Power supply partition fault monitoring control system and method applied to equipment wire controller
By using a modular power consumption measurement and control system, each functional unit of the wired controller is independently monitored and fault diagnosed, which solves the problems of delayed fault detection and widening fault range, realizes early detection and precise isolation, and improves the reliability and maintenance efficiency of the wired controller.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- 青岛海尔暖通空调设备有限公司
- Filing Date
- 2026-01-26
- Publication Date
- 2026-05-15
AI Technical Summary
The circuit design of existing equipment wire controllers suffers from problems such as delayed fault detection, expanded fault range, loss of critical status data, and difficulty in maintenance, resulting in high maintenance costs and poor user experience.
A modular power consumption measurement and control system is adopted. Each functional unit is independently monitored and fault diagnosed through independent power consumption monitoring circuits and power control circuits, so as to achieve early detection and accurate isolation. The main control unit is used for fault judgment and power control.
It enables early detection and precise location of faults, limits the scope of fault impact, improves the reliability and maintainability of wired controllers, reduces maintenance costs and time, and enhances user satisfaction.
Smart Images
Figure CN122052297A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of equipment wired controller technology, and in particular to a power zone fault monitoring and control system and method for equipment wired controllers. Background Technology
[0002] Currently, the wired controllers for home appliances such as heating and cooling equipment typically adopt an integrated circuit design, which contains multiple functional units. This design has the following significant drawbacks.
[0003] First, fault detection can only be performed after the equipment has completely failed, resulting in a significant delay in protection measures. Second, when a functional unit experiences a short circuit or other fault, the fault range can easily expand, potentially affecting the entire wired controller or even other functional units or external devices, causing irreparable damage, such as a fuse blowing and causing a power outage. Third, critical status data is completely lost at the moment of the fault, and due to the lack of effective fault information during post-fault troubleshooting, maintenance personnel can only rely on experience to make inferences, making it impossible to reproduce the fault. This leads to time-consuming, labor-intensive, and costly factory repairs, which not only reduces the user experience but also significantly increases after-sales costs. Summary of the Invention
[0004] This invention provides a power zone fault monitoring and control system and method for equipment wired controllers, which can independently monitor power consumption, diagnose faults and control power isolation of each functional unit inside the wired controller, so as to realize early detection, accurate location and effective isolation of faults, and improve the reliability and maintainability of the wired controller.
[0005] This invention provides a power zone fault monitoring and control system for equipment wired controllers, comprising: The system comprises a main control unit, a power management unit, and multiple functional units, wherein the power management unit is electrically connected to the main control unit and the multiple functional units respectively; wherein the multiple functional units include at least two of a display unit, a sound unit, a touch unit, and a communication unit. Multiple power consumption monitoring circuits are configured corresponding to the power supply lines provided by the power management unit for the functional units, and are used to monitor the power consumption of the corresponding functional units; Multiple power control circuits are configured to correspond to the power supply lines provided by the power management unit for the functional units, and to control the power supply on / off of the corresponding functional units; The main control unit is electrically connected to the plurality of power consumption monitoring circuits and the plurality of power control circuits respectively, and is used to control the power control circuit corresponding to the functional unit to cut off the power supply when the functional unit is determined to have a fault based on the power consumption monitoring data of the functional unit.
[0006] According to the present invention, a power zone fault monitoring and control system for a device wired controller is provided, wherein the power consumption monitoring circuit includes: A sampling resistor unit is connected in series in the corresponding power supply line; wherein the equivalent resistance of the sampling resistor unit is less than or equal to a preset resistance value; The amplifier circuit is electrically connected to both ends of the sampling resistor unit and the main control unit, respectively.
[0007] According to the present invention, a power zone fault monitoring and control system for a device wired controller is provided, wherein the amplification circuit includes: The preamplifier circuit includes a differential operational amplifier circuit and two non-inverting proportional operational amplifier circuits. The non-inverting input terminals of the two non-inverting proportional operational amplifier circuits are electrically connected to the two ends of the sampling resistor unit, respectively. The output terminals of the two non-inverting proportional operational amplifier circuits are electrically connected to the non-inverting input terminal and the inverting input terminal of the differential operational amplifier circuit, respectively. A filter circuit, wherein the input terminal of the filter circuit is electrically connected to the output terminal of the differential operation circuit; The post-amplifier circuit is electrically connected to the output of the filter circuit and is used to amplify and adjust the polarity of the filtered signal, and output it to the main control unit.
[0008] According to the present invention, a power zone fault monitoring and control system for a device wired controller further includes: The analog switch unit includes a sampling resistor unit comprising multiple sampling resistors with different resistance values. The analog switch unit is electrically connected to the main control unit and the multiple sampling resistors with different resistance values. The main control unit is also used to control the analog switch unit to select the sampling resistor with the corresponding resistance value to connect to the power supply line according to the power consumption monitoring data.
