Industrial grade power supply control module

Abstract

The utility model provides an industrial-grade power supply control module, and belongs to the technical field of power supplies. Comprising a power supply module used for providing load voltage and current; and the real-time monitoring unit is electrically connected with the power supply module and is used for monitoring the health of the power supply in real time. According to the utility model, the soft start unit is arranged to control the current rise rate when the power supply module is started and reduce the peak value of the starting current, the transient voltage suppression unit is arranged to quickly absorb overvoltage when voltage transient is detected, and the multi-stage buffer unit is arranged to smooth the change of current and voltage through multi-stage buffer, so that the transient response is reduced; by arranging the energy storage and recovery unit, energy is stored or released when the load demand changes, and transient current and voltage fluctuation is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of power supply, in particular to an industrial-grade power supply control module. Background Art

[0002] Industrial-grade power control modules are high-performance power management devices designed specifically for industrial environments. They provide stable and reliable power supply in complex and harsh industrial environments. Industrial control equipment and PLCs usually need to operate stably for a long time in complex and harsh industrial environments. Industrial-grade power control modules can effectively resist electromagnetic interference from the outside world with their excellent anti-interference capabilities.

[0003] At present, when starting large equipment or the load suddenly changes, a high starting current will be generated due to the establishment of a magnetic field, causing a transient voltage drop and current shock, and causing an excessive current shock to the power module, causing the power supply to be temporarily shut down or enter a protection mode. Therefore, the present application provides an industrial-grade power control module to meet the needs. Utility Model Content

[0004] The technical problem to be solved by the utility model is to provide an industrial-grade power supply control module to solve the problem that when the existing large equipment is started or the load changes suddenly, transient voltage and current shocks are generated, causing damage to the power supply module.

[0005] In order to solve the above technical problems, the utility model provides the following technical solutions:

[0006] An industrial-grade power supply control module comprises: a power supply module for providing load voltage and current; a real-time monitoring unit electrically connected to the power supply module for real-time monitoring of power supply health; a safety protection unit electrically connected to the real-time monitoring unit for taking corresponding measures to protect the power supply module when abnormal conditions are detected, wherein the safety protection unit comprises: a soft start unit electrically connected to the real-time monitoring unit for controlling the current rise rate when the power supply module is started to avoid startup shock; a transient voltage suppression unit electrically connected to the soft start unit for rapidly absorbing overvoltage when voltage transients are detected; a filtering protection unit electrically connected to the transient voltage suppression unit for filtering out clutter and interference in the power supply; a multi-stage buffer unit electrically connected to the filtering protection unit for buffering the impact on the power supply when the load suddenly changes; an energy storage and recovery unit electrically connected to the multi-stage buffer unit for storing or releasing energy when load demand changes, reducing transient current and voltage fluctuations, and improving energy utilization efficiency.

[0007] Preferably, the real-time monitoring unit includes: an induced electromotive force unit, electrically connected to the power supply module, for monitoring the induced electromotive force generated when the motor starts; a reverse electromotive force unit, electrically connected to the induced electromotive force unit, for monitoring the reverse electromotive force when the motor decelerates or stops, including a voltage monitoring circuit, a current monitoring circuit, and an energy absorption circuit.

[0008] Preferably, it also includes: an electromagnetic interference prevention unit, which is electrically connected to the back electromotive force unit and is used to reduce the influence of external electromagnetic interference on the power supply module.

[0009] Preferably, it also includes: an isolation amplifier unit, electrically connected to the energy storage and recovery unit, for providing electrical isolation and signal integrity.

[0010] Preferably, the energy storage and recovery unit includes: an energy storage unit, which quickly releases the stored energy to supplement the output of the power supply when the load demand suddenly increases; and a recovery unit, which absorbs instantaneous excess energy when the load changes frequently.

[0011] Preferably, it also includes: a control unit, which is electrically connected to the safety protection unit and is used to intelligently adjust the output parameters of the power module according to real-time monitoring data and a preset control strategy.

[0012] Preferably, it also includes: a fault diagnosis unit, which is electrically connected to the control unit and is used for rapid fault location.

[0013] Preferably, it also includes: a remote management unit, which is electrically connected to the fault diagnosis unit and is used for remote monitoring and fault handling.

[0014] Compared with the prior art, the utility model has at least the following beneficial effects:

[0015] In the above scheme, by setting a soft start unit, the current rise rate when the power module starts is controlled to reduce the starting current peak value. By setting a transient voltage suppression unit, when a voltage transient is detected, the overvoltage is quickly absorbed. By setting a multi-stage buffer unit, the changes in current and voltage are smoothed through multi-stage buffering to reduce transient response. By setting an energy storage and recovery unit, energy is stored or released when the load demand changes, reducing transient current and voltage fluctuations. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the present disclosure and, together with the description, further serve to explain the principles of the present disclosure and to enable those skilled in the relevant art to make and use the present disclosure.

