A stable and compatible industrial light power supply and controller integrated system

Abstract

The application discloses a stable and compatible industrial light power supply and controller integrated system, and relates to the technical field of industrial lighting.The system comprises a sampling and prediction module, which samples industrial mains at a high frequency and predicts disturbance; a voltage stabilizing and converting module, which receives mains and outputs stable direct-current voltage in combination with a prediction signal; a working condition acquisition module, which acquires working condition parameters with the stable voltage output as a power supply; an operation instruction module, which constructs a double-core architecture and generates adjustment instructions through comprehensive operation; and an adaptive adjustment module, which receives instructions, dynamically adjusts power supply power and light parameters, and adapts to different scene equipment.The application constructs a sampling and prediction and voltage stabilizing cooperative mechanism, senses power grid fluctuation in advance, guarantees stable direct-current output, avoids affecting industrial light equipment, further combines a double-core control and working condition-power matching algorithm, realizes intelligent regulation and control of power supply and light linkage, dynamically adjusts power and light parameters, and enhances adaptability through a self-defined interface, thereby providing a high-quality solution for industrial lighting.

Description

Technical Field

[0001] This invention relates to the field of industrial lighting technology, specifically to a stable and compatible integrated system for industrial lighting power supply and controller. Background Technology

[0002] The industrial lighting sector is increasingly demanding higher standards for the stable operation and adaptability of lighting equipment. As a core supporting component, the power supply's output stability and control precision directly affect the working efficiency and lifespan of the lighting equipment. Industrial power grid environments are complex, with frequent voltage fluctuations. At the same time, changes in various parameters such as temperature and humidity under different operating conditions can significantly impact power supply operation and lighting effects. With the improvement of industrial automation, industrial lighting equipment not only needs a continuous and stable power supply, but also needs to dynamically adapt power and lighting parameters according to on-site conditions to meet the lighting needs of different industrial scenarios and ensure the safety and efficiency of production operations. Therefore, developing an integrated system of industrial lighting power supplies and controllers that combines stability and compatibility has become an important direction for industry development.

[0003] Compared with this invention, the ring-shaped multi-module intelligent industrial and mining lamp with application number CN118912437A, although realizing the modular lighting and sensor adaptation of the ring-shaped multi-module, does not involve the early prediction of power grid disturbances and voltage stability regulation, and lacks a linkage adaptation mechanism between power supply and lighting parameters; the light source control circuit and light source control system with application number CN223452134U can focus on the signal isolation and flexible adjustment of multiple light sources, but does not integrate the acquisition and comprehensive calculation of multiple working condition parameters in industrial sites, and the adaptation scenarios are relatively limited; the intelligent control thyristor stable output circuit and dimming driver with application number CN223231353U only provides a solution for the current stability problem of thyristor dimming, and does not form a complete system design from power grid prediction, working condition perception to linkage regulation. In contrast, this invention, through the deep integration of five major modules, realizes the integrated functions of power grid disturbance prediction, stable power supply, working condition adaptation, linkage regulation and multi-scenario compatibility, making up for the shortcomings of existing solutions in system integration, prediction and adaptation flexibility.

[0004] Existing technologies still have many problems that urgently need to be solved: Traditional industrial lighting power supplies mostly use a single feedback control method for voltage regulation, which makes it difficult to detect grid disturbances in advance and can only passively correct them after voltage deviations occur, resulting in insufficient voltage output stability and susceptibility to grid fluctuations; there is a lack of comprehensive collection and consideration of various operating parameters in industrial sites, resulting in a disconnect between power regulation and changes in operating conditions, and an inability to achieve precise linkage control between power output and lighting parameters; the compatibility between power supplies and controllers is poor, the interface standardization is low, and it is difficult to be compatible with different types of industrial lighting equipment and diverse industrial scenarios; the control response speed is slow, and the energy utilization efficiency is low, which cannot meet the modern industrial demand for efficient, flexible, and stable lighting systems. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a stable and compatible integrated system for industrial lighting power supply and controller. This system integrates five modules: sampling and prediction, voltage regulation and conversion, operating condition acquisition, calculation instructions, and adaptation and adjustment. It predicts voltage fluctuations through high-frequency sampling and power grid disturbance prediction algorithms, and achieves stable power supply by combining dual-loop control and PID regulation. It relies on multiple sensors to collect on-site operating condition parameters, and generates power and lighting parameter adjustment instructions through a dual-core collaborative architecture and operating condition-power matching algorithm. The adaptation and adjustment module dynamically adjusts the output power and lighting operating parameters, and a customizable interface meets the needs of different scenarios and equipment.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a stable and compatible industrial lighting power supply and controller integrated system, the system comprising: Sampling and prediction module: High-frequency sampling of 220V / AC industrial mains power, synchronously converting electrical signals into digital waveform data, transmitting the digital waveform data, processing the data through the built-in power grid disturbance prediction algorithm, outputting the power grid disturbance prediction signal, and temporarily storing the processing results of the power grid disturbance prediction algorithm; Voltage regulator module: Receives 220V / AC industrial mains power and performs preliminary rectification. It adopts a feedforward-feedback dual-loop control architecture to receive the grid disturbance prediction signal output by the sampling prediction module, and combines PID regulation to carry out voltage conversion and voltage regulation operations, and outputs a stable DC voltage. Operating condition acquisition module: Powered by the stable DC voltage output from the voltage regulator module, it collects multiple operating condition parameters in real time from the industrial site, converts the collected operating condition parameters into standard electrical signals, and then transmits them. Calculation instruction module: Constructs a dual-core collaborative control architecture, retrieves the temporary results of the sampling prediction module and the corresponding operating parameters of the standard electrical signals transmitted by the operating condition acquisition module, performs comprehensive calculations through the built-in operating condition-power matching algorithm, and generates power adjustment instructions and lighting parameter linkage adjustment signals. Adaptive adjustment module: Receives power adjustment commands from the calculation command module to dynamically adjust the power output. Simultaneously, it receives lighting parameter linkage adjustment signals from the calculation command module to synchronously adjust the lighting operating parameters. It can also customize operating parameters through a custom interface to adapt to different industrial scenarios and industrial lighting equipment.