[0009] According to the present invention, a power zone fault monitoring and control system for a device wired controller is provided, wherein the power control circuit includes: The transistor has its base electrically connected to the main control unit and its emitter connected to a reference potential. A field-effect transistor (FET) is provided, wherein the gate of the FET is electrically connected to the collector of the transistor, the drain of the FET is electrically connected to the corresponding functional unit, and the source of the FET is connected to a power supply.
[0010] According to the present invention, a power zone fault monitoring and control system for a device wired controller further includes: A temperature sensor, electrically connected to the main control unit, is used to monitor the real-time temperature of the power consumption monitoring circuit. The main control unit is used to call the corresponding correction parameters based on the real-time temperature to compensate the currently acquired power consumption monitoring data.
[0011] The present invention also provides a power zone fault monitoring and control method for a device wired controller, used to control any of the power zone fault monitoring and control systems described above for a device wired controller, wherein the power zone fault monitoring and control method for a device wired controller includes: The multiple power control circuits are controlled to be turned on in a preset sequence to power on the corresponding functional units. During the power-on period of the functional unit, the power consumption monitoring data of the corresponding functional unit is obtained through the corresponding power consumption monitoring circuit; When a fault is detected in the functional unit based on the power consumption monitoring data of the functional unit, the power control circuit corresponding to the functional unit is controlled to cut off the power supply.
[0012] A power zone fault monitoring and control method for a device wired controller provided by the present invention further includes: The first type of functional unit is powered on first; After the first preset delay, the second type of functional unit is powered on. The third type of functional unit is powered on after the second preset delay. The first type of functional unit, the second type of functional unit, and the third type of functional unit are classified according to the current surge and / or noise intensity generated when the functional unit is powered on.
[0013] A power zone fault monitoring and control method for a device wired controller provided by the present invention further includes: The functional unit that controls at least one non-continuous working requirement operates intermittently according to a preset duty cycle.
[0014] The present invention also provides a wired controller, including any of the above-described power zone fault monitoring and control systems applied to a device wired controller.
[0015] The present invention also provides an air conditioning system, including any of the above-described power zone fault monitoring and control systems applied to the equipment wire controller.
[0016] This invention utilizes modular power consumption measurement and control, equipping each functional unit with an independent monitoring and control path. Through power consumption monitoring circuits and power control circuits, coupled with reasonable software processing logic, it achieves self-testing of the power consumption and functionality of each functional module, thereby realizing the detection of the wired controller's circuit operating status, fault detection, and fault control. When a single functional unit fails, the system can quickly identify and cut off the power to only that functional unit, thus limiting the scope of the fault's impact to a minimum. This avoids the abnormal escalation seen in traditional designs, where a single component failure leads to a cascading failure of the wired controller, and consequently, damage to related equipment, such as the entire circuit board. This significantly improves the reliability and fault tolerance of the wired controller and provides a foundation for subsequent rapid repair and troubleshooting. Simultaneously, the main control unit facilitates the identification of the root cause of the fault, reducing equipment rework time, saving manpower and material costs, improving rework efficiency, and providing more operational space for subsequent edge computing and control of the wired controller, thereby increasing user satisfaction and reducing operating costs. Attached Figure Description
[0017] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0018] Figure 1 This is a schematic diagram of a power zone fault monitoring and control system applied to a device wired controller provided by an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of a power consumption monitoring circuit provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the simulation results of a preamplifier circuit provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the simulation results of an amplifier circuit provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of a power control circuit provided in an embodiment of the present invention; Figure 6 This is a flowchart illustrating the power zone fault monitoring and control method for equipment wired controllers provided in this application. Detailed Implementation
[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.
[0020] Figure 1 This is a schematic diagram of a power zone fault monitoring and control system applied to a device wired controller, provided by an embodiment of the present invention. Figure 1 As shown, the power zone fault monitoring and control system applied to the equipment wired controller includes a main control unit 101, a power management unit 102, multiple functional units, multiple power consumption monitoring circuits, and multiple power control circuits. The power management unit 102 is electrically connected to the main control unit 101 and the multiple functional units. The multiple functional units include at least two of a display unit 103, a sound unit 104, a touch unit 105, and a communication unit 106. The multiple power consumption monitoring circuits are configured corresponding to the power supply lines provided by the power management unit 102 for the functional units, and are used to monitor the power consumption of the corresponding functional units. The multiple power control circuits are configured corresponding to the power supply lines provided by the power management unit 102 for the functional units, and are used to control the power supply to the corresponding functional units. The main control unit 101 is electrically connected to the multiple power consumption monitoring circuits and the multiple power control circuits, and is used to control the power control circuit corresponding to the functional unit to cut off the power supply when a fault occurs in the functional unit based on the power consumption monitoring data of the functional unit.
