Industrial multi-channel IO acquisition control module and anti-interference method

Abstract

The application discloses an industrial multi-channel IO acquisition control module and an anti-interference method, relates to the field of IO control module technology, and comprises a main control unit, a multi-channel IO acquisition unit, an IO output control unit, an isolation protection unit, a communication unit and a power unit; the main control unit is responsible for receiving acquisition data transmitted by the multi-channel IO acquisition unit, filtering, analyzing and processing the data, simultaneously receiving a control instruction sent by an upper computer through the communication unit, sending corresponding control signals to the IO output control unit after analysis, and realizing precise control on external actuators. When the application is used, the main control unit is responsible for receiving acquisition data transmitted by the multi-channel IO acquisition unit, filtering, analyzing and processing the data, simultaneously receiving a control instruction sent by an upper computer through the communication unit, sending corresponding control signals to the IO output control unit after analysis, and realizing precise control on external actuators, so that effective filtering is realized, and the purpose of preventing data distortion is achieved.

Description

Technical Field

[0001] This application relates to the field of IO control module technology, and in particular to an industrial multi-channel IO acquisition and control module and an anti-interference method. Background Technology

[0002] In industrial automation control systems, the I / O acquisition and control module is a core component connecting field sensors, actuators, and host computers / PLCs. It undertakes crucial functions such as signal acquisition, command output, and data interaction. Its stability, anti-interference capability, and acquisition accuracy directly determine the system's operational reliability. With the increasing integration of industrial field equipment and the growing complexity of control scenarios, traditional I / O modules can no longer meet the application requirements of high precision, high flexibility, and high reliability. The main technical defects are as follows: 1. Fixed channel configuration and poor compatibility: Existing I / O modules mostly have fixed acquisition and output channel functions, making it impossible to flexibly switch according to field needs. The channel types are limited, supporting only single switch or analog signal acquisition, making it difficult to simultaneously accommodate multiple signal types such as voltage, current, RTD, and thermocouple signals. This necessitates the use of multiple modules, increasing system cost and wiring complexity. 2. Weak anti-interference capability: Industrial fields are subject to significant electromagnetic interference, ground loop interference, surge impacts, and electrostatic discharge. Traditional I / O modules lack comprehensive electrical isolation, surge suppression, and ESD protection, easily leading to signal drift, data jumps, and control mis-triggers, which can severely damage ports and cause system shutdowns. 3. Insufficient acquisition accuracy and lack of intelligent filtering: Most modules lack dedicated signal conditioning, linear amplification, and channel calibration circuits, resulting in large acquisition errors. The use of only simple mean or median filtering fails to effectively distinguish between transient interference and sudden changes in the true signal, easily leading to data distortion in strong interference environments and failing to meet high-precision process control requirements. 4. Insufficient scalability and configurability: Traditional IO modules have a fixed number of channels and do not support flexible expansion; communication methods are limited, address configuration is cumbersome, making it difficult to adapt to multi-node, distributed acquisition and control scenarios, thus restricting system upgrades and expansion. Summary of the Invention

[0003] To address the shortcomings of the prior art, this application provides an industrial multi-channel IO acquisition and control module and an anti-interference method.

[0004] This application provides an industrial multi-channel IO acquisition and control module, including a main control unit, a multi-channel IO acquisition unit, an IO output control unit, an isolation and protection unit, a communication unit, and a power supply unit. The main control unit is responsible for receiving the acquired data transmitted by the multi-channel IO acquisition unit, filtering, parsing, and processing the data, and simultaneously receiving control commands sent by the host computer through the communication unit. After parsing, it sends corresponding control signals to the IO output control unit to achieve precise control of external actuators. The multi-channel IO acquisition unit is used to receive data collected by various sensors in the field and transmit it to the main control unit. The IO output control unit is used to transmit the commands from the main control unit to the execution unit.

[0005] Furthermore, the main control unit has a built-in data processing unit. The data processing unit adopts a dynamic response filtering mechanism based on a state machine to divide the processing flow of the collected data into multiple working states and automatically migrate them; it judges the reliability of the data by accumulating confidence and distinguishes between instantaneous interference and real signal changes by using an inertial breakthrough mechanism.

