Portable satellite antenna driving control cabinet

Abstract

The invention relates to the technical field of satellite measurement and control, and provides a portable satellite antenna drive control cabinet which comprises a cabinet shell and a cabinet body. The cabinet body is surrounded by the cabinet shell, and the cabinet body comprises a power supply system, a driving system and a control system; the power supply system is used for supplying power to the driving system and the control system and comprises a two-way power supply UPS system and a 24V uninterrupted UPS system; the driving system is used for driving a satellite antenna and comprises a servo driver; and the control system is used for controlling the state in the driving control cabinet. According to the scheme, the size of the control cabinet can be reduced, the physical protection capability is improved, key equipment and key data are prevented from being damaged under severe conditions, and the maintenance and operation efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of satellite telemetry and control technology, and in particular to a portable satellite antenna drive control cabinet. Background Technology

[0002] Satellite telemetry, tracking, and command (TT&C) antennas are a core component of satellite ground stations, undertaking the critical tasks of tracking, telemetry, remote control, and data transmission of satellites in orbit. A typical TT&C antenna system includes the antenna itself, a servo drive system, a high-power amplifier, a low-noise amplifier, and a central processing unit located indoors. The control cabinet, which provides a stable and reliable power supply and logic control for these devices, is the cornerstone of the entire system's stable operation.

[0003] With the rapid development of global space information networks, the construction needs of satellite tracking and control stations are showing a trend towards diversification, decentralization, and concealment. In addition to large fixed stations, numerous small stations, mobile stations, portable stations, and even temporary emergency stations are deployed in various complex environments, such as mountainous areas, islands, border outposts, research vessels, and emergency communication vehicles. These application scenarios place unprecedentedly stringent demands on the support equipment of the tracking and control system, especially the control cabinets: First, deployment space is extremely limited, requiring equipment to be small and lightweight; second, deployment environments are mostly unobstructed outdoor areas, where equipment must directly face the corrosive effects of harsh weather conditions such as wind, frost, rain, snow, sandstorms, and salt spray; finally, the external power grids of these stations are often unstable, sometimes even relying on generators for power, leading to frequent voltage fluctuations, frequency flicker, and even sudden power outages.

[0004] However, the design concepts of existing satellite telemetry and control antenna control cabinets are mostly derived from traditional industrial electrical control cabinets, which exposes many inherent defects when dealing with the above-mentioned new requirements.

[0005] Currently, in the field of satellite telemetry, tracking, and command (TT&C), common power supply and control schemes mainly take the following forms, which constitute the technologies most relevant to this application: Technical Solution A: Traditional discrete power supply control system This solution uses multiple independent cabinets or chassis to implement different functions. For example, a standard industrial electrical cabinet is used to install control components such as circuit breakers, contactors, and PLCs; a separate UPS cabinet provides uninterruptible power; and a distribution box is responsible for mains power access and distribution. The devices are connected via numerous external cables. This solution has a clear logical architecture and is easy to maintain, but the overall system footprint is large, the connections are complex, and reliability is significantly affected by external cables and connectors.

[0006] Technical Solution B: Functionally Integrated Control Cabinet This solution is a preliminary integration based on technical solution A, consolidating power distribution, control, and basic UPS functions into a larger cabinet. It reduces inter-cabinet cabling and improves system integration. However, its internal layout is typically loose, resulting in low space utilization and a still bulky cabinet size. Furthermore, its UPS units are mostly general-purpose industrial UPS units, which are large, heavy, and have fixed backup time configurations, making them difficult to adjust flexibly according to actual needs. The cabinet's protection rating is usually only IP20 or IP31, suitable only for clean, dry indoor environments and unsuitable for direct outdoor deployment. Based on the above most relevant existing technologies, their main drawbacks can be systematically summarized as follows: 1. The contradiction between space volume and integration is prominent, resulting in poor deployment flexibility: Both technical solutions A and B are too large to meet the deployment requirements of extremely narrow spaces (such as inside mobile vehicle cabins, prefabricated modular cabins, and small equipment rooms on rooftops).

[0007] 2. Insufficient environmental adaptability and reliability challenges: The cabinet protection level of technical solutions A and B is low, and they are not waterproof or dustproof at all. They cannot resist corrosion from salt spray, condensation and other factors. Once placed outdoors, the internal components will age rapidly and short-circuit due to moisture and dust accumulation, leading to system failure.

[0008] 3. Weak power supply continuity and high risk of system downtime: Existing technologies generally lack a fast and reliable automatic dual-power switching mechanism. When the mains power fails, the system will face a complete power outage. The UPS or backup power supply in technical solution B is either insufficient in capacity due to size limitations, or has excessively long switching time or distorted output waveforms due to design flaws. It cannot effectively support the continuous operation of critical control units such as HMI and PLC at critical moments, causing the entire "brain" of the station to crash, the servo system to lose lock, and the communication link to be interrupted.

[0009] 4. Lack of data preservation mechanisms and low level of intelligent operation and maintenance: In the instant of a sudden power outage, data being processed by the PLC, operation logs recorded by the HMI, and status information will be lost if not saved in time. This data loss is fatal for analyzing the cause of the fault and tracing the operation process. Furthermore, current technology lacks precise monitoring of the cabinet's microenvironment (temperature and humidity) and key electrical parameters (battery health, load current), making predictive maintenance impossible. Problems are often only discovered after a complete equipment failure, increasing operation and maintenance costs and system downtime.

[0010] Therefore, there is a need for a portable satellite antenna drive control cabinet that can reduce the size of the control cabinet, increase physical protection capabilities, avoid damage to critical equipment and data under harsh conditions, and improve maintenance and operation efficiency.

[0011] The information disclosed in the background section is only intended to enhance the understanding of the background of this application, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0012] The main purpose of this invention is to overcome the problems of contradiction between space volume and integration, insufficient environmental adaptability, and easy damage to key equipment and key data in the existing technology. It provides a portable satellite antenna drive control cabinet that can reduce the size of the control cabinet, increase physical protection capabilities, avoid damage to key equipment and key data under harsh conditions, and improve maintenance and operation efficiency.

