Integrated relay module based on industrial Ethernet

Abstract

The utility model relates to the technical field of relays, in particular to an integrated relay module based on an industrial Ethernet, which comprises a hardware expander, a processor, an Ethernet switch chip and a power supply module, and the Ethernet switch chip is electrically connected with an RJ45 network port after passing through a network isolation transformer; a first path of the hardware expander is connected with a digital input port through an optocoupler, a second path of the hardware expander is connected with a relay through a driving circuit, a third path of the hardware expander is connected with a high-power driving circuit through an optocoupler, and a fourth path of the hardware expander is connected with a low-power driving circuit through a driving circuit; the fifth path of the hardware expander is electrically connected with one interface connector through the operational amplifier; and the processor is connected with the RS422 drive circuit and the RS422 drive circuit. According to the utility model, various input and output interfaces are integrated, AC signals can be effectively controlled, the response speed is reduced, large-current and large-power electric appliances are controlled, the use of cables is reduced, and wiring and maintenance are facilitated.

Description

Technical Field

[0001] The utility model relates to the technical field of integrated relays, in particular to an integrated relay module based on industrial Ethernet. Background Art

[0002] Industrial Ethernet is a network communication protocol specifically used in the field of industrial control. It is based on Ethernet technology, but has been specially improved and optimized to meet the requirements of real-time, reliability and stability in industrial environments. Industrial Ethernet is widely used in fields such as factory automation, process control and robotics, providing reliable data communication and control functions for industrial equipment and systems.

[0003] Relay modules are one of the common devices in industrial control systems, used to control electrical signals and perform switching operations. Traditional relay modules are usually controlled by contactors or relays, while modern relay modules use more electronic components to achieve control functions. Relay modules play an important role in the field of industrial automation and are used to implement various types of electrical control and protection functions.

[0004] Integration is the integration of the above two devices into a motherboard. In addition to the above main devices, there are also conventional input and output interfaces, transistor high-power output interfaces, analog output interfaces, and communication interfaces to form an integrated product.

[0005] At present, there are two conventional industrial Ethernet-based control methods used in the market:

[0006] The first type is a control module composed of a main control system unit and an IO unit control board. Usually, the communication between the above-mentioned main control system and the control unit is connected by industrial Ethernet or RS485 interface communication. The IO unit then outputs to the relay module and transistor output board through a splitter. The control board is composed of some integrated chip IO ports that output low current and low voltage. The conventional use is that these low current and low voltage IO ports use a splitter to control some AC 220V electrical appliances, while the transistor output board is used in some low voltage 24V high power electrical appliances. This type of IO unit control board needs to go through a splitter to the actual relay module or transistor output module. In this usage mode, there are more splitters and several more output boards. For conventional distribution cabinets, the space is limited, and the addition of these cables and circuit boards will make this limited space more crowded.

[0007] The second type is also composed of a control module consisting of a main control system unit and an IO unit control board. The communication between them also uses industrial Ethernet or RS485 interface communication, but the IO unit control board is equipped with some small current transistor outputs, and then this single small current drives a single AC or DC high-power relay and a high-power transistor. The relay controlled by this control mode will have a larger power, but the amount is relatively small. The conventional IO port control circuit can achieve some control using the above low-power and low-current transistors. In the second type, due to the lack of relay modules, the IO port of the IO unit is directly connected to the controlled relay, so that for the controller that controls some AC power, an additional row of relays must be built on the power distribution cabinet. It is impossible to use transistors to control some large current controlled electrical appliances, and then relays are needed to control them, but the response speed of the relay is relatively slow, and the places that need fast response cannot meet the requirements. In terms of the use of cables, more cables are also needed. Cables are needed between the IO unit and the relay, which is equivalent to the first type of splitter, and the thickness and length of the cables will be different. Utility Model Content

[0008] In order to solve the technical problems existing in the prior art, the utility model provides an integrated relay module based on industrial Ethernet, integrating digital IO input, high-power output, transistor output, analog output, RS422 communication interface and RS485 communication interface, which can effectively solve the control of AC signals, solve the speed of response, control large-current and high-power electrical appliances, reduce the use of cables, facilitate wiring electricians and maintenance engineers, and have multiple control methods and diversified functions.

[0009] In order to solve the above problems, the technical solution adopted by the utility model is:

[0010] An integrated relay module based on industrial Ethernet includes a hardware expander, a processor, an Ethernet switch chip and a power module. The hardware expander is electrically connected to the processor and the Ethernet switch, respectively. The power module is electrically connected to the hardware expander and the processor, respectively. One Ethernet switch chip is electrically connected to RJ45 network port 1 through a network isolation transformer, and another Ethernet switch chip is electrically connected to RJ45 network port 2 through a network isolation transformer.