[0006] Furthermore, the dynamic response filtering mechanism of the state machine distinguishes the data into normal state, suspected interference state, continuous abnormal state and hard fault state, and determines which state the received data is in, and then processes it according to different states.

[0007] Furthermore, the main control unit uses an STM32F103VET6 microcontroller to realize multi-channel IO acquisition and output.

[0008] Furthermore, the multi-channel I / O acquisition unit includes at least 8 configurable acquisition channels, supporting analog signals and direct access to RTD and thermocouple signals. Each configurable acquisition channel can independently configure acquisition parameters, filtering thresholds, and sampling frequencies. The multi-channel I / O acquisition unit has a built-in signal conditioning module, which includes a filtering circuit, an amplification circuit, and a calibration circuit. The filtering circuit is used to suppress high-frequency noise in the acquired signal; the amplification circuit is used to amplify weak analog signals; and the calibration circuit is used to perform accuracy calibration on each acquisition channel, ensuring that the acquisition error is ≤0.1%FS.

[0009] Furthermore, the IO output control unit includes at least 8 independent output channels, using zero-crossing optocouplers and thyristors as contactless high-speed switching switches; the IO output control unit has overload protection and status feedback functions, and has a built-in status detection module to collect the working status of each output channel in real time and feed the status data back to the main control unit to realize real-time monitoring of output status and fault early warning.

[0010] Furthermore, the isolation and protection unit includes an optocoupler isolation module, a surge protection module, and an ESD protection module. The optocoupler isolation module is located between the main control unit and the multi-channel IO acquisition unit and IO output control unit, with an isolation voltage ≥2500VAC, effectively blocking ground loop interference and surge impact. The surge protection module is located at the input and output ends of the control module, using transient suppression diodes and varistors to suppress surge impacts in industrial environments. The ESD protection module provides electrostatic discharge protection of ±8kV for contact discharge and ±15kV for air discharge.

[0011] Furthermore, the power supply unit supports a wide voltage input of DC15V-36V and has overvoltage, overcurrent, and reverse connection protection functions. The power supply unit outputs a stable DC voltage to provide stable power to all units of the entire control module.

[0012] An anti-interference method based on an industrial multi-channel IO acquisition and control module, comprising the control module described in any one of the above claims, and the steps include: S1, hard fault state, performs range verification on the original acquired values. If the value exceeds the sensor's physical range, it is determined to be a hard fault. The current data is discarded and the previous valid value is maintained for output. S2, Normal acquisition state: The original acquired value is within the physical range of the sensor, and the change amplitude from the previous valid value does not exceed the physical response rate threshold. It is determined to be a real and valid signal, and the current value is updated and output. S3, Suspected Interference State: When the change in the original acquired value exceeds the physical response rate threshold, it is determined to be transient interference, enters the suspected interference state, keeps the output of the previous frame's valid value unchanged, and starts the confidence counter to begin accumulating; S4, Inertial Breakthrough State, also known as Continuous Abnormal State: Confirm the real change. If the change amplitude of the original acquired value exceeds the physical response rate threshold for multiple consecutive samplings, the confidence counter reaches the inertial breakthrough counting threshold, and the inertial breakthrough is executed, forcibly updated to the current original acquired value and output; if the normal state is restored after a single abnormality, the confidence counter returns to zero and returns to the normal acquisition state.

[0013] In summary, this application includes at least one of the following beneficial technical effects: This invention establishes a main control unit, a multi-channel IO acquisition unit, an IO output control unit, and an isolation protection unit. The main control unit is responsible for receiving the acquired data transmitted by the multi-channel IO acquisition unit, filtering, parsing, and processing the data. At the same time, it receives control commands sent by the host computer through the communication unit, parses them, and sends corresponding control signals to the IO output control unit, thereby achieving precise control of the external actuator and realizing effective filtering to prevent data distortion.