[0013] To achieve the above objectives, the first aspect of the present invention provides a portable satellite antenna drive control cabinet, comprising: a cabinet shell and a cabinet body; The cabinet shell surrounds the cabinet body, which includes a power supply system, a drive system, and a control system. The power supply system is used to supply power to the drive system and control system, including a dual-power UPS system and a 24V uninterruptible UPS power supply system. The drive system is used to drive the satellite antenna and includes a servo driver; The control system is used to control the state inside the drive control cabinet.

[0014] According to an exemplary embodiment of the present invention, the cabinet housing includes a front door, a rear door, and a side panel. An air conditioning compressor is installed inside the front door, a human-machine interface device is installed in the rear door, and an aviation plug is installed in the side panel.

[0015] According to an exemplary embodiment of the present invention, the power conversion module is used to convert 380V voltage to 220V voltage and 220V voltage to 24V voltage.

[0016] According to an exemplary embodiment of the present invention, the cabinet shell is a cuboid structure, with each side having a length of less than or equal to 1500 mm.

[0017] According to an exemplary embodiment of the present invention, the cabinet housing further includes a rainproof top cover and a rain shield, the rainproof top cover being disposed on the top of the cabinet housing and the rain shield being disposed above the human-computer interaction device.

[0018] According to an exemplary embodiment of the present invention, the dual-power UPS system includes a primary 380V input terminal, a backup 380V input terminal, and a dual power switching switch, which is used to switch between the primary 380V input terminal and the backup 380V input terminal.

[0019] According to an exemplary embodiment of the present invention, the 24V uninterruptible UPS power supply system includes a 24V uninterruptible backup battery, an AC input terminal, and a protection board with equalization circuit. The protection board with equalization circuit is placed between the 24V uninterruptible backup battery and the AC input terminal and is used to shut down the charging circuit when the 24V uninterruptible backup battery is fully charged.

[0020] According to an exemplary embodiment of the present invention, the power supply system further includes a first protection system and a second protection system, wherein the first protection system is used to protect the dual-power UPS system and the second protection system is used to protect the 24V uninterruptible UPS power supply system.

[0021] According to an exemplary embodiment of the present invention, the drive system further includes a braking resistor unit and a main contactor, wherein the braking resistor unit is used to consume the regenerative energy generated when the servo driver brakes, and the main contactor is used to realize the timing power-on and soft start of the drive system.

[0022] According to an exemplary embodiment of the present invention, the control system includes a programmable logic controller (PLC) and a human-machine interface (HMI) device interconnected with each other. The PLC is used to monitor the air conditioning status and environmental status, and to control the operation of the drive control cabinet according to the real-time status of the drive control cabinet. The HMI device is located on the outside of the rear door and includes an HMI, a normal indicator light, an abnormal indicator light, a local control indicator light, a remote control indicator light, an emergency stop indicator light, a master switch button, an X-axis limit release button, a Y-axis limit release button, and an emergency stop button.

[0023] According to an exemplary embodiment of the present invention, the programmable logic controller is further configured to save data and stop driving the satellite antenna movement in the event of insufficient power.

[0024] The advantages of this invention are: This invention adopts a "power-control-drive" trinity architecture, creating a closed-loop integrated unit for "power supply-control-drive". Through systematic design, it seamlessly integrates a high-power servo drive system into an uninterruptible power supply control cabinet, enabling all energy flow, data flow, and control flow to be completed within a highly protected physical space. This fundamentally solves the problems of size, connectivity, and reliability inherent in discrete systems. Simultaneously, the PLC, acting as a unified brain, not only manages the antenna's motion trajectory but also makes decisions regarding the enable and power consumption of the drive system in emergency power mode, achieving cross-system collaborative management—something discrete systems cannot achieve. This solution successfully addresses the heat dissipation and heating of the control and drive systems within a sealed cabinet. Through an integrated industrial air conditioning thermal management design, the heat dissipation power reaches 1.5kW, meeting the requirements of high-power devices. With an IP65 protection rating, it is dustproof and waterproof, adapting to harsh industrial environments and ensuring the long-term stable operation of the integrated cabinet housing high-power devices under harsh conditions. This invention incorporates a pre-defined hardware and software safety strategy. In the event of a power grid anomaly, the system not only ensures the operation of the control unit and data preservation but also prevents the antenna from moving uncontrollably through orderly management of the drive system, achieving dual protection for both data and equipment. Specific advantages are as follows: 1. Ultimate integration and space saving: Compared with the traditional "control cabinet + drive cabinet" solution, this invention integrates all the core equipment of the system into a single cabinet, reducing the overall footprint by 50% and greatly expanding its application in space-sensitive scenarios.

[0025] 2. Extremely high system reliability: The system significantly reduces the number of external cables and connectors, lowering interconnect failure rates and electromagnetic interference risks. Internal bus communication improves motion control accuracy and reliability. The overall system MTBF (Mean Time Between Failures) is significantly improved by 30%.

[0026] 3. Seamless power supply continuity and comprehensive equipment protection: The dual protection of "STS (Stabilized Transfer Switch) + UPS" combined with intelligent collaborative energy management ensures seamless power switching from the power grid to the core load, effectively preventing various damages caused by sudden power outages.

[0027] 4. Excellent environmental adaptability: The high protection level of IP65 combined with powerful internal environmental control enables this cabinet to withstand harsh outdoor environments and achieve reliable operation around the clock.

[0028] 5. Intelligent Operation and Maintenance & Low-Cost Maintenance: Comprehensive status monitoring, fault early warning, and remote management functions make operation and maintenance work efficient and convenient. High system integration enables faster fault location, significantly reducing MTTR (Mean Time To Repair) to 30 minutes, resulting in a clear cost advantage throughout the entire lifecycle of operation and maintenance. Attached Figure Description

[0029] The above and other objects, features, and advantages of this application will become more apparent from the detailed description of exemplary embodiments with reference to the accompanying drawings. The drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0030] Figure 1 An exploded view of a three-dimensional model of a portable satellite antenna drive control cabinet is shown schematically.