[0021] Specifically, the main control unit 101 is the core processing unit of the system, such as a microcontroller or microprocessor. The power management unit 102 is responsible for receiving external input power and converting it into the various voltages required by the system. Functional units refer to circuit modules in the wired controller that perform specific functions, such as the display unit 103 for information output, the sound unit 104 for prompts, the touch unit 105 for human-computer interaction, and the communication unit 106 for data transmission, etc. Among them, the main control unit 101 is, for example, a main control chip unit, the sound unit 104 is, for example, a buzzer unit, and the communication unit 106 is, for example, a WIFI (Wireless Fidelity) unit or a BLE (Bluetooth Low Energy) unit, etc. The power consumption monitoring circuit is a hardware circuit used to collect the current signal flowing through the functional units and feed it back to the main control unit 101. The power control circuit is an electronic switch circuit controlled by the main control unit 101, used to connect or disconnect the power supply path of the corresponding functional unit. It should be noted that... Figure 1The example shown is merely an example of setting node A for the power consumption monitoring circuit and the power control circuit. The specific connection relationship of the power consumption monitoring circuit and the power control circuit in the line is described in detail in the following embodiments.
[0022] After the system is powered on, the power management unit 102 provides the operating voltage to the main control unit 101 and, according to a preset sequence, provides the operating voltage to each functional unit through the power control circuit. The main control unit 101 can independently power on each functional unit by controlling each power control circuit. During the operation of each functional unit, the power consumption monitoring circuit connected to it monitors the operating current of the functional unit in real time, thereby obtaining the power consumption of the functional unit. The main control unit 101 uses its internal ADC (Analog-to-Digital Converter) to continuously or periodically read the power consumption monitoring data of the functional units. Through preset algorithms, such as comparing with preset thresholds and analyzing changing trends, the main control unit 101 can determine whether any functional unit has experienced an abnormality, such as overcurrent or short circuit. Once a fault is determined in one or more functional units, the main control unit 101 immediately sends a command to the power control circuit controlling that functional unit, causing it to cut off the power supply to the faulty functional unit, thereby achieving electrical isolation of the faulty unit and preventing the fault from spreading.
[0023] Therefore, this embodiment of the invention utilizes modular power consumption measurement and control, equipping each functional unit with an independent monitoring and control path. Through power consumption monitoring circuits and power control circuits, combined with reasonable software processing logic, it achieves self-testing of the power consumption and function of each functional module, thereby realizing the detection of the wired controller circuit's operating status, fault perception, and fault control. When a single functional unit fails, the system can quickly identify and cut off the power supply to only that functional unit, thus limiting the scope of the fault's impact to a minimum. This avoids the abnormal expansion in traditional designs, i.e., the avalanche damage to the wired controller caused by the failure of a single component, and thus avoids damage to related equipment, such as damage to the entire circuit board. This significantly improves the reliability and fault tolerance of the wired controller and provides a foundation for subsequent rapid repair and location. At the same time, the main control unit 101 facilitates the troubleshooting of the root cause of the fault, reduces equipment return and troubleshooting time, saves manpower and material costs, improves return and repair efficiency, and also provides more operational space for the subsequent edge computing and control of the wired controller, thereby improving user satisfaction and reducing usage costs.
[0024] Figure 2 This is a schematic diagram of a power consumption monitoring circuit provided in an embodiment of the present invention. (Combined with...) Figure 1 and Figure 2The power consumption monitoring circuit includes a sampling resistor unit and an amplifier circuit. The sampling resistor unit is connected in series in the corresponding power supply line. The equivalent resistance of the sampling resistor unit is less than or equal to a preset resistance value. The amplifier circuit is electrically connected to both ends of the sampling resistor unit and the main control unit 101. The sampling resistor unit can be composed of a resistor R_d, where the resistor R_Load represents the load of the connected functional unit.
[0025] Specifically, the sampling resistor unit can be, for example, a precision resistor with an extremely small resistance value, connected in series in the power supply line for current sampling. Its resistance value is small enough to negligibly affect the operation of the original circuit; for example, the equivalent resistance value of the sampling resistor unit can be set to a range of a few milliohms to a few ohms. The amplifier circuit is used to amplify the small voltage difference signal generated across the sampling resistor to a level suitable for acquisition and processing by the main control unit 101, for example, to a level suitable for acquisition and processing by the ADC inside the main control unit 101. When the functional unit is working, current flows through the series-connected sampling resistor unit, generating a weak voltage difference signal proportional to the current across the sampling resistor unit. This voltage difference signal is sent to the amplifier circuit for amplification. The amplified signal is output to the analog-to-digital converter pin of the main control unit 101, where it is converted into a digital quantity for processing by the main control unit 101, realizing non-invasive and accurate measurement of the operating current of each functional unit.
[0026] Therefore, this embodiment of the invention uses a series small-resistance sampling resistor unit combined with amplification to achieve real-time, accurate and low-impact monitoring of the operating current of the functional unit, providing an accurate data source for subsequent fault diagnosis. The preset resistance value ensures that the sampling behavior will not significantly change the electrical characteristics of the original power supply line.