[0014] This invention utilizes a built-in data processing unit in the main control unit. The data processing unit employs a dynamic response filtering mechanism based on a state machine to divide the data acquisition process into multiple working states that can be automatically migrated. It judges data reliability by accumulating confidence levels and distinguishes between instantaneous interference and real signal changes through an inertial breakthrough mechanism, thereby intelligently identifying data authenticity and avoiding acquisition jumps caused by interference. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the terminal layout and functional partitioning of the industrial multi-channel IO acquisition and control module described in this invention; Figure 2 This is a schematic diagram of the PCB layout of the industrial multi-channel IO acquisition and control module described in this invention; Figure 3 This is a block diagram of the state machine logic judgment of the present invention; Figure 4 This is a schematic diagram of the installation structure of the multi-channel IO acquisition and control module of the present invention. Detailed Implementation

[0016] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0017] This application discloses an industrial multi-channel IO acquisition and control module, including a main control unit, a multi-channel IO acquisition unit, an IO output control unit, an isolation and protection unit, a communication unit, and a power supply unit.

[0018] The main control unit is responsible for receiving the acquired data transmitted by the multi-channel IO acquisition unit, filtering, parsing and processing the data, and receiving the control commands sent by the host computer through the communication unit. After parsing, it sends the corresponding control signals to the IO output control unit to achieve precise control of the external actuator.

[0019] The multi-channel I / O acquisition unit is used to receive data collected by various field sensors and transmit it to the main control unit. It also reads feedback from external devices to detect the equipment's operating status.

[0020] The IO output control unit is used to transmit instructions from the main control unit to the execution unit, which includes solenoid valves, contactors, and indicator lights.

[0021] The isolation and protection unit is installed between the main control unit and the multi-channel IO acquisition unit and IO output control unit to achieve electrical isolation between the input, output, and isolation and protection unit, effectively blocking ground loop interference and surge impacts. Ground loop interference refers to the interference phenomenon in industrial sites where, when sensors, actuators, IO modules, and controllers are grounded separately, potential differences exist between different grounding points, forming a closed current loop in the signal circuit, leading to signal drift, jitter, distortion, and control malfunctions. Surge impact refers to the sudden spike in voltage to hundreds or thousands of volts in a very short time (microseconds), causing a sudden surge in current that impacts lines and equipment (PLC, IO modules, sensors, frequency converters). There are many causes of surges, such as the start-up and shutdown of high-power equipment, lightning strikes, and short-circuit tripping.

[0022] The communication unit provides an industrial serial bus communication interface; multiple multi-channel IO acquisition units are connected in parallel to the main control unit via the bus, and each acquisition unit is configured with an address via a rotary switch. The module supports up to 10 acquisition units for expansion; the rotary switch is a hardware address setting device, and address setting does not require software configuration and supports direct configuration on site; the bus adopts an RS485 bus, which supports multi-machine parallel communication, and the main control unit distinguishes the data of different independent acquisition groups by address.

[0023] The power supply unit outputs DC power to provide stable power to all units of the entire IO acquisition and control module.

[0024] In this embodiment, the main control unit has a built-in data processing unit. The data processing unit adopts a dynamic response filtering mechanism based on a state machine to divide the data acquisition process into multiple working states and automatically migrate them. The reliability of the data is judged by the accumulation of confidence and the inertial breakthrough mechanism is used to distinguish between instantaneous interference and real signal changes, thereby intelligently identifying the authenticity of the data and avoiding acquisition jumps caused by interference.

[0025] In this embodiment, the dynamic response filtering mechanism of the state machine distinguishes the data into normal state, suspected interference state, continuous abnormal state and hard fault state, and determines which state the received data is in, and then processes it according to different states.

[0026] In this embodiment, the hard fault state is handled as follows: the range validity of the original acquired value is checked, and abnormal data that obviously exceeds the physical range of the sensor is directly removed. The judgment rule is: if the original acquired value exceeds the preset upper and lower limits of the physical range, it is judged as a hard fault. The processing action is to discard the current invalid value and keep the output unchanged from the previous valid value to avoid interference data from polluting the system.

[0027] Under normal conditions, if the original acquired value falls within the upper and lower limits of the preset physical range, the program will enter a suspected interference state.

[0028] Judgment formula: set up, This is the current original collected value; This is the valid output value from the previous frame; This is the sensor's minimum range; This is the maximum range of the sensor.