[0031] Figure 2 The diagram schematically shows a front view of a portable satellite antenna drive control cabinet.

[0032] Figure 3 A schematic diagram of the structure inside the front door is shown.

[0033] Figure 4 The diagram schematically illustrates the structure of the outer side of the rear door.

[0034] Figure 5 A schematic diagram of the structure on the outside of the side panel is shown.

[0035] Figure 6 The cabinet layout diagram is shown schematically.

[0036] Figure 7 A schematic diagram of AC380V power distribution is shown.

[0037] Figure 8 A schematic diagram of the AC220V control power supply distribution is shown.

[0038] Figure 9 A schematic diagram of the DC24V control power supply distribution is shown.

[0039] Figure 10 A schematic diagram of the DC24V control power distribution is shown (another diagram).

[0040] Figure 11 The schematic diagram shows the DC24V brake power distribution.

[0041] Figure 12 The schematic diagram shows the secondary wiring diagram of the X-axis driver.

[0042] Figure 13 The schematic diagram shows the secondary wiring diagram of the Y-axis driver. Detailed Implementation

[0043] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein; rather, they are provided so that this application will be thorough and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted.

[0044] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0045] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0046] The flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily need to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0047] It should be understood that although the terms first, second, third, etc., may be used herein to describe various components, these components should not be limited by these terms. These terms are used to distinguish one component from another. Therefore, the first component discussed below may be referred to as the second component without departing from the teachings of this application. As used herein, the term "and / or" includes all combinations of any one and more of the associated listed items.

[0048] Those skilled in the art will understand that the accompanying drawings are merely schematic diagrams of exemplary embodiments, and the modules or processes in the drawings are not necessarily essential for implementing this application, and therefore cannot be used to limit the scope of protection of this application.

[0049] According to a first specific embodiment of the present invention, the present invention provides a portable satellite antenna drive control cabinet, comprising: a cabinet shell and a cabinet body.

[0050] like Figure 1 and Figure 2As shown, the cabinet shell surrounds the main unit. The cabinet shell is made of SUS304 stainless steel air conditioning cabinet, welded from 2mm thick cold-rolled steel plate, with powder-coated inner and outer surfaces in motor gray color. The cabinet shell has a cuboid structure, with each side length less than or equal to 1500mm. As a preferred embodiment, the dimensions of the cabinet shell are 750mm*750mm*1400mm.

[0051] The cabinet enclosure includes a front door, rear door, side panels, bottom plate, rainproof top cover, multiple uprights, drainage channels, waterproof gaskets, and rain guards. The uprights form a cuboid frame structure to support the cabinet. The front door is located on the front of the cuboid frame, the rear door on the rear, the side panels on the left and right sides, the base at the bottom, the rainproof top cover at the top, the waterproof gaskets at the connections between the uprights and the front, rear, and side panels, and the drainage channels at the top of the uprights. Figure 3 As shown, a 1500W air conditioning compressor is installed on the inside of the front door. Figure 4 As shown, the back door is used to install human-computer interaction devices. Figure 5 As shown, the side panel is used to install the following connectors: a 380V main connector, a 380V backup connector, a channel control connector, an X-axis second encoder, a Y-axis second encoder, X-axis limit 1, X-axis limit 2, Y-axis limit 1, Y-axis limit 2, a timing connector, a network port connector, and a backup network port connector. The channel control connector provides power and communication to the "channel switching unit" in the antenna feeder system. X-axis limit 1 is the positive end limit of the X-axis, and X-axis limit 2 is the negative end limit of the X-axis. Y-axis limit 1 is the positive end limit of the Y-axis, and Y-axis limit 2 is the negative end limit of the Y-axis. The X-axis rotation range is -90 degrees to +90 degrees, and the Y-axis rotation range is -90 degrees to +90 degrees. The limits are installed at +90 degrees and -90 degrees on the X-axis and Y-axis, respectively. This is a switch that "should never be touched under normal circumstances." Once any axis is triggered, the signal bypasses PLC logic processing and directly connects to the driver's emergency stop circuit or the main contactor's control circuit. This instantly and unconditionally cuts off the driver's enable signal, causing the antenna to brake abruptly. Simultaneously, it triggers the highest-level "hardware limit alarm," which typically requires manual intervention to reset. Manual intervention involves pressing the limit release button on the cabinet door. A rainproof top cover is located on the top of the cabinet shell, and a rain shield is positioned above the human-machine interface device.

[0052] In a preferred embodiment, a middle partition is provided inside the cabinet shell to isolate the various systems. The middle partition and the bottom plate are provided with ventilation and heat dissipation holes, and the inner walls of the holes are spot-welded with mesh, with a protection level of not less than IP65.

[0053] As a preferred embodiment, such as Figure 4 As shown, the rear door is equipped with a special door lock.

[0054] The cabinet includes a power supply system, a drive system, and a control system.

