatedly below the threshold, the system will be reported to the host computer, allowing the operator to decide whether to power off the system based on actual needs. If everything is normal, the DC-DC module will continuously and stably output voltage, providing an excellent human-machine interface experience. The specific circuit diagram of the MCU module is shown below. Figure 3 As shown.

[0015] The drive pins of the MCU module are connected to the relay via a transistor amplifier circuit. Because the drive capability of the MCU pins is limited, typically only 20mA, a transistor amplifier circuit is needed to enhance the pin's drive capability. When the MCU determines that the PFC module is normal, it pulls the PG4 pin high to control the relay to conduct, thereby achieving the purpose of powering the DC-DC voltage conversion module. The schematic diagram of the transistor amplifier circuit is shown below. Figure 4 As shown; The power board uses 24V power, but the device requires both 12V and 3.3V. Since the device is used in an industrial environment, the power input needs to be isolated to prevent damage to internal components. Therefore, the Xi'an Weijing WK422812S-6G power module was selected to convert the 24V voltage to 12V, and then an LDO (HYM1117-3.3) was used to output 3.3V. 0.1uf and 10uf filter capacitors were added on both sides of the LDO to enhance the stability of the entire system. The schematic diagram of its power circuit is shown below. Figure 5 As shown; Regarding the storage module, the HYM32F407ZET6 has standard SD card bus pins. When a fault occurs in the PFC module or a DC-DC module inside the power supply, the MCU can store the fault information into the SD card. During subsequent repairs, a card reader can be used to retrieve the fault information and quickly locate the faulty component. A schematic diagram of its storage module circuit is shown below. Figure 6 As shown; Regarding the communication module, in this device, information interaction with the outside world mainly relies on the RS485 bus, IIC bus, and CAN bus, which are used to communicate with the PFC module, DC-DC module, and host computer of the power supply unit, respectively. This allows for real-time monitoring and processing of the internal information of the power supply unit and reporting problems to the host computer so that the operator can take timely action. The structural diagram of the CAN communication circuit is shown below. Figure 7 As shown in the figure, the schematic diagram of the 485 communication circuit is as follows: Figure 8 As shown in the diagram, the structure of the IIC communication circuit is as follows: Figure 9 As shown; The reset circuit operates on the principle of RC reset, while the HYM32F407ZET6 chip uses a low-level reset. At the instant of power-on, capacitor C7 begins charging, becoming short-circuited, resulting in a low voltage across it. This pulls the MCU reset pin low, initiating the MCU reset. When a button is pressed, the reset pin is shorted to ground, completing the low-level reset. The reset circuit is as follows: Figure 10 As shown; Figure 11 It serves as the clock circuit, acting as the external crystal oscillator for the entire device, providing a high-precision clock signal to the device during serial communication.

[0016] The device reserves some input / output signals for subsequent MCU functional debugging. Because of the high voltage present in industrial environments, to protect low-voltage circuits, match circuit levels, and suppress environmental interference, all input / output signals are optocoupled for isolation, i.e., input isolation circuitry (such as...). Figure 12 (as shown) and output isolation circuit (such as) Figure 13 (As shown).

[0017] The device operates as follows: Upon system power-on reset, the MCU enters the working state. The MCU obtains information such as voltage and current of the PFC module via the 485 serial port and performs a system self-test. If the PFC module malfunctions, the relay is deactivated, the SD card records the PFC module malfunction, and the information is reported to the host computer via the CAN bus. If the PFC module is functioning normally, the relay is activated, and the DC / DC module of the power supply unit begins operation. The MCU monitors various information channels in real time via the IIC bus. If the voltage, current, or temperature of a certain DC / DC module exceeds a set threshold, the relay is deactivated, the SD card records the corresponding DC / DC module malfunction, and the information is reported to the host computer via the CAN bus. If the voltage or current fluctuates frequently within the threshold range, the MCU reports the information to the host computer, and the operator decides whether to disconnect the power supply unit based on the actual site requirements, forming a good human-machine interaction. If everything is normal, a command is issued to keep the relay activated, and the power supply unit provides normal power.

[0018] This patent constructs a single-chip microcomputer minimum system and its peripheral circuits. It communicates with both the host computer and the power supply via a communication bus. The system can perform self-tests on the power supply through the internal control logic of the chip, monitoring the voltage and current of the power module in real time and automatically shutting it off. Simultaneously, it sends a warning to the host computer when the power output is unstable, receives and parses the instructions from the host computer, and performs corresponding operations, achieving excellent human-computer interaction.

[0019] When the system self-tests or the power module malfunctions, the fault information can be stored on the SD card and reported to the host computer. During subsequent maintenance, the faulty module can be quickly and accurately located. The HYM32F407ZET6 was selected as the main control MCU chip. Developed by Chengdu Honglixin, this microcontroller is based on the ARM Cortex-M4 core, features rich peripheral interfaces, a high clock frequency of up to 168MHz, fast response speed, and a wide operating temperature range. Other core components include the HYM65HVD230 CAN transceiver chip, the TLP281-4 isolation optocoupler, and the WK422812S-6G power supply. The device manufacturers can provide proof of complete domestic production, ensuring a high level of independent controllability.

[0020] The above embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

Claims

1. A power management device based on domestically produced components, the power module including a PFC module and a DC / DC module, characterized by, The power module includes an MCU module for managing the power module, the MCU module is powered, clocked, isolated, and stored; the MCU module is further connected with the PFC module through a 485 serial port and a relay, respectively; the PFC module is further connected with the MCU module through an IIC communication connection of a DC / DC module; when the power module is powered on, the MCU module is self-checked and detects the PFC module; if the PFC module is abnormal, the relay is disconnected, the SD card records the abnormal PFC module, and reports the upper computer; if the PFC module is normal, the relay is attracted, the DC / DC module communicates with the MCU module through an IIC bus, and the MCU module monitors whether there is an abnormality in real time; If there is an abnormality, the relay is disconnected, the SD card records the abnormal DC / DC module of a certain road and reports the upper computer; if the voltage and current fluctuate frequently, the upper computer is reported and the relay instruction is further given.

2. The power management device based on domestically manufactured components according to claim 1, wherein, The driving pin of the MCU module is connected with the relay through a transistor amplification circuit.

3. The power management device based on domestically manufactured components according to claim 1, wherein, The power module can convert 24V voltage into 12V voltage, and then output 3.3V voltage by using an LDO, and 0.1uf and 10uf filter capacitors are added on both sides of the LDO.

4. The power management device based on domestically manufactured components according to claim 1, wherein, The MCU module is a HYM32 series HYM32F407ZET6.

5. The power management device based on domestically manufactured components according to claim 3, wherein, The power module selects a Xi'an Weijing WK422812S-6G.

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