[0007] Furthermore, the sampling prediction module performs high-frequency sampling of the 220V / AC industrial mains power in a nanosecond-level continuous and uninterrupted manner. The sampling frequency can be adjusted within a set range, and the sampling interval is adaptively adjusted according to the voltage fluctuation of the mains power. The conversion of electrical signals to digital waveform data adopts a high-precision digital-to-analog conversion method, controlling the conversion error within a set range. The digital waveform data includes three types of data: sampling period, instantaneous voltage value, and voltage change. The transmission of digital waveform data adopts a high-speed communication method, with a transmission baud rate configurable within the range of 1Mbps to 5Mbps. During transmission, a CRC check method is used, with a check code length of 16 bits.

[0008] Furthermore, the mathematical expression for the power grid disturbance prediction algorithm in the voltage regulation conversion module is: ,in This is the coefficient for predicting power grid disturbance trends. For digital isolation sampling weighting coefficients, This represents the instantaneous change in grid voltage during the current sampling period. This represents the instantaneous change in grid voltage during the previous sampling period. The sampling period for high-frequency sampling. This is the correction factor for power grid disturbance trends. This is the voltage deviation weighting coefficient. The peak voltage of the power grid over three consecutive sampling periods. The rated input voltage is 220V / AC industrial mains power.

[0009] Furthermore, the feedforward-feedback dual-loop control architecture employed in the voltage regulation module includes a feedforward control loop and a feedback control loop. The feedforward control loop receives the grid disturbance prediction signal output by the sampling prediction module, analyzes the signal to obtain disturbance information, and adjusts the voltage regulation parameters based on the analysis results. The feedback control loop samples the output voltage after voltage conversion and regulation in real time, compares the sampled voltage data with a preset voltage standard value, and generates voltage deviation data. The feedforward control loop and the feedback control loop work in parallel. The feedback control loop transmits the generated voltage deviation data to the PID control loop. The PID control loop, combined with the voltage regulation parameters and voltage deviation data from the feedforward control loop, jointly participates in the parameter calibration of voltage conversion and regulation operations.

[0010] Furthermore, when the voltage conversion module performs voltage conversion and regulation operations in conjunction with PID control, it first converts the 220V / AC industrial mains power into an unregulated DC voltage through preliminary rectification, and then inputs the unregulated DC voltage to the voltage conversion stage. The PID control stage receives voltage regulation parameters from the feedforward control loop and voltage deviation data from the feedback control loop, processes them, and outputs the corresponding regulation parameters. The voltage conversion stage adjusts its own operating state according to the regulation parameters output by the PID control stage to perform voltage reduction conversion of the unregulated DC voltage. At the same time, the PID control stage receives the output voltage sampling data transmitted from the feedback control loop in real time, compares it with the preset voltage value, and continuously corrects the output regulation parameters based on the comparison results. It also coordinates with the control signal of the feedforward control loop to complete the entire voltage conversion and regulation operation, and finally outputs a stable DC voltage.

[0011] Furthermore, when the operating condition acquisition module collects multiple operating condition parameters in real time at the industrial site, it collects ambient temperature data from the industrial site through a temperature sensor, ambient humidity data from the industrial site through a humidity sensor, grid voltage fluctuation data through a voltage detection sensor, operating temperature rise data of the lighting fixtures through a temperature rise sensor, and vibration frequency data from the site through a vibration sensor. At the same time, it classifies and records the collected data of each type of operating condition parameter.

