A two-wire dc current management module

Abstract

The application discloses a two-wire DC current management module, and relates to the technical field of DC speed regulation and current management. The module is connected in series in a power supply loop of a DC power supply and a controlled load in a two-wire series connection structure. The module comprises an MCU master control unit, a power management chip, a current and voltage acquisition unit, a MOS tube power unit, a parameter adjustment unit, a state indication unit and a multiple protection circuit. The MCU master control unit is electrically connected with the power management chip, the current and voltage acquisition unit, the MOS tube power unit, the parameter adjustment unit and the state indication unit, and is used for completing signal acquisition, instruction response, working condition judgment and protection control. The two-wire DC current management module adopts a two-wire series connection wiring structure, and can be installed by using only two cables, without distinguishing complex control lines. The two-wire DC current management module can directly reuse an existing two-wire power supply line, without re-trenching and rewiring, and greatly reduces construction difficulty, transformation cost and wiring failure probability.

Description

Technical Field

[0001] This invention relates to the field of DC speed regulation and current management technology, specifically a two-wire DC current management module. Background Technology

[0002] DC speed control technology is now widely used in smart homes, small industrial control equipment, auto parts modification, agricultural irrigation, and other scenarios, mainly for regulating the speed and operating power of various DC loads. Currently, most mainstream DC speed control switches and current management modules on the market adopt a three-wire or four-wire wiring structure. The circuit connection logic is that the load and the module share the positive terminal of the power supply, the negative terminal of the module is connected to the negative terminal of the power supply, and the negative terminal of the load is connected in series to the internal MOS transistor circuit of the module. The voltage adaptation range of this type of conventional module is only DC12V~24V.

[0003] Existing multi-wire DC speed control modules have many defects in practical use, which seriously restrict their application scope and safety: Three-wire / four-wire structures require distinguishing between different functional lines such as power positive and negative terminals and load control lines, and installation requires connecting 3 to 4 cables, making the operation cumbersome. In the scenario of upgrading old equipment, the original wiring usually only has two power supply lines. Adding traditional modules requires re-grooving and rewiring, which not only increases construction costs and extends the construction period, but also makes wiring errors very likely.

[0004] Traditional modules do not have a dedicated reverse connection protection circuit. If the positive and negative terminals of the power supply are reversed during installation, it will directly damage the internal MOSFETs, main control chips and other core components, causing the module to be scrapped, or even causing the circuit to overheat, posing a safety hazard.

[0005] Conventional modules only support a narrow voltage range of DC 12V~24V, which cannot adapt to different industry power supply standards such as 12V for automotive parts, 36V for industrial control, and 48V for agricultural irrigation. They are also not compatible with voltage fluctuations in lithium batteries, ranging from 28V when fully charged to 18V when depleted. Users need to purchase multiple specifications of modules according to different scenarios, resulting in high usage costs.

[0006] The existing modules lack accurate abnormal operating condition detection and protection circuits. When the load experiences stalling, short circuit, or momentary overvoltage fluctuations, the power supply cannot be cut off in time. Continuous abnormal current and voltage can burn out the module fuse, and in severe cases, may even cause safety accidents such as circuit fires.

[0007] Traditional modules only have basic voltage and speed regulation functions and cannot adaptively adjust current parameters according to load type. When applied to motor loads, they cannot achieve soft start, and the starting inrush current can easily damage the device; when applied to LED loads, they cannot provide stable constant current output, and current fluctuations will accelerate LED light decay; at the same time, they do not have the ability to monitor and dynamically adjust the current in real time, resulting in poor load operation stability and shortened service life. Summary of the Invention

[0008] The purpose of this invention is to provide a two-wire DC current management module to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a two-wire DC current management module, wherein the module is connected in series in the power supply circuit between the DC power supply and the controlled load using a two-wire series structure; the module includes an MCU main control unit, a power management chip, a current and voltage acquisition unit, a MOSFET power unit, a parameter adjustment unit, a status indication unit, and multiple protection circuits; the MCU main control unit is electrically connected to the power management chip, the current and voltage acquisition unit, the MOSFET power unit, the parameter adjustment unit, and the status indication unit respectively, and is used to complete signal acquisition, command response, operating condition judgment, and protection control.