[0027] In some embodiments, combined with Figure 1 and Figure 2 The amplifier circuit includes a preamplifier circuit, a filter circuit, and a postamplifier circuit U3. The preamplifier circuit includes a differential operational amplifier circuit U2 and two non-inverting proportional operational amplifier circuits U1. The non-inverting input terminals of the two non-inverting proportional operational amplifier circuits U1 are electrically connected to the two ends of the sampling resistor unit, respectively. The output terminals of the two non-inverting proportional operational amplifier circuits U1 are electrically connected to the non-inverting input terminal and the inverting input terminal of the differential operational amplifier circuit U2, respectively. The input terminal of the filter circuit is electrically connected to the output terminal of the differential operational amplifier circuit U2. The postamplifier circuit U3 is electrically connected to the output terminal of the filter circuit and is used to amplify and adjust the polarity of the filtered signal and output it to the main control unit 101.
[0028] Specifically, the preamplifier circuit is the first stage of the amplification chain, mainly responsible for preliminary amplification and common-mode interference suppression. The non-inverting operational amplifier circuit U1 is an operational amplifier circuit whose output signal is in phase with the input signal and amplifies it proportionally. The differential operational amplifier circuit U2 is an operational amplifier circuit whose output signal is proportional to the voltage difference between the two input terminals. The two non-inverting operational amplifier circuits U1 and the differential operational amplifier circuit U2 constitute an instrumentation amplifier, characterized by high input impedance, high common-mode rejection ratio, low noise, low drift, and high linearity. The filter circuit is used to filter out high-frequency noise components in the signal. For example, a filter circuit consists of... Figure 2 The resistor R20 and capacitor C1 shown constitute the circuit. The subsequent amplifier circuit U3 is used to further amplify the signal and adjust its polarity.
[0029] Two non-inverting proportional operational amplifier circuits U1 are connected to the two ends of a sampling resistor unit with high input impedance, respectively, to follow and initially amplify the voltage across the sampling resistor unit. The voltage across the sampling resistor unit includes both common-mode and differential-mode voltages. The outputs of the two non-inverting proportional operational amplifier circuits U1 are fed into a differential operational amplifier circuit U2. The differential operational amplifier circuit U2 subtracts the two input signals. Since the common-mode voltage is essentially the same in both inputs, the differential operation greatly suppresses common-mode interference, such as power supply noise, while amplifying the differential-mode voltage signal representing current information. The signal after differential amplification may contain high-frequency noise interference, which is filtered out by a low-pass filter circuit composed of resistors and capacitors to obtain a smooth analog signal. Finally, the subsequent amplifier circuit U3, such as an inverting proportional amplifier circuit, performs final gain adjustment on the filtered signal and adjusts the polarity of the signal to positive as needed, that is, restoring the inverted signal output from the previous operational amplifier to positive, and outputting a stable and appropriately amplituded DC voltage signal to the main control unit 101.
[0030] Figure 3 This is a schematic diagram illustrating the simulation results of a preamplifier circuit provided in an embodiment of the present invention. Figure 3 As shown, in the MATLAB simulation of the preamplifier circuit, R1, R2, R3, R4, and R5 are all equal to 1KΩ, and R6 and R7 are all equal to 10KΩ. For the two non-inverting proportional operational circuits U1, the amplification factor A11 = (R1 + R2 + R3) / R1 = 3, and the amplification factor A12 = -R7 / R5 = -10 for the differential operational circuit U2. The amplification factor of the entire preamplifier circuit is Ao1 = A11 * A12 = -30.
[0031] Figure 4 This is a schematic diagram illustrating the simulation results of an amplifier circuit provided in an embodiment of the present invention. Figure 4As shown, in the overall amplifier circuit simulated in MATLAB, R13, R14, R15, R16, and R17 are all equal to 1KΩ, and R18 and R19 are all equal to 10KΩ. For the two non-inverting proportional operational circuits U1, i.e., the circuit composed of two voltage followers in the front stage, the amplification factor A11 = (R13 + R14 + R15) / R13 = 3. The amplification factor of the differential operational circuit U2 is A12 = -R18 / R16 = -10. The amplification factor of the subsequent amplifier circuit U3 is -R21 / R20 = -10. The amplification factor of the entire front-stage amplifier circuit is Ao1 = A11 * A12 = -30. The amplification gain of the entire amplifier circuit is 300, which is the same as the simulation result.
[0032] Therefore, this embodiment of the invention employs a pre-amplifier structure consisting of two in-phase proportional operational amplifiers and one differential operational amplifier, providing extremely high input impedance and common-mode rejection ratio. This ensures that the current sampling accuracy is unaffected by the monitored circuit and effectively resists environmental noise interference. Combined with filtering and subsequent amplification, a high-quality signal is ultimately output, greatly improving the accuracy and reliability of power consumption monitoring. For example, the power consumption monitoring circuit can also be implemented using specialized power management chips such as coulomb counters.