[0017] Figure 1 This is a schematic diagram of the industrial-grade power supply control module structure;

[0018] Figure 2 It is a structural diagram of the real-time monitoring unit;

[0019] Figure 3 This is a schematic diagram of the protection unit structure.

[0020] In the figure: 1. Power module; 2. Real-time monitoring unit; 3. Safety protection unit; 4. Control unit; 5. Fault diagnosis unit; 6. Remote management unit; 21. Induced electromotive force unit; 22. Reverse electromotive force unit; 23. Electromagnetic interference prevention unit; 31. Soft start unit; 32. Transient voltage suppression unit; 33. Filter protection unit; 34. Multi-stage buffer unit; 35. Energy storage and recovery unit; 36. Isolation amplifier unit.

[0021] As shown in the figure, in order to clearly implement the structure of the embodiment of the utility model, specific structures and devices are marked in the figure, but this is only for illustrative purposes and is not intended to limit the utility model to the specific structure, device and environment. According to specific needs, ordinary technicians in this field can adjust or modify these devices and environments, and the adjustments or modifications made are still included in the scope of the attached claims. DETAILED DESCRIPTION

[0022] The following is a detailed description of an industrial-grade power supply control module provided by the utility model in combination with the accompanying drawings and specific embodiments. At the same time, it is explained here that in order to make the embodiments more detailed, the following embodiments are the best and preferred embodiments. For some known technologies, those skilled in the art may also adopt other alternative methods to implement them; and the accompanying drawings are only for more specific description of the embodiments, and are not intended to specifically limit the utility model.

[0023] like Figure 1 and Figure 3As shown, an embodiment of the utility model provides an industrial-grade power supply control module, including: a power supply module 1, which is used to provide load voltage and current; a real-time monitoring unit 2, which is electrically connected to the power supply module 1, and is used to monitor the health of the power supply in real time; a safety protection unit 3, which is electrically connected to the real-time monitoring unit 2, and is used to take corresponding measures to protect the power supply module 1 when an abnormal situation is detected, and the safety protection unit 3 includes: a soft start unit 31, which is electrically connected to the real-time monitoring unit 2, and is used to control the current rise rate when the power supply module 1 is started to avoid startup shock; a transient voltage suppression unit 32, which is electrically connected to the soft start unit 31, and is used to quickly absorb overvoltage when voltage transients are detected; a filtering protection unit 33, which is electrically connected to the transient voltage suppression unit 32, and is used to filter out clutter and interference in the power supply; a multi-stage buffer unit 34, which is electrically connected to the filtering protection unit 33, and is used to buffer the impact on the power supply when the load suddenly changes; an energy storage and recovery unit 35, which is electrically connected to the multi-stage buffer unit 34, and stores or releases energy when the load demand changes.

[0024] The soft start unit 31 is provided, including a time relay: used to control the time of the start process to ensure that the current gradually rises to a predetermined value; a silicon-controlled rectifier or an insulated gate bipolar transistor: controlling the current rise rate by adjusting the conduction angle of these semiconductor switches; a resistor network: in the early stage of start-up, the current is limited by connecting large resistance resistors in series, and these resistors are bypassed as the power module 1 enters a stable state; a current sensor: monitoring the actual current during the start-up process and feeding it back to the control circuit for precise adjustment; a microprocessor or a digital signal processor: responsible for executing the soft start algorithm and dynamically adjusting the start-up process according to preset parameters.

[0025] A transient voltage suppression unit 32 is provided, including a metal oxide varistor: when the voltage exceeds the threshold, its resistance drops sharply to absorb the overvoltage; a TVS diode: has a very fast response speed, can be turned on immediately and clamp the voltage at a safe level; a capacitor group: stores energy during voltage transients to smooth voltage fluctuations; a discharge tube: for extremely high voltage transients, the discharge tube can be turned on in a short time to provide additional protection; a monitoring circuit: continuously monitors the power supply voltage and immediately activates the protection mechanism once a transient is detected; a microprocessor: is used for intelligent control and configuration of the protection threshold to make transient voltage suppression more accurate.

[0026] like Figure 1 and Figure 2 As shown, the real-time monitoring unit 2 includes: an induced electromotive force unit 21, which is electrically connected to the power module 1 and is used to monitor the induced electromotive force generated when the motor starts; a reverse electromotive force unit 22, which is electrically connected to the induced electromotive force unit 21 and is used to monitor the reverse electromotive force when the motor decelerates or stops.