[0010] Preferably, the wiring method of the two-wire series structure is as follows: the positive terminal of the DC power supply is connected to the positive terminal of the module, the negative terminal of the module is connected to the positive terminal of the controlled load, and the negative terminal of the controlled load is connected to the negative terminal of the DC power supply.

[0011] Preferably, the multiple protection circuit includes a reverse power connection protection circuit, an overvoltage protection circuit, an overcurrent protection circuit, and a leakage current protection circuit; the reverse power connection protection circuit is used to cut off the internal circuit and trigger an alarm when the power polarity is reversed; the leakage current protection circuit is built into the MCU program logic, and the control module stops working when leakage current is detected.

[0012] Preferably, the module operates in the range of DC1V to 72V and can withstand a DC90V input voltage for a short time under full load conditions; the overall signal acquisition, command response, and abnormal protection feedback time of the module is 500ms to 2s.

[0013] Preferably, the parameter adjustment unit is a potentiometer, which is used to send current and speed adjustment commands to the MCU main control unit.

[0014] Preferably, the status indicator unit is an LED indicator light. When the module is working normally, the indicator light will light up normally. When a power reverse connection, overvoltage, or overcurrent fault occurs, the red LED light will light up as an alarm.

[0015] Preferably, the MOS power unit adopts a thermoelectric separation layout, and a silicone heat dissipation insulating sheet, a Teflon heat dissipation insulating sheet, or a ceramic heat dissipation insulating sheet is provided between the MOS transistor and the module profile housing to achieve electrical isolation and heat dissipation.

[0016] Preferably, the PCB board of the module is coated with conformal coating.

[0017] Preferably, the MCU main control unit can be customized to configure overcurrent protection points and overvoltage protection points, and supports multiple protection action modes such as power failure, constant current, trickle / reduction power.

[0018] Compared with the prior art, the beneficial effects of the present invention are: This two-wire DC current management module adopts a two-wire series wiring structure, which only requires two cables to complete the installation. There is no need to distinguish complex control lines. Existing two-wire power supply lines can be directly reused without the need to re-groove and rewire, which greatly reduces the difficulty of construction, the cost of modification and the probability of wiring errors. It integrates a quadruple protection mechanism against reverse power connection, overvoltage, overcurrent, and leakage current. In case of reverse power connection, only an indicator light will alarm, preventing component burnout. It can quickly disconnect the circuit or reduce power operation in case of load short circuit, stalled rotor, or abnormal power supply voltage. It will promptly shut down in case of leakage current, comprehensively avoiding safety hazards such as electric shock, fire, and component burnout. Meanwhile, the PCB board is coated with conformal coating, and high-power components employ an electrically isolated heat dissipation structure, further enhancing the equipment's operational reliability. The traditional module's narrow voltage range of DC12V~24V has been widened to DC1V~72V, and it can withstand a short-term input voltage of DC90V under full load. It is compatible with power supply standards of multiple industries such as automotive parts, industrial control, and agricultural irrigation, and is also adapted to the wide voltage fluctuation conditions of lithium batteries. One module can meet the needs of multiple scenarios and reduce procurement costs.

[0019] Intelligent control is achieved by relying on MCU, which can flexibly set overcurrent and overvoltage protection thresholds and support multiple protection modes such as power failure, constant current, and power reduction; soft start is achieved for motors to suppress inrush current; constant current output is achieved for LEDs to delay light decay; and real-time current monitoring and dynamic adjustment functions are combined to ensure stable operation of various loads and effectively extend the service life of equipment. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the circuit principle structure of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1This invention provides a technical solution: a two-wire DC current management module, wherein the module is connected in series in the power supply circuit between the DC power supply and the controlled load using a two-wire series structure; the module includes an MCU main control unit, a power management chip, a current and voltage acquisition unit, a MOSFET power unit, a parameter adjustment unit, a status indication unit, and multiple protection circuits; the MCU main control unit is electrically connected to the power management chip, the current and voltage acquisition unit, the MOSFET power unit, the parameter adjustment unit, and the status indication unit respectively, and is used to complete signal acquisition, command response, operating condition judgment, and protection control.