[0033] In some embodiments, combined with Figure 1 and Figure 2 The power zone fault monitoring and control system applied to the equipment wire controller also includes an analog switch unit and a sampling resistor unit, which includes multiple sampling resistors with different resistance values. The analog switch unit is electrically connected to the main control unit 101 and multiple sampling resistors with different resistance values. The main control unit 101 is also used to control the analog switch unit to select the sampling resistor with the corresponding resistance value to connect to the power supply line according to the power consumption monitoring data.
[0034] Specifically, the analog switch unit is a collection of electronic switching devices whose on / off state can be controlled by electrical signals, used for switching between different paths. The sampling resistor unit consists of multiple precision resistors with different resistance values, with an analog switch connected in series in each resistor branch. The main control unit 101 judges based on the voltage value currently read from the amplifier circuit: if the voltage value is too low, it indicates that the current sampling resistor value may be too large, the signal generated by the small current is too weak, and the measurement accuracy decreases. In this case, the main control unit 101 can control the analog switch unit to switch to a sampling resistor with a smaller resistance value, so that the signal voltage generated under the same current increases; conversely, if the voltage value is too high, there is a risk of exceeding the measurement range, and the main control unit 101 can switch to a sampling resistor with a larger resistance value. Through dynamic switching, the sampling signal is always kept within the optimal measurement range of the amplifier circuit.
[0035] Therefore, the embodiments of the present invention enable a single monitoring circuit to adapt to situations where the operating current of different functional units varies greatly, as well as situations where the current of the same functional unit changes significantly under different operating modes. It automatically optimizes the measurement range and achieves wide-range, high-precision current measurement without adding multiple sets of hardware, thereby enhancing the versatility and measurement accuracy of the system.
[0036] Figure 5 This is a schematic diagram of a power control circuit provided in an embodiment of the present invention. (Combined with...) Figures 1 to 5 The power control circuit includes a transistor Q3 and a field-effect transistor Q2. The base of transistor Q3 is electrically connected to the main control unit 101, and the emitter of transistor Q3 is connected to the reference potential. The gate of field-effect transistor Q2 is electrically connected to the collector of transistor Q3, the drain of field-effect transistor Q2 is electrically connected to the corresponding functional unit, and the source of field-effect transistor Q2 is connected to the power supply.
[0037] Specifically, transistor Q3 can be, for example, an NPN bipolar transistor used as a control switch, and field-effect transistor Q2 can be, for example, a P-channel metal-oxide-semiconductor field-effect transistor Q2 used as a main power supply switch. The reference potential refers to the circuit ground potential. One input / output pin (I / O) of the main control unit 101 is connected to the base of the NPN transistor Q3, and Load represents the load, i.e., the corresponding functional unit. When the main control unit 101 needs to power on a certain functional unit, it outputs a high level to the input / output pin (I / O), turning on the NPN transistor Q3 and pulling its collector potential down to near ground potential. This low level is applied to the gate of the P-channel field-effect transistor Q2, causing Q2 to conduct, allowing the power supply, such as +5V, to flow from the source to the drain of Q2, thereby powering the corresponding functional unit. When the main control unit 101 needs to cut off the power supply, it outputs a low level to the field-effect transistor Q2, and the NPN transistor Q3 is turned off. Its collector potential is pulled up to the power supply voltage by the pull-up resistor, which makes the gate-source voltage of the P-channel field-effect transistor Q2 close to zero. The field-effect transistor Q2 is turned off, cutting off the power supply to the functional unit.
[0038] Therefore, this embodiment of the invention provides a reliable and efficient implementation method for directly controlling the on / off state of the main power supply of the functional unit by the digital signal of the main control unit 101. It utilizes a P-channel field-effect transistor Q2 as a switch, which has low on-resistance and low power consumption. Level conversion and driving are performed through a transistor Q3, enabling the main control unit 101 to safely and conveniently control the power supply line. Furthermore, the selection of transistor Q3 and field-effect transistor Q2 can be specifically configured according to requirements, and the specific components and connections in the power control circuit can also be specifically configured according to requirements. For example, as... Figure 5As shown, D1 is the parasitic diode of the field-effect transistor Q2, and F1 and F2 are current-limiting fuses. Alternatively, the power control circuit can also be implemented using isolation chips such as optocouplers.
[0039] In some embodiments, the power partition fault monitoring and control system applied to the device wire controller further includes a temperature sensor electrically connected to the main control unit 101 to monitor the real-time temperature of the power consumption monitoring circuit. The main control unit 101 is used to call the corresponding correction parameters according to the real-time temperature to compensate the currently acquired power consumption monitoring data.
[0040] Specifically, the correction parameters can be a set of data or coefficients pre-determined experimentally and stored in the main control unit 101 to compensate for measurement errors caused by temperature. A temperature sensor is installed in a critical part of the power consumption monitoring circuit, such as near the sampling resistor or operational amplifier, to monitor the temperature of the power consumption monitoring circuit in real time. The main control unit 101 reads the temperature value. Since parameters such as the resistance of the sampling resistor, the offset voltage of the operational amplifier, and the gain will drift with temperature, the fixed conversion formula will have errors. Therefore, the system is temperature calibrated before leaving the factory, measuring the output value corresponding to the standard current at different temperature points to obtain a set of temperature-comprehensive error compensation coefficient mapping relationships, i.e., a correction parameter table, which is then stored. During actual operation, the main control unit 101 looks up the corresponding correction parameters based on the real-time temperature and calculates compensation for the currently collected raw power consumption monitoring data, such as multiplying by the gain compensation coefficient and adding an offset compensation amount, to obtain current data closer to the true value. Subsequently, when judging functional unit faults, the temperature-compensated power consumption monitoring data is used.