[0011] The first path of the hardware expander is connected to the digital input port through an optical coupler, the second path of the hardware expander is connected to multiple relays through a drive circuit, and the multiple relays are electrically connected to the relay output interface respectively; the third path of the hardware expander is connected to the high-power drive circuit through an optical coupler, and the high-power drive circuit is electrically connected to the high-power output interface, the fourth path of the hardware expander is connected to the low-power drive circuit through the drive circuit, and the low-power drive circuit is connected to the low-power output interface; the fifth path of the hardware expander is electrically connected to the analog output interface through an operational amplifier, and the power module is electrically connected to the operational amplifier;

[0012] One path of the processor is connected to the RS422 drive circuit, and the other path of the processor is connected to the RS485 drive circuit. The RS422 drive circuit is electrically connected to the RS422 communication interface, and the RS485 drive circuit is electrically connected to the RS485 communication interface.

[0013] Specifically, the model of the processor is STM32F103, the hardware expander is an FPGA field programmable gate array, and the processor and the FPGA field programmable gate array communicate using an FSMC bus.

[0014] Specifically, the model of the driving circuit is ULN2803, the model of the high-power driving circuit is NCE01P13K, the model of the low-power driving circuit is IRF7342, and the model of the operational amplifier is TL1282L.

[0015] Specifically, the power module includes a 1.2v voltage regulator and a 3.3v DC TO DC buck converter. The 1.2v voltage regulator is electrically connected to the 3.3v buck converter and the hardware expander respectively. The 3.3v buck converter is electrically connected to the processor and the hardware expander respectively.

[0016] Specifically, the model of the 1.2v voltage regulator tube is LD1117, and the model of the 3.3v buck converter is LMR16010.

[0017] Specifically, the RJ45 network port is connected to an external Ethernet communication circuit.

[0018] Specifically, the integrated relay modules are cascaded in this connection mode: the OUT interface of each integrated relay module is electrically connected to the IN interface of the next integrated relay module.

[0019] Compared with the prior art, the utility model has the following advantages and beneficial effects:

[0020] The utility model provides an integrated relay module based on industrial Ethernet, which adopts an integrated approach, integrates digital IO input, high-power output, transistor output, analog output, RS422 communication interface and RS485 communication interface, can effectively solve the control of AC signals, solve the speed of response, control large current and high-power electrical appliances, reduce the use of cables, and facilitate wiring electricians and maintenance engineers. In the traditional control method, the controller and each module are separate, and this relay module integrates the controller and the module together, reducing the use of cables. The cable from the controller to the module is also directly connected on the PCB board. This approach reduces the problem of external interference on the cable, thereby reducing the probability of failure. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic diagram of the overall structure of the integrated relay module of the utility model;

[0022] Figure 2 This is a schematic diagram of the specific structure of the integrated relay module of the utility model;

[0023] Figure 3 It is a structural schematic diagram of a CNC lathe control system in an embodiment of the utility model;

[0024] The numbers in the figure are: 10-relay module based on industrial Ethernet, 20-industrial Ethernet bus, 30-system main control unit, 40-servo drive, 50-extension module. DETAILED DESCRIPTION

[0025] The following will further describe the technical solution of the utility model in detail with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of them, and the implementation methods of the utility model are not limited thereto. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0026] Example 1

[0027] like Figure 1As shown, the integrated relay module based on industrial Ethernet described in the utility model includes a hardware expander, a processor, an Ethernet switch chip and a power module. The hardware expander is electrically connected to the processor, the Ethernet switch and the power module respectively, and the Ethernet switch chip is electrically connected to the RJ45 network port through a network isolation transformer. Among them, one Ethernet switch chip is electrically connected to an RJ45 network port through an isolation transformer, and can be used as an input interface of an external Ethernet bus, and another Ethernet switch chip is electrically connected to another RJ45 network port through an isolation transformer, and can be used as an output interface of an external Ethernet bus;

[0028] The first path of the hardware expander is connected to the digital input port through an optical coupler, the second path of the hardware expander is connected to a relay through a drive circuit, and the relay is electrically connected to an interface connector; the third path of the hardware expander is connected to a high-power drive circuit through an optical coupler, and the high-power drive circuit is electrically connected to an interface connector; the fourth path of the hardware expander is connected to a low-power drive circuit through a drive circuit, and the low-power drive circuit is electrically connected to an interface connector; the fifth path of the hardware expander is electrically connected to an interface connector through an operational amplifier;