[0012] Furthermore, when constructing a dual-core collaborative control architecture, the computation instruction module sets up a first control core and a second control core, which respectively undertake computational functions and main control functions. A bidirectional high-speed communication connection is established between the two control cores, and data is transmitted using a fixed frame format. The first control core is specifically responsible for retrieving the temporary results of the sampling prediction module, the operating condition parameters transmitted by the operating condition acquisition module, and running the built-in operating condition-power matching algorithm to perform comprehensive calculations. The second control core is specifically responsible for receiving computational data and processing signal transmission operations. The two control cores operate independently and synchronously perform their respective tasks. Real-time data synchronization is achieved through bidirectional communication, together forming a complete dual-core collaborative control architecture.

[0013] Furthermore, the mathematical expression for the operating condition-power matching algorithm in the calculation instruction module is: ,in The target value for dynamic adjustment of power supply output power. The rated operating power of industrial lighting equipment. This is the overall system adjustment coefficient. This is the coefficient for predicting power grid disturbance trends. This is the coefficient representing the impact of grid disturbances on power regulation. These are the parameter serial numbers for non-grid-related operating conditions in industrial sites. For the first The weighting coefficients of the operating condition parameters, For the first Real-time collected values ​​of the operating parameters, For the first The rated threshold of the operating condition parameters.

[0014] Furthermore, in the calculation instruction module, the specific steps for generating the power adjustment instruction and the lighting parameter linkage adjustment signal are as follows: the first control core and the second control core respectively obtain the temporary storage result of the sampling prediction module and the real-time operating condition parameters of the operating condition acquisition module, and input the two into the operating condition-power matching algorithm for comprehensive calculation; during the calculation, the real-time operating condition parameters are first matched with the pre-stored operating condition-power-lighting parameter mapping relationship to obtain the initial power value and the initial lighting parameters, and then the initial value is dynamically corrected in combination with the power grid disturbance prediction result; after the correction is completed, the two cores work together to generate a power adjustment instruction containing the target operating power and adjustment timing, and simultaneously generate a lighting parameter adjustment signal linked with the power adjustment instruction. The linkage signal contains target parameters such as lighting brightness, color temperature and flicker frequency that are synchronized with the power adjustment rhythm.

[0015] Furthermore, the dynamic adjustment range of the power output in the adapter adjustment module is 5W-1000W, the adjustment step is 0.05W, the adjustment response time is no more than 5ms, and the power adjustment command output by the real-time tracking operation command module is provided. The synchronous adjustment of the lighting operating parameters specifically includes the adjustment of luminous brightness, operating current, and operating frequency, wherein the luminous brightness adjustment range is 0-100%; the operating current adjustment range is 0.1A-20A; and the operating frequency adjustment range is 50Hz-1kHz.

[0016] Compared with existing technologies, this stable and compatible industrial lighting power supply and controller integrated system has the following advantages: I. This invention achieves accurate prediction of power grid disturbances and stable voltage control by constructing a collaborative mechanism of sampling prediction and voltage regulation. Relying on high-frequency sampling and power grid disturbance prediction algorithms, it can detect the trend of power grid voltage fluctuations in advance. Combined with a feedforward-feedback dual-loop control architecture and PID regulation, it efficiently completes voltage conversion and voltage regulation operations, ensuring the stability of DC output voltage and avoiding the impact of power grid fluctuations on the operation of industrial lighting equipment. At the same time, the operating condition acquisition module comprehensively captures various key parameters in the industrial field, providing rich data support for subsequent regulation and control. This allows voltage regulation to dynamically adapt to changes in operating conditions, improving the reliability of power supply operation and reducing equipment losses caused by voltage instability, ensuring the continuous and stable operation of industrial lighting equipment in complex power grid environments.

[0017] II. This invention achieves intelligent linkage control of power output and lighting parameters through the deep integration of a dual-core collaborative control architecture and a working condition-power matching algorithm. The dual cores work together to efficiently complete data retrieval, comprehensive calculation, and instruction generation, ensuring rapid response and accurate output of control instructions. The adaptation and adjustment module dynamically adjusts the power output based on the calculation results, simultaneously optimizing the lighting operating parameters to achieve precise matching between power and lighting effects. The custom interface design allows the system to adapt to different industrial scenarios and lighting equipment, enhancing application flexibility, meeting diverse usage needs, and improving energy utilization efficiency, providing a stable, efficient, and highly adaptable solution for industrial lighting.

[0018] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0020] Figure 1 Workflow diagram for a stable and compatible industrial lighting power supply and controller integration system; Figure 2 Connection framework diagram for a stable and compatible industrial lighting power supply and controller integrated system module; Figure 3 A schematic diagram of the integrated system structure for a stable and compatible industrial lighting power supply and controller. Detailed Implementation

[0021] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0022] Example 1: Industrial lighting control scene in a large machinery manufacturing workshop.