[0029] Judgment conditions: or ; Meets hard fault requirements, , Do not save. This represents the output value; like If the normal state is met, the program will enter a suspected interference state.

[0030] In this embodiment, the suspected interference state program calculates the relative rate of change between the original acquired value and the previous valid value, determines whether the relative rate of change exceeds the physically possible rate of change, and intercepts instantaneous spike interference.

[0031] In this embodiment, the procedure for judging suspected interference states calculates the relative rate of change. If it exceeds the physical response rate threshold, it is judged as unreliable and suspected interference. When entering the suspected interference state, the output remains unchanged, and the confidence verification process is started.

[0032] Formula for judging suspected interference state: set up: This represents the change in a single sample (instead of the rate of change); The physical response rate threshold; This is a confidence counter (initial value = 0).

[0033] |; when At that time, it satisfies the suspected interference. Then, it enters the confidence verification process.

[0034] In this embodiment, the confidence verification process includes a built-in confidence counter. and inertia exceeding the counting threshold (Configurable 3-5 times), the confidence verification process is also known as the continuous abnormal state.

[0035] when At that time, it satisfies the suspected interference. and confidence counter Start counting: If At that point, the confidence level is met, and the inertial breakthrough takes effect. ,at the same time ;like hour, ,but .

[0036] Physical response rate threshold: refers to the maximum allowable change in the physical quantity measured by the sensor per unit time. It is preset by the physical characteristics of the object being measured, the response speed, and the actual working conditions of the industrial site. It is used to determine whether the rate of change of the collected data exceeds the real physical possible range, thereby identifying instantaneous interference.

[0037] In this embodiment, the main control unit adopts the STM32F103VET6 microcontroller, which utilizes its high-performance ARM Cortex-M3 core and rich peripheral resources to achieve efficient collaborative control of multi-channel IO acquisition and output, avoiding the non-simultaneous safety hazards caused by traditional sequential control.

[0038] In this embodiment, the multi-channel IO acquisition unit includes at least 8 configurable acquisition channels, supporting analog signals (0-10V voltage, 4-20mA current), and also supporting direct access to RTD (PT100, PT1000) and thermocouple (K, J, T type) signals. Each configurable acquisition channel can independently configure acquisition parameters, filtering thresholds, and sampling frequencies to adapt to different types of field sensors. The multi-channel IO acquisition unit has a built-in signal conditioning module, including a filtering circuit, an amplification circuit, and a calibration circuit: the filtering circuit is used to suppress high-frequency noise in the acquired signal to ensure signal stability; the amplification circuit is used to amplify weak analog signals to improve acquisition sensitivity; and the calibration circuit is used to perform accuracy calibration on each acquisition channel to ensure that the acquisition error is ≤0.1%FS, meeting the requirements for high-precision acquisition.

[0039] In this embodiment, the IO output control unit includes at least 8 independent output channels. It uses zero-crossing optocouplers and SCRs as contactless high-speed switching devices to drive high-power devices such as solenoid valves, contactors, and indicator lights. This provides fast response and is suitable for high-precision, high-frequency control scenarios. The output control unit features overload protection and status feedback functions. It has a built-in status detection module that collects the real-time operating status (on / off, load current) of each output channel and feeds the status data back to the main control unit, enabling real-time monitoring and fault warning of the output status.

[0040] In this embodiment, the isolation and protection unit includes an optocoupler isolation module, a surge protection module, and an ESD protection module. The optocoupler isolation module is located between the main control unit and the multi-channel IO acquisition unit and IO output control unit, with an isolation voltage ≥2500VAC, effectively blocking ground loop interference and surge impact. The surge protection module is located at the input and output terminals of the control module, using transient suppression diodes and varistors to suppress surge impacts (±2kV line to ground) in industrial environments. The ESD protection module provides electrostatic discharge protection of ±8kV for contact discharge and ±15kV for air discharge, meeting the electromagnetic compatibility requirements of industrial environments and preventing module damage or signal distortion caused by interference.