[0055] like Figure 6 As shown, Figure 6 The cabinet layout diagram is shown, from top to bottom as the first, second, third, fourth, fifth, and sixth functional areas. The first functional area, from left to right, contains an N-class circuit breaker, an R-class circuit breaker, a dual power transfer switch, fuses, a low-voltage surge protector, and a power filter. The second functional area, from left to right, contains surge protectors, a 2P circuit breaker, a DC circuit breaker, an AC contactor, a switch, a PLC, and terminal blocks. The third functional area, from left to right, contains Beckhoff modules, a thermostat, sockets, a 24V uninterruptible UPS module, and thin-plate relays. The fourth functional area, from left to right, contains the X-axis and Y-axis servo drives of the drive system; the bottom of the fourth functional area contains cable entry and connection points. The fifth functional area contains the UPS main unit. In the first implementation, the UPS main unit includes a UPS rectifier and a UPS inverter. The energy conversion path is: external 380V AC power → static transfer switch (STS) → UPS rectifier (AC / DC) → (charging the battery or supplying power to the inverter) → UPS inverter (DC / AC) → load. In the second implementation, the UPS main unit includes a bidirectional AC / DC converter, replacing the two independent, unidirectional energy flow units of "UPS rectifier" and "UPS inverter" with an integrated, intelligent "bidirectional AC / DC converter." This converter can be connected to solar panels to form a hybrid power supply system of "mains power-photovoltaic-energy storage," greatly extending backup time. The sixth functional area, from top to bottom, consists of 8U-battery pack 1 and 8U-battery pack 2. Each 8U-battery pack includes two battery packs. These two battery packs are different from the 24V uninterruptible backup battery-U22; they are used to power external devices.

[0056] The power supply system supplies power to the drive and control systems. It includes a dual-power UPS system, a power conversion module, a 24V uninterruptible UPS system, a first protection system, and a second protection system. The dual-power UPS system includes a primary 380V input terminal, a backup 380V input terminal, and a dual power transfer switch. The dual power transfer switch switches between the primary and backup 380V input terminals, providing two inputs: primary (N) and backup (R). The switching time is ≤10ms. Figure 7As shown, the dual power transfer switch is equipped with isolation protection switches QF5 / QF6 at its front end. The main 380V input terminal and the backup 380V input terminal are connected to the 380V main connector and 380V backup connector on the side panel, respectively. The backup power is connected to a rack-mounted UPS, model SPM10KL-33, with a full power of 8000W and a total operating time of approximately 14 minutes. The 380V voltage is used to power the servo drive and servo motor. It is an external power input to the cabinet, powering the entire cabinet. After reaching the cabinet, the internal design draws the first phase L1 (live wire), neutral wire N, and PE of the 380V three-phase power to form 220V AC power. The power conversion module is used to convert 380V voltage to 220V voltage and 220V voltage to 24V voltage. The 220V AC power provides power to the 220V to 24V power supply, circuit breakers, relays, fuses, surge protectors, low-voltage surge protectors, filters, etc. The 24V voltage provides power to switches, PLCs, Beckhoff modules, temperature controllers, etc. The 24V uninterruptible UPS power supply system includes a 24V uninterruptible backup battery-U22, an AC input terminal, and a protection board with a balancing circuit. The protection board is located between the 24V uninterruptible backup battery-U22 and the AC input terminal, and is used to shut down the charging circuit when the 24V uninterruptible backup battery-U22 is fully charged. The 24V uninterruptible backup battery-U22 has a capacity of 24V 10.4AH (approximately 220Wh) and is a lithium battery. The AC input terminal accepts AC power (AC100-240V), automatically resets, and charges while supplying power. Seamless switching between AC power and the 24V uninterruptible backup battery - U22, with a switching time ≤10ms; automatic charging and automatic switching ensure normal operation even during power outages; equipped with a balancing circuit protection board, it balances and charges at 4.23V, automatically shutting off the charging circuit when the battery is fully charged; when the AC power is normal, the 24V uninterruptible backup battery - U22 only charges and does not participate in power supply (battery power is not output, only input); this module ensures continuous power supply for at least 30 minutes. As a preferred implementation, for scenarios with drastic load fluctuations, a hybrid energy storage system of lithium-ion batteries and supercapacitors can be used in the 24V uninterruptible UPS power supply system to improve system power response speed and cycle life. The first protection system is used to protect the dual-power UPS system, and the second protection system is used to protect the 24V uninterruptible UPS power supply system.

[0057] like Figure 7 As shown, Figure 7 The diagram shows the AC 380V power distribution, specifically the connection relationship between the dual-power UPS system and the first protection system. The main 380V input terminal is located at... Figure 7 The bottom left corner features the high-current aviation socket - HXZ1, with the backup 380V input terminal located at... Figure 7To the right of the primary 380V input terminal is the high-current navigation socket - HXZ2. The high-current navigation socket uses the Y50DX-22051ZJ10 design and includes L1, L2, L3, N, and PE ports. Both the primary and backup 380V input terminals are connected to the dual-power automatic transfer switch - U21. Specifically, the L1, L2, L3, and N ports of the high-current navigation socket - HXZ1 are connected to the dual-power automatic transfer switch - U21 via the isolation protection switch - QF6, while the L1, L2, L3, and N ports of the high-current navigation socket - HXZ2 are connected to the dual-power automatic transfer switch - U21 via the isolation protection switch - QF5. This dual-power automatic transfer switch uses a dual-power 4P100A design. The dual-power automatic transfer switch-U21 includes three socket groups: the first socket group, the second socket group, and the third socket group. Each socket group includes an L1 port, an L2 port, an L3 port, a neutral (N) port, and a protective earth (PE) port. The first socket group connects to the main 380V input terminal, the second socket group connects to the backup 380V input terminal, and the third socket group connects to the UPS battery pack and the main unit-U23, which is AC380V and 10kW. The UPS battery pack and main unit-U23 includes two socket groups: an input socket group and an output socket group. Each socket group includes an L1 port, an L2 port, an L3 port, an N port, and a PE port. The input socket group is connected to the third socket group, and the output socket group is connected to the surge protector-U2. Specifically, the L1, L2, and L3 ports of the output socket group are connected to the surge protector-U2 via fuse-F2. A low-voltage surge protector-SCB is installed between fuse-F2 and surge protector-U2. The N port of the output socket group is connected to the surge protector-U2 via the low-voltage surge protector-SCB. The L1, L2, and L3 ports of the output socket group are connected to the fuse-F2 via terminals, which are respectively the first L1 phase live wire terminal-XL1, the first L2 phase live wire terminal-XL2, and the first L3 phase live wire terminal-XL3 for 380V three-phase power. The N port of the output socket group is connected to the low-voltage surge protector-SCB via a 380V three-phase neutral wire terminal-XN. The PE port of the output socket group is connected to the PE port of the surge protector-U2 via a 380V three-phase ground wire terminal-XLPE. The surge protector-U2 includes L1, L2, L3, N, and PE ports, each corresponding to one of the output sockets, and uses a DZ47sY-1 40kA 4P 385V capacitor. The fuse - model F2 is RTX8-125X-3P, socket RT18-63A fuse. The low-voltage surge protector - SCB is DZ47SCB-40 40kA 4P.The L1, L2, and L3 ports of the output socket group are also connected to the input ports of the three-phase filter-U1 via the circuit breaker-QF1. The output ports of the three-phase filter-U1 are output via the AC contactor-KM1. The N port of the output socket group is also output via the circuit breaker-QF1. The PE port of the output socket group is also connected to port 1 of the grounding copper busbar-U20. The grounding copper busbar-U20 includes ports 1 to 8, of which ports 2 to 7 are grounded, and port 8 is the output. A parallel circuit of the contactor surge suppressor-FS and the AC contactor-KM1 is also provided between the three-phase filter-U1 and the AC contactor-KM1. The contactor surge suppressor-FS is a combination of a resistor and a capacitor in series. Its main function is to suppress the high voltage spike caused by the reverse electromotive force generated when the contactor coil is disconnected, thereby protecting the electronic equipment in the circuit from damage. The contactor surge suppressor-FS adopts FS652RC. The output of the three-phase filter-U1 is connected to the AC contactor-KM1, and the output of the AC contactor-KM1 is connected to the load. The AC contactor is mainly used for frequently connecting or disconnecting AC and DC circuits. It has a large control capacity, can be operated remotely, and can achieve timed operation, interlocking control, various quantitative control, and undervoltage and overvoltage protection when used with relays. It is widely used in automatic control circuits. Its main control object is the motor, but it can also be used to control other electrical loads.