[0023] Large-scale machinery manufacturing workshops are densely packed with equipment. Frequent start-ups and shutdowns during production cause significant fluctuations in the power grid voltage. There are also large differences in temperature and humidity in different areas. The continuous vibration generated by machinery operation and the tendency of lighting fixtures to overheat during prolonged use necessitate a stable and compatible industrial lighting power supply and controller integration system. This system must rely on stable voltage output and adaptability to complex operating conditions to ensure continuous and stable lighting operation, providing uniform and suitable illumination for machining processes, thereby helping to improve machining accuracy and production efficiency. Specific steps are as follows... Figure 1 As shown.

[0024] After the sampling and prediction module is activated, it performs nanosecond-level continuous and uninterrupted high-frequency sampling of the 220V / AC industrial mains power connected to the workshop. The sampling frequency is adaptively adjusted within a set range according to the voltage fluctuations of the mains, and the sampling interval is dynamically adapted synchronously to ensure accurate capture of subtle changes and fluctuation trends in the mains voltage. The acquired electrical signals are then converted into digital waveform data containing the sampling period, instantaneous voltage value, and voltage change through a high-precision digital-to-analog converter. The conversion error is strictly controlled within a set range to ensure that the data accurately reflects the mains voltage status. The digital waveform data is transmitted via high-speed communication configured with a baud rate between 1Mbps and 5Mbps. A 16-bit CRC check effectively prevents data loss or errors during transmission. The module's built-in grid disturbance prediction algorithm performs in-depth data processing and quickly outputs a grid disturbance prediction signal. The mathematical expression of the grid disturbance prediction algorithm is: ,in This is the coefficient for predicting power grid disturbance trends. For digital isolation sampling weighting coefficients, This represents the instantaneous change in grid voltage during the current sampling period. This represents the instantaneous change in grid voltage during the previous sampling period. The sampling period for high-frequency sampling. This is the correction factor for power grid disturbance trends. This is the voltage deviation weighting coefficient. The peak voltage of the power grid over three consecutive sampling periods. The rated input voltage is 220V / AC industrial mains power, providing a basis for advance prediction of subsequent voltage regulation operations. At the same time, the algorithm processing results are temporarily stored for later use.

[0025] The voltage regulator module receives 220V / AC industrial mains power and performs preliminary rectification, converting the AC mains power into unregulated DC voltage. A feedforward-feedback dual-loop control architecture operates efficiently. The feedforward control loop receives grid disturbance prediction signals from the sampling and prediction module, quickly analyzes disturbance-related information, and adjusts voltage regulation parameters in a timely manner to proactively address potential grid fluctuations. The feedback control loop samples the converted and regulated output voltage in real time, accurately comparing the sampled data with preset voltage standard values ​​to generate accurate voltage deviation data and provide real-time feedback on the voltage output status. The feedforward and feedback control loops work in parallel. Voltage deviation data is transmitted to the PID control loop, which combines the voltage regulation parameters from the feedforward control loop with the voltage deviation data to output precise regulation parameters. The voltage conversion stage adjusts its operating state based on these parameters, smoothly stepping down the unregulated DC voltage. Simultaneously, the PID control loop continuously receives output voltage sampling data from the feedback control loop, compares it with preset voltage values ​​in real time, and continuously corrects the regulation parameters. Combined with the feedforward control loop's control signals, this ensures a stable and reliable final output DC voltage, meeting the power supply requirements of industrial lighting equipment.

[0026] The operating condition acquisition module is powered by a stable DC voltage output from the voltage regulator module. Various sensors are fully activated to collect real-time operating parameters from the workshop. Temperature sensors accurately collect ambient temperature data from different areas, humidity sensors simultaneously acquire corresponding ambient humidity data, voltage sensors capture details of grid voltage fluctuations, temperature rise sensors monitor the temperature rise of each lamp in real time, and vibration sensors capture on-site vibration frequency data from the mechanical operating area. All collected operating condition parameters are categorized and recorded to ensure clear data classification for easy subsequent processing. Converting the data into standard electrical signals ensures efficient and accurate data transmission within the system, providing comprehensive and accurate operating condition data for subsequent calculations.