[0023] Specifically, this overall architecture abandons the traditional three-wire and four-wire wiring scheme and simplifies the hardware layout by relying on modular integrated design; with the MCU as the core hub to coordinate the collaborative work of all units, it realizes the integrated operation of parameter acquisition, manual adjustment, power output, status feedback and fault protection. The overall structure is simple and highly integrated, and can be adapted to the management and control needs of various small DC loads.

[0024] The wiring method of the two-wire series structure is as follows: the positive terminal of the DC power supply is connected to the positive terminal of the module, the negative terminal of the module is connected to the positive terminal of the controlled load, and the negative terminal of the controlled load is connected to the negative terminal of the DC power supply. This series wiring method only uses two external connection wires and does not require additional control wires. The original two-wire power supply line of the equipment can be directly used. When upgrading old equipment, there is no need to re-drill grooves and rewire, which greatly reduces the installation difficulty, construction cost and the probability of wiring errors, and significantly improves versatility and field adaptability.

[0025] The multiple protection circuits include a reverse power connection protection circuit, an overvoltage protection circuit, an overcurrent protection circuit, and a leakage current protection circuit. The reverse power connection protection circuit cuts off the internal circuit and alarms when the power polarity is reversed. The leakage current protection circuit is built into the MCU program logic. When leakage current is detected, the control module stops working. Through the combination of hardware circuits and software programs, a comprehensive protection system is formed, which can cope with various risk conditions such as wiring errors, power abnormalities, load failures, and line leakage. It effectively avoids the burning of internal components and controlled loads, and at the same time prevents safety accidents such as electric shock and line overheating, thus comprehensively improving the safety and reliability of equipment operation.

[0026] The module operates within a DC 1V~72V voltage range and can withstand a short-term DC 90V input voltage under full load conditions. The overall signal acquisition, command response, and fault protection feedback time is 500ms~2s. The wide voltage input design is compatible with different DC voltage standards in various scenarios such as automotive parts, industrial control, agricultural equipment, and lithium battery power supply. It can also withstand short-term extreme voltage surges, making it suitable for a wide range of operating conditions. With a response speed of milliseconds to seconds, it can promptly capture changes in operating conditions and execute adjustment and protection actions, ensuring sensitive control and timely fault handling.

[0027] The parameter adjustment unit is a potentiometer, which is used to send current and speed adjustment commands to the MCU main control unit. The potentiometer achieves continuous mechanical adjustment, which is intuitive and easy to use. It can linearly change the output current of the circuit, thereby accurately adjusting the speed of the motor, fan, water pump, as well as the working power of LED and resistive load. The adjustment is smooth and there are no sudden changes in gear, resulting in a good user experience.

[0028] The status indicator unit is an LED indicator. When the module is working normally, the indicator light will light up normally. When a power reverse connection, overvoltage, or overcurrent fault occurs, the red LED light will light up as an alarm. The LED light enables a visual distinction of the operating status, making normal operation and fault status clear at a glance. The equipment condition can be quickly judged without the need for professional testing equipment, making it easier for operators to find and troubleshoot faults in a timely manner and reducing the difficulty of operation and maintenance.

[0029] The MOSFET power unit adopts a thermoelectric separation layout. A silicone heat dissipation insulating sheet, Teflon heat dissipation insulating sheet, or ceramic heat dissipation insulating sheet is set between the MOSFET and the module profile housing to achieve electrical isolation and heat dissipation. On the one hand, it can quickly dissipate the heat generated by the MOSFET during operation, avoid the power device from aging and failure due to high temperature, and extend the service life of the device. On the other hand, it can achieve electrical isolation, prevent the metal casing from becoming electrified, eliminate the risk of electric shock, and take into account both heat dissipation performance and electrical safety.