[0041] Therefore, by introducing real-time temperature monitoring and software compensation, the embodiments of the present invention effectively eliminate the impact of ambient temperature changes on the accuracy of current measurement, enabling the system to maintain high-precision fault diagnosis capabilities over a wider temperature operating range, and improving the reliability and stability of the system in complex environments.
[0042] This application also provides a power zone fault monitoring and control method for a device wired controller, used to control the power zone fault monitoring and control system for a device wired controller as described in the above embodiments. Figure 6 This is a flowchart illustrating the power zone fault monitoring and control method for equipment wired controllers provided in this application. Figure 6 As shown, the power zone fault monitoring and control method applied to the equipment wired controller includes the following steps: S201. Control multiple power control circuits to conduct in a preset sequence to power on the corresponding functional units.
[0043] S202. During the power-on period of the functional unit, the power consumption monitoring data of the corresponding functional unit is obtained through the corresponding power consumption monitoring circuit.
[0044] S203. When a functional unit is found to be faulty based on the power consumption monitoring data of the functional unit, the power control circuit corresponding to the functional unit is controlled to cut off the power supply.
[0045] Specifically, the power zone fault monitoring and control method applied to the equipment wired controller begins with system power-on initialization. The main control unit 101 controls the power control circuits corresponding to each functional unit to power on according to a preset ordered list, for example, core units first, then peripheral units. During the operation of each functional unit after power-on, the main control unit 101 collects real-time power consumption data of the corresponding functional unit through the corresponding power consumption monitoring circuit. The main control unit 101 runs a fault diagnosis algorithm, such as comparing the real-time data with a preset normal operating threshold range or analyzing its short-term trend. Once the power consumption data of a functional unit is determined to be abnormal, such as continuous exceeding limits or sudden changes, the functional unit is considered to have failed. Subsequently, the main control unit 101 immediately generates a control command and sends it to the power control circuit responsible for the failed functional unit, ordering it to cut off the power supply path.
[0046] Therefore, the embodiment of the present invention sets up orderly power-on, avoiding the surge impact that may be caused by the simultaneous start-up of all circuits. Real-time diagnosis based on independent monitoring data enables rapid fault detection, and targeted power cut-off commands perform fault isolation. The entire process runs automatically without manual intervention, realizing autonomous monitoring, diagnosis and protection of wired controller faults.
[0047] In some embodiments, the power partition fault monitoring and control method applied to the device wired controller further includes controlling the first type of functional unit to power on first; controlling the second type of functional unit to power on after a first preset delay; controlling the third type of functional unit to power on after a second preset delay; wherein the first type of functional unit, the second type of functional unit, and the third type of functional unit are classified according to the current surge and / or noise intensity generated when the functional unit is powered on.
[0048] Specifically, the first, second, and third categories of functional units are classified according to the magnitude of the impact or interference on the system when the functional units are powered on. For example, digital logic circuits, i.e., the main control unit 101, belong to the low-impact category, display backlights belong to the medium-impact category, and wireless communication modules belong to the high-impact category. Delay refers to a specific period of time after the main control unit 101 issues a control command. During system startup or wake-up, the main control unit 101 does not simultaneously activate all functional units. It first controls the first category of functional units, such as sensors and core logic units, which have the lowest current surge and electrical noise. After a first preset delay, once the power supply to the first batch of units has stabilized and the initial current spike has passed, it then controls the second category of functional units, such as display drivers, to power on. After a second preset delay, it finally controls the third category of functional units, such as RF transmitting circuits, to power on. This staggered peak current timing reduces the total instantaneous current demand on the bus and the risk of voltage drops.
[0049] Therefore, this embodiment of the invention, through timing control, disperses the instantaneous high currents that might otherwise be superimposed into different time points, transforming continuous wide-spectrum interference into discontinuous, more manageable narrow-band interference. The discontinuous interference signals provide the filter circuit with recovery and stabilization time, preventing all high noise sources from working simultaneously and preventing noise from superimposing to reach a peak. This significantly reduces the peak load of the power network and the resulting conducted noise, helps improve the stability of the system power supply, reduces the probability of abnormal reset due to power-on surges, and also helps reduce the electromagnetic radiation of the system and improve electromagnetic compatibility performance.
[0050] In some embodiments, the power partition fault monitoring and control method applied to the device wire controller further includes: controlling at least one functional unit with non-continuous working requirements to work intermittently according to a preset duty cycle.