[0029] One serial port of the processor is connected to the RS422 drive circuit, and another serial port of the processor is connected to the RS485 drive circuit. The RS422 drive circuit and the RS485 drive circuit are respectively connected to an interface connector. The RS422 drive circuit is composed of two RS485 chips SN65HVD12 to form an RS422 circuit. RS485 belongs to a half-duplex circuit, and receiving and sending cannot be performed at the same time. RS422 belongs to a full-duplex circuit, and receiving and sending can be performed at the same time. This RS422 uses two SN65HVD12 chips, one of which is responsible for receiving and the other is responsible for sending. The chip has a direction control pin, which can control sending and receiving.

[0030] The RS422 interface is a reserved interface. RS422 data transmission can be replaced by industrial Ethernet and communicate directly with the host. RS485 data transmission is an expansion interface in this module. The expansion mode of the RS485 expansion interface can adopt a star connection, with one host and multiple slaves.

[0031] In this embodiment, the processor uses a CPU-STM32F103 with an ARM 32-bit Corte-M3 core, the hardware expander uses FPGA-EG4X20BG256I8, the processor and the hardware expansion device FPGA use FSMC bus communication, the Ethernet switch chip uses the PHY control chip of KSZ8041, the FPGA is extended to the PHY control chip and then output to the industrial Ethernet bus through an isolation transformer. The isolation transformer can effectively isolate external interference, and its transmission mode is differential transmission. For common mode interference, it can be effectively removed to reduce data errors on the bus. The IN and OUT of the external Ethernet bus are respectively connected to the RJ45 interface of the relay module, and then to the two Ethernet PHY chips KSZ8041 through the isolation transformer to connect the Ethernet physical layer and FPGA to realize data transmission.

[0032] Specifically, the first path of the hardware expander FPGA is connected to the digital input port through an optical coupler, and the digital input port is directly connected to the FPGA by optical coupler isolation, which is used for the input of external digital quantity sensors, generally digital quantity input. The second path of the hardware expander is connected to the relay through the drive circuit, and the relay is electrically connected to the relay output interface; the third path of the hardware expander is connected to the high-power drive circuit through the optical coupler, and the high-power drive circuit is electrically connected to the high-power output interface; the fourth path of the hardware expander is connected to the low-power drive circuit through the drive circuit, and the low-power drive circuit is electrically connected to the low-power output interface; the fifth path of the hardware expander is electrically connected to the analog output interface through an operational amplifier.

[0033] In this embodiment, the digital output port includes a relay output interface, a high-power output interface and a low-power output interface. The relay output interface is a relay output for controlling AC signals and DC signals. The model of the driving circuit is ULN2803. ULN2803 is a transistor array drive and is directly output by FPGA.

[0034] The model of the high-power drive circuit is NCE01P13K, which is connected to the high-power output interface. The model of the low-power drive circuit is IRF7342, which is connected to the low-power output interface. The model of the operational amplifier is TL1282L, which is connected to the low-power output interface. Conventional electrical appliances with low-current signals use the low-power output interface for output. The analog output interface of the analog circuit part is the PWM signal from the FPGA, which is filtered by the RC first-order filter and then given to the TL1282L for operation and output of 0-10V analog voltage. The analog output interface can be used when analog signals are needed for control.

[0035] In this embodiment, the relay uses an AC / DC relay, and the AC signal and the DC signal are controlled by the AC / DC relay. A control specification of this relay is 16A / 250V AC and 24V DC. Regarding the speed of response, the action response of the relay is a response time of seconds, while the response time of the transistor is in the millisecond level, and the action speed is faster than that of the relay. The transistor design used in the utility model can output 2A / 24V, and the response speed of the crystal is also in the millisecond level. Therefore, it can be used for those who need a fast response speed and the load power it controls is relatively large.

[0036] The utility model integrates optocoupler isolation input, relay output, optocoupler isolation high-power PMOS output, low-power PMOS output, and analog voltage output, and uses optocoupler isolation and drive amplifier circuits to effectively isolate external interference and reduce the exposure of internal small signals of 3.3V to the outside. The external output is 24V, alternating current, or an amplified analog signal, thereby greatly increasing the margin for external interference.