[0058] like Figure 8 As shown, Figure 8The diagram shows the AC 220V control power supply distribution. The input is a 380V three-phase power supply, with the output of the first phase L1 (live wire), neutral N, and PE. The L1 live wire is connected via a single-phase 220V AC circuit breaker module-QF2 to the 220V AC input ports of the 220V to 24V control power supply module-U3 and the 220V AC input port of the 220V to 24V brake power supply module-U5. The neutral N is also connected via the same circuit breaker module-QF2 to the 220V AC input ports of both modules. The PE is connected to the same 220V AC input ports of both modules. All three AC input ports are identical, outputting the first phase L1 (live wire), neutral N, and PE. Both the 220V to 24V control power module U3 and the 220V to 24V brake power module U5 output 24V power. The 220V to 24V control power module U3 uses an NDR-240-24|24V10A power supply, with a power of 240W, a voltage of 24V, and a current of 10A. The 220V to 24V brake power module U5 uses an NDR-75-24|24V3.2A power supply, with a power of 75W, a voltage of 24V, and a current of 3.2A. The brake requires a separate 24V power supply for the servo motor, which must be separate from the 24V power supply for the control circuit. This is to ensure the stability of the control circuit, avoid power interference, and guarantee stable braking. Meanwhile, the L1 live wire is connected to the L port of the 24V uninterruptible backup battery U22 via the single-phase 220V AC circuit breaker module-QF2, the N neutral wire is connected to the N port of the 24V uninterruptible backup battery U22 via the single-phase 220V AC circuit breaker module-QF2, and the PE is connected to the PE port of the 24V uninterruptible backup battery U22. The 24V uninterruptible backup battery U22 supplies power to the PLC-U6 (including the PLC power supply) and the display screen-U4. In addition, the live wire L1 is connected to the L port of multiple 5-port navigation sockets (U7, U8) via single-phase 220V AC circuit breaker module-QF2 and single-phase 220V AC circuit breaker module-QF3, the neutral wire N is connected to the N port of multiple 5-port navigation sockets (U7, U8) via single-phase 220V AC circuit breaker module-QF2 and single-phase 220V AC circuit breaker module-QF3, and the PE is connected to the PE port of multiple 5-port navigation sockets (U7, U8).

[0059] like Figure 9 As shown, Figure 9The diagram shows the DC 24V control power supply distribution. The 220V to 24V control power module-U3 outputs a 24V power port and a 0V power port. These two power ports are connected to the DC circuit breaker-QF4. The temperature controller-U18, the first fan-M3, and the second fan-M4 form a combined parallel circuit connected to the power supply. The Beckhoff module-U19 is connected in parallel with this combined parallel circuit. The IN port of the Beckhoff module-U19 is connected to the Y-axis (antenna) drive, and the X1 port is connected to PTP. PTP is a precision clock synchronization protocol used for PLC time calibration. The switch-U15, which includes multiple network ports, is also connected in parallel with this combined parallel circuit.

[0060] like Figure 10 As shown, Figure 10 A DC24V control power supply distribution diagram is shown (another diagram). The 220V to 24V control power module-U3 outputs a 24V power port and a 0V power port. The X-axis encoder mount socket-BMQHX1 and the Y-axis encoder mount socket-BMQHX2 are connected to the power supply. Both the X-axis encoder mount socket-BMQHX1 and the Y-axis encoder mount socket-BMQHX2 include PIN:1, PIN:2, PIN:3, PIN:4, and PIN:5. For the X-axis encoder mount socket-BMQHX1, PIN:1 connects to the 24V power port, PIN:5 connects to the 0V power port, and PIN:2, PIN:3, and PIN:4 connect to the encoder through a shielding layer. For the Y-axis encoder mount socket-BMQHX2, PIN:3 connects to the 0V power supply, PIN:4 connects to the 24V power supply, and PIN:1, PIN:2, and PIN:5 connect to the encoder through a shielding layer. The X-axis encoder connector BMQHX1 and Y-axis encoder connector BMQHX2 are connected to the same encoder and then to the PLC. CAN is a bus interface with three wires: CAN-H, CAN-L, and GND. The encoder uses the CAN protocol. For the X-axis encoder connector BMQHX1, pin 2 is connected to CAN-H, pin 3 to CAN-L, and pin 4 to GND. Similarly, for the Y-axis encoder connector BMQHX2, pin 1 is connected to CAN-H, pin 5 to CAN-L, and pin 2 to GND. The shielding layer primarily blocks the propagation of electromagnetic waves and reduces electromagnetic interference.