[0027] The dual-core collaborative control architecture of the computation instruction module leverages its advantages. The first and second control cores respectively handle computation and main control functions, while bidirectional high-speed communication, coupled with fixed-frame format data transmission, ensures high-speed and accurate data transmission. The first control core efficiently retrieves the temporary results from the sampling prediction module and the operating condition parameters transmitted by the operating condition acquisition module, and runs the built-in operating condition-power matching algorithm to perform comprehensive calculations. The mathematical expression of the operating condition-power matching algorithm is: ,in The target value for dynamic adjustment of power supply output power. The rated operating power of industrial lighting equipment. This is the overall system adjustment coefficient. This is the coefficient for predicting power grid disturbance trends. This is the coefficient representing the impact of grid disturbances on power regulation. These are the parameter serial numbers for non-grid-related operating conditions in industrial sites. For the first The weighting coefficients of the operating condition parameters, For the first Real-time collected values ​​of the operating parameters, For the first The first control core focuses on receiving and processing relevant data and signal transmission operations, while the second control core operates independently and synchronously. Through bidirectional communication, data is synchronized in real time, improving computational and command generation efficiency. During computation, real-time operating parameters are precisely matched with pre-stored operating condition-power-lighting parameter mappings to quickly obtain initial power and lighting parameters. Then, the initial values ​​are dynamically corrected based on grid disturbance prediction results to ensure parameter adaptation to the current operating condition. The two cores collaboratively generate power adjustment commands containing target operating power and adjustment timing, and simultaneously generate lighting parameter adjustment signals linked to these commands. The target parameters in the linked signals—brightness, color temperature, and flicker frequency—are synchronized with the power adjustment rhythm, ensuring coordinated adaptation between lighting parameters and power. Figure 3 As shown.

[0028] The adaptive adjustment module responds quickly to power adjustment commands output by the computational command module, dynamically adjusting the power output in real time according to a dynamic adjustment range of 5W-1000W, an adjustment step of 0.05W, and a response time of no more than 5ms, ensuring that the power output can quickly adapt to changes in operating conditions. It synchronously receives lighting parameter linkage adjustment signals, precisely and synchronously adjusting the lighting operating parameters. The brightness can be flexibly adjusted within the range of 0-100% to adapt to the lighting needs of different areas. The operating current is precisely adapted within the range of 0.1A-20A to ensure stable operation of the luminaires, and the operating frequency is reasonably adapted within the range of 50Hz-1kHz to improve lighting stability. The system's customizable interface allows operators to personalize operating parameters according to the lighting needs of different processing areas in the workshop, enabling the system to flexibly adapt to different industrial scenarios and various industrial lighting equipment within the workshop, improving the system's versatility and practicality.

[0029] In summary, in large-scale machinery manufacturing workshops, the stable and compatible industrial lighting power supply and controller integrated system achieves stable and efficient lighting control through the collaborative operation of its various modules. The sampling and prediction module accurately captures and anticipates power grid fluctuations, providing a foundation for voltage stabilization; the voltage conversion module, relying on dual-loop control and PID regulation, outputs a stable DC voltage; the operating condition acquisition module comprehensively collects various operating condition data, ensuring comprehensive calculation basis; the calculation instruction module generates precise instructions using a dual-core architecture and operating condition-power matching algorithm; and the adaptation and adjustment module dynamically adjusts power and lighting parameters, and supports personalized settings. The entire system effectively copes with complex workshop conditions, ensuring stable lighting adaptation and contributing to improved production efficiency and processing accuracy.

[0030] Example 2: Industrial lighting control scene in a high-precision electronic component manufacturing workshop.

[0031] High-precision electronic component manufacturing workshops have stringent requirements for the stability and accuracy of lighting. Even minor fluctuations in grid voltage and changes in ambient temperature and humidity can affect lighting performance, thereby interfering with the quality of electronic component production. Different production processes have varying requirements for parameters such as light brightness and color temperature, and it is essential to avoid temperature rise issues caused by incompatible lamp power. A stable and compatible industrial lighting power supply and controller integration system, through high-precision voltage stability control, accurate operating condition data acquisition, and flexible parameter adjustment, ensures that the lighting meets production requirements, helping to improve the quality of electronic component production. Specific steps are as follows... Figure 2 As shown.

[0032] After the sampling and prediction module is activated, it performs nanosecond-level continuous and uninterrupted high-frequency sampling of the 220V / AC industrial mains power in the workshop. Considering the relatively smooth voltage fluctuations but high stability requirements of the workshop's mains power, the sampling frequency is set within a reasonable range suitable for this scenario. The sampling interval is adaptively adjusted according to subtle voltage fluctuations in the mains power to ensure the capture of minute voltage changes. The collected electrical signals are converted into digital waveform data containing the sampling period, instantaneous voltage value, and voltage change through high-precision digital-to-analog conversion. Conversion errors are strictly controlled to meet set standards, ensuring the data accurately reflects the mains voltage status. The digital waveform data is transmitted via high-speed communication configured with baud rates between 1Mbps and 5Mbps. A 16-bit CRC check effectively ensures accurate data transmission, preventing data transmission errors from affecting subsequent operations. The module's built-in power grid disturbance prediction algorithm deeply processes the digital waveform data, accurately outputting a power grid disturbance prediction signal. The mathematical expression of the power grid disturbance prediction algorithm is: ,in This is the coefficient for predicting power grid disturbance trends. For digital isolation sampling weighting coefficients, This represents the instantaneous change in grid voltage during the current sampling period. This represents the instantaneous change in grid voltage during the previous sampling period. The sampling period for high-frequency sampling. This is the correction factor for power grid disturbance trends. This is the voltage deviation weighting coefficient. The peak voltage of the power grid over three consecutive sampling periods. The rated input voltage for 220V / AC industrial mains power is used to provide accurate prediction for subsequent voltage regulation operations. The algorithm processing results are temporarily stored for efficient subsequent use.