[0027] The induced electromotive force unit 21 is provided, including a Hall effect sensor: used to detect the change of the magnetic field inside the motor, thereby indirectly measuring the induced electromotive force; a current sensor: monitoring the current flowing through the motor, the induced electromotive force will affect the current characteristics of the motor; a voltage sensor: directly measuring the voltage on the motor terminals to obtain direct information on the induced electromotive force; a filter circuit: eliminating noise and interference, and improving the accuracy of the induced electromotive force measurement; a converter: converting the analog signal into a digital signal.

[0028] like Figure 1 and Figure 2 As shown, it also includes: an electromagnetic interference prevention unit 23, which is electrically connected to the back electromotive force unit 22 and is used to reduce the influence of external electromagnetic interference on the power module 1.

[0029] An electromagnetic interference prevention unit 23 is set up, including electromagnetic shielding materials: a shielding cover made of metal or conductive composite materials is used to wrap the key circuit parts to block the intrusion of external electromagnetic fields; filters: including common mode filters and differential mode filters, which are used to reduce conducted and radiated electromagnetic interference and protect sensitive circuits from being affected; grounding strategy: a good grounding design ensures that the common reference points of all circuits are consistent and reduces interference caused by ground loop currents; cables and connectors: shielded cables and filtering connectors are used to reduce EMI introduced by signal lines and power lines; transient suppression devices: such as TVS diodes, varistors, etc., are used to absorb sudden electromagnetic interference pulses; software control: the timing and mode of the signal are controlled by programming to reduce the radiation interference caused by digital signal switching.

[0030] like Figure 1 and Figure 3 As shown, it also includes: an isolation amplifier unit 36, which is electrically connected to the energy storage and recovery unit 35 and is used to provide electrical isolation and signal integrity.

[0031] By setting up the isolation amplifier unit 36, it includes a memory: used to store the operating system, application code, control strategy parameters and historical data records; an input / output interface: to communicate with the real-time monitoring unit 2, the safety protection unit 3 and other system components, receive data and send control instructions; a digital signal processor: in applications requiring advanced signal processing capabilities; a power management circuit: to ensure the power supply stability and efficiency of the control unit 4 itself; a clock circuit: to provide an accurate time reference for synchronous operation and timestamp recording; a human-computer interaction interface: including an LED display, buttons or a touch screen, so that users can monitor the status and set parameters.

[0032] like Figure 1 and Figure 3As shown, the energy storage and recovery unit 35 includes: an energy storage unit, which quickly releases the stored energy to supplement the output of the power supply when the load demand suddenly increases; and a recovery unit, which absorbs instantaneous excess energy when the load changes frequently.

[0033] By setting up an energy storage unit, when the load demand suddenly increases, the energy storage unit can quickly release the stored energy to supplement the output of the power supply to meet the instantaneous high power demand of the load and avoid voltage drop or system instability due to overload of the power supply; by setting up a recovery unit, in an industrial environment where the load changes frequently, the recovery unit can absorb instantaneous excess energy to avoid overload of the power module 1, while also reducing energy waste and achieving dynamic load balancing.

[0034] like Figure 1 As shown, it also includes: a control unit 4, which is electrically connected to the safety protection unit 3 and is used to intelligently adjust the output parameters of the power module 1 according to real-time monitoring data and preset control strategies.

[0035] By setting up the control unit 4, the output voltage and current are dynamically adjusted according to the load changes and the health of the power supply to ensure stable and efficient power supply. Through real-time feedback and intelligent algorithms, the control unit 4 can optimize the operating point of the power module 1, reduce energy waste and improve overall efficiency.

[0036] like Figure 1 As shown, it also includes: a fault diagnosis unit 5, which is electrically connected to the control unit 4 and is used for rapid fault location. The fault diagnosis unit 5 includes: a fault detection circuit, a fault log recorder, a self-test program, an error recovery mechanism, a safety shutdown power, a communication interface: communicate with the control unit 4 and the remote management unit 6, report fault status and request maintenance, and a predictive maintenance algorithm.

[0037] like Figure 1 As shown, it also includes: a remote management unit 6, which is electrically connected to the fault diagnosis unit 5 and is used for remote monitoring and fault handling. By setting up the remote management unit 6, including a communication module, data encryption and security mechanism, without physically approaching the device, the management personnel can view the device status and operating parameters in real time, including but not limited to key indicators such as temperature, voltage, current, and power consumption, which makes real-time monitoring possible and can effectively manage the device even when it is deployed in remote areas or dangerous environments.