[0061] like Figure 11 As shown, Figure 11The diagram shows the power distribution for the DC 24V brake. The 220V to 24V brake power module-U5 outputs a 24V power port and a 0V power port. The X-axis CNS brake terminal-U9 includes a PIC port, a COM- port, a brake BK+ port, a brake BK- port, a 24V_BK port, and a COM_BK port. The 24V_BK port is connected to the 0V power port, and the COM_BK port is connected to the 24V power port. The Y-axis CNS brake terminal-U10 is connected in series with the X-axis CNS brake terminal-U24. The Y-axis CNS brake terminal-U25 includes a PIC port, a COM- port, a brake BK+ port, a brake BK- port, a 24V_BK port, and a COM_BK port. The 24V_BK port is connected to the 0V power port, and the COM_BK port is connected to the 24V power port. The PIC port, COM- port, brake BK+ port, and brake BK- port are internal interfaces that ensure the normal operation of the drive. The function of the brake is to forcibly lock the motor shaft through a mechanical device when the motor is powered off or stopped, preventing it from rotating accidentally, thereby ensuring equipment safety, maintaining positional accuracy, and avoiding load movement.

[0062] The drive system is the core of achieving "drive and control integration" and is used to drive the satellite antenna. It includes a servo driver, a braking resistor unit, and a main contactor.

[0063] The servo driver features a compact, high-power-density design, controlling the X and Y axes of the antenna separately. It communicates with the PLC 42 via the CANOPEN real-time industrial bus to achieve high-precision synchronous motion control.

[0064] like Figure 12 As shown, Figure 12 The secondary wiring diagram of the X-axis driver is shown. The X-axis driver-U9 is connected to a 380V power supply. The X-axis driver-U9 uses the SY680NT0211, which includes a POWER module, a MOTOR module, an STO Function Terminal module, a Band brake module, and multiple EhterCAT modules. The POWER module includes R port, S port, T port, L1C port, L2C port, and LE2 port. The R port is connected to the 380V output port L1 port (e.g., ...). Figure 7 (As shown) Connections: S port connects to 380V output port L2; T port connects to 380V output port L3; LIC port connects to 380V output port L1 via switch -KM; L2C port connects to 380V output port N; PE2 port is grounded. The MOTOR module and Band brake module connect to the servo motor M. The Band brake module receives a 24V power supply. The STOFunction Terminal module connects to the servo driver. One EhterCAT module connects to the Y-axis driver, and the other EhterCAT module connects to the PLC.

[0065] like Figure 13 As shown, Figure 13 The secondary wiring diagram of the Y-axis driver is shown. The Y-axis driver-U10 is connected to a 380V power supply. The connection method of the Y-axis driver-U10 is the same as that of the X-axis driver, using the SY680NT0211, which includes a POWER module, MOTOR module, STO Function Terminal module, Band brake module, and multiple EhterCAT modules. The POWER module includes R port, S port, T port, L1C port, L2C port, and LE2 port. The R port connects to the 380V output port L1 port (e.g., ...). Figure 7 (As shown) Connections: S port connects to 380V output port L2; T port connects to 380V output port L3; LIC port connects to 380V output port L1 via switch -KM; L2C port connects to 380V output port N; PE2 port is grounded. The MOTOR module and Band brake module connect to the servo motor M. The Band brake module receives a 24V power supply. The STO Function Terminal module connects to the servo driver. One EhterCAT module connects to the X-axis driver, and the other EhterCAT module connects to the PLC.

[0066] The braking resistor unit is used to dissipate the regenerative energy generated when the servo drive brakes, and the main contactor is used to realize the timing power-on and soft start of the drive system to avoid impact on the UPS.

[0067] As a preferred embodiment, the drive system employs a common DC bus design, allowing all drives to share the DC bus. Regenerative energy can be recycled between shafts, reducing braking resistor energy consumption. Excess energy can also be fed back to the grid or used to charge UPS batteries via a bidirectional converter, achieving energy savings.

[0068] The control system is the "brain" of the cabinet, used to control the state inside the drive control cabinet.

[0069] The control system includes interconnected programmable logic controllers (PLCs) and human-machine interface devices. The PLCs execute core logic to monitor the air conditioning status (via built-in sensors) and environmental status (via built-in temperature and humidity sensors), and control the operation of the drive control cabinet based on its real-time status. The PLCs also implement a collaborative energy management strategy: in battery mode, they perform intelligent load scheduling based on preset priorities (control first, then drive); they also execute data preservation and safe shutdown procedures: in the event of insufficient power, they save data and stop driving the satellite antenna; and they perform fault diagnosis, recording, and warnings.

[0070] like Figure 2As shown, the human-machine interface (HMI) displays the overall system status and provides a parameter setting interface. Located on the outside of the rear door, the HMI includes an HMI, normal indicator lights, abnormal indicator lights, local control indicator lights, remote control indicator lights, emergency stop indicator lights, a master switch button, an X-axis limit release button, a Y-axis limit release button, and an emergency stop button.

[0071] The control system also includes a remote communication module that supports 4G / 5G or Ethernet to enable remote monitoring and maintenance.

[0072] In addition, this solution can also achieve status monitoring, fault early warning and remote management.

[0073] Status monitoring: The PLC constructs a multi-dimensional sensor network through its I / O modules and communication interfaces. Electrical monitoring: Voltage / current sensors monitor the voltage of the two STS inputs, UPS input / output, and DC bus voltage of each driver at a sampling rate of no less than 1kHz. The PLC calculates the RMS voltage, frequency, harmonic distortion rate, power, and power factor in real time and compares them with preset thresholds.