[0033] The voltage regulator module receives 220V / AC industrial mains power and performs preliminary rectification, converting the AC mains power into unregulated DC voltage. A feedforward-feedback dual-loop control architecture operates precisely. The feedforward control loop receives the grid disturbance prediction signal output from the sampling and prediction module, meticulously analyzes the disturbance information in the signal, and accurately adjusts the voltage regulation parameters to proactively avoid the impact of grid disturbances on the voltage output. The feedback control loop samples the converted and regulated output voltage in real time, meticulously comparing the sampled data with a preset high-precision voltage standard value to generate accurate voltage deviation data, providing precise feedback on the voltage output. The feedforward and feedback control loops work in parallel and collaboratively. The voltage deviation data is transmitted to the PID control loop, which combines the voltage regulation parameters from the feedforward control loop and the voltage deviation data from the feedback control loop, performing precise calculations to output the regulation parameters. The voltage conversion stage adjusts its working state according to the regulation parameters, and performs high-precision step-down conversion on the unregulated DC voltage. The PID regulation stage continuously receives the output voltage sampling data transmitted by the feedback control loop, compares it with the preset voltage standard value in real time, and continuously corrects the regulation parameters. With the help of the feedforward control loop regulation signal, it realizes high-precision voltage conversion and voltage regulation operation, and finally outputs a stable and accurate DC voltage to meet the stringent power supply requirements of high-precision production.

[0034] The operating condition acquisition module is powered by a stable DC voltage output from the voltage regulator module, enabling various high-precision sensors to accurately acquire workshop operating parameters. Temperature sensors precisely capture subtle changes in ambient temperature in the production area; humidity sensors accurately collect humidity data within the workshop; voltage sensors accurately collect minute fluctuations in grid voltage; temperature rise sensors monitor the temperature rise of each lamp in real time to prevent exceeding temperature limits; and vibration sensors capture the weak vibration frequency data generated by equipment operation within the workshop. All acquired operating parameters are categorized and accurately recorded to ensure data accuracy. The data is then converted into standard electrical signals for efficient and accurate transmission within the system, providing comprehensive, accurate, and detailed operating condition data support for subsequent calculations.

[0035] The dual-core collaborative control architecture of the computation instruction module operates efficiently. The first and second control cores respectively handle computation and main control functions. A bidirectional high-speed communication connection, coupled with fixed-frame format data transmission, ensures high-speed and accurate data transmission. The first control core quickly retrieves the temporary results from the sampling prediction module and the operating condition parameters transmitted by the operating condition acquisition module, and runs the built-in operating condition-power matching algorithm for refined comprehensive calculation. The mathematical expression of the operating condition-power matching algorithm is: ,in The target value for dynamic adjustment of power supply output power. The rated operating power of industrial lighting equipment. This is the overall system adjustment coefficient. This is the coefficient for predicting power grid disturbance trends. This is the coefficient representing the impact of grid disturbances on power regulation. These are the parameter serial numbers for non-grid-related operating conditions in industrial sites. For the first The weighting coefficients of the operating condition parameters, For the first Real-time collected values ​​of the operating parameters, For the first The first control core receives and processes relevant data and performs various operations during signal transmission, while the second control core operates independently and synchronously. Through bidirectional communication, they maintain real-time data synchronization, improving computational efficiency and command accuracy. During computation, the real-time collected operating parameters are precisely matched with pre-stored high-precision operating condition-power-lighting parameter mapping relationships to quickly obtain initial power and lighting parameters. These initial values ​​are then dynamically and finely corrected based on grid disturbance prediction results, ensuring that the parameters accurately adapt to the current operating conditions and high-precision production requirements. The two cores collaboratively generate power adjustment commands containing precise target operating power and adjustment timing, while simultaneously generating lighting parameter adjustment signals linked to these commands. The lighting brightness, color temperature, and flicker frequency in the linked signals are precisely targeted and strictly synchronized with the power adjustment rhythm, perfectly adapting to the lighting needs of different production processes for high-precision electronic components.