[0041] In this embodiment, the power supply unit supports a wide voltage input of DC15V-36V, adapting to different power supply scenarios in industrial sites. It has overvoltage, overcurrent, and reverse connection protection functions, which can effectively prevent module damage caused by power supply abnormalities. The power supply unit adopts a high-efficiency voltage regulator circuit to output a stable DC voltage, providing stable power supply to each unit of the entire control module and ensuring long-term stable operation of the control module.

[0042] The working principle of this invention is as follows: The main control unit is responsible for receiving the acquired data transmitted by the multi-channel IO acquisition unit, filtering, parsing and processing the data through the data processing unit, and receiving the control commands sent by the host computer through the communication unit. After parsing, the host computer sends the corresponding control signals to the IO output control unit to achieve precise control of the external actuator.

[0043] Figure 1 In the middle, the left and right sides are the power supply unit terminal area and communication unit terminal area of ​​the module, respectively, providing 24V, 12V, 5V, 3.3V multi-level power input and RS485 serial communication interface; the upper middle area is the multi-channel IO acquisition unit terminal area, including 4 three-wire PT100 RTD temperature acquisition channels (PT100_1A / 1B1 / 1B2, PT100_4A / 4B1 / 4B2, etc.) and 4 differential analog input channels (V1±~V4±), supporting mixed acquisition of temperature signals and general voltage / current signals; the lower middle area is the IO output control unit terminal area, including 8 digital output channels (DO1~DO8) and the corresponding common terminal COM1, used to drive external execution units.

[0044] Figure 2In the middle, the left side is the signal terminal area of ​​the control module, which includes power input terminals (12V, 24V, GND), i.e., the power supply unit, which supplies power to the control module; RS485 communication terminals, i.e., the communication unit, responsible for communication with the main control unit and the host computer; solid-state relay output terminals (SSR1~SSR6), i.e., the IO output control unit, which controls external loads; status indicator terminals (FAULT, STANDBY), i.e., the multi-channel IO acquisition unit, which collects fault and standby status signals of external devices; analog input terminals (0-10V, 4-20mA), i.e., the multi-channel IO acquisition unit, which collects voltage and current signals from sensors; PWM output terminals (PWM1~PWM4), i.e., the IO output control unit, which provides pulse width adjustment output to control motors, valves, and dimming, etc.; the right side is the power supply and communication unit terminal area, providing 24V, 12V, 5V, 3.3V multi-level power outputs and an RS485 differential communication interface.

[0045] The right side is the power and communication terminal area, providing 24V, 12V, 5V, and 3.3V multi-level power outputs and an RS485 differential communication interface; The onboard core circuit unit includes a main control circuit, signal conditioning circuit, isolation and protection circuit, solid-state relay driver circuit, analog signal acquisition circuit, and servo control circuit, realizing signal acquisition, data processing, contactless output, and communication interaction functions. The analog signal acquisition circuit acquires the field analog signal, which is amplified, filtered, and level adapted by the signal conditioning circuit. Then, it is sent to the main control circuit after electrical isolation, surge and electrostatic suppression by the isolation and protection circuit. The main control circuit has a built-in software filtering algorithm based on a state machine to complete data verification, anti-interference judgment, and calculation processing. According to the calculation results and the host computer instructions, the main control circuit realizes contactless switch output through the solid-state relay driver circuit and speed adjustment and position control through the servo control circuit. At the same time, the main control circuit works with peripheral circuits to complete RS485 communication interaction, realizing the complete functions of high-precision signal acquisition, intelligent data processing, isolation and anti-interference, contactless output, and communication networking.

[0046] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An industrial multi-channel I / O acquisition and control module, characterized in that: It includes a main control unit, a multi-channel IO acquisition unit, an IO output control unit, an isolation and protection unit, a communication unit, and a power supply unit. The main control unit is responsible for receiving the acquired data transmitted by the multi-channel IO acquisition unit, filtering, parsing, and processing the data. At the same time, it receives control commands sent by the host computer through the communication unit, parses them, and sends corresponding control signals to the IO output control unit to achieve precise control of external actuators. The multi-channel IO acquisition unit is used to receive data collected by various sensors on site and transmit it to the main control unit. The IO output control unit is used to transmit the commands from the main control unit to the execution unit.