[0074] Mechanical condition monitoring: Real-time reading of motor position, speed, torque current, driver internal temperature, and fault codes from the servo driver via EtherCAT bus.

[0075] Environmental monitoring: The air conditioning cabinet integrates temperature and humidity sensors and door magnetic switches. The temperature and humidity sensors monitor the temperature and humidity of each zone inside the cabinet; the door magnetic switches monitor the status of the cabinet door and transmit the monitoring information to the PLC via the network port.

[0076] Fault warning: The algorithm embedded in the PLC goes beyond threshold alarms, and also realizes trend analysis and early warning.

[0077] Fan performance warning: Monitors compressor current and fan speed. When the system detects a continuous increase in the current required to achieve the same airflow (indicating bearing wear and increased resistance), it will issue a warning about decreased fan efficiency.

[0078] Contactor / Relay Life Warning: Records the number of operations of contactors and main drive contactors within the STS. Issues an early warning when they approach their mechanical lifespan.

[0079] Filter capacitor life warning: By monitoring the increasing trend of harmonic content of UPS input current and DC bus voltage ripple, we can indirectly determine whether the ESR (equivalent series resistance) of the filter capacitor is increasing, and thus issue a warning.

[0080] Remote management: A 24V uninterruptible UPS power supply system does more than just transmit data; it provides a secure two-way control channel. Remote Diagnostics: Authorized users can remotely log in and view the PLC's real-time variable table, program status, and historical fault records online, just like connecting a programmer on-site. Parameterized Maintenance: Non-core operating parameters, such as alarm thresholds, timed power-on / off times, and battery test plans, can be remotely modified. Remote Program Updates: Supports remote firmware upgrades for the PLC control program and HMI screen, while ensuring safety. Work Order Linkage: When an alert or fault occurs, the system can automatically generate a work order containing detailed diagnostic information and push it to the maintenance personnel's mobile terminal or the maintenance management system.

[0081] Compared to traditional drive cabinets: This solution overcomes the conflict between thermal management and space constraints: Traditionally, drive control is divided into two independent cabinets, one for the drive unit and the other for the PLC control unit. Because high-power servo drives are large and generate significant heat, and heat generation is directly proportional to size and cooling requirements, each cabinet typically contains two high-power servo drives, necessitating a separate drive cabinet with additional cooling. This solution utilizes cutting-edge domestically produced drives and PLCs, resulting in a smaller size and efficiency suitable for the application scenario. Furthermore, a custom-designed outdoor air conditioning cabinet integrates control and drive functions into a single unit, employing zoned active cooling and thermal isolation design to effectively resolve the conflict between heat dissipation and space constraints.

[0082] This solution overcomes the contradiction of electromagnetic interference; when the servo drive is working, the internal high-frequency switch will generate strong conducted electromagnetic interference and radiated electromagnetic interference. This solution implements three-level EMC management: (1) source suppression, a dedicated filter is configured for the power input terminal of the servo drive; (2) path isolation, the power supply lines of the drive module and the control module adopt independent wiring channels, and the signal communication adopts shielded twisted pair cable with single-point grounding. In terms of cabinet layout, the drive module and the control module maintain the maximum physical distance. (3) receptor protection: the communication bus EtherCAT adopts shielded connectors.

[0083] In a separate control cabinet and drive cabinet structure, the PLC in the control cabinet needs to exchange the following signals with the servo drive in the drive cabinet: multiple pulse / direction command lines, analog speed / torque command lines, servo enable signal, alarm signal, servo ready signal, and at least two (X-axis / Y-axis) high-resolution encoder feedback lines (each containing multiple pairs of differential signals such as A+ / A-, B+ / B-, Z+ / Z-). In addition, high-voltage power lines (three-phase 380V) are required from the power distribution unit to the drive cabinet. These cables are numerous and complex, requiring a large number of aviation plugs or terminal blocks for conversion. In this solution, all the above control and feedback signals are replaced by an integrated industrial real-time Ethernet bus (such as EtherCAT). The three-phase power input of the drive is directly connected from the output of the dual-power supply module inside the cabinet via the terminal block inside the cabinet, without needing to pass through the outside of the cabinet. Externally, only the power output lines (U / V / W) ultimately connected to the servo motor, motor encoder, external second encoder, limit switches, etc., need to be retained—these are unavoidable in any solution.

[0084] Our cabinet's power outage response goes beyond simply "saving data." When the PLC detects a failure in both mains power supplies via the Static Power Switch (STS) and switches to battery mode, it immediately executes a multi-level emergency control system: Level 1 (milliseconds): Immediately locks the current motion command, prohibiting the issuance of new high-dynamic trajectory commands. Level 2 (seconds): Based on the remaining battery power and the antenna's current attitude, it autonomously selects the optimal "safe return" or "stay in place" strategy. If the battery is sufficiently charged, it controls the driver to smoothly decelerate the antenna to a preset safe angle, preventing mechanical impact from free sliding. Level 3 (continuous): While executing the above actions, the system automatically packages key operating parameters, fault points, and the last received remote control commands into the PLC's internal non-volatile memory. Level 4 (final): Before the battery power drops to a critical threshold, the PLC sends a "safe torque shutdown" command to all drivers and then shuts down itself in an orderly manner. The entire process is actively and orderly managed by the control system, not passively waiting for the equipment to lose power.

[0085] The cabinet in this solution is made of SUS304 stainless steel, and all external interfaces are treated with three-proof coating; IP65 requires strict dust protection, and heat dissipation and ventilation are also necessary. Therefore, a 1500W air conditioning compressor is integrated into the cabinet for heat dissipation and heating of the internal equipment; and the internal design adopts zoned active cooling and thermal isolation to achieve heat dissipation while preventing dust from entering, which is a higher level of thermal management design.