[0038] The technical solution provided by the utility model is that when in use, the power module 1 is started, and the real-time monitoring unit 2 is started at the same time. The induction electromotive force unit 21 and the reverse electromotive force unit 22 start to monitor the electromotive force changes during the start and stop process of the motor. The electromagnetic interference prevention unit 23 starts to reduce the influence of external EMI. The soft start unit 31 controls the current rise rate of the power module 1 according to the data of the real-time monitoring unit 2 to avoid the start-up impact. If the real-time monitoring unit 2 detects an abnormal situation, such as voltage transient, the transient voltage suppression unit 32 responds quickly to absorb overvoltage, and the filtering protection unit 33 starts to filter out the clutter and interference in the power supply to improve the purity of the power supply. When the real-time monitoring unit 2 detects a load change, the multi-stage buffer unit 34 runs to buffer the impact on the power supply when the load changes suddenly. When the load demand suddenly increases, the energy storage unit in the energy storage and recovery unit 35 quickly releases the stored energy to supplement the output of the power supply. When the load changes frequently, the recovery unit absorbs instantaneous excess energy. The control unit 4 intelligently adjusts the output parameters of the power module 1 according to the real-time monitoring data and the preset control strategy to optimize the system performance. The fault diagnosis unit 5 The system status is continuously monitored. Once a fault is found, the problem is quickly located and fault information is provided. The remote management unit 6 allows remote monitoring of the system status, receives fault information from the fault diagnosis unit 5, and supports remote troubleshooting and system optimization.

[0039] The present invention covers any substitution, modification, equivalent method and scheme made on the essence and scope of the present invention. In order to make the public have a thorough understanding of the present invention, specific details are described in detail in the above preferred embodiments of the present invention, and those skilled in the art can fully understand the present invention without the description of these details. In addition, in order to avoid unnecessary confusion about the essence of the present invention, well-known methods, processes, procedures, components and circuits are not described in detail.

[0040] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the protection scope of the present invention.

Claims

1. An industrial-grade power supply control module, characterized in that: include: A power module (1), used for providing load voltage and current; A real-time monitoring unit (2), electrically connected to the power module (1), and used for real-time monitoring of power health; A safety protection unit (3) is electrically connected to the real-time monitoring unit (2) and is used to take corresponding measures to protect the power module (1) when an abnormal situation is detected. The safety protection unit (3) comprises: A soft start unit (31), electrically connected to the real-time monitoring unit (2), and used to control the current rising rate when the power module (1) is started, so as to avoid a start-up shock; A transient voltage suppression unit (32) is electrically connected to the soft start unit (31) and is used to quickly absorb overvoltage when a voltage transient is detected; A filtering protection unit (33), electrically connected to the transient voltage suppression unit (32), and used to filter out clutter and interference in the power supply; A multi-stage buffer unit (34), electrically connected to the filtering protection unit (33), and used for buffering the impact on the power supply when the load suddenly changes; An energy storage and recovery unit (35) is electrically connected to the multi-stage buffer unit (34) and stores or releases energy when load demand changes.

2. The industrial-grade power supply control module according to claim 1, characterized in that: The real-time monitoring unit (2) comprises: An induced electromotive force unit (21), electrically connected to the power module (1), and used to monitor the induced electromotive force generated when the motor is started; The reverse electromotive force unit (22) is electrically connected to the induced electromotive force unit (21) and is used to monitor the reverse electromotive force when the motor is decelerating or stopping.

3. The industrial-grade power supply control module according to claim 2, characterized in that: Also includes: An electromagnetic interference prevention unit (23) is electrically connected to the back electromotive force unit (22) and is used to reduce the influence of external electromagnetic interference on the power module (1).

4. The industrial-grade power supply control module according to claim 1, characterized in that: Also includes: An isolation amplifier unit (36) is electrically connected to the energy storage and recovery unit (35) and is used to provide electrical isolation and signal integrity.

5. The industrial-grade power supply control module according to claim 1, characterized in that: The energy storage and recovery unit (35) comprises: Energy storage units that quickly release stored energy to supplement the power supply output when load demand suddenly increases; The recovery unit absorbs instantaneous excess energy when the load changes frequently.

6. The industrial-grade power supply control module according to claim 1, characterized in that: Also includes: A control unit (4) is electrically connected to the safety protection unit (3) and is used to intelligently adjust output parameters of the power module (1) according to real-time monitoring data and a preset control strategy.

7. The industrial-grade power supply control module according to claim 6, characterized in that: Also includes: A fault diagnosis unit (5) is electrically connected to the control unit (4) and is used for rapid fault location.

8. The industrial-grade power supply control module according to claim 7, characterized in that: Also includes: A remote management unit (6) is electrically connected to the fault diagnosis unit (5) and is used for remote monitoring and fault handling.

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