[0036] The adaptive adjustment module accurately receives power adjustment commands from the computational command module, dynamically adjusting the power output in real time according to a dynamic adjustment range of 5W-1000W, a fine adjustment step of 0.05W, and a fast adjustment response time of no more than 5ms. This ensures that the power output precisely matches the stringent requirements of high-precision production. It synchronously receives lighting parameter linkage adjustment signals and precisely adjusts the lighting operating parameters accordingly. The brightness is precisely adjusted within the 0-100% range according to the needs of different processes, ensuring that the lighting brightness meets the standards for each process. The operating current is precisely adapted within the 0.1A-20A range to avoid inappropriate current affecting the stability and lighting effect of the lamps. The operating frequency is flexibly adjusted within the 50Hz-1kHz range to ensure the stability and accuracy of the lighting. The system's customizable interface allows operators to personalize the operating parameters according to the specific requirements of different production processes. This enables the system to perfectly adapt to the special industrial scenarios of high-precision electronic component production workshops and various industrial lighting equipment, improving the adaptability and accuracy of lighting during production.

[0037] In summary, this integrated system demonstrates high-precision control capabilities to meet the stringent requirements of high-precision electronic component manufacturing workshops. The sampling and prediction module captures minute fluctuations in the power grid, ensuring data accuracy; the voltage regulation and conversion module outputs a high-precision, stable voltage through dual-loop control and PID regulation; the operating condition acquisition module uses high-precision sensors to acquire detailed operating condition data, supporting precise calculations; the calculation instruction module generates precise instructions adapted to specific processes using dual-core collaboration and matching algorithms; and the adaptation and adjustment module achieves fine-grained synchronous adjustment of power and lighting parameters, and supports personalized adaptation. The system comprehensively meets the workshop's requirements for lighting stability and accuracy, avoids interference from environmental and power grid factors on production, and helps improve the quality of electronic component production.

[0038] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A stable and compatible integrated system for industrial lighting power supply and controller, characterized in that, The system includes: Sampling and prediction module: High-frequency sampling of 220V / AC industrial mains power, synchronously converting electrical signals into digital waveform data, transmitting the digital waveform data, processing the data through the built-in power grid disturbance prediction algorithm, outputting the power grid disturbance prediction signal, and temporarily storing the processing results of the power grid disturbance prediction algorithm; Voltage regulator module: Receives 220V / AC industrial mains power and performs preliminary rectification. It adopts a feedforward-feedback dual-loop control architecture to receive the grid disturbance prediction signal output by the sampling prediction module, and combines PID regulation to carry out voltage conversion and voltage regulation operations, and outputs a stable DC voltage. Operating condition acquisition module: Powered by the stable DC voltage output from the voltage regulator module, it collects multiple operating condition parameters in real time from the industrial site, converts the collected operating condition parameters into standard electrical signals, and then transmits them. Calculation instruction module: Constructs a dual-core collaborative control architecture, retrieves the temporary results of the sampling prediction module and the corresponding operating parameters of the standard electrical signals transmitted by the operating condition acquisition module, performs comprehensive calculations through the built-in operating condition-power matching algorithm, and generates power adjustment instructions and lighting parameter linkage adjustment signals. Adaptive adjustment module: Receives power adjustment commands from the calculation command module to dynamically adjust the power output. Simultaneously, it receives lighting parameter linkage adjustment signals from the calculation command module to synchronously adjust the lighting operating parameters. It can also customize operating parameters through a custom interface to adapt to different industrial scenarios and industrial lighting equipment.

2. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, The sampling prediction module performs high-frequency sampling of the 220V / AC industrial mains power in a continuous, uninterrupted manner at the nanosecond level. The sampling frequency can be adjusted within a set range, and the sampling interval is adaptively adjusted according to the voltage fluctuations of the mains power. The conversion from electrical signal to digital waveform data adopts a high-precision digital-to-analog conversion method, controlling the conversion error within a set range. The digital waveform data includes three types of data: sampling period, instantaneous voltage value, and voltage change. The transmission of digital waveform data adopts a high-speed communication method, with a transmission baud rate configurable within the range of 1Mbps to 5Mbps. During transmission, a CRC check is used, with a check code length of 16 bits.

3. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, The mathematical expression for the power grid disturbance prediction algorithm in the voltage regulation conversion module is: ,in This is the coefficient for predicting power grid disturbance trends. For digital isolation sampling weighting coefficients, This represents the instantaneous change in grid voltage during the current sampling period. This represents the instantaneous change in grid voltage during the previous sampling period. The sampling period for high-frequency sampling. This is the correction factor for power grid disturbance trends. This is the voltage deviation weighting coefficient. The peak voltage of the power grid over three consecutive sampling periods. The rated input voltage is 220V / AC industrial mains power.

4. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, The voltage regulation module employs a feedforward-feedback dual-loop control architecture, comprising a feedforward control loop and a feedback control loop. The feedforward control loop receives the grid disturbance prediction signal output by the sampling and prediction module, analyzes the signal to obtain disturbance information, and adjusts the voltage regulation parameters based on the analysis results. The feedback control loop samples the output voltage after voltage conversion and regulation in real time, compares the sampled voltage data with a preset voltage standard value, and generates voltage deviation data. The feedforward control loop and the feedback control loop operate in parallel. The feedback control loop transmits the generated voltage deviation data to the PID control loop. The PID control loop, combined with the voltage regulation parameters and voltage deviation data from the feedforward control loop, jointly participates in the parameter calibration of the voltage conversion and regulation operation.

5. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, When the voltage conversion module combines PID regulation to perform voltage conversion and regulation, it first converts the 220V / AC industrial mains power into an unregulated DC voltage through preliminary rectification, and then inputs the unregulated DC voltage to the voltage conversion stage. The PID regulation stage receives voltage regulation parameters from the feedforward control loop and voltage deviation data from the feedback control loop, processes them, and outputs the corresponding regulation parameters. The voltage conversion stage adjusts its own operating state according to the regulation parameters output by the PID regulation stage to perform voltage reduction conversion of the unregulated DC voltage. At the same time, the PID regulation stage receives the output voltage sampling data transmitted from the feedback control loop in real time, compares it with the preset voltage value, and continuously corrects the output regulation parameters according to the comparison results. It works in sync with the control signal of the feedforward control loop to complete the entire voltage conversion and regulation operation, and finally outputs a stable DC voltage.

6. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, When the operating condition acquisition module collects multiple operating condition parameters in real time at the industrial site, it collects ambient temperature data through a temperature sensor, ambient humidity data through a humidity sensor, grid voltage fluctuation data through a voltage detection sensor, operating temperature rise data of lighting fixtures through a temperature rise sensor, and vibration frequency data through a vibration sensor. At the same time, it classifies and records the collected data of each type of operating condition parameter.

7. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, When constructing a dual-core collaborative control architecture, the computation instruction module sets up a first control core and a second control core, which respectively undertake the computation function and the main control function. A bidirectional high-speed communication connection is established between the two control cores, and data is transmitted using a fixed frame format. The first control core is specifically responsible for retrieving the temporary results of the sampling prediction module, the operating condition parameters transmitted by the operating condition acquisition module, and running the built-in operating condition-power matching algorithm to perform comprehensive calculations. The second control core is specifically responsible for receiving computation data and processing signal transmission operations. The two control cores operate independently and synchronously perform their respective tasks. Real-time data synchronization is achieved through bidirectional communication, together forming a complete dual-core collaborative control architecture.

8. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, The mathematical expression for the operating condition-power matching algorithm in the calculation instruction module is: ,in The target value for dynamic adjustment of power supply output power. The rated operating power of industrial lighting equipment. This is the overall system adjustment coefficient. This is the coefficient for predicting power grid disturbance trends. This is the coefficient representing the impact of grid disturbances on power regulation. These are the parameter serial numbers for non-grid-related operating conditions in industrial sites. For the first The weighting coefficients of the operating condition parameters, For the first Real-time collected values ​​of the operating parameters, For the first The rated threshold of the operating condition parameters.

9. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, In the calculation instruction module, the specific steps for generating the power adjustment instruction and the lighting parameter linkage adjustment signal are as follows: the first control core and the second control core respectively obtain the temporary storage result of the sampling prediction module and the real-time operating condition parameters of the operating condition acquisition module, and input the two into the operating condition-power matching algorithm for comprehensive calculation; during the calculation, the real-time operating condition parameters are first matched with the pre-stored operating condition-power-lighting parameter mapping relationship to obtain the initial power value and the initial lighting parameters, and then the initial value is dynamically corrected in combination with the power grid disturbance prediction result; after the correction is completed, the two cores work together to generate a power adjustment instruction containing the target operating power and adjustment timing, and simultaneously generate a lighting parameter adjustment signal linked with the power adjustment instruction. The linkage signal contains target parameters such as lighting brightness, color temperature and flicker frequency that are synchronized with the power adjustment rhythm.

10. The stable and compatible industrial lighting power supply and controller integrated system according to claim 1, characterized in that, The dynamic adjustment range of the power output in the adapter adjustment module is 5W-1000W, with an adjustment step of 0.05W and an adjustment response time of no more than 5ms. It tracks the power adjustment command output by the calculation command module in real time. The synchronous adjustment of the lighting operating parameters specifically includes the adjustment of luminous brightness, operating current, and operating frequency. The luminous brightness adjustment range is 0-100%, the operating current adjustment range is 0.1A-20A, and the operating frequency adjustment range is 50Hz-1kHz.

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