[0086] This invention adopts a "power-control-drive" trinity architecture, creating a closed-loop integrated unit for "power supply-control-drive". Through systematic design, it seamlessly integrates a high-power servo drive system into an uninterruptible power supply control cabinet, enabling all energy flow, data flow, and control flow to be completed within a highly protected physical space. This fundamentally solves the problems of size, connectivity, and reliability inherent in discrete systems. Simultaneously, the PLC, acting as a unified brain, not only manages the antenna's motion trajectory but also makes decisions regarding the enable and power consumption of the drive system in emergency power mode, achieving cross-system collaborative management—something discrete systems cannot achieve. This solution successfully addresses the heat dissipation and heating of the control and drive systems within a sealed cabinet. Through an integrated industrial air conditioning thermal management design, the heat dissipation power reaches 1.5kW, meeting the requirements of high-power devices. With an IP65 protection rating, it is dustproof and waterproof, adapting to harsh industrial environments and ensuring the long-term stable operation of the integrated cabinet housing high-power devices under harsh conditions. This invention incorporates a pre-defined hardware and software safety strategy. In the event of a power grid anomaly, the system not only ensures the operation of the control unit and data preservation but also prevents the antenna from moving uncontrollably through orderly management of the drive system, achieving dual protection for both data and equipment. Specific advantages are as follows: 1. Ultimate integration and space saving: Compared with the traditional "control cabinet + drive cabinet" solution, this invention integrates all the core equipment of the system into a single cabinet, reducing the overall footprint by 50% and greatly expanding its application in space-sensitive scenarios.

[0087] 2. Extremely high system reliability: The system significantly reduces the number of external cables and connectors, lowering interconnect failure rates and electromagnetic interference risks. Internal bus communication improves motion control accuracy and reliability. The overall system MTBF (Mean Time Between Failures) is significantly improved by 30%.

[0088] 3. Seamless power supply continuity and comprehensive equipment protection: The dual protection of "STS+UPS" combined with intelligent collaborative energy management ensures a seamless power switch from the grid to the core load, effectively preventing various damages caused by sudden power outages.

[0089] 4. Excellent environmental adaptability: The high protection level of IP65 combined with powerful internal environmental control enables this cabinet to withstand harsh outdoor environments and achieve reliable operation around the clock.

[0090] 5. Intelligent Operation and Maintenance & Low-Cost Maintenance: Comprehensive status monitoring, fault early warning, and remote management functions make operation and maintenance work efficient and convenient. High system integration enables faster fault location, significantly reducing MTTR (Mean Time To Repair) to 30 minutes, resulting in a clear cost advantage throughout the entire lifecycle of operation and maintenance.

[0091] Exemplary embodiments of the present invention have been specifically shown and described above. It should be understood that the present invention is not limited to the detailed structures, arrangements, or implementations described herein; rather, the present invention is intended to cover various modifications and equivalent arrangements contained within the spirit and scope of the appended claims.

Claims

1. A portable satellite antenna drive control cabinet, characterized in that, include: Rack exterior and cabinet body; The cabinet shell surrounds the cabinet body, which includes a power supply system, a drive system, and a control system. The power supply system is used to supply power to the drive system and control system, including a dual-power UPS system and a 24V uninterruptible UPS power supply system. The drive system is used to drive the satellite antenna and includes a servo driver; The control system is used to control the state inside the drive control cabinet.

2. The portable satellite antenna drive control cabinet according to claim 1, characterized in that, The cabinet shell includes a front door, a rear door, and side panels. An air conditioning compressor is installed inside the front door, a human-machine interface device is installed in the rear door, and an aviation plug is installed in the side panel.

3. The portable satellite antenna drive control cabinet according to claim 1, characterized in that, The power supply system also includes a power conversion module, which is used to convert 380V voltage to 220V voltage and 220V voltage to 24V voltage.

4. The portable satellite antenna drive control cabinet according to claim 2, characterized in that, The cabinet shell has a rectangular parallelepiped structure, with each side having a length of less than or equal to 1500mm.

5. The portable satellite antenna drive control cabinet according to claim 1, characterized in that, The dual-power UPS system includes a primary 380V input terminal, a backup 380V input terminal, and a dual power transfer switch. The dual power transfer switch is used to switch between the primary 380V input terminal and the backup 380V input terminal.

6. The portable satellite antenna drive control cabinet according to claim 1, characterized in that, The 24V uninterruptible UPS power system includes a 24V uninterruptible backup battery, an AC input terminal, and a protection board with a balancing circuit. The protection board with the balancing circuit is placed between the 24V uninterruptible backup battery and the AC input terminal and is used to shut down the charging circuit when the 24V uninterruptible backup battery is fully charged.

7. The portable satellite antenna drive control cabinet according to claim 1, characterized in that, The power supply system also includes a first protection system and a second protection system. The first protection system is used to protect the dual-power UPS system, and the second protection system is used to protect the 24V uninterruptible UPS power supply system.

8. The portable satellite antenna drive control cabinet according to claim 1, characterized in that, The drive system also includes a braking resistor unit and a main contactor. The braking resistor unit is used to consume the regenerative energy generated when the servo driver brakes, and the main contactor is used to realize the timing power-on and soft start of the drive system.

9. The portable satellite antenna drive control cabinet according to claim 2, characterized in that, The control system includes an interconnected programmable logic controller (PLC) and a human-machine interface (HMI). The PLC monitors the air conditioning status and environmental status, and controls the operation of the drive control cabinet based on its real-time status. The HMI is located on the outside of the rear door and includes an HMI, normal indicator light, abnormal indicator light, local control indicator light, remote control indicator light, emergency stop indicator light, main switch button, X-axis limit release button, Y-axis limit release button, and emergency stop button.

10. The portable satellite antenna drive control cabinet according to claim 8, characterized in that, The programmable logic controller is also used to save data and stop driving the satellite antenna movement in the event of insufficient power.

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