[0051] Specifically, non-continuous operation requirements mean that the functional unit does not need to remain active throughout the entire operation of the device. The preset duty cycle refers to the ratio of the power-on time to the total number of cycles within a single work cycle. For some functional units, such as wireless communication units used for periodic data reporting or display backlights during standby, their operation is intermittent. The main control unit 101 is configured to control the power supply of these units according to a preset time schedule. For example, the wireless communication unit is controlled to power on for 30 seconds every 10 minutes to transmit data, and its power supply is completely cut off during the remaining time via a power control circuit. The duty cycle can be set and adjusted according to specific functional requirements; during power-off periods, the functional unit consumes almost no static power.
[0052] Therefore, by actively shutting off the power to idle functional units, this invention fundamentally eliminates the static and standby power consumption of these units. This is particularly beneficial for battery-powered wireless controllers, significantly reducing the average operating current and thus substantially extending the usage time per charge or the battery replacement cycle. Furthermore, the intermittent operating mode can indirectly improve the lifespan of electronic components.
[0053] In some embodiments, the main control chip unit is further configured to periodically or continuously acquire power consumption monitoring data waveforms of at least one target functional unit; perform time-domain analysis on the power consumption monitoring data waveforms to obtain current stability parameters, and / or perform frequency-domain analysis to obtain harmonic component parameters; calculate the health score of the target functional unit based on the current stability parameters and / or harmonic component parameters, combined with the operating time of the target functional unit; and generate predictive maintenance warning information when the health score is lower than a preset threshold.
[0054] Specifically, the power consumption monitoring data waveform refers to the digital sequence continuously acquired by the main control unit 101 through an analog-to-digital converter at a certain sampling rate, reflecting the change of the operating current of the target functional unit over time. Time domain analysis refers to processing the waveform data in the time dimension to extract characteristic parameters such as mean, variance, rise time, and peak value. Frequency domain analysis refers to converting the time domain waveform to the frequency dimension through mathematical transformations to analyze the amplitude of each frequency component, thereby obtaining harmonic component parameters. The health score is a numerical index calculated comprehensively, used to quantitatively assess the degree to which the target functional unit deviates from its health status. Predictive maintenance early warning information is a signal issued by the system in advance when the health score deteriorates but has not reached the immediate failure threshold, indicating the need for preventive inspection or maintenance.
[0055] When the target functional unit is operating normally, the main control unit 101 periodically or during specific tasks acquires raw digital waveforms of the current at a high sampling rate for a period of time. First, in the time domain, the system calculates the statistical or transient characteristics of this waveform segment to obtain current stability parameters. Second, frequency domain analysis is performed on the same waveform data segment to calculate the proportion of energy of other frequency components (excluding the fundamental operating frequency) to the total energy, obtaining harmonic component parameters. Simultaneously, the system records the cumulative operating time of the functional unit. Then, the main control unit 101 uses a preset algorithm model to calculate a health score. This score gradually decreases as components age, contact resistance increases, and performance degrades. The system continuously monitors this score; when it falls below a preset warning threshold, it determines that the unit has a potential degradation risk and automatically generates predictive maintenance warning information containing the unit identifier and warning level. This information can be stored locally or uploaded to a cloud management platform.
[0056] Therefore, by deeply analyzing the multi-dimensional characteristics of the current waveform and combining the cumulative effect of working time, the embodiments of the present invention can keenly capture the slow degradation trend of the functional unit performance, enabling the system to identify potential risks in advance and issue predictive maintenance warnings before the functional unit completely fails. This allows maintenance personnel to intervene in advance in a planned and low-cost manner, avoiding greater losses caused by unplanned downtime.
[0057] In summary, the embodiments of the present invention can realize sequential self-testing, power consumption detection, and proactive predictive protective control of the device. When the device is powered on, the power management unit 102 is powered on first, followed by the main control unit 101. After the main control unit 101 is powered on, it performs self-testing of the power consumption and function of each module circuit by controlling the power consumption monitoring circuit, the power control circuit, and reading and collecting operational amplifier data from the ADC within the main control unit 101, according to the designed sequence. This allows for the detection of module circuits with abnormal power consumption and function. After preliminary processing of the energy consumption data of each module in the microcontroller, power cut-off protection can be performed immediately for significant faults, and the fault information can be stored in an external storage component. For non-significant faults, the data is uploaded to a cloud computer via a wireless communication unit for storage and analysis, enabling predictive control and maintenance. Meanwhile, by building the above circuit, the status detection and control of each functional unit of the wired controller can be realized. The modular self-test strategy can help after-sales personnel to quickly locate the fault point, and can cut off the impact of the faulty circuit unit on the peripheral connected equipment in a timely manner. It provides support for the time-division multiplexing of circuit modules, reduces the power consumption of the wired controller, improves the electromagnetic compatibility performance of the circuit, and enables the storage, analysis and uploading of fault information.
[0058] The present invention also provides a wired controller, including a power zone fault monitoring and control system for a device wired controller as described in the above embodiments, and thus possesses the beneficial effects described in the above embodiments, which will not be repeated here.