2. The industrial multi-channel I / O acquisition and control module according to claim 1, characterized in that: The main control unit has a built-in data processing unit. The data processing unit adopts a dynamic response filtering mechanism based on a state machine to divide the data acquisition process into multiple working states and automatically migrate them. It judges the reliability of the data by accumulating confidence and distinguishes between instantaneous interference and real signal changes by using an inertial breakthrough mechanism.

3. The industrial multi-channel I / O acquisition and control module according to claim 2, characterized in that: The dynamic response filtering mechanism of the state machine distinguishes data into normal state, suspected interference state, continuous abnormal state and hard fault state, and determines which state the received data is in, and then processes it according to different states.

4. The industrial multi-channel I / O acquisition and control module according to claim 3, characterized in that: The main control unit uses an STM32F103VET6 microcontroller to achieve multi-channel I / O acquisition and output.

5. The industrial multi-channel I / O acquisition and control module according to claim 1, characterized in that: The multi-channel I / O acquisition unit includes at least 8 configurable acquisition channels, supporting analog signals and direct input of RTD and thermocouple signals. Each configurable acquisition channel can independently configure acquisition parameters, filtering thresholds, and sampling frequencies. The multi-channel I / O acquisition unit has a built-in signal conditioning module, which includes a filtering circuit, an amplification circuit, and a calibration circuit. The filtering circuit is used to suppress high-frequency noise in the acquired signal; the amplification circuit is used to amplify weak analog signals; and the calibration circuit is used to achieve accuracy calibration of each acquisition channel, ensuring that the acquisition error is ≤0.1%FS.

6. The industrial multi-channel IO acquisition and control module according to claim 1, characterized in that: The IO output control unit includes at least 8 independent output channels and uses zero-crossing optocouplers and thyristors as contactless high-speed switching switches. The IO output control unit has overload protection and status feedback functions. It has a built-in status detection module that collects the working status of each output channel in real time and feeds the status data back to the main control unit to realize real-time monitoring of output status and fault early warning.

7. The industrial multi-channel I / O acquisition and control module according to claim 1, characterized in that: The isolation and protection unit includes an optocoupler isolation module, a surge protection module, and an ESD protection module. The optocoupler isolation module is located between the main control unit and the multi-channel IO acquisition unit and IO output control unit, with an isolation voltage ≥2500VAC, effectively blocking ground loop interference and surge impact. The surge protection module is located at the input and output ends of the control module, using transient suppression diodes and varistors to suppress surge impact in industrial environments. The ESD protection module provides electrostatic discharge protection of ±8kV for contact discharge and ±15kV for air discharge.

8. The industrial multi-channel I / O acquisition and control module according to claim 1, characterized in that: The power supply unit supports a wide voltage input of DC15V-36V and has overvoltage, overcurrent and reverse connection protection functions. The power supply unit outputs a stable DC voltage to provide stable power to all units of the entire control module.

9. An anti-interference method based on an industrial multi-channel IO acquisition and control module, comprising the control module as described in any one of claims 1-9, the steps of which include: S1, hard fault state, performs range verification on the original acquired values. If the value exceeds the sensor's physical range, it is determined to be a hard fault. The current data is discarded and the previous valid value is maintained for output. S2, Normal acquisition state: The original acquired value is within the physical range of the sensor, and the change amplitude from the previous valid value does not exceed the physical response rate threshold. It is determined to be a real and valid signal, and the current value is updated and output. S3, Suspected Interference State: When the change in the original acquired value exceeds the physical response rate threshold, it is determined to be transient interference, enters the suspected interference state, keeps the output of the previous frame's valid value unchanged, and starts the confidence counter to begin accumulating; S4, Inertial Breakthrough State, also known as Continuous Abnormal State: Confirm the real change. If the change amplitude of the original collected values ​​exceeds the physical response rate threshold after multiple consecutive samplings, the confidence counter reaches the inertial breakthrough count threshold, and the inertial breakthrough is executed, forcibly updated to the current original collected values ​​and output. If the system recovers after a single anomaly, the confidence counter resets to zero, and the system returns to normal data collection.

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