[0037] like Figure 2 As shown, it is a schematic diagram of the specific structure of the integrated relay module. The power module includes a 1.2V voltage regulator, a 3.3V buck converter and a 15V voltage regulator. The 1.2V voltage regulator is electrically connected to the 3.3V buck converter and the hardware expander respectively, and the 3.3V buck converter is electrically connected to the processor and the hardware expander respectively. The model of the 1.2V voltage regulator is LD1117, the model of the 3.3V buck converter is LMR16010, and the 15V voltage regulator is TL431. The LD1117 voltage regulator outputs 1.2V to power the core of the FPGA, and the switching regulator LMR16010 outputs 3.3V to power the FPGA peripherals and CPU processor and some external peripheral devices. The voltage regulator circuit TL431 outputs 15V, which is used to power the operational amplifier TP1282L of the analog output circuit. Using this voltage regulator circuit to power can reduce the zero drift of the operational amplifier, making its output voltage more stable. The power module outputs 0-10V and 15V power supply, and the fluctuation of the power supply range is smaller, which not only reduces the output ripple response, but also makes the output stable. The power module uses LD1117, LMR16010 and TL431 three voltage regulators to separate three voltages from the external 24V to realize the conversion of various power supply voltages.

[0038] The utility model can realize the on-off control of strong 220V or 110V AC electrical appliances by using relays. In addition to AC power, low-voltage DC power can also be controlled. For electrical appliances that respond quickly to signals and need to output high power, transistors can be used, and they can also be used to control conventional small current signals. For electrical appliances with conventional small current signals, ordinary IO ports can be used for output. In cases where analog signals are required for control, analog signal output can be used, and conventional digital input signals can be used. On this basis, in the case where some of the above-mentioned control resources are insufficient, there is an RS485 expansion interface, which can expand some IO ports, and analog signals, current and voltage and other signal acquisition are all feasible. In addition to the above-mentioned devices, modules such as temperature acquisition, or pressure sensor modules, etc. can also be connected to the expansion interface.

[0039] like Figure 3 As shown, a structural diagram of a CNC lathe control system, a specific application mode of this implementation case, a CNC control system includes a relay integrated relay module 10, an industrial Ethernet bus 20, a CNC numerical control system 30, and a servo controller 40, wherein the relay integrated relay module 10 is an IO port extension of the CNC numerical control system 30, and the servo controller 40 is used to control the motor. The expansion module 50 is extended through the RS485 bus on the basis of the relay integrated relay module 10. The cascade mode of the servo controller is that the OUT of each servo controller is connected to the IN of the next servo controller to realize a networking loop.

[0040] Preferably, the integrated relay module 10 is also cascaded using such a connection method, and the OUT interface of each integrated relay module is electrically connected to the IN interface of the next integrated relay module to realize a networking loop. The FPGA of the integrated relay module 10 will be connected and communicated with the outside world on the bus through the Ethernet switch chip PHY and then to the isolation transformer. The upper-level bus OUT of the industrial Ethernet bus is connected to the bus IN of the next level, and a loop connection is formed in this way. The data obtained by the FPGA on the upper-level bus IN is packaged and sent to the next level through the relevant processing of the FPGA and the processor, and the data of this slave station is finally sent back to the master station to complete a data transmission. This set of application methods uses industrial Ethernet to implement bus networking, which is low in cost, stable and reliable, and has a high communication rate.

[0041] An integrated relay module based on industrial Ethernet works as follows:

[0042] After the Ethernet bus and the power supply of the integrated relay module are connected, the relay module will connect the industrial Ethernet bus to the CNC numerical control system host (main control unit) through RJ45 for high-speed data communication of related protocols, and enter the Ethernet PHY chip. The Ethernet PHY chip will then send the converted digital signal to the FPGA, which will parse the data on the protocol. The CPU can read the parsed data or send instructions to the FPGA. The FPGA sends the data to be output to each output port, and the input data is sent to the CPU for processing by the FPGA.

[0043] In this embodiment, the integrated relay module integrates CPU, FPGA, relay, high-power PMOS, low-power PMOS, 0-10V analog output, RS422 communication, RS485 expansion, and industrial Ethernet into one board. The existing relay and PMOS circuits may require a separate module, but now they form an integrated module, which reduces the application of multiple boards. The integrated relay module includes various drive circuits, optical coupler isolation and drive amplifier circuits, which effectively isolate the interference from the outside, reduce the situation where the internal small signal is exposed to the outside, and output 24V, alternating current, or amplified analog signal, and differential communication signal, so that the margin of interference from the outside is greatly increased. For the relay, it belongs to the mechanical form, and the response of one of its actions is relatively slow at the second level, and it is used to control the alternating current. Compared with the relay, the PMOS circuit can achieve a response time of milliseconds, which is more suitable for a situation that requires high power and fast response. The Ethernet interface adopts an isolation transformer design and its transmission is differential transmission. Similarly, RS422 and RS485 are differential transmission. It has a strong ability to resist common mode interference, which ensures normal communication function.