[0059] The present invention also provides an air conditioning system, including a power zone fault monitoring and control system for an equipment wire controller as described in the above embodiments, and thus possesses the beneficial effects described in the above embodiments, which will not be repeated here.
[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A power zone fault monitoring and control system applied to a wired controller for equipment, characterized in that, include: The system comprises a main control unit, a power management unit, and multiple functional units, wherein the power management unit is electrically connected to the main control unit and the multiple functional units respectively; wherein the multiple functional units include at least two of a display unit, a sound unit, a touch unit, and a communication unit. Multiple power consumption monitoring circuits are configured corresponding to the power supply lines provided by the power management unit for the functional units, and are used to monitor the power consumption of the corresponding functional units; Multiple power control circuits are configured to correspond to the power supply lines provided by the power management unit for the functional units, and to control the power supply on / off of the corresponding functional units; The main control unit is electrically connected to the plurality of power consumption monitoring circuits and the plurality of power control circuits respectively, and is used to control the power control circuit corresponding to the functional unit to cut off the power supply when the functional unit is determined to have a fault based on the power consumption monitoring data of the functional unit.
2. The power zone fault monitoring and control system applied to a wired controller of equipment according to claim 1, characterized in that, The power consumption monitoring circuit includes: A sampling resistor unit is connected in series in the corresponding power supply line; wherein the equivalent resistance of the sampling resistor unit is less than or equal to a preset resistance value; The amplifier circuit is electrically connected to both ends of the sampling resistor unit and the main control unit, respectively.
3. The power zone fault monitoring and control system applied to a device wired controller according to claim 2, characterized in that, The amplifier circuit includes: The preamplifier circuit includes a differential operational amplifier circuit and two non-inverting proportional operational amplifier circuits. The non-inverting input terminals of the two non-inverting proportional operational amplifier circuits are electrically connected to the two ends of the sampling resistor unit, respectively. The output terminals of the two non-inverting proportional operational amplifier circuits are electrically connected to the non-inverting input terminal and the inverting input terminal of the differential operational amplifier circuit, respectively. A filter circuit, wherein the input terminal of the filter circuit is electrically connected to the output terminal of the differential operation circuit; The post-amplifier circuit is electrically connected to the output of the filter circuit and is used to amplify and adjust the polarity of the filtered signal, and output it to the main control unit.
4. The power zone fault monitoring and control system applied to a wired controller of equipment according to claim 2, characterized in that, Also includes: The analog switch unit includes a sampling resistor unit comprising multiple sampling resistors with different resistance values. The analog switch unit is electrically connected to the main control unit and the multiple sampling resistors with different resistance values. The main control unit is also used to control the analog switch unit to select the sampling resistor with the corresponding resistance value to connect to the power supply line according to the power consumption monitoring data.
5. The power zone fault monitoring and control system for equipment wired controllers according to claim 1, characterized in that, The power control circuit includes: The transistor has its base electrically connected to the main control unit and its emitter connected to a reference potential. A field-effect transistor (FET) is provided, wherein the gate of the FET is electrically connected to the collector of the transistor, the drain of the FET is electrically connected to the corresponding functional unit, and the source of the FET is connected to a power supply.
6. The power zone fault monitoring and control system applied to a wired controller of equipment according to claim 1, characterized in that, Also includes: A temperature sensor, electrically connected to the main control unit, is used to monitor the real-time temperature of the power consumption monitoring circuit. The main control unit is used to call the corresponding correction parameters based on the real-time temperature to compensate the currently acquired power consumption monitoring data.
7. A power zone fault monitoring and control method applied to a device wired controller, characterized in that, For controlling the power zone fault monitoring and control system applied to a device wired controller as described in any one of claims 1-6, the power zone fault monitoring and control method applied to the device wired controller includes: The multiple power control circuits are controlled to be turned on in a preset sequence to power on the corresponding functional units. During the power-on period of the functional unit, the power consumption monitoring data of the corresponding functional unit is obtained through the corresponding power consumption monitoring circuit; When a fault is detected in the functional unit based on the power consumption monitoring data of the functional unit, the power control circuit corresponding to the functional unit is controlled to cut off the power supply.
8. The power zone fault monitoring and control method applied to a device wired controller according to claim 7, characterized in that, Also includes: The first type of functional unit is powered on first; After the first preset delay, the second type of functional unit is powered on. The third type of functional unit is powered on after the second preset delay. The first type of functional unit, the second type of functional unit, and the third type of functional unit are classified according to the current surge and / or noise intensity generated when the functional unit is powered on. The functional unit that controls at least one non-continuous working requirement operates intermittently according to a preset duty cycle.
9. A wired controller, characterized in that, Including the power zone fault monitoring and control system applied to the equipment wire controller as described in any one of claims 1-6.
10. An air conditioning system, characterized in that, Including the power zone fault monitoring and control system applied to the equipment wire controller as described in any one of claims 1-6.