[0030] The module's PCB board is coated with conformal coating, which forms a protective layer for the PCB board, components, and solder joints. It is moisture-proof, dust-proof, and corrosion-proof, enabling the module to work stably for a long time in complex and harsh environments such as humid, dusty, and outdoor environments, thus improving the product's environmental adaptability and service life.

[0031] The MCU main control unit can be customized with overcurrent protection points and overvoltage protection points, and supports multiple protection action modes such as power failure, constant current, trickle / power reduction. Protection parameters and handling logic can be flexibly customized according to the type, power, and usage scenario of the controlled load. The optimal protection strategy is matched for motors, LEDs, and resistive loads respectively. The module functions can be flexibly expanded, and one product can meet the differentiated usage needs of multiple types of loads, reducing the user's procurement and usage costs.

[0032] It should be noted that, in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0033] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only for the purpose of helping to understand the method and core ideas of the present invention. The above descriptions are only preferred embodiments of the present invention. It should be noted that due to the limitations of textual expression, while there are objectively infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other situations without modification, should all be considered within the scope of protection of the present invention.

Claims

1. A two-wire DC current management module, characterized in that: The module is connected in series in the power supply circuit between the DC power supply and the controlled load using a two-wire series structure. The module includes an MCU main control unit, a power management chip, a current and voltage acquisition unit, a MOSFET power unit, a parameter adjustment unit, a status indication unit, and multiple protection circuits. The MCU main control unit is electrically connected to the power management chip, the current and voltage acquisition unit, the MOSFET power unit, the parameter adjustment unit, and the status indication unit, respectively, and is used to complete signal acquisition, command response, operating condition judgment, and protection control.

2. The two-wire DC current management module according to claim 1, characterized in that: The wiring method of the two-wire series structure is as follows: the positive terminal of the DC power supply is connected to the positive terminal of the module, the negative terminal of the module is connected to the positive terminal of the controlled load, and the negative terminal of the controlled load is connected to the negative terminal of the DC power supply.

3. The two-wire DC current management module according to claim 2, characterized in that: The multiple protection circuits include a reverse power connection protection circuit, an overvoltage protection circuit, an overcurrent protection circuit, and a leakage current protection circuit. The reverse power connection protection circuit is used to cut off the internal circuit and trigger an alarm when the power polarity is reversed. The leakage current protection circuit is built into the MCU program logic, and the control module stops working when leakage current is detected.

4. The two-wire DC current management module according to claim 3, characterized in that: The module operates within a voltage range of DC1V to 72V and can withstand a short-term DC90V input voltage under full load conditions. The overall signal acquisition, command response, and fault protection feedback time of the module is 500ms to 2s.

5. A two-wire DC current management module according to claim 4, characterized in that: The parameter adjustment unit is a potentiometer, which is used to send current and speed adjustment commands to the MCU main control unit.

6. A two-wire DC current management module according to claim 1, characterized in that: The status indicator unit is an LED indicator. When the module is working normally, the indicator light will light up normally. When a power reverse connection, overvoltage, or overcurrent fault occurs, the red LED light will light up as an alarm.

7. A two-wire DC current management module according to claim 6, characterized in that: The MOSFET power unit adopts a thermoelectric separation layout. A silicone heat dissipation insulating sheet, a Teflon heat dissipation insulating sheet, or a ceramic heat dissipation insulating sheet is provided between the MOSFET and the module profile housing to achieve electrical isolation and heat dissipation.

8. A two-wire DC current management module according to claim 7, characterized in that: The PCB board of the module is coated with conformal coating.

9. A two-wire DC current management module according to claim 8, characterized in that: The MCU main control unit can be customized to configure overcurrent protection points and overvoltage protection points, and supports multiple protection action modes such as power failure, constant current, trickle / reduction power.

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