[0044] The utility model integrates several modes of AC, DC, high power and fast response on one board, so that one board can solve the problem of multiple boards. Therefore, the use of a splitter is not needed, and the wires from the splitter are no longer needed. The board is integrated with relays, and the power of the external power that does not exceed that of this relay can be used on this board. The output is directly output from the board, and there is no need to connect the splitter wire. In this application, because the relay part and the transistor part are separated by certain areas, it is also helpful to find fault problems. In the power distribution cabinet, the space used is limited. The use of boards is reduced, and the use of cables is reduced, so the space can be optimized.

[0045] The relay module uses an integrated approach to combine controllers for multiple voltages and multiple different power loads. In traditional control methods, the controller and each module are separate, and this relay module integrates the controller and the module together. The use of cables can be reduced, and the cables from the controller to the module are also directly connected on the PCB board. This approach reduces the problem of external interference with the cables, thereby reducing the probability of failure. When the installation engineer is actually wiring, he only needs to pull the wire directly from the load to the module, which is easier to install and reduces the amount of wiring. In terms of the installation space of the distribution cabinet, it also makes the installation easier, and one module replaces the use of multiple modules. It can control AC and DC, large and small power loads, and is suitable for a variety of response speed requirements. This relay module is highly integrated, has strong anti-interference, optimizes the distribution cabinet space, is easy to quickly wire on site, and reduces the use of cables.

[0046] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited by the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principle of the present invention should be equivalent replacement methods and are included in the protection scope of the present invention.

Claims

1. An integrated relay module based on industrial Ethernet, characterized in that: It includes a hardware expander, a processor, an Ethernet switch chip and a power module. The hardware expander is electrically connected to the processor and the Ethernet switch respectively. The power module is electrically connected to the hardware expander and the processor respectively. One Ethernet switch chip is electrically connected to RJ45 network port 1 through a network isolation transformer, and another Ethernet switch chip is electrically connected to RJ45 network port 2 through a network isolation transformer. The first path of the hardware expander is connected to the digital input port through an optical coupler, the second path of the hardware expander is connected to multiple relays through a drive circuit, and the multiple relays are electrically connected to the relay output interface respectively; the third path of the hardware expander is connected to the high-power drive circuit through an optical coupler, and the high-power drive circuit is electrically connected to the high-power output interface, the fourth path of the hardware expander is connected to the low-power drive circuit through the drive circuit, and the low-power drive circuit is connected to the low-power output interface; the fifth path of the hardware expander is electrically connected to the analog output interface through an operational amplifier, and the power module is electrically connected to the operational amplifier; One path of the processor is connected to the RS422 drive circuit, and the other path of the processor is connected to the RS485 drive circuit. The RS422 drive circuit is electrically connected to the RS422 communication interface, and the RS485 drive circuit is electrically connected to the RS485 communication interface.

2. The integrated relay module based on industrial Ethernet according to claim 1, characterized in that: The model of the processor is STM32F103, the hardware expander is an FPGA field programmable gate array, and the processor and the FPGA field programmable gate array communicate using an FSMC bus.

3. The integrated relay module based on Industrial Ethernet according to claim 2, characterized in that: The model of the driving circuit is ULN2803, the model of the high-power driving circuit is NCE01P13K, the model of the low-power driving circuit is IRF7342, and the model of the operational amplifier is TL1282L.

4. The integrated relay module based on industrial Ethernet according to claim 1, characterized in that: The power module includes a 1.2V voltage regulator tube and a 3.3V step-down converter. The 1.2V voltage regulator tube is electrically connected to the 3.3V step-down converter and the hardware expander respectively. The 3.3V step-down converter is connected to the processor and the hardware expander respectively.

5. The integrated relay module based on industrial Ethernet according to claim 4, characterized in that: The model of the 1.2v voltage regulator tube is LD1117, and the model of the 3.3v step-down converter is LMR16010.

6. The integrated relay module based on industrial Ethernet according to claim 1, characterized in that: The RJ45 network port is connected to an external Ethernet communication circuit.

7. The integrated relay module based on industrial Ethernet according to claim 1, characterized in that: The integrated relay modules are cascaded in this connection mode: the OUT interface of each integrated relay module is electrically connected to the IN interface of the next integrated relay module.

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